U.S. patent application number 11/984636 was filed with the patent office on 2008-05-22 for foam core panel for prefabricated buildings.
Invention is credited to Bernard J. Nadon, Shelley A.M. Nadon, Suzanne E. Nadon.
Application Number | 20080115455 11/984636 |
Document ID | / |
Family ID | 39415545 |
Filed Date | 2008-05-22 |
United States Patent
Application |
20080115455 |
Kind Code |
A1 |
Nadon; Bernard J. ; et
al. |
May 22, 2008 |
Foam core panel for prefabricated buildings
Abstract
The present invention relates to a building panel for forming
walls, roofs and floors in a building constructed with a frame
including an expanded foam plastic core rectangular in shape,
circular voids extending through the thickness of said core, each
of the plurality of circular voids spaced apart to receive tension
members, a coating applied to at least one face providing added
rigidity and a frame comprising elongated members having channels
sized to fit on the end faces of the panels for joining a pair of
said building panels together.
Inventors: |
Nadon; Bernard J.; (Notre
Dame de Salette, CA) ; Nadon; Suzanne E.; (Notre Dame
de Salette, CA) ; Nadon; Shelley A.M.; (Notre Dame de
Salette, CA) |
Correspondence
Address: |
Robert G. Hendry
1240 Lassiter Terrace
Ottawa
ON
K1J 8N1
omitted
|
Family ID: |
39415545 |
Appl. No.: |
11/984636 |
Filed: |
November 20, 2007 |
Current U.S.
Class: |
52/798.1 ;
52/309.4 |
Current CPC
Class: |
E04B 2001/3583 20130101;
E04B 1/3205 20130101; E04B 1/34315 20130101; E04C 2/296
20130101 |
Class at
Publication: |
52/798.1 ;
52/309.4 |
International
Class: |
E04C 2/32 20060101
E04C002/32 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 21, 2006 |
CA |
2,568,610 |
Claims
1. A building panel for forming walls, roofs and floors in a
building constructed with a frame comprising: an expanded foam,
plastic core substantially rectangular in shape, first and second
faces defined by the ends of said core, said core also including a
plurality of circular voids extending through the thickness of said
core between said first and second face, each of said plurality of
said circular voids being essentially parallel and each of said
circular voids being spaced apart to receive tension members, a
coating, applied to at least said first face, said coating
providing added rigidity; and said frame comprising elongated
members having channels and being sized to fit on the end faces of
the panels for joining a pair of said building panels together.
2. A panel for walls, roofs and floors as in claim 1, wherein said
coating on said building panel is plywood.
3. A panel as in claim 1, wherein said building panel foam expanded
plastic core is made of styrene.
4. A panel as in claim 1, wherein said building panel plastic foam
core is made of urethane.
5. A panel as in claim 1, wherein said frame is plastic pipe of a
diameter to fit in recessed channels in the end faces of the
panels.
6. A panel as claimed in claim 1 wherein said coating on said
building panel is corrugated plastic board.
Description
FIELD OF THE INVENTION
[0001] This invention relates to a prefabricated building assembly
for low-cost construction of walls, roofs, and floors that includes
the use of a plurality of prefabricated building modules made of
panels having a foam plastic core of the desired thickness, with
the side edges of the building panel having prefabricated
semicircular channels that engage tubular connectors for joining
the panels together to form walls, roofs, and floors. Each panel
also includes a polymer coating, corrugated plastic or wood
sheeting on its outsides to provide a finish, structural strength,
and rigidity. Each panel also includes a plurality of circular
bores or voids that extend all the way through the thickness of the
panel across the width of each panel from side to side, each of the
passages being parallel and spaced at a predetermined and equal
distance apart to accommodate partially threaded steel rods or
cables which fasten the modules together to provide rigidity for
the structure.
[0002] The modules may be used to construct walls of various sizes
provided that the diameter of the tubular members or pipes vary
accordingly. Tubular flange type connectors are inserted at the
bottom of each pipe to secure the wall units to the floor by
fastening means such as screws. The pipes or channels may be made
of plastic or metal.
[0003] Plywood or cement floors or foundations are also possible
with system. The building system may be used vertically for
traditional or arch-type buildings and for dome-type structures.
The exterior of the modules is preferably covered with a waterproof
fabric such vinyl.
BACKGROUND OF THE INVENTION
[0004] U.S. Pat. No. 4,194,919 to Hattori, et al., describes a
method for increasing flexural strength of cement compositions. The
flexural strength of hydraulic cement compositions are increased by
water-soluble epoxy resins.
[0005] U.S. Pat. No. 5,921,046 to Hammond, et al., provides a
plastic foam core for epoxy cement concrete. There is no
description or discussion to provide a foam core with a coating of
epoxy resin and plastic pipe as described in Applicant's invention
herein.
[0006] None of the references cited herein disclose Applicant's
building block having a foam core with an integral vertical plastic
pipes nor provide a low-cost lightweight construction block that
includes preformed voids for horizontal steel rods and a low-cost
permanent coating that prevents lateral buckling.
SUMMARY OF THE INVENTION
[0007] A prefabricated building assembly for constructing walls,
roofs, and floors, comprising a prefabricated building panel made
up of substantially a foam plastic core. Each of the building
panels has horizontal spaced circular voids to receive threaded
steel rods or cables.
