Patent Grant
10287770
The invention relates to building materials, components, and methods of construction, and, more particularly, to non-traditional construction using a structural insulated building unit with inherent structural integrity, prefinished surfaces, and/or precision alignment, foamed concrete, composite materials and constructions, and self-sustainable buildings.
Almost half of the world's population lives in inadequate housing, including in slums and squatter settlements. Current worldwide need for low-cost, affordable housing is significant and growing. Modern utilities distributions are also inefficient and many people still do not have basic sanitation facilities. Where utilities are available, the approach to utilities has been to make it easy for the provider rather than efficient to the user. Unfortunately, traditional home construction and the building industry have not changed to address these challenges. Typical construction practices are increasingly expensive, inefficient, and require specific skilled labor.
Traditional building construction relies on various types of skilled workers to complete discrete components of a building or phases of construction, including framing, insulation, utilities, interior and exterior architectural finishes; each step separate from the other and requiring different skills. Modular building construction allows some of the assembly to be performed in a manufacturing facility off-site and once on-site the pre-built sections can be assembled into the building using traditional building methods; however, this prefab method is limited in design and still requires the same skilled workers and processes. For example, one type of pre-built component used in modular construction is the structural insulated panel (SIP). SIPs allow for insulation to be included in a panel and are constructed off-site. On-site, the SIPs are assembled into a building using traditional building methods including the use of separate structural framing with posts and beams, and with attachment using screws, nails, etc. Further steps are needed to complete the building, including providing interior and exterior finishes, and connecting utilities, for example. These conventional building techniques, including conventional SIPs, do not address or contemplate a total home building solution. Thus, inefficiencies remain in terms of speed, quality, cost, and utilities, and there is currently no high-quality, low-cost, flexible, efficient system for building construction.
What is needed is a total home building solution that is sustainable, secure, high-quality, efficient, fast and easy to construct, and economical. Housing and building construction in accordance with the principles of the present invention is based on the principles of high technology, high efficiency, and high quality. Buildings can be built on-site with local labor and no special skills and/or equipment in accordance with the principles of the invention. The inventive technology can have factory-finished interior and exterior surfaces to ensure high tolerances and high quality at the highest efficiency and lowest cost. In addition to finishes, utilities such as plumbing and electrical systems can be integrated into the building solution to reduce the need for additional time, expertise, and materials. Indeed, there can be no need for utility hook-ups. The inventive solution can include the lowest energy profiles for any and all climates as well as high seismic and fire resistance.
This better building construction can be achieved through the use of various embodiments of the invention. The inventive technology includes the use of inventive building materials, building units, and construction methods. The inventive construction method is both efficient and economical in terms of time to build, amount of complexity and discrete components needed, and skill required. Some of the building units of the invention are referred to herein as structural insulated building units (SIBUs). The SIBUs can provide inherent structural integrity to a building and can include an insulating core. The interior and exterior surfaces of the structural insulated building units can be factory-finished to simplify and shorten the construction process. Electricity can be provided via local solar, wind, or mechanical power with 12 volt electrical systems. Water and waste management systems are also available locally to enable a self-sufficient structure. Novel cementitious materials and composites of the invention can include extruded cementitious materials, fiber-reinforced concrete, and foamed concrete. The panel units incorporate the preferred structural strength, bacterial and/or fungal resistance, surface characteristics and finishes, and freeze and/or thaw resistance to achieve an inventive total home building solution.
Embodiments of the invention address the above problems and needs in traditional building construction using a structural insulated building unit (SIBU) with an innovative jointing and assembly feature. The SIBU is suitable for use as part of a floor, wall, or ceiling of a building, for example. The SIBU can have a laminar composition and exhibit high stiffness, sound and thermal insulation, and strength compared to traditional building elements and compositions. These properties can be further exploited by creating a box beam from the laminar element. The box beam has the capability of distributing loads throughout a wall or floor, for example, rather than concentrating loads on posts and beams that are used in traditional construction. In embodiments of the invention, the units are not continuous, but can employ a connection system to align and fasten multiple units together without the need for separate columns or beams that are used in traditional construction. The improved systems, methods, apparatus, and compositions for building construction and materials of the invention enable much reduced time of construction of high quality structures with optimized lower-cost and highest-quality finishes without skilled labor requirements. With this improved construction system and materials, construction steps are reduced while maintaining precise and improved alignment of the building elements to enhance structural integrity of the resulting structure.
An embodiment of the present invention includes a structural insulated building unit for constructing a building or structure. The structural insulated building unit can include an insulating core, first and second cementitious panels, and a connecting portion. The insulating core is defined by a plurality of sides and opposing first and second faces of the insulating core. The first and second cementitious are panels coupled to the first and second faces of the insulating core, and the connecting portion is provided on one of the sides of the insulating core. The connecting portion can align the structural insulated building unit with an adjacent structural insulated building unit having a complementary connecting portion when constructing a building or structure.
