U.S. patent number 3,597,890 [Application Number 04/868,956] was granted by the patent office on 1971-08-10 for construction assembly.
Invention is credited to Alfred A. Hala.
United States Patent |
3,597,890 |
Hala |
August 10, 1971 |
CONSTRUCTION ASSEMBLY
Abstract
A construction assembly comprising a plurality of individual
construction units connected together. Each of the construction
units comprises a pervious resin-impregnated fibrous mesh material.
The walls of the construction units have a cementitious material
secured to the exterior surface thereof by permeating the pervious
resin-impregnated fibrous mesh material and forming an integral
structure therewith.
Inventors: |
Hala; Alfred A. (Islip,
NY) |
Family
ID: |
25352635 |
Appl.
No.: |
04/868,956 |
Filed: |
September 15, 1969 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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647463 |
Jun 20, 1967 |
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Current U.S.
Class: |
52/309.17; 52/86;
52/439; 52/577; 52/381; 52/444 |
Current CPC
Class: |
E04B
1/32 (20130101); E04B 5/36 (20130101); E04B
1/166 (20130101); E04B 2001/3288 (20130101); E04B
2001/3264 (20130101); E04B 2001/3276 (20130101) |
Current International
Class: |
E04B
1/16 (20060101); E04B 1/32 (20060101); E04b
001/32 (); E04b 002/14 (); E04c 002/16 () |
Field of
Search: |
;52/454,443,309,381,444,577,576,439 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Murtagh; John E.
Parent Case Text
The present application is a continuation-in-part of my earlier
filed application, Ser. No. 647,463 entitled CONSTRUCTION UNIT and
filed on June 20, 1967 now abandoned.
Claims
I claim:
1. A construction assembly comprising in combination a structural
base, a plurality of individual construction units having spaced
walls, means for interconnecting adjacent ones of said individual
units, said connected construction units being positioned upon said
structural base, each of said units comprising a pervious resin
impregnated fibrous mesh material forming the walls of said units,
and a hydraulic cementitious material filling the interior of
selective ones of said construction units and forming an integral
structure with said base.
2. A construction assembly in accordance with claim 1, wherein said
construction units have a backing layer secured to the walls
thereof exteriorly of said units enabling said units to serve as a
form for the pouring of said cementitious material and forming an
integral structural assembly therewith.
3. A construction assembly in accordance with claim 1, including
another construction unit filled with a cementitious material
disposed substantially perpendicularly to said connected
construction units and positioned thereon, and a cementitious
material applied to the exterior of all of said construction units
thereby forming an integral structural assembly between said
construction units and said base.
4. A construction assembly in accordance with claim 1, wherein
said assembly is in the form of an arcuate roof construction,
selective ones of said construction units being of trapezoid
configuration, and the ends of adjacent end walls of said units
being disposed in abutting secured engagement, whereby the outer
and inner walls of said units define an arc.
5. A construction assembly in accordance with claim 1, wherein
said assembly is in the form of an arcuate roof construction, the
ends of adjacent end walls of said units being disposed in abutting
secured engagement and the outer and inner walls of said connected
units defining arcs which are substantially concentric with one
another.
6. A construction assembly comprising in combination a structural
base, a plurality of individual construction units, means for
interconnecting adjacent ones of said individual units, said
connected construction units being positioned upon said structural
base, each of said units comprising a pervious resin impregnated
fibrous mesh material forming the walls of said units, a
cementitious material filling the interior of selective ones of
said construction units and forming an integral structure with said
base, and said construction units having a backing layer secured to
the walls thereof interiorly of said units enabling said units to
serve as a form for the pouring of said cementitious material.
7. A construction assembly in accordance with claim 6, wherein said
backing layer is fabricated of paper.
8. A construction assembly comprising in combination a structural
base, a plurality of individual construction units having spaced
walls, means for interconnecting adjacent end walls of said
individual units, each of said units comprising pervious resin
impregnated fibrous mesh material forming the walls thereof, a
hydraulic cementitious material permeating the walls of said units
and forming an exterior surface thereon and an integral structure
therewith, the outer and inner walls of said connected units
defining arcs substantially concentric with one another so that
said units comprise an arcuate roof construction, and means for
positionally securing said arcuate roof construction upon said
structural base.
9. A construction assembly in accordance with claim 8, wherein
at least selective ones of said construction units are of
trapezoidal configuration.
