CA1166865A - Structural building element - Google Patents
Structural building elementInfo
- Publication number
- CA1166865A CA1166865A CA000384202A CA384202A CA1166865A CA 1166865 A CA1166865 A CA 1166865A CA 000384202 A CA000384202 A CA 000384202A CA 384202 A CA384202 A CA 384202A CA 1166865 A CA1166865 A CA 1166865A
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- matrix
- density
- wall
- section
- lateral
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Abstract
ABSTRACT OF THE DISCLOSURE
A structural building element in the form of a panel, block or related configuration having a continuous phase of cementitious material which includes an intercon-nected matrix having a first density and a plurality of zones dispersed within the matrix, wherein the zones have a second density lower than the first density. Reinforcement members may be embedded within portions of the interconnected matrix to impart additional strength to the element.
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A structural building element in the form of a panel, block or related configuration having a continuous phase of cementitious material which includes an intercon-nected matrix having a first density and a plurality of zones dispersed within the matrix, wherein the zones have a second density lower than the first density. Reinforcement members may be embedded within portions of the interconnected matrix to impart additional strength to the element.
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Description
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3ACXGROUND OF THE INV~NTION
, _ 1. Field of the Invention This invention generally relates to the field of art which includes materials and structural elements or com-ponents for use in the building or construction industry.
More particularlv, this invention relates to a structural building element in the form of a panel, block or related shape which is particularly useful for constructing wall, 100r, ceiling and/or column systems.
3ACXGROUND OF THE INV~NTION
, _ 1. Field of the Invention This invention generally relates to the field of art which includes materials and structural elements or com-ponents for use in the building or construction industry.
More particularlv, this invention relates to a structural building element in the form of a panel, block or related shape which is particularly useful for constructing wall, 100r, ceiling and/or column systems.
2. Description of the Prior Art The prior art is replete with many ~orms o~ ~uildin~-or co~struction elements which are used to form a larger structure. Such elements may take the form of sheet panelsr bloc~s or columns and ma~r be made from a variety of materials. -~For example, a building panel may be formed entirely from pre-cast concrete or similar cementitlous material. Such a panel might also be made from a combination of cementitious material provided with internal reinforcements, such as wood or metal rods. It has also been suggested that bu;1ding panels or elements may be made from vaxious comblnations of organic plastic compositions and materials.
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As is evident, known building elements or panels made substantially of concrete and related cementitious materials are quite strons under compressive loading, but are difficult to handle because of their heavv weight and further 5 do not provide good insulative qualities. The prior art attempts at utilizing organic plastics, wood and other light-weiqh~ materials fox making building elemen~s have resulted in products which possess improved insulative qualities over their concrete or cementitious counterparts, but do not begin to exhibit the compressive loading strengths inherent with the latter.
SUMMARY OF TH~ INVENTION
~ t is therefore an object of the present invention to provide an improved building element which possessesa~high ~ 15 degree of compressive strength.
It is another object of the present lnventionto pro-vide a building element which is light in wei~ht and easily handled or manipulated.
It is a further object of the present invention to provide a building ele~ent which is characterized by good thermal and acoustical insulating qualities.
It is yet a further objact of the present invention to provide for an improved building panel which is simple in construction and economical to manufacture.
~ 25 The present invention serves to overcome the dis-advantageous characteristics of prior art building elements ~2-:L 1 6~8~5 a~d to achieve the foregoing objects by providing a ~uilding element formed entirely of a continuous phase o~ cementitious material, whereby the continuous phase includes an intercon-nected matrix having a first density which substantially com-pletely surrounds a plurality of lower density zones di~-persed within the matrix. The matrix is formed from a com-position which includes cementitious material and a disson-tinuous phase of discrete particles, fibers or related addi-tives which provide the matrix with a cumulative average high density. The zones dispersed within the matrix are comprised of cementitious material ha~ing dispersed therein a discon-tinuous phase of discrete particles, fibers or related struc-tures of materials which provlde the zones with a cumulative average low density. The element of the present invention ma~-assume a variety of structural shapes, such as block,pla~r ofcolumnar, and may further be provided w~th additional re~force - ing members embedded within the matrix portion of the el ~ nt Other objects, features and advantages of the pre-sent inventlon will be apparent from the follow~g descri~ion.
of specific embodiments thereof, with reference to the accom-panyiny drawings, which form a part of this specification, wherein like refe_ence characters designate corresponding parts of the several views.
1 16686~
In th~ Drawings:
FIGURE 1 is an isometric view o.~ a building element of the present inYention;
FIGURE 2 is an enlarged transverse sec~ional view, through tXe element of FIGUR~ 1, taken on the line 2-2 thereof;
FIGURE 3 is an enlarged plan view of another e~x~i-ment of the building ele~ent of the present invention,~.ly broken away to show the internal struc.ure;
- 10 PIGURE 4 is an enlarged fragmentary longitudi~al section view, taken on the li~e 4-4 of FIGURE 3;
FIGURE 5 is an enlarged transverse sectional view, taken on ~he line 5-5 of FIGU~E 3;
FIGURE 6 is an isometric view of the building ele-15 ment of FIGURE 3 shown in a partially assembled condition, with the adjacent structure being depicted in phantom lines for purposes of clarity;
FIGURE 7 is a vertical sectional vi~w showing yet another embodiment of the building element or the present . 20 i~ven~ion;
FI~URE 8 is a horizontal sectional view, tak~n along -; the line 8-8 of FIGURE 7, partly broken away to depict the structure o the element at a lower level;
FIGURE 9 is a perspective view of one of the struc-~ 25 tural components utilized in the kuilding element shown in FIGURES 7 a~d 8;
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FIGUR~ lO is an isometric view o~ still ano~her e.~bo~iment of the buildins element of the present inv~ntion;
FIGURE 11 is a horizontal sectional view t~e~ alcng the line ll-ll of FIGURE 10:
FIGURE lZ is a fragmentary plan view of-~two buildinq elements according to the embodiment of FIGURE lO disposed in interlocking engagement;
FIGURES 13-17 are isometric views of several modi~
fications of the embodiment deplcted by FIGURE lO; and FIGURE 18 is a fragme~tary isometric view of a wall assembly constructed of the elements of YIGURES 13, 14 and 16.
DETAILED DESCRIPTION OF` PRE~ERRED EMBODIMENTS
, Referring now to FIGS. 1 and 2 of the drawings, .here is depicted an embodiment Oc the building element o' the present invention in the Eorm of a panel 1 hav1ng a r~la-tively flat or planar configuration. Panel 1 includes an interconnected matrix 3 which complqtely surrounds and encloses a plurality of zones S embeddec therein. ~s ind~-cated in FIG. 2, the general planar structure o panel 1 isefrectively provided with three continuous matrix layers 3a, 3b and 3c, which layers extend to the extremities o' panel l.
Matrix 3 is comprised basically of inorganic cementitious materïal such as Portland cemen~ based coMpositions, concrete, various compositlons of hydraulic cement or any other such related material having a ceme t base. E~am~les o' such ~ 16~;86 suitable cementitious materials are disclosed in the tex~
"Manual of Lathing and Plastering" by John R. Diehl, A. X.A., and include calcined gypsum, hydrated lim~, Portland cement and admixtures thereof. Matrix 3 is also provided with a discontinuous phase or dispersion of discrete additives in the form of aggregates, par~icles, fibers or related such structures well known in the art for the purpose of strength-ening the cementitious base of matrix 3 and providing the desired cumuLative average density. Such additives may be in the form of inorganic aggregate particles, including sand, stone, marble, rock, expa~ded clay and other related mater~ls well known in the ar~. Also, both organic and inorganic - fibers, such as those derived from plastics, glass, asbestos, and metal, may also be utiiized as additive material dis-persed throughout matrix 3. It is further to be understood that any combinations or mixtures of the aforementioned addi-tivés may also be utilized to advantage in deriving the over-all composition of matrix 3. ~owever, because of the desir-ability of imp~rting hardness and strength to matrix 3, it is appropriate that the cumulative average density of matrix 3, including cementitious material and additives, be within the inclusive range of from 6b to 200 pounds per cubic foot, with a preferred density of matrix 3 being within the inclusive range of 90 to 150 pounds per cubic foot.
As seen in FIG. 2, zones 5 comprise generally rectan-gular-shaped cross sections of material surrounded by matrix
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As is evident, known building elements or panels made substantially of concrete and related cementitious materials are quite strons under compressive loading, but are difficult to handle because of their heavv weight and further 5 do not provide good insulative qualities. The prior art attempts at utilizing organic plastics, wood and other light-weiqh~ materials fox making building elemen~s have resulted in products which possess improved insulative qualities over their concrete or cementitious counterparts, but do not begin to exhibit the compressive loading strengths inherent with the latter.
