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The present invention relates to systems and methods for construction of buildings. More particularly, the invention relates to systems and methods for constructing buildings using lightweight standardized modular blocks capable of withstanding extreme temperatures, weight and forces, are heat and flame retardant, easily transported and easily assembled.
There are many conventional construction techniques currently in use. Prevalent techniques include wood frame construction, masonry frame construction, and light-gauge steel construction. Each of these construction techniques has its own advantages and disadvantages, taking into consideration various factors such as cost, energy efficiency, durability, aesthetics, difficulty of assembly, and reliance upon special tools or components which may be necessary for assembly.
Wood frame construction is currently the most commonly used system for residential construction. Although wood as a construction material remains relatively inexpensive, there is growing concern over the quality and quantity of the world's dwindling wood supply. These concerns are particularly acute in countries where native forests have been depleted, and reforestation is not practiced. In terms of difficulty in assembly, wood frame construction requires a basic knowledge of the structural characteristics and capabilities of a variety of wood products and pieces. The carpenter must also have adequate skills and experience to employ the appropriate framing techniques for the structural project at hand. Further, the connection system for the wood components relies upon mechanical fasteners. These fasteners must be selected and assembled through the application of professional skills.
Masonry frame construction is still used in many parts of the world, particularly in third-world countries. Masonry construction can be inexpensive if the raw materials are available locally and the components are manufactured close to the building site. Nevertheless, proper assembly of masonry blocks is labor intensive, time consuming, and requires a fairly high level of skill and experience. After the blocks have been assembled, a suitable roof system must still be constructed and structurally integrated with the upper layer of wall blocks. The point of connection between the walls and the roof is critical, as high winds may cause a catastrophic separation of the two, if the connection is defective or weak. Masonry construction is also subject to damage or complete failure as the result of earthquakes, prevalent in many areas where such construction is commonly undertaken.
A third prior art construction technique which has become more popular in recent years for both commercial and residential structures, is light-gauge steel construction. One advantage of such steel construction is that is does not directly, at least, have a negative impact on the world's forests. Also, steel construction is relatively light weight, and pest-proof However, a disadvantage is that steel construction is structurally similar to wood frame construction, and requires an even higher level of construction knowledge and on-site training. The connection system for steel structural and panel components is based entirely upon mechanical fasteners. The assembly of components with such fasteners must be done properly, through the application of learned skills and the use of necessary tools.
More recently, yet another building technique, using Structural Insulated Panels (“SIPS”), has emerged. In a standard SIPS system, a pre-manufactured panel replaces the framing, sheathing, and insulation used in prior art construction. Typically, a SIP includes either polystyrene foam or polyurethane foam as material for its core. This rigid and dense foam spans the entire thickness of each panel, and provides a desirably high R-factor. Consequently, structures made from SIPS are generally stronger, more energy efficient, and offer a higher and more consistent level of quality than structures employing wood frame construction. However, the fastening system used in the standard SIPS system is similar to that used in wood frame construction. Even though assembly of the standard SIPS system requires a lower degree of construction knowledge than that necessary for wood-stick framing, it still requires basic carpentry skills and the use of heavy equipment to move and locate the large panels which are usually employed.
Wood-plastic composites (WPCs) have been proposed as new building materials for use in constructing homes, offices, factories, sheds, warehouses, or any other type of edifices, and walls, barriers, floors, decks, or other structure. As compared with wood, WPC profiles or planks 200 can have greater durability, lower maintenance costs, and favorable aesthetics, while preserving the use of natural resources. WPC offers improved dimensional stability, a lower moisture absorption, and resistance to fungi. Wood-plastic composites of the disclosure are recyclable, and can be used in traditional thermoplastics processing routes such as extrusion, injection molding, and calendaring.
Thermoplastics which can be combined with wood in the manufacture of WPCs, which in turn are usable in accordance with the disclosure, can include, but are not limited to, High Density Polyethylene (HDPE); Polyvinyl Chloride (PVC); Polypropylene (PP), and Polystyrene (PS). In comparison to lumber, which shows apparent density of 0.35 g/cc for pines and 0.54 g/cc for red maple, wood-plastic composites typically range within 1 and 1.4 g/cc, depending on the formulation, lending to greater strength and durability.