In an aspect of the embodiment, the connecting portion can be a spline extending along the side of the insulating core. The connecting portion includes a three-dimensional surface facing outward from the structural insulated building unit, the three-dimensional surface being arranged for mating engagement with a three-dimensional surface on the complementary connecting portion. The mating engagement of the three-dimensional surface can align the structural insulated building unit with the adjacent structural insulated building unit in three orthogonal directions parallel to x-, y-, and z-axes. The connecting portion can further include a mounting side and a coupling side, where the mounting side is configured to couple to the side of the insulating core and the coupling side is on an opposite side of the connecting portion relative to the mounting side. The coupling side includes the three-dimensional surface. According to aspects of the embodiment, the three-dimensional surface can align the structural insulated building unit with the adjacent structural insulated building unit with precision such that the first and second cementitious panels of the structural insulated building unit and the adjacent structural insulated building unit form continuous planar surfaces across edges of adjacent first and second cementitious panels. The three-dimensional surface can include at least one of the following: at least one raised portion and at least one recessed portion.
Where the three-dimensional surface includes at least one raised portion, the at least one raised portion is configured for mating engagement with at least one recessed portion of the three-dimensional surface on the complementary connecting portion. The at least one raised portion can be tapered as the raised portion extends away from the insulating core such that the raised portion is tapered in at least one direction that is parallel to the x-axis, y-axis, and z-axis. In addition, the at least one raised portion can have an end surface that is parallel to a mating surface of the at least one recessed portion of the three-dimensional surface of the adjacent structural insulated building unit when in mating engagement with the adjacent structural insulated building unit.
Where the three-dimensional surface includes at least one recessed portion, the at least one recessed portion is configured for mating engagement with at least one raised portion of a three-dimensional surface on the adjacent structural insulated building unit. The at least one recessed portion can be tapered as the recessed portion extends toward the insulating core such that the recessed portion is tapered in at least one direction that is parallel to the x-axis, y-axis, and z-axis. In addition, the at least one recessed portion can have an end surface that is parallel to a mating surface of the at least one raised portion of the three-dimensional surface on the adjacent structural insulated building unit when in mating engagement with the adjacent structural insulated building unit.
In a further aspect of the embodiment, the structural insulated building unit can accommodate at least one of an adhesive, a seal, and a gasket on at least a portion of the three-dimensional surface when in mating engagement with the adjacent structural insulated building unit. In some aspects of the embodiment, the spline further includes opposing longitudinal sides, the longitudinal sides each including an alignment feature configured to align the first and second cementitious panels with the insulating core and the spline. The alignment feature can be a flange. The spline can include a cam chase to allow a cam to extend between the structural insulated building unit and the adjacent structural insulated building unit. The spline can further include an access hole through which the cam can be actuated for engaging or disengaging with one of the structural insulated building unit and the adjacent structural insulated building unit.
In some aspects of the embodiment, at least one of the first or second cementitious panels can have a pre-finished surface that faces outward from the structural insulated building unit. The pre-finished surface requires no additional finishing or modification after connecting the structural insulated building unit with adjacent structural insulated building units to erect the building or structure. The pre-finished surfaces can include at least one of a cementitious material, a ceramic, a concrete, a siding, or a wood, and at least one of the first or second cementitious panels can include one or more layers. The first or second cementitious panels can include a fiber-reinforced concrete layer.
In some aspects of the embodiment, the structural insulated building unit can be aligned and joined with the adjacent structural insulated building unit without screws or nails. The structural insulated building unit can further include a cam with a hook. The cam can hold, via the hook, the connecting portion in mating engagement with the complementary connecting portion at least while an adhesive sets. The structural insulated building unit and the adjacent structural insulated building unit can include an integrated alignment system whereby the structural insulated building unit and the adjacent structural insulated building unit can be aligned without additional alignment components. The structural insulated building unit can also include an access hole through which a cam can be actuated for engaging or disengaging with a hook receiving portion of an adjacent structural insulated building unit.
The structural insulated building unit can form an air- and water-tight structure or building, according to an aspect of the embodiment. The structural insulated building unit can form the air- and water-tight structure or building without sealing the structural insulated building unit in plastic wrap. The structural insulated building unit itself can be air- and water-tight. In an aspect of the embodiment, the structural insulated building unit can further include connecting portions on the other sides of the insulating core, where the connecting portions are splines. The splines and the first and second cementitious panels can create an air- and water-tight box around the insulating core.
In some aspects of the embodiment, splines extend along the sides of the insulating core for a total of four splines on four side of the insulating core, where at least one of the four splines is the connecting portion. When components of the structural insulated building unit are assembled, the structural insulated building unit can have a location precision between the components of at least one of: plus or minus one tenth of 1 mm, plus or minus one half of 1 mm, and plus or minus 1 mm. Referring to this location precision, the components can include the insulating core, the first and second cementitious panels, and the connecting portion. The splines can have a location precision of one-tenth of 1 mm with respect to each other. In some aspects of the embodiment, at least two of the splines that are on adjacent sides of the structural insulated building unit can include alignment holes on mating surfaces of the two splines, where the alignment holes are sized and shaped to receive a dowel or pin that spans from one of the two splines to the other of the two splines to align the two splines. The structural insulated building unit can further include a dowel or pin configured to be inserted into the alignment holes.
