Patent Application
20140237910
This invention's product and processes of manufacturing and construction are for creating uniform cementitious units for a component system that when designed and employed in a uniform grid result in an environmentally friendly, cost effective and energy efficient habitat that is fire proof, termite proof, mold proof and nondecaying with minimal VOCs. The invention's methodologies and processes of manufacturing employ factory applied wall coatings (“liquid sheetrock”) on the interior surface for replacing sheetrock and on the exterior surface the factory formed, integral, architecturally finished surface result in a structural component that facilitates mechanical requirements and requires no further interior nor exterior finishing. The present invention's completely finished weatherproof components install in a one step on site system superior to factory manufacturing systems.
As all languages evolve and improve, to avoid confusion of what mold is being referenced in the numerous cites in this teaching of present invention the use of British English, Australian and Canadian word “mold” refers to architectural features and the English word mold refers to the bacteria.
Wood has been the standard building material for centuries. But now due to the demand for human habitats outstripping the earth's natural ability to meet the need, as eco-ecology experts teach, the result is lower quality and increased prices for wood habitats. There is a construction material developed in Europe in 1920's called Autoclaved Aerated Concrete (“AAC”). In Europe AAC is a popular building material. AAC is a building code and UL listed product. USA needs cementitious building products, like AAC, due to deforestation and global warming. Regrettably the reason AAC has not been accepted is AAC has not been economically competitive due to additional labor and material required. This invention transforms cementitious products into an accepted standard construction material and is a continuation in the goal to make possible environmentally friendly habitats that are structurally superior and cost competitive compared to other materials and systems.
Over the millennia humans have had various processes for constructing habitats in relation to the finished product. There is a Biblical record that in approximately 1,000 BC King Solomon built the temple for God by purposefully cutting and architecturally finishing stones in the quarry, away from site, and then bringing the finished stones to the site where the stones were installed. Many modern day construction systems use secondary factories to construct components, and even entire habitats that are then transported and installed at the site.
In our modern society there is a strong need for a computerized dimensional grid system that can efficiently coordinate the design of aesthetic habitats while simultaneously giving accurate component and reduced cost estimates in a simplified manner while increasing legal American citizen workers' pay and benefits with the resultant being a superior structural habitat that is environmentally smart.
Construction of habitats in part or whole in factories and then transporting them to the site has evolved due to the advantages of materials being protected from damage and labor delays due to inclement weather, storage for less waste, labor stream lining. The problem with secondary factories to construct components is the great additional cost involved in constructing a secondary assembly factory, the costs in transporting the units to the site, and the weather can still cause delays on site. There are books on the subject of cost effective construction written by experts who advise the use of nominal sized lumber in an optimal 2′ grid system. Wall studs are available in a length so that when the bottom plate and double top plate are added the height equals a standard 8′ piece of sheetrock. But no one has developed a complete component construction system from floor to roof that has great flexibility for custom floor plans and is aesthetically pleasing architecturally. Therefore a strong need exists for a healthy, superior product that can be quickly designed via a computerized grid system that increases pay and benefits for legal US citizens while cost effectively constructed.
Over the history of constructing habitats various wall coatings have been applied to wood and stone. In the early 1900's century residential construction in the USA used a plaster applied to a wood lathe for interior walls. This system was replaced by sheetrock applied directly to wood studs. Sheetrock is labor intensive, has a great deal of waste and is susceptible to water damage and mold. Ideally there needs be a climate resistant wall coating that is economical.
Conventional sheetrock is not weatherproof so it cannot be factory attached to components and transported in a manner that would expose it to rain. There have been many coatings for concrete developed, but there is a strong need for a product that has attributes needed for this invention to be compatible with AAC and compatible with existing sheetrock construction materials.
AAC exterior walls required a labor intensive and costly thick stucco or wood furring with architectural features applied to wood furring. The additional materials deplete natural resources and cause habitats to have a higher embodied energy consumption and contribute to global earning and pollution. There are precast concrete pieces that have an architectural finished surfaces but precast concrete has minimal insulation value, is cumbersome heavy and basically impossible to modify.