To reduce weight, WPC can be foamed during production. Provided a requisite amount of strength is retained for a particular application of the disclosure, such foamed materials can also be used herein. While plastic lumber formulations of the disclosure can make use of almost 100% of post-consumer recycled plastics, care must be taken with regard to the total amount of recycled resin used, in order to retain the requisite strength, processability and aesthetics of the final product.
Plastic extrusions can be used to form wall and ceiling panels, and modular building systems, such as are described in U.S. Pat. No. 6,931,803.
WPC can be fabricated with cellulosic fillers melt compounded with polyolefins and vinyl resins, or other thermoplastic material, taking care to avoid overheating and damaging the cellulosic material. Wood-plastic composites (WPC) have been used to construct decking and fences, furniture, car parts, and applicances.
The extrusion of WPC is described, for example, in U.S. Pat. Nos. 5,938,994 and 6,066,680. Reference may further be had to www.strandex.com.
Log homes, such as are popular in Scandanavian countries and North America, are constructed using interlocking wooden planks.
Accordingly, the primary object of the present invention is to provide an improved system and method of building construction utilizing standardized modular units or components that may be rapidly and easily transported and assembled
In accordance with an embodiment of the disclosure, one type of modular unit or component for building construction comprises an elongate plank defining a longitudinal axis and having upper, lower, front and back surfaces. The upper and lower surfaces may have mechanisms for interconnecting two or more stacked planks which extend substantially parallel to the longitudinal axes of the units. The interconnectable mechanisms of an upper surface of a lower unit may be configured to mate with corresponding interconnectable mechanisms on a lower surface of a upper unit. The units or components of the invention may be comprised of WPC, such as a fabricated composite or aggregate mixture if cellulosic material and plastic.
In various embodiments thereof, the cellulosic material may be 15 to 85 wt % of the mixture, 25 to 75% of the mixture, 35 to 65 wt % of the mixture or 45 to 55 wt % of the mixture.
In some embodiments, one or more surfaces of the unit may be concave. The concave surface includes an overhanging ledge extending along the longitudinal axis; the plank further comprises an interior extruded with a honeycomb configuration; the plank further comprises interior walls extending from a front of the plank to a back of the plank, and from a top of the plank to a bottom of the plank, the walls mutually intersecting; the interior walls intersect at 90 degree angles; and/or a plurality of planks are stacked to mate the interconnectable shapes of upper and lower surfaces of successively vertically stacked planks.
In further variations thereof, the front surfaces of a plank are sloped with respect to the back surfaces of the plank; an interior of the plank includes one or more hollow channels extending along the longitudinal axis filled with an insulating foam; the foam is produced by a reaction of reagents within the one or more hollow channels; the reagents include a soy based material and vegetable oil; the mixture further includes one or more chemicals which retard degradation of the plank due to sunlight; and/or the mixture further includes one or more chemicals which retard a flammable combustion of the plank.
In another embodiment of the disclosure, a method of building structures comprises providing an extruded plank defining a longitudinal axis and having upper, lower, front and back surfaces, the upper and lower surfaces having an interconnectable shape extending along the longitudinal axis, the interconnectable shape of an upper surface of a first plank shaped to mateably interconnect with the interconnectable shape of a lower surface of a second plank, the plank fabricated with a melted mixture if cellulosic material and plastic.
These and other objects and advantages of the present invention will become apparent from a reading of the attached specification and appended claims. There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As required, detailed embodiments are disclosed herein; however, it is to be understood that the disclosed embodiments are merely examples and that the systems and methods described below can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present subject matter in virtually any appropriately detailed structure and function. Further, the terms and phrases used herein are not intended to be limiting, but rather, to provide an understandable description of the concepts.