SUMMARY OF TH~ INVENTION
~ t is therefore an object of the present invention to provide an improved building element which possessesa~high ~ 15 degree of compressive strength.
It is another object of the present lnventionto pro-vide a building element which is light in wei~ht and easily handled or manipulated.
It is a further object of the present invention to provide a building ele~ent which is characterized by good thermal and acoustical insulating qualities.
It is yet a further objact of the present invention to provide for an improved building panel which is simple in construction and economical to manufacture.
~ 25 The present invention serves to overcome the dis-advantageous characteristics of prior art building elements ~2-:L 1 6~8~5 a~d to achieve the foregoing objects by providing a ~uilding element formed entirely of a continuous phase o~ cementitious material, whereby the continuous phase includes an intercon-nected matrix having a first density which substantially com-pletely surrounds a plurality of lower density zones di~-persed within the matrix. The matrix is formed from a com-position which includes cementitious material and a disson-tinuous phase of discrete particles, fibers or related addi-tives which provide the matrix with a cumulative average high density. The zones dispersed within the matrix are comprised of cementitious material ha~ing dispersed therein a discon-tinuous phase of discrete particles, fibers or related struc-tures of materials which provlde the zones with a cumulative average low density. The element of the present invention ma~-assume a variety of structural shapes, such as block,pla~r ofcolumnar, and may further be provided w~th additional re~force - ing members embedded within the matrix portion of the el ~ nt Other objects, features and advantages of the pre-sent inventlon will be apparent from the follow~g descri~ion.
of specific embodiments thereof, with reference to the accom-panyiny drawings, which form a part of this specification, wherein like refe_ence characters designate corresponding parts of the several views.
1 16686~
In th~ Drawings:
FIGURE 1 is an isometric view o.~ a building element of the present inYention;
FIGURE 2 is an enlarged transverse sec~ional view, through tXe element of FIGUR~ 1, taken on the line 2-2 thereof;
FIGURE 3 is an enlarged plan view of another e~x~i-ment of the building ele~ent of the present invention,~.ly broken away to show the internal struc.ure;
- 10 PIGURE 4 is an enlarged fragmentary longitudi~al section view, taken on the li~e 4-4 of FIGURE 3;
FIGURE 5 is an enlarged transverse sectional view, taken on ~he line 5-5 of FIGU~E 3;
FIGURE 6 is an isometric view of the building ele-15 ment of FIGURE 3 shown in a partially assembled condition, with the adjacent structure being depicted in phantom lines for purposes of clarity;
FIGURE 7 is a vertical sectional vi~w showing yet another embodiment of the building element or the present . 20 i~ven~ion;
FI~URE 8 is a horizontal sectional view, tak~n along -; the line 8-8 of FIGURE 7, partly broken away to depict the structure o the element at a lower level;
FIGURE 9 is a perspective view of one of the struc-~ 25 tural components utilized in the kuilding element shown in FIGURES 7 a~d 8;
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FIGUR~ lO is an isometric view o~ still ano~her e.~bo~iment of the buildins element of the present inv~ntion;
FIGURE 11 is a horizontal sectional view t~e~ alcng the line ll-ll of FIGURE 10:
FIGURE lZ is a fragmentary plan view of-~two buildinq elements according to the embodiment of FIGURE lO disposed in interlocking engagement;
FIGURES 13-17 are isometric views of several modi~
fications of the embodiment deplcted by FIGURE lO; and FIGURE 18 is a fragme~tary isometric view of a wall assembly constructed of the elements of YIGURES 13, 14 and 16.
DETAILED DESCRIPTION OF` PRE~ERRED EMBODIMENTS
, Referring now to FIGS. 1 and 2 of the drawings, .here is depicted an embodiment Oc the building element o' the present invention in the Eorm of a panel 1 hav1ng a r~la-tively flat or planar configuration. Panel 1 includes an interconnected matrix 3 which complqtely surrounds and encloses a plurality of zones S embeddec therein. ~s ind~-cated in FIG. 2, the general planar structure o panel 1 isefrectively provided with three continuous matrix layers 3a, 3b and 3c, which layers extend to the extremities o' panel l.
Matrix 3 is comprised basically of inorganic cementitious materïal such as Portland cemen~ based coMpositions, concrete, various compositlons of hydraulic cement or any other such related material having a ceme t base. E~am~les o' such ~ 16~;86 suitable cementitious materials are disclosed in the tex~
"Manual of Lathing and Plastering" by John R. Diehl, A. X.A., and include calcined gypsum, hydrated lim~, Portland cement and admixtures thereof. Matrix 3 is also provided with a discontinuous phase or dispersion of discrete additives in the form of aggregates, par~icles, fibers or related such structures well known in the art for the purpose of strength-ening the cementitious base of matrix 3 and providing the desired cumuLative average density. Such additives may be in the form of inorganic aggregate particles, including sand, stone, marble, rock, expa~ded clay and other related mater~ls well known in the ar~. Also, both organic and inorganic - fibers, such as those derived from plastics, glass, asbestos, and metal, may also be utiiized as additive material dis-persed throughout matrix 3. It is further to be understood that any combinations or mixtures of the aforementioned addi-tivés may also be utilized to advantage in deriving the over-all composition of matrix 3. ~owever, because of the desir-ability of imp~rting hardness and strength to matrix 3, it is appropriate that the cumulative average density of matrix 3, including cementitious material and additives, be within the inclusive range of from 6b to 200 pounds per cubic foot, with a preferred density of matrix 3 being within the inclusive range of 90 to 150 pounds per cubic foot.
As seen in FIG. 2, zones 5 comprise generally rectan-gular-shaped cross sections of material surrounded by matrix
3. However, it is understood that zones 5 may assume any suitable~configuration, even free form, with the only r~
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ment for the embodiment depioted in FIGS. 1 and 2 bei~g that zones 5 are individually substantially ~n~irely surrounded enclosed within in~erconnec~ed matrix 3. Matrix lavers 3a, 3b and 3c ser~e to generally divide zones 5 into two tiers, spaced by a plurality of vertical walls 6, and separated by continuous central matrix layer 3b. By virtue of this layere~
arrangement, great compressive strength is imparted to overall panel 1. Though th tiers of zones 5 are depicted as rather uniform or regular staggered sections of blocks, it is to be 10 understood that any desired arrangement or configuration of zones 5 is suitable for the practice o the present invention in a building element having a generally planar conliguration.
A significant aspect of such a planar con~iguration is the provision of at least a continuous matrix layer 3b disposed substantially centrally along the lonsitudinal axis of the element.
Like matrix 3, zones 5 are basically formed from a cementitious material, which material may comprise the same constituents or compositions as previously indicated forma~
3. Since zones 5 are not subjected to the direct application of external stress as is the case of matrix 3, it is desirabl~
that zones 5 be of a lower density such that the entire panel 1 shall have a corresponcingly lower weight. To this end, zones 5 include additives in the form of a discontinuousphase or dispersion of discrete particles which, when considered cumulatively with the ce~.entitious material in which it is dispersed, will provide an appropriate density ranse inclusive of from 10 to 50 pounds per cubic foot. The pre,erred;density ~ 7 _ ~1~6~
o~ zones 5 is of the range inclusive from 18 to 35 pounds per cubic foot. In order to achieve the lower density of zones S, the cementitious materlal comprising the ~asis ~hereof may include additive material in the form o, iscrete particles having a relatively light weight, for example perlite, vermi-culite, polymeric materials and mixtures ~hereof. The poly meric materials may advantageously be comprised of expandable or foamable particLes derived from polyurethane, polystyrene polyolefin or similar such resins. Further, plastic or 19 polymeric materials of the non- oamable or non-expandable type may also be utilized to advantage.
Because of the similar cementitious materlalut~lized as the basis of the composition for matrix 3 as well as that of zones 5, panel l can thus be defined as an integral and continuous phase of cementitious material. Notwithstanding variation between the average densities of higher density matrix 3 and lower density zones 5, by virtue of theaifferent additive materials incorporated therein, matrix 3 is rigi~ly and strongly bound to zones 5 and vice versa by virtue of the cementitious material being common to both. This unique rela-tionship of materialc results in panel 1 having an extremely high degree of compressive strength, based primarily upon the interconnected high density matrix 3 which produces a ceLlular structure that exhibits good load absorption characteristics.
Thus, when a load is applied to panel 1, the energy of com-pression and bending of matrix 3 is absorbed by zones 5,there-by permitting panel 1 to be subjected to stress conditions that would normally cause failure of known concre~e or cement panelc 686~
Such strength characteristics of panel 1 make it particularly useful and safe for buildings in earthquake prone loca~ions.