[0008] The side face of the building panel includes a half-round or
semicircular groove or channel faces. The purpose of these
semicircular channels is to provide connection between adjacent
panels when joined together, such that a cylindrical circular
connector is disposed therein for alignment and connection of
adjacent panels.
[0009] The building panel includes an epoxy or acrylic resin
coating, corrugated plastic board or plywood on its side walls to
provide strength and a finished surface on the plastic foam core of
the building panel. The connector system, which includes a
plurality of cylindrical, elongated members, which are also made of
plastic and may be filled with foam. The basic foam panel is also
coated with the epoxy or acrylic resin. The coating is also used as
adhesive along the connectors and wall interface.
[0010] The building panel also includes a plurality of small
passageways, both horizontally and vertically disposed, for
electrical wiring, the passageways being approximately 3/4 in. in
diameter.
[0011] The building assembly may be used to construct walls, roofs,
and floors. The building assembly system described herein can also
be used to form roof connections and a building roof with
supporting trusses.
[0012] One of the purposes of the building assembly in the present
invention is the use of styrene or urethane foam blocks for the
construction, that it can be prefabricated in a factory environment
and then shipped to the building site, so that less manual labor or
finishing is required. The building assembly in accordance with the
present invention has impact and compressive load strength. When
using the present building assembly, the time of construction is
greatly reduced. The building panels and assembly connectors are
prefabricated in a factory and come in a finished condition.
[0013] After the footer and slab have been poured, a building panel
in accordance with the present invention will be placed on top of
tubular flange connectors that are secured to the slab by screws. A
roof type second building panel will be mounted on top of the first
building panel and will include cylindrical connectors. Again, the
epoxy or acrylic resin coating can be used for adhering the
cylindrical connectors to the recessed walls of each of the
building blocks, apart in the building panels, with the tubes
progressing vertically up to the top of the wall. The same
construction technique can be used on roofs, as described in
greater detail below.
[0014] The present invention seeks to provide a building panel for
forming walls, roofs and floors in a building constructed with a
tubular frame including an expanded foam, plastic core
substantially rectangular in shape, first and second faces defined
by the ends of said core, the end faces each having a concave,
semicircular recessed channel, said core also including a plurality
of circular voids extending through the thickness of said core
between said first and second face, each of said plurality of said
circular voids being essentially parallel and each of said circular
voids being spaced apart to receive tension members, a plastic
resin forming a coating, integrally applied to at least said first
face, said coating being approximately one quarter inch thick for
added rigidity; and the tubular frame comprising cylindrical,
elongated members, sized in radius to fit snugly within said
semicircular recessed channels in the core faces, said connector
being formed of a plastic pipe for joining a pair of said building
panels together.
[0015] The present invention also seeks to provide a panel, wherein
the building panel foam expanded plastic core is made of styrene or
acrylic the building panel plastic foam core is made of urethane
and wherein the frame is constructed of channel members which
engage the sides of the plastic foam panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of wall and roof panels in
accordance with this invention
[0017] FIG. 2 is a perspective view of side by side panels
[0018] FIG. 3 is a perspective view of an assembled building
structure
[0019] FIG. 4 is a perspective view of a dome shaped building
structure, and
[0020] FIG. 5 is a perspective view of the pipe arrangement of the
structure of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] The building assembly in accordance with the present
invention uses prefabricated modules. These modules or panels 10
comprise rigid foam plastic that has wood sheeting 11 provided with
adhesive on both interior and exterior sides of panels to ensure
its rigidity as shown in FIG. 1-5. Both vertical sides of panels
have a semicircular concave recessed vertical channel 14, to
receive a plastic pipe 16 of the same diameter provided with
adhesive as shown in FIG. 1-2. Each building panel is provided with
horizontal holes or voids ( 5/16 in.) 20, in order to insert
partially threaded, 24 in. long, reinforcing steel rods 12 spaced
every 2 ft., as shown in FIG. 1-2 and 4-5. A washer 26 and bolt
connector 28 is placed on reinforcing steel rods 12 outside of
vertical plastic pipe 16 as shown in FIGS. 2 and 4. The steel
connector 28 is used to join the horizontal reinforcing steel rods
12 after each panel is in place to secure the panels 10 together in
order to form one unit as shown in FIGS. 2, 4 and 5. Plastic or
metal angled connectors 30, 30a with set screws 38 are used, to
join side wall panels to roof panels as shown in FIG. 3-4. In
addition, the wall panels have a pre-determined angle at the top
15, where as the roof panels have a pre-determined angle at the top
15a and bottom 15b, in order for both panels (wall and roof or both
roof panels) to join perfectly to create a 45 degree angle, as
shown in FIG. 1. A metal anchor connector 30b is used, with set
screw 38, at bottom of each pipe 16 on either side of panels to
secure them to the foundation with 3 or 4 lag screws 36 at
predrilled holes on steel plate of connector, whether it is wood or
concrete as shown in FIG. 2-5. The building unit is covered with a
waterproof, fire retardant and U.V. protected vinyl membrane 22
which has a horizontal loop 32 placed at the bottom of each side,
to insert a horizontal plastic or metal pipe 34, as shown in FIG.
4-5. It is fastened with lag screws 36 spaced every foot of the
foundation or floor, whether it is concrete or wood as shown in
FIG. 2-5. Specifications above, also apply to arch-type dome or
semi-circular structures as shown in FIG. 5. It is very important
that all dimensions of materials are subject to change depending on
the size of building required.
* * * * *