The terms “a” or “an”, as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms “including” and “having,” as used herein, are defined as comprising (i.e., open language). The term “coupled,” as used herein, is defined as “connected,” although not necessarily directly, and not necessarily mechanically.
The term “WPC” as used here in refers to a wood plastic composite material. Wood plastic composite materials may be formed from many different materials in various combinations and in various different ratios. They may also include many different additives that may affect the materials' durability, appearance, flame retardancy, tensile strength, rigidity, flexibility, melting point change in volume in response to change in temperature and other parameters or factors. Unless indicated otherwise, either expressly or by implication, a different material may be used in place of WPC so long as the replacement material has suitable qualities.
As used herein, “components” and “units” are generally used interchangeably and refer to individual pieces that when used together facilitate and are incorporated into a system of constructing buildings as described herein. The components of a system in accordance with the principles of the invention may be further categorized into panels, blocks, posts, planks, plates, platforms, lintels and other components commonly found in building construction. These various components may be described as modules or as module blocks to indicate that they are discrete units which may be combined to form a single building or structure. The components may be considered standardized because each type of components generally has similar geometries and have standard sized and shaped interconnection mechanisms.
A system of building construction in accordance with the principles of the invention may utilize several different interconnected components having standardized connection means. The various components may be connected to one another, i.e. interconnected, and less time and with less effort than in any conventional building construction methods.
Formation of a component for use in accordance with the principles of the invention from WPC formulation into a desired final geometry may be accomplished using various techniques. For example, molten WPC may be extruded through a die section to form various components. During optimization of the process, the concentrations of cellulosic material and other materials forming the WPC mixture may be adjusted as required.
Construction systems and methods in accordance with the principles of the invention provide building constructions systems which may be assembled, such as for example, by stacking and interconnecting standardized modular blocks between standardized modular posts. The modular posts may be comprised of a sleeve of WPC or other composite material surrounding a reinforced concrete core. The blocks, posts and other components in accordance with the principles of the invention may have a variety of geometries and features. These components may together form the basis of a modular, standardized method and system of constructing dwellings or other buildings.
In an embodiment of the disclosure, the units of the modular standardized building system may have interior cavities such that may include a plurality of hollow spaces within the units. These cavities may be filled with insulating foam or other material, such as for example foam which is produced by a chemical reaction of two agents, for example in a Reaction Injection Molding (RIM) process, while the agents are injected into the hollow spaces. The inclusion of insulating foam may provide a thermal and/or acoustic barrier.
In one embodment, the WPC used in the manufacture of the components or units of the system may be a blend of polyolefinic thermoplastics, woodflour, and additives which combine to provide structural integrity, flame resistance, and sound and weather shielding, and which can comply with acceptance criteria of applicable building codes.
The following examples, which are exemplary and non-limiting, illustrate some suitable materials for use in some embodiments of the invention for use in forming the units or components of the modular, standardized construction system.
One WPC formulation which may be used for manufacturing extruded WPC profiles of the disclosure, can include a composition of:
from 35 to 65 wt % of a polyolefin, for example a virgin or newly produced High Density Polyethylene (HDPE) and/or a blend of virgin HDPE;
up to 10 wt % of recycled post-consumer HDPE, for example recycled bottles;
up to 10 wt % of a mineral filler, for example calcium carbonate or talc;
from 0.5 to 2.0 wt % of a non-metallic stearate lubricant;
from 1.0 to 3.0 wt % of a maleic coupling agent;
from 0.1 to 0.5 wt % of a thermal stabilizer comprising a blend of an organophosphate and a hindered phenolic antioxidant, the amount of thermal stabilizer dependent on the amount of post-consumer recycled content;
from 0.1 to 0.5 wt % of an ultraviolet stabilizer comprising a blend of an ultraviolet absorber and a hindered amine light stabilizer (HALS); and 5 to 15% Halogen-free flame retardants based on monoammonium and diammonium phosphate.