Panel 1 is also characterized by comparatively lisht weight, when compared ~o prior art panels made of concrete or cement, by virtue of zones 5 having a comparatively low average density because of the discrete lightweight particles dispersed therein. Accordingly, the preferred cumulative average density of panel 1 is of a range inclusive from 20 to 200 pounds per cubic foot. As is therefore evident, a build- :
ing element constructed according to the present invention can be varied greatly in overall weight in order to accommodate its desired manner or environment of use. .
~ urther, if panel 1 is to be utilized in an e.nviron-ment whereby a face thereof is to be exposed to the exterior, such as in a wall of a building, the matrix portion so exposec may include a larger amount of additive materlal in the form of rock or aggregate particles so that it will have maximum physical resistance to varying and extreme weather conditions.
Similarly, should it be desired that a face o' panel 1 be utilized as an interior wall of a building or the like, the portion of matrix 3 forming such an inter or face mav include additive material comprising a greater amount OL ~ Or be entirely of, organic or inorganic fibers sinc~ the interior face will not be subjected to harsh weather conditions or other severe structural abuse, thereby reducing the overall weight of panel 1. It is clearl~ understood that the respec-tive additive materials utilized in both matrix 3 and zones 5 ma~ be varied in composition and amount throughout the entlre _9_ panel 1 i. such variation is deemed desirable or necessary.
Referring now to PIGS~ 3 through 5, there is depic-tPc another embodiment of ~he building element o the present invention. In this embodiment, the element is also in the 5 form of a panel 7 which includes an interconnected higher density matrix 9 and a plurality of lower density zones or blocks 11 dispersed within and surrounded by matrix 9. The compositions of matrix 9 and bloc~s 11 may be the same as that previously indicate~ for matrix 3 and zones 5, respec-10 tively, of the embodiment depicted by FIGS. 1 and 2. As -. similarly indicated for panel 1 of FIGS. 1 and 2, ?anel 7 also includes three continuous spaced mat-ix layers 9a, 9b and 9c whlch serve to enclQse and divide blocks 11 into two separate tiers. Central matrix layer 9b, extending trans-15 versely and longitudinally to the extremities of panel 7 s ~ esas the foundation for the great compressive strength of panel 7.
As seen more clearly in FIGS. 3 and 5, blocks ll axe of substantially rectangular-shape and have voids 13 provided 20 therethrough. Blocks 11 are disposed in linear parallel a.rra~
along the longitudinal axis of panel 7 such that voids 13 o.
adjacent blocks are aligned to form a series o' parallel - channels 15 throughout the length of panel 7, as clearly de-picted in the cut-away section of FIG. ~. The number of chan-25 nels 15 formed in panel , according to this manner will varywith the number of voids 13 provided in each individua} block 11. If desired, only one such channel 15 may ~e previded in the entire panel or a parallel series of channels m~y be fo~d ~ 1~686~
as shown in FIGS. 3 and 5. Channels 15 may be utilized to receive electrical wiring, ca~les or conduits i panel 7 is employed in the construction of a buildins or si~ilar struc-ture. Voids 13 may be filled with insulation material to ~ 5 better control thermal and acoustical transmissions through panel 7. Also, voids 13 may be used for reducing substan-tially the weight of lndividual blocks ll,'thereby ser~ing to lighten the overall weight of panel 7. To this latter end, it is entirely possible that voids 13 in blocks 11 may be ~rcvided-- 10 as needed for purposes of weight reduction and, as suchj it would not then be necessary ~o align voids 13 to for,m continu-ous channels 15.
As seen in ~IG. 3, matrix 9 of panel 7 substantially completely encloses and surrounds blocks 11 with the exception of the portions of spaces 17 between adjacent blocks where voids 13 are aligned to form channels 15, For added overall strength, a continuous section o matrix 9 is disposed ~sta~-tially along the longitudinal axis of panel 7, as indicated at 19, to still further increase the overall strength and ri~idit~
of panel 7, For even further strengthening of panel 7, rein-forcing members 2} in the form of metal rods may be ~ispersed and embedded within matrlx 9 alon~ the outer ~eripheral edge ~f the panel as well as through the portion of matrix 9 dis?osed along the longltl~dinal axis of the elemen'; as indicated at 19. -~
In order to assure a strona cementitious bond betwe~n ma.rix 9 and blocks 11, the latter may be provided with g-ooves 23 along the edge portions thereof, thereby affording a greater surface area for bondinc. It is to be ur.derstood tha' ?anel 1 16i~5 7 may also be reinforced by any well known rein~orcement materials or member~ well known i~ the art for this purpose~
~or example, i~stead of rods 21, matrix 9 may be embedded with reinforcing members in the form of mesh structures, truss structures, pre-stressed metallic cables, or similar systems and devic s well known in the art for this purpose.
Panel 7, as seen in FIG. 5, may also be provided with a male tongue or ridge 25 and a corresponding female groove or channel 26 along its opposite longitudinal edges for the purpose of facilitatina the interlocking or adjacent panels together, as shown in ~IG. 6. Both tongue 25 and~
27 serve-to facilitate the handllng and manipulation of panel 7 during construction use. Wood plates 29 may also be utilized to secure the upper or lower portions of adjacent panels to-gether in wood construction environments.
FIGS. 7 and 8 depic~ yet another embodiment of thebuilding element of the present invention. In this case, the element is in the form of a column 31. Though column 31 is depicted as haYing a generally circular cross section, it is to be understood that any other cross-sectional configuration or design, such as triangular, rectangular, square or the l.~e;
may be utilized according to the desires and needs of anv given application of the present invention.
As in the case of the two earlier described embodi-ments, column 31 comprises a third embodiment which also in-cludes an interconnected higher density matri~ 33 which sur-rounds and encloses a plurality of lower density zones 35.
The compositions, materlals and densities of matrix 33 and 6 8 6 ~
zones 35 are the same as those indicated for the earlier des-cribed embodimen~s.
Disposed substantially centrallv and along the lon-gitudinal axis of column 31 is a continuous and relatively - 5 thick portion of matrix 33, as indicated at 33a. Spaced cen-trally along the length of matrix 33a are a plurality of a~ertured washers 37. As depicted in FIG. 9, each washer 37 may be of circular confisuration and provided with a central aperture 39 and a pluxality of circumferential apertures 41 surrounding aper~ure 39. A steel reinforcing rod 43 may be passed through the aligned central apertures 39 of washers 37 to impart additional strength and rigidity to column 31.
Washers 37 are securely held in place within matrix 33a which becomes e~bedded through circumferential apertures 41. Outer-most washers 37, located at the o~.er ends of column 31, maybe covered by correspondingly shaped solid metal ~lates 45 which are sealed and secured in place by means of matrix 33.
As seen in FIGS. 7 and 8, lower densitv zones 3;
may assume the configuration of generall-~ arcua~e sections surrounded on all sides by a plurality of internal vertical walls 47 and a plurality of horizontal walls 49 of ma~rix 33, in addition to central matrix 33a and t~e outer c~lin~rical wall portion of matrix 33. In this structure, vertical walls 47 may ~e spaced 90 apart ir. successive vertical tiers sepa-rate~ by horizontal walls 49. However, adjacent tiers ofvertical walls 47 may be offset from each other by 45 as indicated in the cut-awav sec,ion of ~IG. 8 to further ~crease the overall compressive strensth of colu~n 31.
~ 1~68~
Re~erxing now to ~IGS. 10 and 11, there is shownstill another embodiment of the present invention. In this emDodiment, the building element is in the form of a rectan-gular-shaped block 50 that is provided with a continuous outer ~ 5 wall structure 52 of high density matrix material. As in the case of panel 1 and.panel 7 of the former embodiments, matr~x 52 includes three continuous spaced layers ;4, 56 and 58, with such layers serving to collectively define a pair of separate and independent s;ections 60 and 52 of low density material.
Matrix layer 54 comprises a back exterior wall of block 50 and is provided with a pair of internal reinforcing lateral sections 64 and 66 integrally form~d therewith.
Lateral sections 64 and 66 extend inwardly from wall 54 and terminate short of opposing matri~ layer 56, the latter com-: 15 prising an interior wall of block S0. The free ends of lateral -sections 64 and 66 terminate in substantially L-shaped single flanges 68 and 70, respectively. Flanges 68 and 70 may be directed in opposite directions towards each other.
Wall 56 includes an integrally formed internal rein-~ 20 forcing plate section 72 extending away therefxom and termina-ting short of wall 54 in a substantially T-shaped configura-tion having a pair of lateraLly extending flanges 74 and 76.