Description
BACKGROUND OF THE INVENTION
The construction assembly of the present invention is primarily
intended for use in the fabrication of building partitions and
walls. The construction assembly permits construction of the cores
of walls and partitions having a weight of approximately 0.1 pounds
per square foot, as compared to approximately 20 pounds per square
foot for masonry and approximately 3.5 pounds per square foot for
stud partitions. Additionally, construction assemblies formed of
metal sheet or mesh-type materials are extremely difficult to shape
and install. They are not readily workable and the utilization of
metal mesh building units has been shown to be highly
impractical.
SUMMARY
It is therefore the principal object of the present invention to
provide a construction assembly of very light weight for use in the
construction of partitions and walls.
It is another object of the present invention to provide a new and
novel construction assembly which is easily fabricated and which
exhibits a high degree of workability.
It is another object of the present invention to provide a new and
novel construction assembly which is relatively brittle and which
has a relatively high tensile strength.
It is a further object of the present invention to provide a
construction assembly employing construction units which are
fabricated from a sheet material and more particularly from a
mesh-type sheet material.
It is another object of the present invention to provide a
construction unit fabricated from mesh-type sheet material having a
thermosetting plastic applied to at least one of the surfaces
thereof.
It is yet a further object of the present invention to provide a
construction assembly which is water and fire-resistant and whose
size is substantially unaffected by changes in temperature and
humidity.
It is still a further object of the present invention to provide
construction units which are capable of having exterior surface
materials secured thereto, such as plaster, gypsum board, stucco
and the like to form the construction assembly.
It is yet another object of the present invention to provide
construction units having generally hollow rectangular
parallelepiped configurations.
It is still a further object of the present invention to provide
construction units having tongue and groove portions to permit the
units to be placed in engaging relationship with one another.
It is yet a further object of the present invention to provide
hollow construction units having reinforcing members disposed
therein.
It is another object of the present invention to provide a
construction assembly for the fabrication of dome and arch-type
roof structures.
It is a further object of the present invention to provide a
construction assembly for the fabrication of bearing walls.
It is still another object of the present invention to provide a
construction assembly for the fabrication of floors, roofs and
ceilings.
It is yet a further object of the present invention to provide a
construction assembly for the fabrication of structural support
columns.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of the present
invention will become more apparent when considered in conjunction
with the accompanying drawings, wherein:
FIG. 1 is a perspective view of a construction unit employed in the
construction assembly of the present invention utilized to form
interior partitions, walls and the like;
FIG. 2 is a sectional view taken on the line 2-2 of FIG. 1;
FIG. 3 is a sectional view taken on the line 3-3 of FIG. 1;
FIG. 4 is a sectional view similar to FIG. 3 of two units joined
together, wherein said units have a highly impact-resistance
material applied to the sides thereof to form the construction
assembly;
FIG. 5 is a sectional view similar to FIG. 3 depicting a
construction unit having reinforcing crossmembers;
FIG. 6 is a sectional view similar to FIG. 2, wherein the walls of
the construction unit are formulated of a perforated plastic-type
material;
FIG. 7 is a sectional view similar to FIG. 2, wherein the walls of
the construction unit are formed of a mesh-type material having an
interior backing layer;
FIG. 8 is a perspective view of a construction unit fabricated in
accordance with a second embodiment of the present invention;
FIG. 9 is a sectional view taken in the line 9-9 of FIG. 8;
FIG. 10 is a sectional view taken on the line 10-10 of FIG. 8,
showing the construction unit having stiffening members positioned
therewithin; and
FIG. 11 is a top view of a sheet of mesh-type material used to
fabricate the construction unit shown in FIG. 8;
FIG. 12 is an enlarged cross-sectional view of a portion of the
pervious resin impregnated fibrous mesh material used in the
fabrication of the walls of the construction assembly of the
present invention;
FIG. 13 is a partial cross-sectional view of an alternate
embodiment of a wall of the construction assembly of the present
invention;
FIG. 14 is a perspective view of a dome roof construction
assembly;
FIG. 15 is a perspective view of an arch roof construction
assembly;
FIG. 16 is a sectional view taken on the line 16-16 of FIG. 14;
FIG. 17 is a partial perspective view of a bearing wall
construction assembly;
FIG. 18 is a sectional view taken on the line 18-18 of FIG. 17;
FIG. 19 is a partial perspective view of a floor or flat roof
construction assembly;
FIG. 20 is a sectional view taken on the line 20-20 of FIG. 19;
FIG. 21 is a perspective view of a hung ceiling construction
assembly;
FIG. 22 is a perspective view of a construction assembly fabricated
by the formation of nonreinforced concrete form walls;
FIG. 23 is a sectional view taken on the line 23-23 of FIG. 22;
FIG. 24 is a sectional view similar to FIG. 23 wherein the
resultant walls are reinforced;
FIG. 25 is a section elevational view of one type of column
construction assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and more particularly to FIG. 1
thereof, there is shown a construction unit 20 having the
configuration of a rectangular parallelepiped whose interior is
void. The block consists of sidewalls or wall members 22 and 24,
end walls 26 and 28, top wall 30 and bottom wall 32. The walls are
preferably formed of a mesh layer 34, such as fiberglas mesh cloth
to which is preferably applied a thermosetting plastic resinous
layer 36, such as an epoxy layer (as shown in FIG. 2 through 7).