The foregoing ingredients may be blended, for example in a dryblender, then melt compounded with 35 to 65 wt % of a controlled moisture content powdered wood flour. The composition is advantageously formed into pellets in a manner known in the art, for extrusion as planks 200 in a subsequent step. If PVC is used instead of HDPE, a lower percentage of wood flour or other natural fiber may be advantageous, for example up to 30 to 50 wt %. It should further be understood that about 30-75% natural fiber can be used in various embodiments. It should be understood that the foregoing example is a representative formulation that is advantageously used in carrying out the disclosure, and that there are many different possible formulations which can be used, depending upon the particular requirements of the application.
In one embodiment, the wood flour, which may be from either or both of soft and hard woods, may have a mesh size of between 40 and 100 mesh, and a moisture content lower than 1%. This may reduce processing fluctuations and equipment wear. Less than about 10 wt % of post-consumer polyethylene may be sourced from bottle scrap, in order to obtain highly predictable strength, durability, and appearance attributes for the final extruded product.
The above composition may be modified in order to advantageously produce a desired melting flow index suitable for extrusion. In accordance with the disclosure, to produce the disclosed profile geometries, flow indexes ranging from 0.1 to 2.0 g/10min (ASTM D-1038) can be achieved with the disclosed formulation of dry blended ingredients which are then melt compounded with treated woodflour in a twin screw extruder. Without being bound to any particular theory, respective roles of various constituents of the formulation are detailed as follows.
The addition of 5 to 15% mineral filler, for example precipitated calcium carbonate (CaCO3) and/or talc may provide improved structural strength of the extruded profiles, while improving their appearance improving the smoothness of the finish Cellulose degradation typically occurs at 200-220 degrees C., and this may be a constraint on WPC processing, as cellulose degradation can release volatiles, cause wood bleaching and colour fading, produce unstable flow and output fluctuations, which may impair the mechanical properties of the WPC product. In accordance with the disclosure, the formulation may include specific chemical additives, including primary and secondary antioxidants, which can retard thermo-oxidative degradation of cellulosic materials during extrusion of the WPC formulation. These may include, for example, synergistic blends of organophosphites and hindered phenolic antioxidants which have low volatility and high resistance to hydrolysis. The use of antioxidant additives may promote proper extrudability of the profiles while avoiding damage due to degradation, which may include discoloration and yellowness.
A light stabilizing additive may protect from damage due to ambient light, including UV light, and resultant fading and reduced integrity of the matrix resin. In an embodiment, the additive can include any or all of the pigment titanium dioxide, for example from 0.5-3 wt %, and light or UV stabilizers, such as UV absorbers (UVAs), that act by shielding the polymer from ultraviolet light, and hindered amine light stabilizers (HALS), that act by scavenging the radical intermediates formed in the photo-oxidation process. Examples include benzophenones and benzotriazoles, or blends of these, as described in U.S. Pat. No. 8,901,209.
To improve interface properties between the cellulosic filler and the polyethylene co-polymer, a maleic coupling agent, for example maleic anhydride with a melt flow index within the range of 20 to 100 grams/10 min, may be added. This may produce, for example, maleic anhydride grafted polyolefins with a melt flow index ranging from 100 to 120g/10min). (ASTM D 1238-190° C./2.16 k) with maleic graft index ranging from 1 to 3.0%. The coupling agent may improve wettability of the cellulose filler by reducing the surface tension at the wood-plastic interface, improving mechanical strength and resistance to delamination and moisture uptake by the composite. This may result in improved dimensional stability of the extruded profile embodiments by reducing moisture uptake during a service life of the planks 200, posts 240, or other extruded WPC components of the disclosure.
Improved filler dispersion, and wetting of the filler surface may be achieved by using a lubricant, for example a non-metallic stearic lubricant. The result is improved processability and rheology for higher extrusion throughput. Lubricants can also include a blend of complex modified fatty acid esters.
Fire retardancy, for example to meet IBS standards, can be improved by the addition of halogen-free flame retardants and smoke suppressants, such as zinc borate or a molybdenum derivatives.
Organic or other pigments may be added for improved aesthetics and long-term proof resistance to colour fading.