Whether factory-built or built on site, the concrete slab and/or basement wall is the foundation for all subsequent work, yet their top surface inherently undulates due to the often ‘rough and tumble’ construction site and unavoidable element of human error in construction and finishing. The subsequent unleveled and undulating surface creates problems for subsequent conventional construction. But the imperfect slab's surface causes even more problems for AAC because AAC is dimensionally accurate to within ⅛″ of an inch with mortar joints of only 1/8″ and is not flexible.
As known in the art, conventional installation of AAC blocks is similar as to CMU. Comparably, conventional CMU has ¼″ mortar joints that allow for greater correction capacity to compensate for slab imperfections. The first course of no longer than 24″ long AAC blocks are individually placed and leveled. This is a very time consuming and labor intensive process. The first course requires waiting for mortar to cure before subsequent construction can continue because the first course must remain as level as possible. It is customary to wait a day before laying subsequent courses of block. Then the blocks would be routed for electrical, etc., and repaired or wood furring and sheetrock applied to interior walls. When panels are employed instead of blocks, the panels are installed vertically, but again the 24″ widths are affected by inherit uneven slab requiring each vertical panel to be plumbed, which is time consuming. The time factor in placing vertical panels is especially critical because cranes are employed which are very expensive to operate hourly. The Germans invented a machine that levels the base course of mortar.
Conventional AAC construction installs AAC in alternating stacked blocks or expensive panels that create a great disparity of face deflections requiring expensive and labor intensive multiple coats of plaster to create a smooth surface.
The current art due to the solid nature of AAC requires the interior face to be routed for electrical and plumbing if the walls are not furred in and sheetrock applied to wood. Alternatively, the repaired routing and surface face deflections require plaster to be applied in a two layer application being built up to a minimum ⅜″ thick. The labor required to apply the plaster in several coats makes the cost equal to furred walls with sheetrock so the result is that current use of AAC is priced out of the market because it costs 30% more than the average home constructed of wood or CMU. What is needed is a construction system that reduces face deflection and retains a measured grid so minimizes the labor, time and cost of field cutting many individual pieces to custom match each plan.
AAC historically has had problems with being a solid material that inhibits installation of mechanical air ductwork that is usually hidden in unfinished areas of wood frame construction. These unfinished areas result in wasted unlivable areas. Such areas, like attics, are not insulated and thereby cause air supply ducts to loose effectiveness as they travel distances to supply temperature desired air to insulated areas. Current art AAC has wood roofs and attic areas or costly and time consuming dropped ceilings, etc. Present invention employs either the 2″ air chases and/or architecturally finished insulated crown molding that has 2″ ducts inside.
Precast concrete panels that are used for floors and ceilings have the problem of the underneath joint not being able to be finished due to its design of a curved base. The result is an unfinished ceiling surface requiring additional finishes or dropped ceiling, or, the contemporary exposed and simply spray painted warehouse look.
There are many waterproof coatings that are not vapor permeable and therefore cannot be used for concrete products because cementious products must be vapor permeable so the moisture in the concrete can escape. If the moisture does not escape it can cause condensation on interior surface and that leads to damages and mold. The present invention allows for a 2″ thick section of closed cell spray insulation to be sandwiched between two panels of AAC, the interior panel 6″ thick and the exterior panel being 2″ thick. The sandwiching creates an unanticipated exponential increase to thermal values as compared to foam insulation on the inside or outside surfaces. Also are the benefits from exterior architecturally featured AAC of fire resistance and protection from elements and creatures, etc.
Alternatively, the present invention has an architecturally featured foam panel that is applied with a zero VOC adhesive to the exterior surface of AAC and is coated on the architectural surface with colored coating so the resultant panels look like natural wood and stone but have superior insulating properties and less environmental negative impact. The energy savings and other advantages of foam insulation far surpass any negatives. Being factory installed, in the present invention's system, is also another advantage.
The present invention allows for entire walls of 8′+tall and 10′+long to be manufactured and shipped to site and then openings cut out as desired for doors and windows. This is unprecedented in present construction that requires vapor barrier house wraps, etc.