Lateral sections 64, 66 and 72, along with their associated flanges 68, 70, 74 and 76, extend throughout the entire height of block 50 and are integrally joined to a top matrix layer 78 and an opposing bottom matrix layer ~not shown). Walls 54, 56 and 58 are disposed substantially in parallel array with the~r op?osed ends integrally joined to a pair of matrix layers 80 1 6 ~an~ 82, the latter forming the end walls, with w~ll 58 form-ing the front wall of block 50.
Ref erring again to FIG . 11, the overall streng~h o~
bloc~ 50 can be still urther enhanced by disposing portions of cementitious material having a density intermediate the density range between the higher density mat-ix and lower density zones wi~hin those areas of low density zone 60 bridg-ins the ends of adjacent pairs of flanges 68, 74 and 70, 76.
Such portions of cementitious material havins a~ intermediary density are generally designated at 84 an~ 86, respectively.
Portions 84 and 86 may continuously extend between and be integrally joined to opposing top and bottom wall sections o~
block 50 and, moreover, may be formed from the same basic com-position as low density zone 60, which composition is mo~ified by incorporating a higher percentage of cementitious mater al therein. Portions 84 and 86 may each be o- rec.ansular shape or, if desired, essentially free form in overall con'igura~ion~
The internal intersections between the adjacent wall sections, lateral sections and flanges of matrix 52 may be pro-vided with angular fillet corners 88 for the purpose of opti-mizing stress distribution and thereby ir.crease overall s~ren in these areas.
As seen in FIGS. 10 and 11, opposing en~ walls 80 and 82 of matrix 52 may be provLded with _rangible sectio~s 9Q and 92 for the purpose of interlocking adjacent blocks 50 together. This is shown in FIG. 12 wherein two adjacentblocks 50 are disposed in abutting end to end relationship with their respective corresponding adjacent frangible portions 90 and 92 ~ ~686~
re~oved. The spaces 90a and 92a formed by the removal offrangibl~ sections 90 and 92, respectively, cooperativel~
define a recess ga having a lonsitudinal axis which extends from the top to the bottom of adjacent blocks 50. An inter-loc~ing member 96 havina an exterior configuration correspon-ding to the interio~ configuration of recess 94 is inserted into the latter, thereby serving to lock adjacent blocks 50 together against shifting movement. Member 96 may be formed substantially of low density material, such as perlite, but may also include cementitious material so that its density can be varied in accordance with the requirement of any speci-fic application or use. Recess 94 formedby the removal of frangible sections 90 and 92 is depicted as being rectangular in shape, but it ~s to be understood that recess 94 may assume any desired shape or size simplv by varying the confiauration of frangible sections 90 and 92.
Though block 50 has been sho-~n to include a low density zone 62 having a substantially rectangular configura-tion, it is to be understood that the space defined by zone 62 may be completely or partially devoid o~ low density matexial and, moreover, may include one or more partitions servina to subdivide this space into two or more separate chambers. This-permits varying the overall weight of block 50 or providing necessary channels therethrough for the passage of electrical wi-es and plumbing conduits through a wall structure made up of blocks 50.
It is further understood that the constituents and compositional ranges thereof making up matrix 52 and lower ~ ~6~36~
density zones 60 and 62 may be the same as that previouslyindicated for the other e.~bodiments of the inve~tion as de-picted in FIGS. 1-9. The inclusion of clay aggregates, such as expanded clay, in ma~rix 52 serves to considerably enhance the thermal insulation qualities thereof. Moreover, matrix 52 may also include similar reinforcing members embedded therein as previously shown in FIGS. 3-5 for panel em~odi-ment 7.
Several specific modifications of block 50 are shown in FIGS. 13-17, with such modifica~ions beinc prlmarily characterized by the absence of top matrix layer 78 and its opposing bottom matrix laver (not shown). Further, fransible sections 90 and 92 have been removed from these modified bloc~s, with the latter beins depicted in substantially final form for actual use.
The modification of FIG. 13 includes a block 97 provided with a ribbed bac.~ wall 98 which serves as a decora-tive facade when wall 98 is disposed ~o form part of either an exterior or interior sur~ace or a complete wall assembly.
As is apparent, zone 62 o low density material has been omitted and the space normally occupied thereby has been formed into a pair of transverse channels 100 and 102 defined by a matrix wall section 104, the latter integrallv bridgins exterior wall 58 anà interior wall 56. Alternatively, block 97 may be providec with non-ribbed wall 54 o. blocX S0 in substitution for ribbed wall 98.
The modification of FIG.- 14 lncludes a bloc~ 106 whe-ein space 92a normally formed b-.y t~e removal of fran~i-le ~17-fi ~section 92 is omitted and a similar space 108a is provided in wall 58. Channels 100 and 102 ar~ filled wlth low density m2terial 62. The locations of spaces 90a and 108a in block 106 renders the latter particularly useful as ~ corner bloc~
5 in a wall assembly.
The modification of FIG. 15 is snown as a block 110 which is particularly use ul as a partition block in a wall assembly. Block 110 includes, in additian to spaces 90a and 92a, a third space 112a formed in wall section 58.
The modification of FIG. 16 comprises a block 114 which has the same physi~al characteristics of block 97 with the.exception that ribbed wall 98 has been replaced by non~
ribbed wall 54 and a rec~angular section of block 114 has been removed to form a top longitudinal channel 116 there-15 th~ough. Channel 116 has a width substantially equal to the width of space 92a and a length substantially eaual to the distance between the opposing interior sur'aces of end walls 80 and 82. The presence of channel 116 renders block 114 particularly useful as a lintel block ror forming the upper-20 most peripheral layer of a wall assembly. When a pluralityof blocks 114 are disposed in end-to-end abutting relation-ship, consecutive channels 116 serve to deflne a continuous channel along the top o~ a wall assembly or receivi~g the traditional steel strapping or similar bracing means in lintel 25 fashion.
The modification of FIG. 17 includes a block 118 having the same basic characteristics of bloc~ 97 with the exceptlon that lateral sec~ions 64, 66 an~ 72 terminate in -la-~6~8~5 ends having subs~antially rounded or cylin~rical-shaped ed~e portio~s 120, 122 and 124, respectively. The overall configu-ration OL block 118 is particularly suited for use in making bloc~s having smaller overall dimensions~
Referring now to ~IG. 18, ~hexe is shown a wall assembly 126 constructed rom a pluralitv of bloc~s 97, 106 and 114 disposed in even vertical stacks or "jac~ form" and secured.together by a plurality of interlocking members 96 being inserted in recesses 94 defined by cooperatinc spaces 90a, 92a and 108a. The e~ternal and lnternal surraces o' wall 126, generally designated at 128 and 130, respectively, mav each be coated with a layer of bonding mate-ial, such as fiberglass-reinforced cementitious material, which serves to structurally unify and waterproof wall 126. In this manner, wall 126 may be contructed in the absence of utillzing mortar between the individual blocks, though it is to be understood that mortar may be e~.ployed, if desired, LOr bonding a~Jacent blocks together.
Because of the continuous convo~ute or corrugated configuration of lower density zone 60 in block 50 and all the modifications thereo' as shown in FIGS. 13-17, lt is ap2arent that the abuttinc relationships between l~wer density zone 60 and interlocking members 96, the latter also beins formed substantially of the same lower density material, collectively serve to def~ne a substantially conti~uous "thermal barrier" that e~;ten~s in both the ~lertical and hori-zontal directions to the ~lanar extremities of wall 126. This "thermal barr-er" is ef~ectively disposed between ex~e--o. and 1 l B6865 in~erior surfaces 128 and 130, the lat~er beiny ~or~e~ OL
matrix or higher density material sections 54 and 58, respec-tively. Thus, an ex~remely e~f~ctive thermal insulation qu21ity is inherent in wall 126, which quality greatly en-hances energy conservation in any housing or building struc-ture constructed from the bloc~s of the present invention.
The primary thermal insulation Oc wall 126 is de-rived from the "thermal barrier" formed from low density zones 60 and abutting interlocking members 96, aIl of which are formed substantially from perlite. However, by incorporating aggregate in the form of clay, such as expanded clay pa~icles,-in tne composition of mat-ix sections 54 and 58, an even greater degree of thermal insulation is imparted to exterior and interior walls 128 and 130.
In a preferred embodiment of the present invention, which embodiment is to be understood as exemplary and not limiting, a building element was formed from compositions as follows: For the high density matrix, 2,660 pounds of sand having an ASTM specification of C33~ of Group 1 were mixed wi~
9 sacks of cement (about 9~ pounds/sack) and 54 gallons of water. This produced one cubic yard of matrix composition.