Resistance to degredation by insects may be improved by the addition of a biocide, for example zinc borate, advantageously with proven resistance to termites, mildew and fungus.
Using the foregoing example formulation, or other suitable WPC compositions, components cmay be produced in accordance with the disclosure using the following process. Processing of pelletized wood plastic composite is performed using a counter-rotating conical twin screw extruder, having a screw diameter front and rear of 92 and 188 mm, respectively. Five heating zones are provided in the barrel, and degassing means are positioned at half of the length of the screws. The counter-rotating twin screw extruder used in the invention was designed to meet throughput rates up to 2,600 lbs/hr. The screws have three distinct zones: feeding, conveying, and metering, which are designed to provide high head pressure capabilities and high torque for gentle plastification of the melt to feed the die shown in
In accordance with the disclosure, it may be advantageous to have a melt temperature of about 150 to 170 degrees C, and a die temperature of 130 to 180 degrees C. Screw speed may be between about 10 and 20 rpm, with a melt pressure of between 5 and 15 Mpa.
An embodiment of tooling to provide the final geometry of a profile of the disclosure is shown in
Referring now to
The plank 200 shown in
Numerous other complementary connecting surfaces are known in the art and many may be suitable. For example ridges and channels without ribs or grooves may be used. Connecting mechanisms may utilize interference fit, snapping into place, nuts, bolts, screws, rivets and other devices.
Planks 200 of any length may be extruded, but may typically be about 20 feet long for convenience in storage, packaging, and/or distribution. The longitudinal length of the plank 200 may be defined by the end surfaces 209. As may be seen from viewing and in surface 209, the interior 207 of the plank 200 has been shaped to form a plurality of cavities 220 parallel to the longitudinal axis of the plank. These cavities 220 may be defined by interior walls 222 that are parallel to the connecting surfaces 210 and several interior walls 223 that may be substantially perpendicular to interior walls 222. The perpendicular relationship of interior walls 222 and interior walls 223 results in the cavities 220 having a substantially rectangular cross-section and having a substantially parallelepiped shape. The cavities 220 may generally extend the entire longitudinal length of the plank 200. When as here one of the surfaces is convex or other shape, some of the channels may be rectangular or curved or have other geometries. The placement of cavities 220 with in the planks 200 may reduce their weight and the amount of material required to form them. The honeycomb structure may allow this reduction in weight and materials without sacrificing strength.
Planks may have any length, and that the lengths illustrated in the Figures of this disclosure are not to be construed as limiting. Further, planks may have any length and width, subject to applicable constraints of production and use.
Referring now to
A series of walls 230 formed by interconnected planks 200 may form a dwelling with the appearance of a log home, or any other structure, including a shed or barn, or any other building, or an open structure, such as a fence, corral, or barrier, for example using planks 200 to form walls disposed in alternating directions.
End caps 284 are shown in
The post 350 may include a hollow exterior comprised of WPC or a similar material and may include one or more aesthetically pleasing surfaces such as facing surfaces 352. In other embodiments, post 350 may be made of another material, and may have increased strength relative to planks 200. The posts 350 may be constructed to support a load, such as a roof, or to provide additional strength to connected walls, for example to bear forces imparted by a high wind load. For example, a post 350 may be formed with steel reinforced concrete, or metallic tubing or channels. Post 350 may be larger or smaller than depicted. Post 350 may optionally have a triangular profile, or a partly circular profile.
During construction, it may be desirable to first erect one or more posts 350 at a desired location and fill the post 350 with reinforced concrete, for example including rebar. Planks may then be successively stacked on top of one another as they are slid down the connecting beds of the posts.
Planks 500 are interconnected along top connecting surface 510 and bottom connecting surface. Plank 500 may include a slanted surface 503 from which a lip 515 extends downward covering the interface between the bottom connecting surface 510 and the top connecting surface 512 of the plank 500 below it.