Starting with the major construction practices, there are many examples of good factory construction systems to compare, but one of the most innovative is a whole-house construction system (U.S. Pat. No. 6,253,504 Cohen, et al. Jul. 3, 2001) wherein a complete factory is built in the subdivision, then entire house is built in the on site factory with the completed house being trucked within subdivision to individual lot and placed on foundation. The purpose of building a secondary factory wherein to assemble parts is to protect the materials and laborers adversely affected by inclement weather. This system requires a large subdivision of many homes to be cost effective and is not feasible with projects that have steep topography due to transporting the entire house and requires fairly good weather conditions for crane and workers to install house on foundation. Other factory manufactured homes constructed in units have sheetrock and must be protected from elements.
Wood frame and precast concrete habitats as well as other factory sized component design systems fail in maintaining adherence to the discipline of a grid design that is easily coordinated with a precast roof system that has zero waste as present invention teaches. They also lack flexibility, variety and uniqueness in architectural design without compromising the discipline of the dimensional grid system.
Computer software for framing and materials are common to the industry, but these prior art programs are inadequate because they require human input for each component and coordinating of various subcontractors and materials.
Conventional AAC walls are furred in with wood stud walls cover with sheetrock or a thick ⅜″ two coat application of interior plaster. Sheetrock has susceptibility to mold and is permanently damaged when introduced to water. When there is a house fire sometimes the greatest damage done to a house is by the water used to extinguish the fire ruining the sheetrock, insulation and lumber. There are coatings for concrete for various functions such as water proof and fireproof, but none to replace the need for sheetrock by being of a composition that conventional sheetrock mud can adhere itself and can withstand the elements while in transit and installation in the field.
Prior art U.S. Pat. No. 6,682,617 Gregg, et al., is an AAC sheetrock that has better fire protection than standard sheetrock but has all the inherent disadvantages of sheetrock. U.S. Pat. No. 5,283,279 Hara et al. is for fire proof coating for cement and U.S. Pat. No. 4,614,755 Rodgers, Sep. 30, 1986 is for waterproofing cement objects, but neither have the composition of present invention that provides the additional attributes necessary to replace sheetrock for interior walls and ceilings. U.S. Pat. No. 5,599,634 Davies, Feb. 4, 1997 is basically a super thin self leveling concrete specifically to be applied to horizontal floors at a thickness no greater than “1 mm”, that is 0.0393701, or basically only 1/25 of an inch thin. This indeed is a neat feat for what is basically a super thin self leveling concrete, but the claim “durable” is relative in regard to being able to withstand normal wear from the abrasiveness of commercial foot traffic, but at least claiming such hardness as durable for a floor means that the required sanding of joint compound to finish seams would leave a noticeable difference in surface texture between this product and a sanded joint compound. The chemical composition is not as compatible as desired for good adhesion with sheetrock joint compound required for joints and touch up for a wall and ceiling application. None of the prior art coatings are compatible with conventional AAC construction due to being too thin and with the quick absorption rate of AAC would leave inevitable cracks, seams and uneven places when applied in sections over a large surface area. The alternative of conventional plaster that does create a smooth surface across a wall of varying deflection block faces is a labor intensive, multi coat, ⅜″ thick hand applied finish. What is needed is a product that is chemically and workability compatible with sheetrock joint compound, is smooth and can be applied while AAC is vertical, horizontal and even upside down for ceilings when needed.
One of the problems with conventional construction is the uneven and unlevelness of poured slabs on which walls are constructed. Prior art solved the inherent problem of uneven slab surface by removing the human element and employing a precast member in one fashion or another, whether precast footings, or entire wall sections. U.S. Pat. No. 4,142,340, Howard, shows a precast footing 12, that requires stairs to cross over and so is not a primary course, structural component of wall surface, positioned on a poured at site, human finished slab. U.S. Pat. No. 3,952,471 Mooney, shows a standard footing, 31, employing the problematic precast wall sections having windows already positioned so that no field relocating can be made.