Another embodiment of the present invention includes a building or structure comprising a plurality of structural insulated building units according to the above-described embodiment. In the building or structure of this embodiment, the insulating core can include a foam insulating layer and foamed concrete. The connecting portion can align the structural insulated building unit with the adjacent structural insulated building unit with precision such that the first and second cementitious panels of the structural insulated building unit and the adjacent structural insulated building unit form continuous planar surfaces across edges of adjacent first and second cementitious panels. The connecting portion can align the structural insulated building units without additional alignment tools.
According to another embodiment of the present invention, a building or structure including a plurality of structural insulated building units is provided, where at least some of the structural insulated building units are connected using the connecting portion of the above-discussed embodiments.
According to an embodiment of the present invention, a structural insulated building unit system is provided that can enable constructing a building or structure in a single step of joining structural insulated building units to one another. In an aspect of the embodiment, the structural insulated building units include an insulating core and first and second cementitious panels. The insulating core is defined by a plurality of sides and opposing first and second faces of the insulating core. The first and second cementitious panels are coupled to the first and second faces of the insulating core. The structural insulated building units can further include connecting portions to align adjacent structural insulated building units having complementary connecting portions. In some aspects of the embodiment, the first and second cementitious panels have a pre-finished surface that faces outward from the structural insulated building unit. The pre-finished surface can be configured to require no additional finishing or modification after joining the structural insulated building units.
In aspects of the embodiment, the single step of joining the structural insulated building units includes aligning and connecting the structural insulated building units without the structural insulated building units being attached to a separate structural frame. The single step of joining the structural insulated building units can further include applying adhesive to one or more connecting portions of adjacent structural insulated building units. In addition, the single step of joining the structural insulated building units can include aligning and connecting the structural insulated building units without using screws or nails. The structural insulated building units can be configured to achieve, when joined, location precision of equal or less than one of: plus or minus 0.5 millimeters, plus or minus 1 millimeter, plus or minus 3 millimeters, and plus or minus 6 millimeters across a 2 meter span. The structural insulated building units can achieve precision without skilled labor in the constructing of the building or structure. At least some of the structural insulated building units can incorporate utility components such that connecting utilities of the building or structure is integrated into the single step of joining the structural insulated building units. The utility components can include electrical system components, plumbing system components, and/or sanitation system components.
An embodiment of the present invention provides an improved structural insulated panel for constructing a building or structure. The improved structural insulated panel includes an insulating core defined by a plurality of sides and opposing first and second faces of the insulating core, and first and second cementitious panels coupled to the first and second faces of the insulating core. The first and second cementitious panels can include fiber-reinforced concrete. In an aspect of the embodiment, the insulating core can include fiber-reinforced foamed concrete, expanded polystyrene foam, or both. In some aspects of the embodiment, the insulating core can include three layers that include an insulating layer as a central layer, and first and second foamed concrete layers on opposite faces of the insulating layer, where the insulating layer can include polystyrene foam, and the first and second foamed concrete layers can include fiber-reinforced foamed concrete. The insulating layer can be affixed to the first and second foamed concrete layer via an adhesive.
Another embodiment of the present invention is a foamed concrete material for use in construction of buildings or structures. The foamed concrete material can include a cement mixture, and a foaming agent. The cement mixture is fiber-reinforced, and the foamed concrete material is arranged as a porous foam structure having a fiber-reinforced matrix of the cement mixture with pores of air dispersed throughout the fiber-reinforced matrix. In aspects of the embodiment, the foamed concrete material is about 60% to 75% air by volume. In a further aspect, the foamed concrete material is about 75% air by volume. The foaming agent can be a polymer-based foaming agent or a surfactant-based foaming agent. The cement mixture can include: from about 25 to 40 percent by mass of cement; from about 10 to 20 percent by mass of fly ash; from about 1 to 5 percent by mass of polyvinyl alcohol fiber; from about 10 to 20 percent by mass of fire clay; from about 10 to 20 percent by mass of gypsum; and from about 10 to 20 percent by mass of acrylic binder. In some aspects, the cement mixture can further include from about 1 to 5 percent by mass of silica. In another aspect, the cement mixture further includes from about 0 to 5 percent by mass of acrylic fiber. The cement mixture can further include water.
In aspects of the embodiment, the cement mixture includes glass fibers for fiber-reinforcement. The cement mixture can include fibers greater than 10 μm in diameter. The fibers can be about 30 μm in diameter, and can be about 6 to 12 mm in length. The cement mixture can include fibers for fiber-reinforcement, the fibers being about 10 to 20 percent of the cement mixture by volume.
Additional features, advantages, and embodiments of the invention are set forth or apparent from consideration of the following detailed description, drawings and claims. Moreover, it is to be understood that both the foregoing summary of the invention and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the invention as claimed.