For the low density zones, 6.75 sacks of cement (about 94 pounds/sac~) were mixed with 27 cubic feet of perlike (about 8 pounds/ft.3) and 61 gallons of water to produce one cubic yard of low density zone composition.
The final high density composition was approg~tel~
150 pounds per cubic foot. The final low density composition was approximately 36 pouncs per cubic foot. However, by v ~ -~686~
ing the amounts of sand and perlite, the respective pre~erred high and low densities were ascertained to be on the order of about 90-150 pounds per cubic foot and 22-36 poun~s ~er cubic foot. The overall density of the formed building element will S vary, of course, depending upon the configuration and sizes of the low density zones and the thickness of the high densit~
matrix.
A preferred embodiment of a building element utiliz-ing the latter described compositions may assume a ger.erally planar configuration similar to panel l of FIG. ] or panel 7 of ~IG. 3. Such prefexred embodiment may also assume the basic block configuration depicted by FIG. lO and its several modifications as shown by FIGS. 13-17. The interconnected matrix, having a density of approximately 150 pounds per cubic - 15 foot, substantially completely surrounds the plurality of lower density zones with the latter having a densitv Oc approxi-mately 36 pounds per cubic foot. I'he ma.rix effectively in-cludes three spaced sections which divide the zones into two portions or tiers. The spaced sections o matrix are conti-nuous and extend to the extremities of the panel in the manneras indicated for panel 1 in FIG. 2, panel 7 in FIG. 5, block 50 in PIG. lO and modifications of the la~ter as depicted in FIGS. 13-17.
The building elemer.t of the present invention may be - made by first individuallv molding the lower densitv 7Ones from the desir~d composition. The molded zones, in the form of blocks or other shapes, are then placed, while still in ~
"green" state, in a larger mold having the form or thefinished --~6g~6~
element. The zones are spaced Crom each o~ner and rom thewalls of the larger mold. The desired matrix composition is then injected into the spaces of the lat~er mold such ~hat it surrounds and embeds each zone in m~trix material and completely fills the spacesO Because the zones are utilized in a "green" conditlon, the cementitious material in the matrix forms a secure bond with the cementitious material in the~ zones to thereby create a continuous cementitious phase throughout the entire element.
The building element may also be made bv continu-ously extruding a layer or matrix between and around a suc-cession of zones in the form of blocXs or o,her sha?es.
It is to be understood that the forms of the inven-tion herewith sho~n and described are to be ~aken as preferred examples of the same, and that various chanaes in thP shape, size and arrangement of parts and compositions may be ~ed _ to, without departing from the spirit OL the invention or scope of the subjoi~ed claims.
:~ ~6~86~
ment for the embodiment depioted in FIGS. 1 and 2 bei~g that zones 5 are individually substantially ~n~irely surrounded enclosed within in~erconnec~ed matrix 3. Matrix lavers 3a, 3b and 3c ser~e to generally divide zones 5 into two tiers, spaced by a plurality of vertical walls 6, and separated by continuous central matrix layer 3b. By virtue of this layere~
arrangement, great compressive strength is imparted to overall panel 1. Though th tiers of zones 5 are depicted as rather uniform or regular staggered sections of blocks, it is to be 10 understood that any desired arrangement or configuration of zones 5 is suitable for the practice o the present invention in a building element having a generally planar conliguration.
A significant aspect of such a planar con~iguration is the provision of at least a continuous matrix layer 3b disposed substantially centrally along the lonsitudinal axis of the element.
Like matrix 3, zones 5 are basically formed from a cementitious material, which material may comprise the same constituents or compositions as previously indicated forma~
3. Since zones 5 are not subjected to the direct application of external stress as is the case of matrix 3, it is desirabl~
that zones 5 be of a lower density such that the entire panel 1 shall have a corresponcingly lower weight. To this end, zones 5 include additives in the form of a discontinuousphase or dispersion of discrete particles which, when considered cumulatively with the ce~.entitious material in which it is dispersed, will provide an appropriate density ranse inclusive of from 10 to 50 pounds per cubic foot. The pre,erred;density ~ 7 _ ~1~6~
o~ zones 5 is of the range inclusive from 18 to 35 pounds per cubic foot. In order to achieve the lower density of zones S, the cementitious materlal comprising the ~asis ~hereof may include additive material in the form o, iscrete particles having a relatively light weight, for example perlite, vermi-culite, polymeric materials and mixtures ~hereof. The poly meric materials may advantageously be comprised of expandable or foamable particLes derived from polyurethane, polystyrene polyolefin or similar such resins. Further, plastic or 19 polymeric materials of the non- oamable or non-expandable type may also be utilized to advantage.
Because of the similar cementitious materlalut~lized as the basis of the composition for matrix 3 as well as that of zones 5, panel l can thus be defined as an integral and continuous phase of cementitious material. Notwithstanding variation between the average densities of higher density matrix 3 and lower density zones 5, by virtue of theaifferent additive materials incorporated therein, matrix 3 is rigi~ly and strongly bound to zones 5 and vice versa by virtue of the cementitious material being common to both. This unique rela-tionship of materialc results in panel 1 having an extremely high degree of compressive strength, based primarily upon the interconnected high density matrix 3 which produces a ceLlular structure that exhibits good load absorption characteristics.
Thus, when a load is applied to panel 1, the energy of com-pression and bending of matrix 3 is absorbed by zones 5,there-by permitting panel 1 to be subjected to stress conditions that would normally cause failure of known concre~e or cement panelc 686~
Such strength characteristics of panel 1 make it particularly useful and safe for buildings in earthquake prone loca~ions.
Panel 1 is also characterized by comparatively lisht weight, when compared ~o prior art panels made of concrete or cement, by virtue of zones 5 having a comparatively low average density because of the discrete lightweight particles dispersed therein. Accordingly, the preferred cumulative average density of panel 1 is of a range inclusive from 20 to 200 pounds per cubic foot. As is therefore evident, a build- :
ing element constructed according to the present invention can be varied greatly in overall weight in order to accommodate its desired manner or environment of use. .
~ urther, if panel 1 is to be utilized in an e.nviron-ment whereby a face thereof is to be exposed to the exterior, such as in a wall of a building, the matrix portion so exposec may include a larger amount of additive materlal in the form of rock or aggregate particles so that it will have maximum physical resistance to varying and extreme weather conditions.
Similarly, should it be desired that a face o' panel 1 be utilized as an interior wall of a building or the like, the portion of matrix 3 forming such an inter or face mav include additive material comprising a greater amount OL ~ Or be entirely of, organic or inorganic fibers sinc~ the interior face will not be subjected to harsh weather conditions or other severe structural abuse, thereby reducing the overall weight of panel 1. It is clearl~ understood that the respec-tive additive materials utilized in both matrix 3 and zones 5 ma~ be varied in composition and amount throughout the entlre _9_ panel 1 i. such variation is deemed desirable or necessary.
Referring now to PIGS~ 3 through 5, there is depic-tPc another embodiment of ~he building element o the present invention. In this embodiment, the element is also in the 5 form of a panel 7 which includes an interconnected higher density matrix 9 and a plurality of lower density zones or blocks 11 dispersed within and surrounded by matrix 9. The compositions of matrix 9 and bloc~s 11 may be the same as that previously indicate~ for matrix 3 and zones 5, respec-10 tively, of the embodiment depicted by FIGS. 1 and 2. As -. similarly indicated for panel 1 of FIGS. 1 and 2, ?anel 7 also includes three continuous spaced mat-ix layers 9a, 9b and 9c whlch serve to enclQse and divide blocks 11 into two separate tiers. Central matrix layer 9b, extending trans-15 versely and longitudinally to the extremities of panel 7 s ~ esas the foundation for the great compressive strength of panel 7.
As seen more clearly in FIGS. 3 and 5, blocks ll axe of substantially rectangular-shape and have voids 13 provided 20 therethrough. Blocks 11 are disposed in linear parallel a.rra~
along the longitudinal axis of panel 7 such that voids 13 o.
adjacent blocks are aligned to form a series o' parallel - channels 15 throughout the length of panel 7, as clearly de-picted in the cut-away section of FIG. ~. The number of chan-25 nels 15 formed in panel , according to this manner will varywith the number of voids 13 provided in each individua} block 11. If desired, only one such channel 15 may ~e previded in the entire panel or a parallel series of channels m~y be fo~d ~ 1~686~
as shown in FIGS. 3 and 5. Channels 15 may be utilized to receive electrical wiring, ca~les or conduits i panel 7 is employed in the construction of a buildins or si~ilar struc-ture. Voids 13 may be filled with insulation material to ~ 5 better control thermal and acoustical transmissions through panel 7. Also, voids 13 may be used for reducing substan-tially the weight of lndividual blocks ll,'thereby ser~ing to lighten the overall weight of panel 7. To this latter end, it is entirely possible that voids 13 in blocks 11 may be ~rcvided-- 10 as needed for purposes of weight reduction and, as suchj it would not then be necessary ~o align voids 13 to for,m continu-ous channels 15.