Ridges 513 on top connecting surface 512 may be partially compressed during an interference fit into the channels 514 on the lower connecting surface 510 and 514, to form a water tight seal. Additionally or alternatively, a resilient gasket may be intercalated between the connecting surfaces 510 and 512 or at another location to form a watertight and/or gas tight seal between connected planks 500. In all embodiments, a connection between planks, a wall and/or a post may be carried out using clips, screws, bolts, adhesive, or other methods.
Multiple stacked planks 600 may be used to form a wall 630. A wall 630 may include a header 690. A header 690 may include ridges 692 such that it may securely engage a connecting surface 610 of a plank 600. The header 690 may also include flat facing surfaces 694 and a planar, flat upper surface 691.
Walls 630 may be joined consecutively using a post 650, or may be joined in a perpendicular configuration using a post 670. A post 670 may include connecting beds 674 between facing surfaces 673. The post 670 may also define one or more interior cavities 672 that may be filled with concrete, reinforced concrete or other material.
Planks in accordance with the principles of the invention may be tested for resistance to compression loading. A WPC composition suitable for use in the present invention may include 30-50% natural fibers, up to 10% mineral filler, 3-8% lubricants, no coupling agent, 2-6% color and U/V protection, 1-3% heat stabilizer, and up to 2% biocide, with the remainder comprising a PVC polymer.
A plank 900 shown in
In addition to testing, Euler buckling loads were calculated as shown in Table 2, using the thickness of the column sections and their lengths. The moment of inertia was calculated using the formula I=(Lt3/12). Euler buckling load for a single column was determined using the equation P=Nπ2EI/h2, where where: I=the moment of inertia for the column section, L=the length of the test specimen, t=the thickness of the individual column section, P=the Euler buckling load for the individual column, E=Material modulus of elasticity, and h=the height of the column section.
The total cross section buckling capacity was calculated as the sum of the column capacities. A modulus of elasticity of 4140 MPa (about 600,000 psi) was estimated for a PVC based wood-plastic composite, and 2070 MPa (about 300,000 psi) for a polyethylene based wood-plastic composite. These figures were used for calculations of the ultimate buckling load if the structure failure occurs in a brittle manner, as observed during the test performance. Test results are shown in Table 1.
Comparison of the test results with the Euler Buckling analysis illustrate that much greater strength is available within the design of plank 900. The plank segment 900 of
The use of planks and posts in accordance with principles of the invention may have advantages in terms of assembling simplicity, reduced scrap in construction sites, and uses renewable resources in its manufacturing process that qualifies for green building certification LEEDS—Leadership in Energy & Environmental Design. The disclosure can provide modular building systems that are produced from renewable resources, and which contain renewable and recycled materials, in compliance with existing building construction recommendations, such as the International Code Council (ICC) and International Building Code (IBC). Furthermore, the proposed building systems contribute to substantial reduction of materials used in construction sites, and are eligible for points and verifiable attributes within the Green Building Standards, in accordance to ICC-ES Evaluation services.
All references cited herein are expressly incorporated by reference in their entirety. It will be appreciated by persons skilled in the art that the present disclosure is not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. There are many different features to the present disclosure and it is contemplated that these features may be used together or separately. Thus, the disclosure should not be limited to any particular combination of features or to a particular application of the disclosure. Further, it should be understood that variations and modifications within the spirit and scope of the disclosure might occur to those skilled in the art to which the disclosure pertains. Accordingly, all expedient modifications readily attainable by one versed in the art from the disclosure set forth herein that are within the scope and spirit of the present disclosure are to be included as further embodiments of the present disclosure.
Whereas, the present invention has been described in relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention. Descriptions of the embodiments shown in the drawings should not be construed as limiting or defining the ordinary and plain meanings of the terms of the claims unless such is explicitly indicated.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
This application is the National Stage entry from PCT Application No. PCT/US2016/44295 filed on Jul. 27, 2016, which claims benefit of the priority date of U.S. Provisional Application No. 62/197,529 filed on Jul. 27, 2015.
Filing Document | Filing Date | Country | Kind |
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PCT/US16/44295 | 7/27/2016 | WO | 00 |
Number | Date | Country | |
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62197529 | Jul 2015 | US |