Embodiments of the present invention include structural building components, materials, and methods that will revolutionize the building industry by simplifying and accelerating the construction process, while reducing cost and time of construction, decreasing or eliminating the need for skilled labor, and increasing efficiency in the construction process and the resulting buildings. Some embodiments of the present invention include prefabricated building components referred to herein as structural insulated building units (SIBUs). Each SIBU is a discrete component or building block that, when combined with additional SIBUs, can form a building or structure. SIBUs are designed to be put together in specified arrangements to result in a planned design. However, the SIBUs are not only prefabricated structural components, but also an integrated solution for all sub-systems of a building. For example, the SIBUs can provide inherent structural support for a building, eliminating the need for a separate structural frame. SIBUs can also incorporate elements of the utilities systems, such as plumbing and electrical wiring and components. The electrical components can include 12V wiring systems, which may not require transformers, and local power generation through renewables such as solar, wind, or mechanical power generation resulting in efficient and environmentally friendly buildings. Further, SIBUs can be factory finished so that all desired finishes are provided on the SIBUs, and no separate finishes need to be installed on-site. In some embodiments, an entire building—with all finishes, utilities, and structural support—can be completed with nothing more than SIBUs. Moreover, a SIBU-based system can be assembled on-site without the need for skilled labor due to simple alignment and connection mechanisms integrated into SIBUs. Thus, the SIBUs of the present invention are an integrated solution to many challenges in traditional construction.
Furthermore, according to some embodiments of the invention, SIBUs also provide improved performance in terms of strength and other characteristics, as discussed herein. The improved performance exhibited by SIBUs and structures built using SIBUs include increased strength, stiffness, durability, and lifespan, for example. In some aspects, the SIBU and the resulting structures exhibit improved handling of moisture and air- and water-tight sealing.
In some embodiments, a SIBU can include two structural panels with an insulating core between the structural panels. The two structural panels may each have exposed surfaces that are prefinished according to the desired aesthetic and/or function of that panel within the building. In addition, the structural panels can be formed of a material having sufficient strength to provide structural support to the SIBU and the resulting building. The insulating core can also provide strength and load distribution, in addition to thermal and noise insulation. The structural panels may be made of a cementitious material, such as fiber-reinforced concrete, for example. The insulating core may comprise expanded polystyrene (EPS), or foamed concrete, or both. The foamed concrete of the insulating core can be fiber-reinforced foamed concrete. Additional details of these components and materials are discussed below.
One advantage of the fiber-reinforced foamed concrete in some embodiments is the improved tolerance to condensation inside the SIBU. Condensation often forms inside of SIPs, for example, due to temperature differences between sides of the SIP. Such condensation can have a destructive effect on the insulation used in SIPs, especially when the condensation is localized or pools in an area. Freezing and thawing cycles of the condensation can further damage buildings. However, according to embodiments of the invention, the foamed concrete of the insulating core provides avenues for the condensation to dissipate and prevent pooling. In some embodiments, passageways and ports can be provided to allow the moisture to drain from one SIBU to another SIBU, or to an exterior of the SIBUs through one-way valves or membranes, for example.
The SIBU can also include a joining mechanism on one or more sides of the SIBU. This joining mechanism may be referred to herein as a spline. In some embodiments, the spline is formed of fiber-reinforced concrete, including, for example, extruded fiber-reinforced concrete. As discussed below, the spline can have an integrated alignment and connection system for aligning and connecting corresponding splines together. In this way, the SIBUs can be aligned and connected with each other. According to embodiments of the invention, this alignment and connection system is designed to align the SIBUs within design tolerances such that no additional alignment tools or manual alignment is needed to align the SIBUs and the degree of alignment of SIBUs can be controlled with high precision. Thus, the SIBUs can be self-aligning and the resulting building has a pleasing appearance due to even, aligned surfaces, which reduces the need for skilled labor to construct a building and reduces the need to take additional steps to correct or hide imperfectly aligned surfaces—a common problem in some traditional building techniques, including traditional SIPs.
The precise alignment of the splines can be accomplished in three-dimensions. This three-dimensional alignment (or x-y-z alignment) can be achieved, according to some embodiments, by a three-dimensional surface on a face of the spline that mates with a corresponding spline. As used herein, “x-y-z alignment” refers to alignment in directions having component directions parallel to three orthogonal axes, such as the x-, y-, and z-axes. As discussed below, a three-dimensional surface can be used for aligning the spline in three directions. In addition, the splines provide structural integrity to the SIBUs and the resulting building, as discussed in further detail below.
Due to the self-aligning system, and the integration of all needed building systems into the SIBUs, the construction process can be reduced to a one-step process of joining the SIBUs. Once the SIBUs are joined, the utilities, insulation, structural support, and finishes for the building are all provided by the integration of all of those elements into the SIBUs. In some embodiments, this single step process of combining SIBUs is accomplished without the need for screws, nails, and/or fasteners, or supporting structure such as beams and posts. Thus, contrary to conventional building construction, including traditional SIPs and other prefabricated building materials, it is not necessary to build a structural frame and attach the SIBUs to the frame with nails or screws, for example. The single step of joining the SIBUs can include applying adhesive to one or more splines.
Further details and embodiments of the present invention can be appreciated from the following detailed description of the figures.
“Continuous surface” is intended to mean an outer surface created from a combination of SIBUs that are aligned with a high degree of precision such that the outer surfaces create a sufficiently smooth and unbroken surface that is satisfactory as an exposed, finished surface of the completed structure. Accordingly, the continuous surface 118 can be formed of SIBUs that are prefinished to provide the desired appearance of the built structure. In this way, it is not necessary to add additional structures to the SIBUs or to use additional alignment tools to achieve a surface suitable for an exposed surface of the finished structure. In some embodiments, alignment of the SIBUs has a location precision of less than or equal to 0.25 inches per SIBU, or less than or equal to 0.25 inches per eight feet. In some embodiments, the structural insulated building unit is configured to achieve location precision when assembled of equal or less than one of: plus or minus 0.5 millimeters, plus or minus 1 millimeter, plus or minus 3 millimeters, and plus or minus 6 millimeters across a 2 meter span. “Location precision” is intended to mean deviation from an absolute design and/or accuracy to a design dimension.
