CN112823228A

CN112823228A - Cementitious composite structure

Info

Publication number: CN112823228A
Application number: CN201980066695.4A
Authority: CN
Inventors: 科伦·E·卡斯诺夫; 安东宁尤吉·美野
Original assignee: Cortex Composites Inc
Current assignee: Cortex Composites Inc
Priority date: 2018-09-04
Filing date: 2019-09-03
Publication date: 2021-05-18
Also published as: EP3847317A4; CA3111442A1; WO2020051126A1; US20210270030A1; AU2019335197A1; EP3847317A1

Abstract

A kit for a structure comprising a plurality of frame members that facilitate construction of a frame structure of the structure and a plurality of cementitious composite mats. A plurality of frame members and a plurality of cementitious composite mats may be assembled to provide the structure. In response to the cementitious composite mat being hydrated in situ, the plurality of cementitious composite mats are cured to provide a cementitious panel for the structure.

Description

Cementitious composite structure

Cross reference to related patent applications

This application claims priority to U.S. provisional patent application 62/726,627 filed on 04/09/2018, the entire contents of which are incorporated herein by reference.

Background

Long-term placement solutions for citizens, disasters and other low-cost housing situations are typically of poor construction quality, include inexpensive materials and can take a long time to build.

Disclosure of Invention

One embodiment of the invention relates to a construction kit. The kit includes a plurality of frame members that facilitate construction of a frame structure and a plurality of cementitious composite mats of the structure. The plurality of frame elements and plurality of cementitious composite mats are assemblable to provide the structure. In response to the plurality of cementitious composite mats hydrating in situ, the plurality of cementitious composite mats curing to provide a cementitious panel for the structure.

Further embodiments relate to cementitious composite panels for construction. The cementitious composite panel includes a frame and a cementitious composite mat coupled to the frame. The cementitious composite mat includes an inner layer (disposed along the framework), an outer layer (permeable to water), and a cementitious mixture (disposed between the inner and outer layers). The frame is configured to be connected to an adjacent frame of an adjacent panel of the structure. In response to in situ hydration of the cementitious composite mat, the plurality of cementitious composite mats cure to provide a cementitious panel for the structure.

Further embodiments relate to structures. The structure includes a plurality of interconnected cementitious composite mats. Each of the plurality of cementitious composite panels comprises a sub-frame assembly interconnected with a sub-frame assembly of an adjacent cementitious composite panel to provide a frame structure of the structure, and an inner, impermeable layer disposed along the sub-frame assembly; and an outer, water permeable layer; and a cementitious mixture disposed between the inner, non-permeable layer and the outer, water-permeable layer. In response to in situ hydration of the cementitious composite panel, the cementitious mixture cures to provide a cementitious panel of the structure.

This summary is intended to be illustrative only and not limiting in any way. Other aspects, inventive features, and advantages of the devices or methods described herein will become apparent from the following detailed description, taken in conjunction with the accompanying drawings in which like reference numerals identify similar elements.

Drawings

FIG. 1 is an exploded schematic view of a cementitious composite in accordance with an exemplary embodiment;

FIG. 2 is a schematic illustration of a crimped cementitious composite according to an exemplary embodiment;

FIGS. 3-7 are various views of a cementitious composite residence according to an exemplary embodiment;

8-18 are various detailed views of a cementitious composite residence according to an exemplary embodiment;

FIGS. 19 and 20 are various views of a cementitious composite residence including a plurality of overlapping plates according to an exemplary embodiment;

21-24 are various views of a plate for a cementitious composite residence according to an exemplary embodiment;

fig. 25A and 25B are various views of a support for the plate shown in fig. 21-24, according to an exemplary embodiment.