As seen in ~IG. 3, matrix 9 of panel 7 substantially completely encloses and surrounds blocks 11 with the exception of the portions of spaces 17 between adjacent blocks where voids 13 are aligned to form channels 15, For added overall strength, a continuous section o matrix 9 is disposed ~sta~-tially along the longitudinal axis of panel 7, as indicated at 19, to still further increase the overall strength and ri~idit~
of panel 7, For even further strengthening of panel 7, rein-forcing members 2} in the form of metal rods may be ~ispersed and embedded within matrlx 9 alon~ the outer ~eripheral edge ~f the panel as well as through the portion of matrix 9 dis?osed along the longltl~dinal axis of the elemen'; as indicated at 19. -~
In order to assure a strona cementitious bond betwe~n ma.rix 9 and blocks 11, the latter may be provided with g-ooves 23 along the edge portions thereof, thereby affording a greater surface area for bondinc. It is to be ur.derstood tha' ?anel 1 16i~5 7 may also be reinforced by any well known rein~orcement materials or member~ well known i~ the art for this purpose~
~or example, i~stead of rods 21, matrix 9 may be embedded with reinforcing members in the form of mesh structures, truss structures, pre-stressed metallic cables, or similar systems and devic s well known in the art for this purpose.
Panel 7, as seen in FIG. 5, may also be provided with a male tongue or ridge 25 and a corresponding female groove or channel 26 along its opposite longitudinal edges for the purpose of facilitatina the interlocking or adjacent panels together, as shown in ~IG. 6. Both tongue 25 and~
27 serve-to facilitate the handllng and manipulation of panel 7 during construction use. Wood plates 29 may also be utilized to secure the upper or lower portions of adjacent panels to-gether in wood construction environments.
FIGS. 7 and 8 depic~ yet another embodiment of thebuilding element of the present invention. In this case, the element is in the form of a column 31. Though column 31 is depicted as haYing a generally circular cross section, it is to be understood that any other cross-sectional configuration or design, such as triangular, rectangular, square or the l.~e;
may be utilized according to the desires and needs of anv given application of the present invention.
As in the case of the two earlier described embodi-ments, column 31 comprises a third embodiment which also in-cludes an interconnected higher density matri~ 33 which sur-rounds and encloses a plurality of lower density zones 35.
The compositions, materlals and densities of matrix 33 and 6 8 6 ~
zones 35 are the same as those indicated for the earlier des-cribed embodimen~s.
Disposed substantially centrallv and along the lon-gitudinal axis of column 31 is a continuous and relatively - 5 thick portion of matrix 33, as indicated at 33a. Spaced cen-trally along the length of matrix 33a are a plurality of a~ertured washers 37. As depicted in FIG. 9, each washer 37 may be of circular confisuration and provided with a central aperture 39 and a pluxality of circumferential apertures 41 surrounding aper~ure 39. A steel reinforcing rod 43 may be passed through the aligned central apertures 39 of washers 37 to impart additional strength and rigidity to column 31.
Washers 37 are securely held in place within matrix 33a which becomes e~bedded through circumferential apertures 41. Outer-most washers 37, located at the o~.er ends of column 31, maybe covered by correspondingly shaped solid metal ~lates 45 which are sealed and secured in place by means of matrix 33.
As seen in FIGS. 7 and 8, lower densitv zones 3;
may assume the configuration of generall-~ arcua~e sections surrounded on all sides by a plurality of internal vertical walls 47 and a plurality of horizontal walls 49 of ma~rix 33, in addition to central matrix 33a and t~e outer c~lin~rical wall portion of matrix 33. In this structure, vertical walls 47 may ~e spaced 90 apart ir. successive vertical tiers sepa-rate~ by horizontal walls 49. However, adjacent tiers ofvertical walls 47 may be offset from each other by 45 as indicated in the cut-awav sec,ion of ~IG. 8 to further ~crease the overall compressive strensth of colu~n 31.
~ 1~68~
Re~erxing now to ~IGS. 10 and 11, there is shownstill another embodiment of the present invention. In this emDodiment, the building element is in the form of a rectan-gular-shaped block 50 that is provided with a continuous outer ~ 5 wall structure 52 of high density matrix material. As in the case of panel 1 and.panel 7 of the former embodiments, matr~x 52 includes three continuous spaced layers ;4, 56 and 58, with such layers serving to collectively define a pair of separate and independent s;ections 60 and 52 of low density material.
Matrix layer 54 comprises a back exterior wall of block 50 and is provided with a pair of internal reinforcing lateral sections 64 and 66 integrally form~d therewith.
Lateral sections 64 and 66 extend inwardly from wall 54 and terminate short of opposing matri~ layer 56, the latter com-: 15 prising an interior wall of block S0. The free ends of lateral -sections 64 and 66 terminate in substantially L-shaped single flanges 68 and 70, respectively. Flanges 68 and 70 may be directed in opposite directions towards each other.
Wall 56 includes an integrally formed internal rein-~ 20 forcing plate section 72 extending away therefxom and termina-ting short of wall 54 in a substantially T-shaped configura-tion having a pair of lateraLly extending flanges 74 and 76.
Lateral sections 64, 66 and 72, along with their associated flanges 68, 70, 74 and 76, extend throughout the entire height of block 50 and are integrally joined to a top matrix layer 78 and an opposing bottom matrix layer ~not shown). Walls 54, 56 and 58 are disposed substantially in parallel array with the~r op?osed ends integrally joined to a pair of matrix layers 80 1 6 ~an~ 82, the latter forming the end walls, with w~ll 58 form-ing the front wall of block 50.
Ref erring again to FIG . 11, the overall streng~h o~
bloc~ 50 can be still urther enhanced by disposing portions of cementitious material having a density intermediate the density range between the higher density mat-ix and lower density zones wi~hin those areas of low density zone 60 bridg-ins the ends of adjacent pairs of flanges 68, 74 and 70, 76.
Such portions of cementitious material havins a~ intermediary density are generally designated at 84 an~ 86, respectively.
Portions 84 and 86 may continuously extend between and be integrally joined to opposing top and bottom wall sections o~
block 50 and, moreover, may be formed from the same basic com-position as low density zone 60, which composition is mo~ified by incorporating a higher percentage of cementitious mater al therein. Portions 84 and 86 may each be o- rec.ansular shape or, if desired, essentially free form in overall con'igura~ion~
The internal intersections between the adjacent wall sections, lateral sections and flanges of matrix 52 may be pro-vided with angular fillet corners 88 for the purpose of opti-mizing stress distribution and thereby ir.crease overall s~ren in these areas.
As seen in FIGS. 10 and 11, opposing en~ walls 80 and 82 of matrix 52 may be provLded with _rangible sectio~s 9Q and 92 for the purpose of interlocking adjacent blocks 50 together. This is shown in FIG. 12 wherein two adjacentblocks 50 are disposed in abutting end to end relationship with their respective corresponding adjacent frangible portions 90 and 92 ~ ~686~
re~oved. The spaces 90a and 92a formed by the removal offrangibl~ sections 90 and 92, respectively, cooperativel~
define a recess ga having a lonsitudinal axis which extends from the top to the bottom of adjacent blocks 50. An inter-loc~ing member 96 havina an exterior configuration correspon-ding to the interio~ configuration of recess 94 is inserted into the latter, thereby serving to lock adjacent blocks 50 together against shifting movement. Member 96 may be formed substantially of low density material, such as perlite, but may also include cementitious material so that its density can be varied in accordance with the requirement of any speci-fic application or use. Recess 94 formedby the removal of frangible sections 90 and 92 is depicted as being rectangular in shape, but it ~s to be understood that recess 94 may assume any desired shape or size simplv by varying the confiauration of frangible sections 90 and 92.
Though block 50 has been sho-~n to include a low density zone 62 having a substantially rectangular configura-tion, it is to be understood that the space defined by zone 62 may be completely or partially devoid o~ low density matexial and, moreover, may include one or more partitions servina to subdivide this space into two or more separate chambers. This-permits varying the overall weight of block 50 or providing necessary channels therethrough for the passage of electrical wi-es and plumbing conduits through a wall structure made up of blocks 50.