The SIBUs may also include additional attachment elements, in some embodiments. For example, as shown in
At least one of the first and second outer layers 204a, 204b can have a prefinished surface 228. The prefinished surface 228 can be an interior and/or exterior surface of a building or structure so that no further finishes are required after the panels are coupled together.
Cam plates 236 are visible on the back of splines 208c and 208d. The cam plates 236 secure the cams to the splines. Each of the splines 208a-208d include a pair of end side walls 240 and a pair of longitudinal side walls 242. In some embodiments, the end side walls 240 and longitudinal side walls 242 are angled or inclined, as shown in
Splines can be formed in various sizes. In some embodiments, the spline is formed of extruded concrete or extruded fiber-reinforced concrete. The splines can be extruded in long sections and that cut to a desired size. The splines can also be formed by pouring fiber-reinforced concrete into forms.
The SIBUs in
In some embodiments, additional modifications to splines or outer layers of a SIBU as possible based on the desired use or location of a SIBU within a structure. For example, the SIBU 602c in
According to aspects of embodiments of the invention, the method can include providing a plurality of structural insulated building units, each of the plurality of structural insulated building units including a first panel, a second panel, and a core between the first and second panels. The first and second panels can have first and second surfaces, respectively, that are prefinished. The method can further include placing the plurality of structural insulated building units in an arrangement next to each other such that the first panels of the plurality of structural insulated building units are adjacent to one another to form a first continuous surface, and the second panels of the plurality of structural insulated building units are adjacent to one another to form a second continuous surface. The first and second surfaces can be finished surfaces and no finishing of the first and second surfaces is needed after placing the plurality of structural insulated building units in the arrangement to form a building or structure. According to some embodiments, the step of placing can further include placing the structural insulating panels so at least one of the first and second panels is on at least one of an interior or exterior of the building or structure. In
According to another embodiment, a method of building construction includes providing a plurality of structural insulated building units, each of the plurality of structural insulated building units including a first panel, a second panel, and a core between the first and second panels. The method includes placing the plurality of structural insulated building units in an arrangement next to each other such that joining sections of the structural insulated building units are brought into close contact, and positioning the structural insulated building units in a final arrangement by allowing the structural insulated building units to self-align with each other using the novel features of the complimentary splines when engaged with each other along the joining sections. In some embodiments, the step of placing further includes placing the structural insulating panels so at least one of the first and second panels is on at least one of an interior or exterior of the building or structure.
According to embodiments of the invention, SIBUs of virtually any size and shape can be produced and used to construct buildings or structures. The SIBUs according to embodiments of the invention are capable of providing inherent structural integrity and support without the need for additional framing. In contrast, pre-existing SIBU systems require additional structural framing. In embodiments of the current invention, structural performance can be provided by fiber-reinforced panels and splines. For provided such structural performance, splines and panels may have flexural strength of at least 20 MPa. In some embodiments, the flexural strength is greater than 20 MPa. The panel can have a thickness of at least 6 mm. Further, the panel and splines can have a high Young's modulus typical of fiber-reinforced concretes. According to various embodiments, the SIBUs can sustain weight in transverse tension and vertical load.
In an example according to embodiments of the invention, a panel was tested for flexural strength of at least 20 MPa according to standards of ASTM D790 and C1185, using testing methods according to ASTM, C1186, and AC90, and resulting in a tested flexural strength of 22 MPa. A compressive strength test to a test specification of 65 MPa (+/−5 MPa) according to ASTM D695 using test methods ASTM C170 and C179 provided a test result of 65 MPa for the panel. Additional testing showed advantageous results in bacterial and fungal resistance, surface burning characteristics, stain resistance, and freeze/thaw resistance. For example, a panel passed testing for no growth of bacteria/fungi according to standard ASTM G21 using test methods ASTM G21 and G22, passed testing for 0-25 flame spread and 0-15 smoke development according to standard ASTM E84 and testing method ASTM EG227, passed stain resistance testing of past 16 hours according to ANSIZ 1246 and test method ASTM C650, and passed testing for no defects and R>0.80 according to standard C1185 using test method ASTM C1186. SIBUs and structures built from SIBUs according to embodiments discussed herein additionally have high seismic resistance.