Prior Art for wood and like material construction requires materials to be cut on site or the factory according to plan. Precast concrete construction does not allow for field modification as U.S. Pat. No. 5,761,862, Hendershot, et al, Jun. 9, 1998 shows the corners being a single component. Precast corner units cannot be made of AAC in current factories and the shipping challenges of a precast corner are more than flat panels being attached in field to make a corner. There is not a coordinated system that allows for a minimal number of components to construct an almost unlimited number of variations for architectural floor plans and elevations.
Prior art for AAC to make an architecturally finished exterior surface composed of any wood or wood like materials (i.e.: Hardi-Plank siding) require furring strips anchored into AAC and then wood siding and roofing attached to woods strips. AAC roof panels required decking or other mechanical means to attach conventional construction materials. This method of finishing the exterior surfaces of walls and roofs is not protected from delays in labor due to inclement weather, the multiple steps are labor and material intensive, and are susceptible to decay.
It is common in the current art to make architectural design features in standard precast concrete panels, but not for AAC. Standard precast concrete is extremely heavy and has very low insulation values. The current method of manufacturing AAC makes it impossible and impractical to manufacture grouped bulks of architecturally featured AAC panels due to need for AAC to foam/rise and be removed from mold, wire cut into dimensional material and then autoclaved. It is not cost effective to do this in a piece-by-piece process as standard precast.
Prior art of large ducts for air condition and heating requires large open spaces and cavities that solid cementious habitats do not provide. What is needed is an improved manner to get heating and air conditioning supplies ductwork in habitats that have solid cementious walls and ceilings with no cavity areas.
Because most prior art habitats' exterior structural walls are usually composed of wood, precast concrete floor panels are prohibited by code because if there is a fire, then the inhabitants are crushed by the concrete panels when the walls fail due to burning. In commercial concrete buildings where precast concrete panels are used for floors and/or ceilings it is usual practice to hide the underside of the panels by installing acoustical ceilings, or cover with sheetrock or spray a popcorn ceiling texture that hides the imperfections. Additionally, due to the precast concrete's bottom edge's standard rounded edge design the joints cannot be finished with tape and mud as does sheetrock joints that have a smooth transition. Now the ceiling surfaces of AAC panels are able to have architectural patterns as desired.
Therefore, all the prior art fails by employing valuable ecosystem resources that would be better left to their created purpose to transform the negative effects of a growing human population, have a higher embodied energy usage, resort to constructing expensive secondary factories so that the habitats that employ prior art materials and methodologies can be constructed in a more organized manner while protected from inclement weather. The few coatings for various uses over concrete were never conceived to be used with ACC walls and ceilings and are not ideally compatible with AAC nor sheetrock joint compound. The exterior architectural effects use materials that deplete the ecosystem's dwindling resources that better serve us undisturbed, create more pollution due to short lifecycle, are subject to fire, mold, decay, etc., are labor intensive and costly in both installation and maintenance.
Throughout history humanity has the strong need for habitats. As our human population increases, so increases the demand for natural resources used to build habitats. As the human population continues to grow, it is proven that the material demand of required earth's resources to construct conventional habitats will outstrip the supply. Additionally, the increased burden of other negative effects imposed upon the earth's ecology, such as disproportionate carbon monoxide and global warming, demands that the habitats we humans build save trees and other valuable resources that transform and reverse the negative effects of carbon monoxide and global warming.
The advantages of the present invention of an extremely environmentally friendly habitat are being cost effective and meeting the human need for the best home of a habitat that is fire proof, termite proof, mold proof, nondecaying, and that is easily and economically constructed. The objects and teachings of this CIP make it possible for a crew of no more than five workers to construct a simpler house plan of a standard two story, 2,000 square foot house, even in light rain and mild winds, to be “dried in” and ready for trades in approximately three days. This is possible by using only materials that will not be damaged by rain or freezing during transport and installation. Because the present teaching does not use the components that cause most of the prior art's waste, the additional factory-type assembly line approach is no longer needed. Once the habitat is dried in, since most of the exterior is finished, the habitat becomes its own little factory protected from inclement weather. Therefore all trades can easily and cost effectively schedule and complete a house with no more waste than in a factory assembly line.