The application of a thermosetting plastic resinous material to the
fiberglass mesh cloth results in walls which are relatively brittle
and which have relatively high tensile strength; the usefulness and
desirability of these features will be described more fully
hereinafter. The thermosetting plastic resinous layer 36 may be
applied to the fiberglass mesh cloth layer 34 by spraying,
painting, brushing, or any other suitable method.
It is herein to be noted that although the construction unit of the
present invention has been described as being fabricated from a
fiberglass mesh, the unit may also be fabricated from any other
suitable mesh-type material, other examples of which are tempered
glass and spun mineral fiber.
In FIG. 4 there is shown a sectional view of two construction units
utilized to form a partition wall or other construction assembly,
which units are joined together at a junction 38 by means of
mortar, adhesive or other suitable bonding agent. The wall 22 has
cement plaster or cement stucco 40 applied thereto as the exterior
surface thereof, the materials forming the walls of said unit being
compatible with plaster, gypsum board, stucco and similar surface
materials. It will be apparent to those skilled in the art that the
resulting structure utilizing one of the aforementioned hydraulic
cementitious materials is a reinforced concrete structure.
In some applications it is necessary to provide construction units
having greater structural rigidity than those previously described.
When this is required, the construction unit may be fabricated
having reinforcing members 42 as shown in FIG. 5. The reinforcing
members may be made of cardboard, plastic, or any other suitable
material, but are constructed so that they do not add appreciably
to the weight of the unit while enhancing the support
characteristics thereof.
In FIG. 6 there is depicted a sectional view of the construction
unit 20, the walls thereof having been fabricated from perforated
plastic-type sheet material. The walls in this case also have an
epoxy resin layer 36 applied thereto.
FIG. 7 depicts a modification of the wall structure of the
construction unit hereinbefore described. The walls are formed of a
fiberglass mesh cloth layer 34 having a backing layer 44 applied to
the inner surfaces thereof, the layer 44 being formed of paper,
cloth, or any other suitable material. The outer surfaces of the
layer 34 have an epoxy resin layer 36 applied thereon. The use of
the backing layer permits the stucco or cement layer 48 applied to
the wall as the outer layer thereof to flow through the mesh
structure, and thus allows it to become positioned against said
backing layer. This results in a wall member wherein the stucco or
cement layer has the mesh structure as a reinforcing member
therein, thereby resulting in the rigid wall structure desired.
The brittleness of the unit enables the mesh to shatter at its
point of impact by means of a sharp blow. This feature permits easy
cutting and fitting of the units, as well as cutting thereof to
build in pipes and other types of obstructions required in the
construction of partitions, walls and the like. The unit may thus
be cut or fitted by hitting it with a hammer, hatchet or the edge
of a mason's trowel. The units may also be cut be utilizing a hand
saw or knife.
The high tensile strength of the block permits it to be effectively
utilized to fabricate walls, partitions and the like.
When an impact resistant material such as cement plaster, cement
stucco, plastic board, wood panelling, masonry or the like, is
connected to the surface of the brittle, high tensile strength
sheet material, there results a highly practical and durable
partition. Moreover, the interior of the unit may be filled to
comply with specific requirements. It will thus be apparent that by
utilizing the various constructions hereinabove set forth in a
selective manner, walls and other construction assemblies having
almost any desired characteristics can be obtained.