26-29 are various views of an assembly of a cementitious composite residence using a prefabricated panel kit, according to an exemplary embodiment;

FIGS. 30-36 are various views of an assembly of a cementitious composite residence using a prefabricated panel kit, according to an exemplary embodiment;

FIGS. 37 and 38 are various views of a cementitious composite residence assembled using a full disassembly kit according to an exemplary embodiment;

FIG. 39 is a schematic view of a frame and cementitious composite with a panel coupled assembly according to an exemplary embodiment;

40-44 are various views of a frame and cementitious composite with a plate of coupling assemblies according to further exemplary embodiments;

45-63 are various alternative ways of assembling a cementitious composite residence, according to an exemplary embodiment;

FIG. 64 is a cementitious composite residence having a rainwater collection basin according to an exemplary embodiment;

FIG. 65 is a front view of a cementitious composite building, according to an exemplary embodiment;

FIG. 66 is an explosive schematic for cementitious composite building panels, according to an exemplary embodiment;

FIG. 67 is an explosive schematic for cementitious composite building panels according to an exemplary embodiment;

FIG. 68 is a detailed view of an interface between conduits of adjacent plates, according to an exemplary embodiment;

69-71 are various views of a cementitious composite building panel having electronic components embedded therein according to an exemplary embodiment.

Detailed Description

Before turning to the figures, which illustrate exemplary embodiments in detail, it is to be understood that the application is not limited to the details and methodology described in the specification or illustrated in the figures. It is also to be understood that the terminology is used for the purpose of description and should not be regarded as limiting.

Cementitious composite mat

The cementitious composite mat may include a dry cementitious mixture embedded in and/or contained by the structural layer. The structural layer may be placed between an impermeable layer and a permeable layer. The cementitious mixture undergoes its normal curing and reinforcement gain process after in situ hydration to produce a hard composite. The osmotic layer may retain moisture (e.g., for a controlled period of time, etc.) for improved curing of the cementitious composite mat (e.g., to promote the release of moisture into the cementitious mixture for a period of time, etc.). Unlike conventional concrete, the cementitious composite mat does not require cementitious components to be mixed (e.g., in a stand-alone mixer, or in a cement mixer truck, etc.). The cementitious mixture of the present invention does not wash out of the cementitious composite mat as easily (e.g., not at all) as a traditional, non-formulated cementitious mixture, and remains fixed within the cementitious composite mat so that it hardens in place without mixing. The cementitious mixture is disposed between the permeable layer and the impermeable layer and includes an accelerator, a retarder, a latex modifier, a setting modifier, other modifiers, fibers, glass additives, metal additives, stone additives, organic additives, water reducing mixtures, shrinkage reducing mixtures, viscosity modifiers, absorbent materials (e.g., superabsorbent materials, superabsorbent polymers, superabsorbent clays, etc.), interconnecting particles (e.g., beads, granules, strands, etc.; from resins, polymers, elastomeric polymers, PVC, polypropylene, polyethylene, metals or metal alloys with low melting points, etc.), adhesives, and/or other gel forming additives, such that the cementitious mixture remains fixed upon hydration. The cementitious mixture remains fixed, facilitating the use of a top layer (e.g., osmotic layer, etc.) that will dissolve and/or have pores when hydrated.

The structural layers of the cementitious composite may be formed within or include separate, non-attached materials. The structural layer may improve the load bearing capacity of the cementitious composite mat by distributing load energy through the structural layer. The structural layer may bridge the fracture faces of the gelled phase to provide improved fracture resistance and/or fix the fracture to reduce fracture propagation. The structural layer may be coupled to at least one of the permeable layer and the impermeable layer using an adhesive, a heat treatment process, and/or a mechanical means (e.g., hooks, fibers, etc.). In some embodiments, the structural layer is made at least in part of an adhesive material, but not an adhesive layer as a structural layer. Cementitious composite mats having structural layers may have improved structural performance per unit volume, have low cost, reduce labor, require less processing relative to other concrete or concrete composites, reduce the potential for gauge variation relative to poured concrete, and/or eliminate the disadvantages of traditional wet mixing (e.g., range limitations for transportation with concrete mixing vehicles, etc.), among other benefits. In addition to holding cementitious composite mats together and/or a cementitious mixture (e.g., prior to hydration, etc.), the structure layer may structurally strengthen the cementitious layer and/or cementitious composite mat after hydration. In some embodiments, the cementitious composite mat does not include a structural layer. In some embodiments, the cementitious composite mat includes a fixed layer (e.g., formed across the cementitious composite mat using a quilting process, a needling process).