One object of the present invention is the computer program for designing and estimating the finished component and grid design system. The Computerized Grid System (CGS) is user friendly. When someone is designing the floor plan, first the desired wall heights are chosen. Then, as the floor area is enlarged to the required grid criteria, the coordinated components automatically are computed. This allows for customers to visit a website and design a house and get a very accurate cost. For geographic location the person's zip code computes the variables, such as shipping cost index. Manufacturing and constructing weatherproof finished components executed within the discipline of the computerized grid system allows for construction in all but the most inclement weather thereby eliminating the need for expensive secondary factories used to assemble materials into a habitat.
Another teaching of present invention is liquid sheetrock, a unique factory applied coating that provides a smooth face superior in appearance and performance to conventional sheetrock boards. It is has a much more even surface than alternative hand applied plaster. It is complimentary to AAC in that it is mold proof, fireproof, nondecaying and vapor permeable. Georgia State University has conducted a test on its mold proof and water resistance and determined it is “as mold proof as stainless steel.” The walls and liquid sheetrock can go through a New Orleans Katrina-type flooding and be submersed for two weeks and simply be washed off. The finish coat can be painted, is repairable and the unique chemical composition is compatible for joint compound to achieve good adhesion and can be sanded for adding small interior wood and sheetrock walls. Additional coats of sheetrock joint compound can be added for joints in a single coat without use of joint tape as is industry standard practice. The invention, liquid sheetrock for AAC, is a blend of dry ingredients composed of up to an approximate two parts Portland Cement, up to an approximate part calcium carbonate powder, up to an approximate part lime and up to an approximate part methylcellulose, and this dry composition is mixed in an approximate one-to-one ratio with a liquid solution that is composed of approximately one half water and one half methyl methacrylate emulsion. This mixture allows for a self-forming smooth surface that can be applied by trowel on a vertical surface and even upside down for ceilings. It cures quickly with the result of an even, smooth surface. When applied on the modular units that are described in U.S. Pat. No. 7,204,060. The result is a wall that requires no subsequent sheetrock or plaster work. When wall blocks are installed, the mortar in the seams is allowed to cure until in a firm state so there is no additional shrinkage. The joints are then scraped clean with an appropriate tool. Then a simple one coat of sheetrock compound is applied without the use of previously required joint tape, the seam then is lightly sanded and the walls can be finished with paint. The entire process for an interior wall finish is reduced to a labor and material saving single skin coat of joint compound on vertical seams.
The structural component and the liquid sheetrock are basically mold proof and emit no harmful gasses as do so many other products. Therefore, the interior air of habitat is as clean and healthy and even healthier than out door air in polluted cities with the assistance of quality air purifiers.
With Smooth Finish on Interior by Employing A Mold.
Another teaching of present invention in this CIP application is the processes and product of an integral architectural features on the exterior surface of component units. The integral exterior architectural ornamentation is fireproof, termite proof, mold proof, nondecaying, insulating and requires minimal maintenance. The architectural ornamentation is very advantageous for both exterior walls and roof panels.
Another advantage of the present invention is a manufacturing process and construction methodology resultant in a product that is a load baring first course called a leveling base panel. Every system requires the site construction to begin on the slab and/or foundation. The leveling base panel allows immediate installation of subsequent construction upon it. The present invention allows for a single base course to be installed in minutes instead of hours painstaking leveling. Another advantage is that the subsequent construction is able to commence immediately instead of waiting hours so the first course can cure before putting weight on it. The house is designed in modular 2′ grid system so the leveling base panel can be cut in the factory, but also cut in the field for onsite modifications. The leveling base panel is architecturally finished and has an interior liquid sheetrock finish applied thereby eliminating several time consuming and costly steps in construction process. The architectural features are functional in that the architectural features are located at the top where there will be the mortar joint for subsequent course of wall block, as taught by the invention. Therefore the ⅛″ seam becomes invisible, again saving time and labor in finishing.
Because the leveling base panel teaches a utility chase incorporated therein, there is no need for further labor. Therefore, the advantages of the present invention are a leveling, structural and immediately load bearing, primary course of leveling base panels that incorporate architectural features which eliminate the need for further finishing and also incorporate a continuous utility chase system so the trades simply install their mechanical wires, piping, etc., requiring no further modifications. The invention's process of cutting out door openings and 45° corners into the leveling base panel after installation allows for greater accuracy, quicker installation, a consistent and precise leveling. Therefore, minimal waste pieces of cut out sections are easily and environmentally transformed to benefit the ecology.