It is further understood that the constituents and compositional ranges thereof making up matrix 52 and lower ~ ~6~36~
density zones 60 and 62 may be the same as that previouslyindicated for the other e.~bodiments of the inve~tion as de-picted in FIGS. 1-9. The inclusion of clay aggregates, such as expanded clay, in ma~rix 52 serves to considerably enhance the thermal insulation qualities thereof. Moreover, matrix 52 may also include similar reinforcing members embedded therein as previously shown in FIGS. 3-5 for panel em~odi-ment 7.
Several specific modifications of block 50 are shown in FIGS. 13-17, with such modifica~ions beinc prlmarily characterized by the absence of top matrix layer 78 and its opposing bottom matrix laver (not shown). Further, fransible sections 90 and 92 have been removed from these modified bloc~s, with the latter beins depicted in substantially final form for actual use.
The modification of FIG. 13 includes a block 97 provided with a ribbed bac.~ wall 98 which serves as a decora-tive facade when wall 98 is disposed ~o form part of either an exterior or interior sur~ace or a complete wall assembly.
As is apparent, zone 62 o low density material has been omitted and the space normally occupied thereby has been formed into a pair of transverse channels 100 and 102 defined by a matrix wall section 104, the latter integrallv bridgins exterior wall 58 anà interior wall 56. Alternatively, block 97 may be providec with non-ribbed wall 54 o. blocX S0 in substitution for ribbed wall 98.
The modification of FIG.- 14 lncludes a bloc~ 106 whe-ein space 92a normally formed b-.y t~e removal of fran~i-le ~17-fi ~section 92 is omitted and a similar space 108a is provided in wall 58. Channels 100 and 102 ar~ filled wlth low density m2terial 62. The locations of spaces 90a and 108a in block 106 renders the latter particularly useful as ~ corner bloc~
5 in a wall assembly.
The modification of FIG. 15 is snown as a block 110 which is particularly use ul as a partition block in a wall assembly. Block 110 includes, in additian to spaces 90a and 92a, a third space 112a formed in wall section 58.
The modification of FIG. 16 comprises a block 114 which has the same physi~al characteristics of block 97 with the.exception that ribbed wall 98 has been replaced by non~
ribbed wall 54 and a rec~angular section of block 114 has been removed to form a top longitudinal channel 116 there-15 th~ough. Channel 116 has a width substantially equal to the width of space 92a and a length substantially eaual to the distance between the opposing interior sur'aces of end walls 80 and 82. The presence of channel 116 renders block 114 particularly useful as a lintel block ror forming the upper-20 most peripheral layer of a wall assembly. When a pluralityof blocks 114 are disposed in end-to-end abutting relation-ship, consecutive channels 116 serve to deflne a continuous channel along the top o~ a wall assembly or receivi~g the traditional steel strapping or similar bracing means in lintel 25 fashion.
The modification of FIG. 17 includes a block 118 having the same basic characteristics of bloc~ 97 with the exceptlon that lateral sec~ions 64, 66 an~ 72 terminate in -la-~6~8~5 ends having subs~antially rounded or cylin~rical-shaped ed~e portio~s 120, 122 and 124, respectively. The overall configu-ration OL block 118 is particularly suited for use in making bloc~s having smaller overall dimensions~
Referring now to ~IG. 18, ~hexe is shown a wall assembly 126 constructed rom a pluralitv of bloc~s 97, 106 and 114 disposed in even vertical stacks or "jac~ form" and secured.together by a plurality of interlocking members 96 being inserted in recesses 94 defined by cooperatinc spaces 90a, 92a and 108a. The e~ternal and lnternal surraces o' wall 126, generally designated at 128 and 130, respectively, mav each be coated with a layer of bonding mate-ial, such as fiberglass-reinforced cementitious material, which serves to structurally unify and waterproof wall 126. In this manner, wall 126 may be contructed in the absence of utillzing mortar between the individual blocks, though it is to be understood that mortar may be e~.ployed, if desired, LOr bonding a~Jacent blocks together.
Because of the continuous convo~ute or corrugated configuration of lower density zone 60 in block 50 and all the modifications thereo' as shown in FIGS. 13-17, lt is ap2arent that the abuttinc relationships between l~wer density zone 60 and interlocking members 96, the latter also beins formed substantially of the same lower density material, collectively serve to def~ne a substantially conti~uous "thermal barrier" that e~;ten~s in both the ~lertical and hori-zontal directions to the ~lanar extremities of wall 126. This "thermal barr-er" is ef~ectively disposed between ex~e--o. and 1 l B6865 in~erior surfaces 128 and 130, the lat~er beiny ~or~e~ OL
matrix or higher density material sections 54 and 58, respec-tively. Thus, an ex~remely e~f~ctive thermal insulation qu21ity is inherent in wall 126, which quality greatly en-hances energy conservation in any housing or building struc-ture constructed from the bloc~s of the present invention.
The primary thermal insulation Oc wall 126 is de-rived from the "thermal barrier" formed from low density zones 60 and abutting interlocking members 96, aIl of which are formed substantially from perlite. However, by incorporating aggregate in the form of clay, such as expanded clay pa~icles,-in tne composition of mat-ix sections 54 and 58, an even greater degree of thermal insulation is imparted to exterior and interior walls 128 and 130.
In a preferred embodiment of the present invention, which embodiment is to be understood as exemplary and not limiting, a building element was formed from compositions as follows: For the high density matrix, 2,660 pounds of sand having an ASTM specification of C33~ of Group 1 were mixed wi~
9 sacks of cement (about 9~ pounds/sack) and 54 gallons of water. This produced one cubic yard of matrix composition.
For the low density zones, 6.75 sacks of cement (about 94 pounds/sac~) were mixed with 27 cubic feet of perlike (about 8 pounds/ft.3) and 61 gallons of water to produce one cubic yard of low density zone composition.
The final high density composition was approg~tel~
150 pounds per cubic foot. The final low density composition was approximately 36 pouncs per cubic foot. However, by v ~ -~686~
ing the amounts of sand and perlite, the respective pre~erred high and low densities were ascertained to be on the order of about 90-150 pounds per cubic foot and 22-36 poun~s ~er cubic foot. The overall density of the formed building element will S vary, of course, depending upon the configuration and sizes of the low density zones and the thickness of the high densit~
matrix.
A preferred embodiment of a building element utiliz-ing the latter described compositions may assume a ger.erally planar configuration similar to panel l of FIG. ] or panel 7 of ~IG. 3. Such prefexred embodiment may also assume the basic block configuration depicted by FIG. lO and its several modifications as shown by FIGS. 13-17. The interconnected matrix, having a density of approximately 150 pounds per cubic - 15 foot, substantially completely surrounds the plurality of lower density zones with the latter having a densitv Oc approxi-mately 36 pounds per cubic foot. I'he ma.rix effectively in-cludes three spaced sections which divide the zones into two portions or tiers. The spaced sections o matrix are conti-nuous and extend to the extremities of the panel in the manneras indicated for panel 1 in FIG. 2, panel 7 in FIG. 5, block 50 in PIG. lO and modifications of the la~ter as depicted in FIGS. 13-17.
The building elemer.t of the present invention may be - made by first individuallv molding the lower densitv 7Ones from the desir~d composition. The molded zones, in the form of blocks or other shapes, are then placed, while still in ~
"green" state, in a larger mold having the form or thefinished --~6g~6~
element. The zones are spaced Crom each o~ner and rom thewalls of the larger mold. The desired matrix composition is then injected into the spaces of the lat~er mold such ~hat it surrounds and embeds each zone in m~trix material and completely fills the spacesO Because the zones are utilized in a "green" conditlon, the cementitious material in the matrix forms a secure bond with the cementitious material in the~ zones to thereby create a continuous cementitious phase throughout the entire element.
The building element may also be made bv continu-ously extruding a layer or matrix between and around a suc-cession of zones in the form of blocXs or o,her sha?es.
It is to be understood that the forms of the inven-tion herewith sho~n and described are to be ~aken as preferred examples of the same, and that various chanaes in thP shape, size and arrangement of parts and compositions may be ~ed _ to, without departing from the spirit OL the invention or scope of the subjoi~ed claims.
Claims (26)
(a) a continuous phase of cementitious material including:
1. a matrix having a first density, and 2. at least one zone dispersed within the matrix having a second density lower than the first density, wherein said continuous phase of cementitious material extends throughout said matrix and said lower density zone;
and wherein (b) the matrix includes a first wall section and a generally parallel and opposing second wall section, said first wall section having at least one first lateral section extending away therefrom at least half the distance between said first and second wall sections but terminating short of said opposing second wall section at a lower density zone disposed between the terminal end of the lateral section and the second wall section, and said second wall section having at least one second lateral section, spaced longi-tudinally from said first lateral section, extending away therefrom at least half the distance between said first and second wall sections but terminating short of said opposing first wall section at a lower density zone disposed between the terminal end of the lateral section and the first wall section.
and wherein (b) the matrix includes a first wall section and a generally parallel and opposing second wall section, said first wall section having at least one first lateral section extending away therefrom at least half the distance between said first and second wall sections but terminating short of said opposing second wall section at a lower density zone disposed between the terminal end of the lateral section and the second wall section, and said second wall section having at least one second lateral section, spaced longi-tudinally from said first lateral section, extending away therefrom at least half the distance between said first and second wall sections but terminating short of said opposing first wall section at a lower density zone disposed between the terminal end of the lateral section and the first wall section.