“Prefinished” or “prefinished surface” can mean a surface of the type that is finished in advance. For example, prefinished can be the finishing of an outer layer of a SIBU before it is used, sold and/or distributed for end use. Prefinished can be the finishing of the panel before it is used in the building process. Prefinished can be of the type that when the panel is ready for use in construction to build a structure, no additional finishing is needed. According to some embodiments, the outer layers of a SIBU can include one or multiple layers, composites, conglomerations, etc. to achieve the prefinished surface. Prefinished can be with an interior prefinish and/or exterior prefinish that is prefinished in accordance with the principles of the structure being built. For example, the type of prefinished surface can be chosen from among multiple possible prefinishes at a design phase of the structure, or when ordering the SIBUs. Thus, interior and/or exterior finishes can be chosen in accordance with aesthetic or other design principles of the structure. Prefinished can be without the need for the application of additional materials to the panels. A prefinished panel for use in building a structure is contemplated in accordance with the principles of the invention. The prefinished interior can be the interior facing side of the panel. The prefinished interior can be finished with ceramic, paint, tiles, wood, textured or decorative concrete, etc. The prefinished exterior can be finished with exterior finishes of the type on the exterior of a building. In building a house, the prefinished panels can have interior finishes prefinished for kitchens, bathrooms, living areas, bedrooms, etc. The prefinished panels can have exteriors finished for exteriors such as ceramic, concrete, siding, wood, etc. The prefinished panels can also include hardware, furnishings, and appliances, including necessary utility hookups integrated into the prefinished panels. Thus, upon completion of positioning and connecting the various SIBUs, the building can be complete without requiring additional steps, including installation of finishes, appliances, or other furnishings. However, the types of finishes for prefinished interior and exterior surfaces are not limited to those listed here, and can include any conventional building materials. Once the prefinished panels are assembled, no additional finishes are needed. The prefinished panels can be used to build any type of structure, including, homes, hospitals, offices, residential structures, commercial structures, etc.
In accordance with the various embodiments of the invention discussed herein, it is possible to provide a system of SIBUs that can be used for constructing a building of any layout or configuration. For example, such system may include a certain number of distinct SIBUs that differ from one another in size, shape, and/or arrangement of splines. Accordingly, with a minimum or predetermined number of distinctly configured SIBUs provided in adequate numbers, SIBUs can be combined in various permutations to build any desired structure using only the minimum number of distinct SIBU configurations. Thus, in an embodiment, the system includes a plurality of SIBUs, each of which can include, for example, two parallel sides, four edges extending between the two sides, and at least one spline to connect the SIBU to a spline of another of the plurality of SIBUs. The plurality of SIBUs includes a base set of SIBUs that are differentiated from each other by an arrangement of at least one spline on each structural insulated building unit of the base set. In addition, the base set is designed such that buildings of numerous configurations can be constructed by joining different numbers and combinations of structural insulated building units of the base set.
Foamed Concrete Compositions
Embodiments of the present invention can include or make use of novel foamed cementitious compositions. Such compositions fiber-reinforced cement-based products having improved structural and performance characteristic. These fiber-reinforced cement-based products can incorporate a variety of different materials such as binders, rheology-modifying agents, and fibers to impart discrete yet synergistically related properties. The resultant composition is a light weight, insulating, fire resistant material that is rigid and structurally sound. Accordingly, the foamed cementitious compositions are capable of use in a variety of building products. Aspects of embodiments of the composition were previously described in U.S. Pat. Nos. 5,549,859; 5,618,341; 5,658,624; 5,849,155; 6,379,446; and U.S. Patent Application Publication Nos. 2010/0136269; 2011/0120349; 2012/0270971; 2012/0276310; and 2015/0239781, all of which are hereby incorporated reference in their entireties.
A product embodying the invention can be a lightweight, tough composite with excellent flexural and compressive strength that exhibits no warping or rotting. Additionally, the product can act as breathable membrane for moisture and condensation control in SIBUs. The invention is environmentally stable and non-toxic. The product embodying the invention is moisture and mold resistant, termite and insect resistant, and heat and rain resistant. These characteristics make the present invention an ideal building material with thermal and acoustic advantages, for example.
One embodiment of the present invention is a cast cementitious composite for use in building construction. The composition at a minimum can include fiber-reinforced cellular concrete made from a cementitious material. The composition may include, for example, fiber, rheology-modifying agents, a binder, and pozzolanic materials. In addition to these components, the cementitious compositions can be mixed with other additives and admixtures to give a foamed cementitious composite having the desired properties to the mixture and final article as described herein.
Testing was performed on some embodiments according to standard testing, including, for example, ASTM C796-12 and ASTM 495-12. The composition can form a member having one or more of the following characteristics in accordance with these ASTM standards: a density in the range of about 0.35 to about 1.0 g/cc; a flexural strength in the range of about 2-12 MPa; a flexural modulus in the range of about 2500 to 5500 MPa, and about 75% or greater of that in water immersion testing; a compressive strength in the range of about 4 to 10 MPa; able to pass about 2,000 hours or greater in accelerated weathering testing; 0 flame and 0 smoke surface burning characteristics; and insect and termite resistance. These properties are summarized in Table 1.
More specifically, a preferred embodiment of the present invention may contain the following components in the given proportions by mass: cement 25 to 40%; acrylic fiber 0 to 5%; fly ash 10 to 20%; PVA fiber 1 to 5%; fumed silica 1 to 5%; fire clay 10 to 20%; gypsum 10 to 20%; and an acrylic binder 10 to 20%. The foregoing add up to 100 mass % of the non-aqueous components of the mix. These components are summarized in Table 2, along with a volume % of the various components.
In this embodiment, Type II cement can be used. However, other cement types can be used to achieve the described desired properties.