Another object of this invention is the filler wall block that is coordinated with the computerized grid system design, in this case employing the preferred 2′ grid, and how the dimensional non-architecturally finished wall block and casing blocks allow for aesthetically pleasing design variations without cutting or waste. At the end of the wall section that terminates at a perpendicular wall there is installed a filler wall block instead of a standard wall block. The filler wall block is a factory modified wall block that has its width reduced by the thickness of the wall it abuts so the 2′ grid is maintained. By employing only these two vertical block types, wall and filler, an entire habitat with a myriad of possible variations can be easily built and coordinated with the zero waste precast cementious roof system so the entire habitat has no waste in its vertical wall sections.
Another object of this invention is the filler wall block that is coordinated with the computerized grid system design, in this case employing the preferred 2′ grid, and how the dimensional non-architecturally finished wall block and casing blocks allow for aesthetically pleasing design variations without cutting or waste. At the end of wall section that terminates at a perpendicular wall there is installed a filler wall block instead of a standard wall block. The filler wall block is a wall block that has its width reduced by the thickness of the wall it abuts so the 2′ grid is maintained. By employing the primary three vertical block types (leveling base panel, wall block and top beam), the teachings of this invention of casing and space components enable an entire habitat to be easily built and coordinated with the zero waste precast cementious roof system so the entire habitat has almost no waste. The trimmings of the wall block are put through the invention's planer/molder machine and become window and door casing that is fireproof, termite proof, mold proof, nondecaying and insulating.
Another alternative object of this invention is for when employing wall blocks that have manufactured architecturally finish on the exterior surface to make a continuous pattern on exterior of house requires 45° cuts on the vertical sides at outside corners so that the grid system, in this case on typical 2′ grid, allows for good architectural design variation. For inside corners the teaching of this invention corner block is employed. Thereby employing only these three vertical block types, wall, casing and corner, an entire habitat is easily built and coordinated with a precast cementious roof system that has zero waste.
Another object of this invention is when the architecturally finished wall blocks use a simulated siding design, it is necessary to replace vertically orientated wall blocks with this invention's horizontal wall blocks. Horizontal wall blocks are approximately 10′ long and have minimal reinforcing for transporting and erecting because their primary function requires compressive strength, not sheer strength. Since the horizontal blocks are employed within the present invention's “CGS” (computerized grid system), there is rarely waste as the 2′ incremental sections are easily installed at various places.
Another teaching of the present invention is the process and product of crown molding air ducts that are an alternative to the internal duct system formed within top beams as taught in U.S. Pat. No. 7,204,060. The air duct crown molding has an approximate 2″ diameter internal air duct channel that is compatible with requirements for high velocity forced air systems as known in the art. This invention enables an entire architecturally finished air duct system to be economically installed by a crew immediately after the habitat is dried in. The professional mechanical heating and air contractors simply connect the mechanical units to the crown ducts. Then, the supply vents are cut into the crown ducts in the desired size and location as specified by a mechanical engineer.
Another teaching of the present invention is a special modification to the edge pattern in molds used to manufacture precast concrete panels. By changing the industry standard bottom rounded edges to an edge that results in a design similar to the tapered edge of sheetrock boards and adding fast curing liquid sheetrock to the panel's bottom surface, the precast panels are able to be used for finished ceilings. The liquid sheetrock is applied while transporting the precast panel to storage by running the panel's bottom side over an applicator. The fast curing liquid sheetrock has cured adequately by the time the panel is put into storage.
By this invention, the result is an extremely environmentally friendly, structurally superior habitat that is fireproof, termite proof, mold proof, nondecaying, zeros VOC and insulating that is now able to be constructed and sold at a price that is economically affordable and competitive to all types of conventional construction. The evolution is to create entire walls at 8′ and 10′ tall and 20+′ long. The walls will have architectural features on the exterior and smooth on the interior with factory applied liquid sheetrock. The walls will be eventually composed of aerated concrete that have a chemical composition replacing the need for autoclaving and another invention of inventor using carbon fiber reinforcing to replace current steel reinforcing. The walls will be very strong and lightweight. The entire wall sections walls will be assembled on site and once erected the openings for doors and windows will be cut with tools in the field. The excessive material is inert and can be ground and become a soil enhancer so there is no off site waste.