2. The element of claim 1 wherein the element is of a substantially rectangular block configuration.
3. The element of claim 2 wherein at least one exterior wall section of the element includes a frangible portion that is removable to define a space for receiving means for inter-locking adjacent elements together.
4. The element of claim 3 wherein:
(a) a frangible portion is provided in each of two opposing exterior wall sections, and (b) each frangible portion has a sub-stantially rectangular configuration that extends for at least a major distance between two opposing extremities of each exterior wall section.
(a) a frangible portion is provided in each of two opposing exterior wall sections, and (b) each frangible portion has a sub-stantially rectangular configuration that extends for at least a major distance between two opposing extremities of each exterior wall section.
5. The element of claim 1 wherein:
(a) the first wall section is an exterior wall of the element that includes two inwardly directed first lateral sec-tions, and (b) the second wall section is an interior wall of the element that includes one second lateral section extending away therefrom and terminating short of the first wall section.
(a) the first wall section is an exterior wall of the element that includes two inwardly directed first lateral sec-tions, and (b) the second wall section is an interior wall of the element that includes one second lateral section extending away therefrom and terminating short of the first wall section.
6. The element of claim 5 wherein:
(a) the second lateral section is disposed between the first lateral sections, and (b) each of the first lateral sections terminates in an end having a single flange, with both single flanges being directed in opposite directions towards each other, and (c) the second lateral section terminates in an end having double flanges that are directed in opposite directions away from each other.
(a) the second lateral section is disposed between the first lateral sections, and (b) each of the first lateral sections terminates in an end having a single flange, with both single flanges being directed in opposite directions towards each other, and (c) the second lateral section terminates in an end having double flanges that are directed in opposite directions away from each other.
7. The element of claim 6 wherein portions of cementitious material having a third density within the density range of the first and second densities are disposed between the flanges of the first lateral sections and the corresponding adja-cent flanges of the second lateral section.
8. The element of claim 1 wherein:
(a) at least two lower density zones are dispersed within the matrix, and (b) the matrix substantially completely surrounds the lower density zones and defines three continuous spaced layers that extend substantially along the longitudinal axis of the element.
(a) at least two lower density zones are dispersed within the matrix, and (b) the matrix substantially completely surrounds the lower density zones and defines three continuous spaced layers that extend substantially along the longitudinal axis of the element.
9. The element of claim 1 wherein the transverse cross-sectional configuration of the lower density zone is substantially convolute.
10. The element of claim 1 wherein:
(a) the first density is of a range from about 60 to 200 pounds per cubic foot, and (b) the second density is of a range from about 10 to 50 pounds per cubic foot.
(a) the first density is of a range from about 60 to 200 pounds per cubic foot, and (b) the second density is of a range from about 10 to 50 pounds per cubic foot.
11. The element of claim 1 wherein the overall average density of the element is of a range from about 20 to 200 pounds per cubic foot.
12. The element of claim 1 wherein:
(a) the matrix has a composition including a continuous phase of cementitious material and a first discontinuous phase selected from the group con-sisting of aggregate particles, organic fibers, inorganic fibers and mixtures thereof, and (b) the lower density zone has a compo-sition including a continous phase of cementitious material and a second discontinuous phase of a filler having a density lower than the density of the cementitious material.
(a) the matrix has a composition including a continuous phase of cementitious material and a first discontinuous phase selected from the group con-sisting of aggregate particles, organic fibers, inorganic fibers and mixtures thereof, and (b) the lower density zone has a compo-sition including a continous phase of cementitious material and a second discontinuous phase of a filler having a density lower than the density of the cementitious material.
13. The element of claim 12 wherein the filler is selected from the group consisting of perlite, vermiculite, expandable polymers and mixtures thereof.
14. The element of claim 13 wherein:
(a) the matrix has a density of a range of about 90 to 150 pounds per cubic foot and the first discontinuous phase is aggregate, and (b) each lower density zone has a density of a range of about 22-36 pounds per cubic foot and the second discontinuous phase is perlite.
(a) the matrix has a density of a range of about 90 to 150 pounds per cubic foot and the first discontinuous phase is aggregate, and (b) each lower density zone has a density of a range of about 22-36 pounds per cubic foot and the second discontinuous phase is perlite.
15. The element of claim 5 wherein:
(a) the second lateral section is dis-posed between the first lateral sections, and (b) the first lateral sections and the second lateral section each ter-minate in an end edge having a substantially cylindrical con-figuration.
(a) the second lateral section is dis-posed between the first lateral sections, and (b) the first lateral sections and the second lateral section each ter-minate in an end edge having a substantially cylindrical con-figuration.
16. The element of claim 2 wherein the matrix includes at least one transverse channel therethrough.
17. The element of claim 16 wherein the matrix includes a bridging portion for subdividing the transverse channel into first and second sub-sidiary transverse channels.
18. The element of claim 17 wherein each of the subsidiary transverse channels are filled with lower density material.
19. The element of claim 17 further including a longitudinal channel for receiving means for securing a plurality of the elements together.
20. The element of claim 2 wherein one exterior wall of the element includes a ribbed formation.
21. The element of claim 1, wherein the matrix comprises an interconnected matrix.
22. The element of claim 5, wherein (a) the second lateral section is disposed between the first lateral sections, and (b) each of the first lateral sections and the second lateral section terminate in an enlarged portion.
23. The element of claim 1, wherein the continuous phase of cementitious material extending throughout said matrix and said lower density zone is produced by substantially simultaneously curing said matrix and said lower density zone.
24. A wall assembly comprising a plurality of longitudinally abutting building elements, wherein each building element comprises:
(a) a continuous phase of cementitious material including:
1. a matrix having a first density, and 2. at least one zone dispersed within the matrix having a second density lower than the first density, wherein said continuous phase of cementitious material extends throughout said matrix and said lower density zone; and wherein (b) the matrix includes a first wall section and a generally parallel and opposing second wall section, said first wall section having at least one first lateral section extending away therefrom at least half the distance between said first and second wall sections but terminating short of said opposing second wall section at a lower density zone disposed between the terminal end of the lateral section and the second wall section, and said second wall section having at least one second lateral section, spaced longi-tudinally from said first lateral section, extending away therefrom at least half the distance between said first and second wall sections but terminating short of said opposing first wall section at a lower density zone disposed between the terminal end of the lateral section and the first wall section.
(a) a continuous phase of cementitious material including:
1. a matrix having a first density, and 2. at least one zone dispersed within the matrix having a second density lower than the first density, wherein said continuous phase of cementitious material extends throughout said matrix and said lower density zone; and wherein (b) the matrix includes a first wall section and a generally parallel and opposing second wall section, said first wall section having at least one first lateral section extending away therefrom at least half the distance between said first and second wall sections but terminating short of said opposing second wall section at a lower density zone disposed between the terminal end of the lateral section and the second wall section, and said second wall section having at least one second lateral section, spaced longi-tudinally from said first lateral section, extending away therefrom at least half the distance between said first and second wall sections but terminating short of said opposing first wall section at a lower density zone disposed between the terminal end of the lateral section and the first wall section.
25. The wall assembly of claim 24 wherein:
(a) the abutting exterior walls of adjacent elements each include a space, which spaces cooperate to define a recess, and (b) an interlocking member is disposed within each recess for securing adjacent elements together.
(a) the abutting exterior walls of adjacent elements each include a space, which spaces cooperate to define a recess, and (b) an interlocking member is disposed within each recess for securing adjacent elements together.
26. The wall assembly of claim 25 wherein the interlocking members are formed of lower density material and directly engage the respective lower density zones of adjacent elements.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000384202A CA1166865A (en) | 1981-08-19 | 1981-08-19 | Structural building element |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000384202A CA1166865A (en) | 1981-08-19 | 1981-08-19 | Structural building element |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1166865A true CA1166865A (en) | 1984-05-08 |
Family
ID=4120747
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000384202A Expired CA1166865A (en) | 1981-08-19 | 1981-08-19 | Structural building element |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1166865A (en) |
-
1981
- 1981-08-19 CA CA000384202A patent/CA1166865A/en not_active Expired
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