Acrylic fibers of about 12 mm and PVA fibers of about 6 mm can be used in combination with each other or separately, and are substantially homogenously dispersed throughout the composition. The fibers act as a reinforcing component to specifically add tensile strength, flexibility, and toughness to the final article. As a result, structures formed from the fiber-reinforced concrete can fail in a non-catastrophic manner. Because the fibers are substantially homogenously dispersed, the final article does not separate or delaminate when exposed to moisture. Other types of fibers that provide the desired tensile strength, flexibility, toughness and resistance to delamination may also be used.
Fly ash and fumed silica are pozzolanic materials. In some embodiments, Class C fly ash is used. However, other types of fly ash and other similar pozzolans can be used to give the desired properties of the composition.
Fly ash and fire clay provide fire protection and act as rheology-modifying agents by enabling uniform dispersion of the mixture. Other compounds providing these properties may also be used.
Gypsum adds additional fire protection and increases the form-stability of the resultant foamed concrete. The gypsum can be of a hemihydrate type. Gypsum also acts as a rheology-modifying agent. Other hydraulically settable materials having these properties may also be used.
An acrylic binder disperses the powder particles of the mixture to create the paste structure during mixing and to maintain adequate levels of workability. Any acrylic binder that maintains these desired properties may be used. The acrylic binder can be water based.
The product embodying the invention is generally prepared by combining the cementitious mixture with a suitable foaming agent, creating a cured cementitious composite with well-dispersed and uniform pore size. The foaming agent aerates the cementitious composition so that it is light-weight while retaining its strength and rigidity. Either surfactant or polymer foaming agents are appropriate, with surfactant-based foaming agents preferred in some embodiments.
The well-dispersed and uniform pores create a matrix of foamed concrete that is light-weight due to a high percentage of air within the pores. According to an embodiment, the fiber-reinforced foam concrete can be, for example, 75% air. However, embodiments are not limited to this specific air ratio, and can have a smaller or larger percentage in some embodiments. The relatively high percentage of air, combined with the strength of the fiber-reinforced foam concrete, results in products with many advantages. For example, due to being light-weight, the products can be easier to transport or to handle by builders when erecting a structure using elements made of the fiber-reinforced foam concrete. In addition, the combination of light weight and high strength means that elements formed from the composition can be used in a large variety of ways within a structure, such as being used as parts of walls, floors, ceilings, roofs, doors, or other building features. The well-defined and evenly distributed pores also result in products that have very good performance in the face of moisture such as condensation or leaks within the products. For example, the pore network within the fiber-reinforced foam concrete can allow water to dissipate or spread out rather than pooling in one location, decreasing the changes of rot, bacterial/fungal growth, or damage from freezing and thawing of the water within the product.
An example of another embodiment of the current invention may contain the following components in ratios indicated by the relative masses shown: water 1.5 to 2.25 kg; cement 1.6 to 2.40 kg; fly ash 0.00 to 1.00 kg; type 100 tabular alumina 0.00 to 0.50 kg; type 325 tabular alumina 0.00 to 0.50 kg; sand 0.25 to 0.38 kg; silica 0.15 to 0.23 kg; fire clay 0.40 to 0.60 kg; gypsum 1.20 to 1.80 kg; glass fiber 0.08 to 0.13 kg; PVA fiber 0.02 to 0.03 kg; and rheology agent 0.00 to 0.10 kg. These components are summarized in Table 3, along with the mass in kg of the various components. The mass of the components is given to illustrate examples of relative proportions. However, the actual mass used in a mixture can vary according to the volume of the mixture.
Aspects of embodiments of the invention incorporate fibers in a way that has not been done in previous reinforced foam concretes.
In an embodiment, a foamed concrete material for use in construction of buildings or structures includes a cement mixture, and a foaming agent. The cement mixture is fiber-reinforced, and the foamed concrete material is arranged as a porous foam structure having a fiber-reinforced matrix of the cement mixture with pores of air dispersed throughout the fiber-reinforced matrix. In one aspect of the embodiment, the foamed concrete material can be about 10% to 80% air by volume. In some embodiments, the foamed concrete material can be about 60% to 75% air by volume. While a high air volume ratio may have previously yielded weak concrete, embodiments of the current invention can have the above-described volume ratios of air while maintaining strength and structural integrity. Lower volume ratios of air result in heavier, less breathable, and, in terms of materials, more expensive concrete.
In some aspects of the embodiment, the foaming agent can be a polymer-based foaming agent or a surfactant-based foaming agent. In some examples, the cement mixture includes from about 25 to 40 percent by mass of cement; from about 10 to 20 percent by mass of fly ash; from about 1 to 5 percent by mass of polyvinyl alcohol fiber; from about 10 to 20 percent by mass of fire clay; from about 10 to 20 percent by mass of gypsum; and from about 10 to 20 percent by mass of acrylic binder. The cement mixture can further include from about 1 to 5 percent by mass of silica. For fiber reinforcement, the cement mixture can further include from about 0 to 5 percent by mass of acrylic fiber, in some embodiments. Embodiments can also include glass fibers for fiber-reinforcement. The type of fiber used can be tailored to different uses and needs. The cement mixture may also include water.