It will be apparent to those skilled in the art that the
construction unit of the present invention will permit the
construction of interior walls and partitions having extremely
light weight, thus resulting in the use of lighter structural
members, due to the lower floor loads, thereby permitting building
designs which are substantially less expensive than those presently
employed. The light weight of the unit also permits much faster
installation, with a resultant saving in the cost of the structure.
This type of partition also lends itself to easy removal, should
removal become desirable. As discussed hereinbefore, a construction
assembly such as a partition fabricated by the use of the
construction unit of the present invention will shatter when dealt
a sharp blow, thus permitting easy removal thereof by any unskilled
craftsman.
A second embodiment of the present invention is depicted in FIG. 8
through 11, wherein similar parts are denoted by similar reference
numerals.
In this embodiment, the unit 20A is formed having sidewalls 22A,
24A and a top wall 30A, again resulting in a unit which has a
configuration which is substantially that of a rectangular
parallelopiped. The top of the unit is formed having a tongue
portion 50, while the right-hand side portion (as seen FIG. 8) is
formed having a tongue portion 52. The left-hand portion (as seen
in FIG. 8) defines a recess 54, while the bottom of the block
defines a recess 56, as best seen in FIG. 9.
One method of forming the unit 20A would be to utilize the printed
sheet 58 depicted in FIG. 11, which sheet is preferably made of
Fiberglas mesh cloth. The sheets are prestamped so as to form
indentations which form the tongue portions 50 and 52 previously
described. The sheets are coated along the entire length thereof,
except for the longitudinally extending fold lines 62, with an
epoxy resin or other suitable thermosetting plastic, which results
in the layer 36A upon the walls of the unit. After the coated sheet
has set, it may be folded along the uncoated flexible fold lines.
The fold lines may then be coated with the epoxy resin, and channel
or stiffening members 60 made of epoxy resin coated Fiberglas mesh
or any other suitable material may be secured within the unit to
lend further rigidity to it.
When the units are utilized to form a wall, the tongue portion 52
of one of the units will fit into the recess 54 in the adjacent
unit disposed to the right thereof, while the tongue portion 50 at
the top thereof will fit into the recess 56 of the unit positioned
on the top thereof. The units may then be bonded together by a
liquid adhesive, or by any other similarly suited method.
It will be appreciated that this type of unit may be readily and
easily constructed on a job site, thus making the problem of
transporting the units, or alternatively the materials therefor, a
rather simple one.
It is also to be noted that, although the three-dimensional unit of
the present invention has been described as having a rectangular
solid configuration, the same may be fabricated having a
three-dimensional triangular, cylindrical, hemispherical,
wedge-shaped, or any other suitable or desirable configuration. In
this context, it should be noted that a flat sheet of the aforesaid
materials can be corrugated, to thus form a unit having a
substantially solid rectangular configuration.
With particular reference to FIG. 12, there is illustrated an
enlarged detailed cross-sectional view of the previous
resin-impregnated fibrous mesh material, herein generally
designated by the reference numeral 70. The mesh material 70
comprises the mesh layer 34 and the plastic resinous layer 36. The
layer 34 includes a plurality of parallel spaced horizontal and
also vertical members 72 which are herein shown as having
substantially circular cross sections but which may have any other
suitable cross-sectional configuration. The plastic resinous layer
36 completely surrounds and impregnates the individual strands such
as members 72 while still leaving the material 70 with apertures
such as at 74 so as to provide the resultant pervious
structure.
FIG. 13 depicts a double thickness construction assembly 76 having
two layers of resin-impregnated fibrous mesh 78 and 80 having a
cementitious material, such as concrete, 82 which permeates the
mesh layers 78 and 80 and forms the integral construction assembly
76 therewith. The permeation of the cementitious material through
the apertures (not Shown) in the layers 78 and 80 is limited by
means of a paper backing layer 84 positioned in back of the layer
80 and secured thereto, such as by stapling or any other suitable
attachment means.
The construction assembly 76 is employed in applications where a
stronger wall structure is desired.
Referring now to FIG. 14, there is shown a dome roof construction
assembly 86 fabricated in accordance with the principles of the
present invention. The assembly 86 includes an arcuate dome portion
88 having an annular base portion 90 depending therefrom and
secured thereto.