According to the exemplary embodiment shown in FIG. 1, the composite mat, shown as cementitious composite mat 10, includes multiple layers. As shown in FIG. 1, the multiple layers include a drawn layer, shown as permeable layer 20; a gelled layer, shown as gelled mixture 30; a three-dimensional volumetric layer (e.g., a fixed layer, a bunched layer, a mesh layer, a non-woven layer, a non-fibrous layer, a pin and/or connector, an interconnecting particle layer, a spiral layer, a tube layer, a 3D woven and/or woven layer, a needled layer, a quilted layer, a plastic layer, a metal layer, a layer configured for bonding with one or more snap-fit connections, etc.), shown as structural layer 40; an impermeable layer (e.g., seal, etc.), shown as impermeable layer 50; and one or more adhesive layers, shown as adhesive layer 60. According to an exemplary embodiment, permeable layer 20, cementitious mixture 30, structure layer 40, impermeable layer 50, and/or adhesive layer 60 may be disposed adjacent to one another and assembled into a sheet to form cementitious composite mat 10. As shown in fig. 1, structure layer 40 may be disposed between (e.g., sandwiched between, etc.) permeable layer 20, impermeable layer 50, and adhesive layer 60. In some embodiments, cementitious composite mat 10 does not include structure layer 40. In this embodiment, the adhesive layer 60 may be a structural layer and/or the cementitious composite mat 10 may include a tie layer that is formed by needling or quilting. According to an exemplary embodiment, cementitious composite 10 has a thickness of between 5 millimeters and 100 millimeters prior to hydration. For example, when the binder is included in the cementitious mixture 30 (e.g., expansive cement, etc.), the cementitious composite mat 10 may exceed the thickness before hydration after hydration. It will be appreciated that references to a structural layer, adhesive layer, anchor layer, and/or cementitious mixture may include any of the structural layers, adhesive layers, anchor layers, and/or cementitious mixtures incorporated or disclosed by reference.

According to an exemplary embodiment, cementitious composite mat 10 includes layers that are coupled to one another (e.g., adhesively coupled, sewn, with pins, with staples, with a snap-fit connection, etc.). The coupling can reduce relative movement between the layers prior to hydration (e.g., during preparation, during transport, during installation, etc.). For example, impermeable layer 50 may be coupled (e.g., selectively bonded, etc.) to structure layer 40 and/or cementitious mixture 30 with or without adhesive layer 60. By way of further example, permeable layer 20 may be coupled (e.g., selectively bonded, etc.) to structure layer 40 and/or cementitious mixture 30 with or without adhesive layer 60. By way of further example, impermeable layer 50 may be coupled to permeable layer 20 (e.g., sewn to one another, pinned, stapled, etc.). The coupling may improve the structural characteristics of cementitious composite mat 10 by facilitating load transfer between permeable layer 20, structure layer 40, adhesive layer 60, and/or impermeable layer 50. Adhesive layer 60 and/or structural layer 40 may act as a bonding agent. Multiple structural and/or adhesive layers may reduce the risk of delamination.

According to various embodiments, cementitious composite mat 10 includes various combinations of layers. By way of further example, cementitious composite mat 10 may include impermeable layer 50, structure layer 40, adhesive layer 60, cementitious mixture 30, permeable layer 20, and/or a securing layer. Such cementitious composites may utilize structure layer 40, adhesive layer 60, and/or a tie layer to retain cementitious mixture 30 during shipping and during application of cementitious composite mat 10, and/or include additional systems for retaining cementitious mixture 30. According to various alternative embodiments, cementitious composite mat 10 includes permeable layer 20 and impermeable layer 50, or only permeable layer 20, or neither permeable layer 20 nor impermeable layer 50. By way of further example, cementitious composite mat 10 may include impermeable layer 50, structure layer 40, adhesive layer 60, cementitious mixture 30, and permeable layer 20. By way of further example, cementitious composite mat 10 may include impermeable layer 50, structure layer 40, adhesive layer 60, and cementitious mixture 30. By way of further example, cementitious composite mat 10 may include an osmotic layer 50, an adhesive layer 60, cementitious mixture 30, and an osmotic layer 20. Still further, impermeable layer 50 may have one or more surface imperfections and/or asperities (e.g., fibers, members, hooks, etc.) configured to facilitate retaining cementitious mixture 30, attaching to, and/or embedding within the hardened concrete prior to and/or after hydration. Further details regarding impermeable layer 50, structure layer 40, adhesive layer 60, cementitious mixture 30, permeable layer 20, and/or fixation layer may be found in (i) U.S. patent No.9,187,902, (ii) U.S. patent application No.15/767,191, and (iii) international patent application PCT/US2018/027984, all of which are incorporated herein by reference in their entirety.