In
This unique construction methodology allows for entire wall sections to be erected and then the door openings cut out of the base panel. Simply securing a sheet of plastic by adhesive tape to the slab where the door openings are to be cut prior to mortar being applied allows the mortar and block to be easily removed when it is time to cut out the opening. When the inventions' teaching of trim blocks 7 are installed, the vertical longitudinal void aligns and allows for a continuous void for uninterrupted wire and pipe installation, whether going up and around the door opening or down and into the concrete floor, and the wires go down the utility channel and into the floor, and then come back up into longitudinal void on other side of opening and into the leveling base panel employing “arcuates” so all wires can be fished through chase in closed walls after doors and windows are installed in an Architecturally Finished Complete Building Envelope System.
The double-sided molds originated in 2004 and system tested and perfected. There is still nothing in the market for AAC, even though others since 2004 have made double sided molds. The incorporation of chemicals that interact with the AAC to help have a bubble free face as well as bond with the future coloring to be added on the site and coating over seam joints 14a combined with the action of short session, intense small vibrating action of only the molds at the perfect time of curing are what create the surface bubble free, architecturally featured, air insulative, cementitious panels. The vibrating vertical support rods 23 are removed from the AAC after the AAC has cured sufficiently to be self-supportive but still soft enough so it can be cut with industry standard wires 18. After the pan sides are removed, the mold vibrating vertical support rods 23 are removed and the AAC is then wire cut to desired dimensions. The double-sided mold patterns 20 are left in the AAC through the autoclaving process. After the autoclaving process is completed, the AAC is removed from the double-sided mold sheets 20 with result being that the smooth wire cut 18 and pan side 17 faces the interior back side whereon the liquid sheetrock 24 is applied. Another unanticipated advantage is in this unique process of double-sided mold patterns 20 and wire cuts 18 whereby the mold patterns are reversed so when the AAC is removed and flipped over so they can be positioned either horizontally one on top of another shown in
The various teachings of present invention shown in
In
In
The teachings of the present various required inventions result in a super energy efficient insulated, fireproof, termite proof, mold proof, nondecaying, low embodied energy, healthy habitat that provides better pay and benefits to residents and construction workers and helps greatly reduce global warming. The houses have minimum 100+ year life span that can be cut into sections and reused.
This application claims the benefit of U.S. provisional application 61/793,918 filed Mar. 15, 2013 and is a continuation-in-part of U.S. patent application Ser. No. 11/982,455 filed Oct. 31, 2007, which is a continuation-in-part of U.S. patent application Ser. No. 11/123,635 filed May 6, 2005, which is a continuation-in-part of U.S. patent application Ser. No. 10/201,035 filed Jul. 23, 2002, now U.S. Pat. No. 7,204,060, which is a continuation-in-part of U.S. patent application Ser. No. 09/784,848 filed Feb. 16, 2001, now abandoned, and a continuation-in-part of U.S. patent application Ser. No. 09/741,787 filed Dec. 21, 2000, now abandoned, which claimed the benefit of U.S. provisional application 60/183,472 filed Feb. 18, 2000, now expired, the disclosures of which patent and patent applications are incorporated by reference as if fully set forth herein.
| Number | Date | Country | |
|---|---|---|---|
| 61793918 | Mar 2013 | US | |
| 60183472 | Feb 2000 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11982455 | Oct 2007 | US |
| Child | 14215922 | US | |
| Parent | 11123635 | May 2005 | US |
| Child | 11982455 | US | |
| Parent | 10201035 | Jul 2002 | US |
| Child | 11123635 | US | |
| Parent | 09784848 | Feb 2001 | US |
| Child | 10201035 | US | |
| Parent | 09741787 | Dec 2000 | US |
| Child | 09784848 | US |