The dome portion 88 comprises a plurality of construction units 20C
of substantially trapezoidal configuration which are connected
together by having their end wall 92 which are disposed in abutting
engagement secured together, such as by adhesive bonding or by any
other suitable securing means. The inner walls 94 of the units 20C
are smaller than the outer walls 96 thereof to provide the
trapezoidal configuration and both the walls 94 and 96 are provided
with inwardly positioned paper backing layers 98 secured to each of
the walls, as described hereinbefore.
A cementitious material such as concrete, plaster or the like is
then coated or sprayed on the inner and outer walls 94 and 96 to
form the dome construction 88. The annular base portion 90 may be
fabricated in a manner similar to the dome 88 and prior thereto;
i.e., the base portion 90 is formed first and the dome 88 is
fabricated thereon. The interior of the units 20C may be filled
with insulating material, if the same is desirable.
The resultant dome roof construction assembly is one which is
extremely light weight, durable and strong. It will be appreciated
that the foregoing construction assembly can be utilized in the
building of enclosed structures, such as sports stadiums, at a cost
which is much less than for existant type of structures. In FIG.
15, there is depicted an arch-type roof construction assembly 100
which is constructed in a manner substantially the same as that of
the dome roof assembly 86.
FIG. 17 depicts a bearing wall construction assembly generally
depicted by the reference numeral 102. The assembly comprises a
concrete footing 104 upon which are vertically disposed a plurality
of interconnected mesh-type construction units 20D. Spaced ones of
the units 20D are filled with concrete, as best seen in FIG. 18. An
upper construction unit 20D disposed horizontally is also filled
with concrete and positioned atop the vertically disposed
construction units. The entire assembly 102 is then coated or
sprayed with concrete to provide the finished bearing wall
construction assembly.
FIG. 19 illustrates a floor or flat roof construction assembly 106
which includes a pair of concrete filled mesh-type construction
units which serve as bearing members 108. Disposed across the
bearing members 108 are a plurality of interconnected construction
units 20E. The units 20E have a paper backing layer 110 secured to
the upper and end walls, as best seen in FIG. 20 and as described
hereinbefore. When the interconnected units 20E are coated or
sprayed with a cementitious material, the interior remains void
(FIG. 20) and may thereafter be filled with insulation or have
electrical wires inserted therethrough.
FIG. 21 depicts a hung ceiling construction assembly 112, wherein a
plurality of construction units 20F are interconnected, as
described hereinbefore. The interconnected units are suspended as
by wires 114 or other convention means and a suitable ceiling
material 116 which is similar to partition covers is secured to the
underside of the units. The units may be left exposed, filled with
insulation material or sprayed with acoustical material.
Another embodiment of a construction assembly is depicted in FIG.
22, wherein construction units 20G are interconnected and
vertically positioned upon a concrete footing 118. The units are
interconnected so as to form a right angle configuration and serve
as forms for the pouring of concrete columns. In this regard,
reference is had to FIG. 23 wherein it is seen that the units 20G
are provided with internally disposed paper-backing layers 120
secured to each of the walls of the units. The cost of the units
20G is so small that they need not even be removed after the
concrete has cured. It will also be appreciated that the units are
set up very quickly and very easily, in contradistinction with
present methods and apparatus for providing forms for the pouring
of concrete.
Another type form for the pouring of concrete is depicted in FIG.
24. In this embodiment the units 20H have backing layers 122
secured to the outer surfaces of the walls of the unit. Thus, when
the concrete is poured into the forms the mesh-type units become
part of the concrete and serve as reinforcing members therein,
thereby forming a reinforced construction assembly.
Another construction assembly fabricated in accordance with the
principles of the present invention is shown in FIG. 25 and
depicted generally by the reference number 124. In this embodiment
a pillar of tapered configuration is defined by a construction unit
or units 20J having concrete secured to the outer surface thereof
and forming an integral structure therewith. A paper backing layer
126 is secured to the inner walls of the unit 20J to limit the
permeation of the concrete thereinto. To increase the density of
the assembly 124 concrete fill may be added to the hollow inner
core 128 of the unit 20J.
It is thus seen that I have described new and novel construction
assemblies for use in the fabrication of various types of walls,
roofs, ceilings and the like which are extremely lightweight,
workable, sturdy, durable and which are relatively inexpensive in
their manufacture.
* * * * *