In some embodiments, fibers may be greater than 10 μm in diameter. The fibers are about 30 μm in diameter, in some preferred embodiments. However, embodiments are not limited to these specific diameters. According to embodiments of the invention, it is possible to achieve high-strength, structurally-sound fiber-reinforced foamed concrete with fibers at larger diameters than previously thought possible for uses contemplated herein that require strength and structural integrity. In some embodiments, fibers can be about 6 to 12 mm in length. The fibers can be about 10 to 20 percent by volume of the cement mixture. Embodiments of the invention can incorporate higher percentages of fiber than in previous reinforced foamed concretes while maintaining desired performance.
Multi-Layered Composite Building Elements
Some embodiments of the present invention relate to a multi-layered composite building elements for building construction and materials. Aspects of these embodiments can include integrated multi-layer units for constructing buildings and other structures. These units can include SIPs, but are not limited to SIPs. Some embodiments include any aspect or material of a building or structure have a multi-layered arrangement as disclosed herein.
In some preferred embodiments, the multi-layered composite building element includes an insulating core layer having first and second faces, and a cementitious sheet on each of the first and second faces. In some embodiments, the insulating core layer comprises foamed concrete. In some preferred embodiments, the insulating core layer includes an insulating foam layer in the middle of the insulating core, and a foamed concrete layer on each side of the insulating foam layer such that the foamed concrete layers comprise the first and second faces of the insulating core. The insulating foam layer can be a polymer-based foam, such as polystyrene foam or other foams suitable for use in constructing buildings and other structures. The foamed concrete layers can be made of fiber-reinforced foamed concrete in accordance of various embodiments discussed herein. The cementitious sheets may be fiber-reinforced concrete.
The addition of fiber-reinforced foamed concrete layers provides additional strength and stiffness to the multi-layered structure, while also providing enhanced thermal and noise insulation, and resistance to freeze/thaw damage and other problems associated with moisture. The fiber-reinforced foam concrete is relatively light for the strength and stiffness it provides, and can contain a high ratio of air within the cellular matrix of the foamed concrete. Thus, the above advantages achieved by the foamed concrete come at a relatively low cost in terms of weight and material expense.
In embodiment of the current invention, a multi-layered composite element for building structures can include an insulating core and first and second cementitious sheets. The insulating core includes a first face and a second face on an opposite side of the insulating core from the first face. The first and second cementitious sheets are on the first and second faces, respectively, of the insulating core, and the first and second cementitious sheets can comprise fiber-reinforced concrete. The insulating core further can include fiber-reinforced foamed concrete.
In some aspects of the embodiment, the insulating core includes a foam insulating layer as a center layer of the insulating core, a first foamed concrete layer on a first side of the foam insulating layer, and a second foamed concrete layer on a second side of the foam insulating layer. The first foamed concrete layer comprises the first face of the insulating core, and the second foamed concrete layer comprises the second face of the insulating core. The first and second foamed concrete layers can comprise fiber-reinforced foamed concrete, in some embodiments.
The foam insulating layer can be a polymer-based foam, and can include, for example, polystyrene foam. The foam insulating layer can affixed to the first and second foamed concrete layer via an adhesive, according to some embodiments.
Self-Sustaining Structures
According to various embodiments of the present invention, a building or structure made of SIBUs can be built to environmentally conscious standards. The resulting building can, for example, include solar panels placed on or within the structure. Solar panels can be placed on the roof or exterior walls of a completed structure built from SIBUs, or solar cells can be incorporated into the SIBUs themselves. Electricity can then be supplied to the structure via solar power with 12-Volt systems. In some embodiments, there may be no need for local utility hook ups to the structure, and the structures may be self-sufficient. As a result, strong, sustainable, efficient structures can be built quickly and economically.
Self-sustaining structures can be built using methods, systems, materials, and apparatus in accordance with various embodiments herein. In some embodiments, the SIBUs, multi-layered composite building elements, and materials and related methods according to embodiments of the invention can produce structural elements that have high R values (a measure of insulating ability) per unit thickness of the material or element. As a result of these high R values per unit thickness, high efficiency solar-powered systems, including HVAC through geothermal current and other electrical systems, can be powered through 12-volt DC current with low power consumption. In some embodiments, all electrical systems the structure can be powered through a 12-volt DC current. Because structures and materials according to embodiments of the invention are designed to meet or exceed applicable fire rating requirements, structures can be built without additional conduit or wiring protection, which reduces time and expense of the structures.
Only exemplary embodiments of the present invention and but a few examples of its versatility are shown and described in the present disclosure. It is to be understood that the present invention is capable of use in various other combinations and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein.
Although the foregoing description is directed to the preferred embodiments of the invention, it is noted that other variations and modifications will be apparent to those skilled in the art, and may be made without departing from the spirit or scope of the invention. Moreover, features described in connection with one embodiment of the invention may be used in conjunction with other embodiments, even if not explicitly stated above.
This application claims priority to provisional U.S. Patent Application Nos. 62/251,022, which was filed Nov. 4, 2015; 62/271,937, which was filed Dec. 28, 2015; and 62/292,080, which was filed Feb. 5, 2016, the disclosures of which are incorporated herein by reference in their entirety.
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