Referring to the exemplary embodiment shown in fig. 2, cementitious composite mat 10 may be arranged as a flexible sheet. Permeable layer 20, structural layer 40 and impermeable layer 50 are all flexible and are placed adjacent to each other as shown in fig. 2. According to an exemplary embodiment, this combination of flexible layers facilitates the crimping of cementitious composite mat 10 to facilitate transportation and reduce the amount of cementitious composite 30 that migrates through permeable layer 20. According to alternative embodiments, the cementitious composite mat 10 may be arranged in additional configurations (e.g., sheets that may be stacked, sheets having a pre-shape, etc.).

Hydration of the cementitious composite mat 10 may be initiated in situ (e.g., in place, or in a work location, etc.). Cementitious composite mat 10 can be shipped to a location (e.g., sheet, rolled, plate) and hydrated in place as a flexible cementitious material in a pre-assembled configuration. The cementitious composite mat 10 may provide commercial, water retention and handling advantages. For example, cementitious composite mat 10 may be used in the form of structural construction (e.g., a shed, warehouse or storage unit, refugee residence, temporary accommodation, temporary dwelling, residence, log house, shed, bungalow, cabin, etc.). Upon hydration in situ, cementitious mixture 30 is configured to set and cure to form a durable, heavy-duty, long-term, self-building, low-cost, water-only housing solution.

Cementitious composite dwelling

According to the exemplary embodiment shown in fig. 3-20, cementitious composite mat 10 is configured to enable assembly and construction of a temporary or more stable structure, shown as cementitious composite dwelling 100. According to an exemplary embodiment, the materials (e.g., frame members, doors, windows, solar panels, insulation, waterproof lining, cementitious composite mat 10, bathroom components, kitchen components, etc.) of the cementitious composite residence 100 are provided (e.g., transported, etc.) as a kit (e.g., as a complete structural kit and as a prefabricated panel kit, etc.) to reach a predetermined location (e.g., refugee camp, disaster camp, homeowner yard, etc.). The kit is assembled by the purchaser at a predetermined location to form the structure of the cementitious composite residence 100. The cementitious composite residence 100 may then be hydrated in situ (e.g., using a stored water source, by rainfall, etc.) to form a durable, heavy-duty, durable residence.

As shown in fig. 8-18, the cementitious composite residence 100 includes a bottom, shown as bottom surface 102; a first longitudinal wall, shown as first sidewall 110; a second longitudinal wall, shown as second sidewall 120, opposite and spaced from first sidewall 110; a first sidewall, shown as first end wall 130, extending between first sidewall 110 and second sidewall 120; a second sidewall, shown as inner wall 140, opposite and spaced from the first end wall 130 and extending between the first sidewall 110 and the second sidewall 120; a third sidewall, shown as a second end wall 150, spaced from the inner wall 140 and extending between the first sidewall 110 and the second sidewall 120; a partition, shown as a dividing wall 152, extending between the inner wall 140 and the second end wall 150; and a top, shown as roof 160, that at least partially encloses the interior space of cementitious composite residence 100. The floor 102 may be or include a substrate, a tarp, a table (e.g., made of cementitious composite mat 10, a conventional concrete slab, a wooden table, a metal table, etc.), and/or other suitable floor, etc.

As shown in fig. 9 and 15-18, first sidewall 110, second sidewall 120, first end wall 130, and inner wall 140 define a main space, shown as living space 170, in which the cementitious composite resides. As shown in fig. 8-11, 15 and 16, the first sidewall 110, the second sidewall 120, the inner wall 140 and the second end wall 150 define a second space, shown as a common space 172. As shown in fig. 9-11 and 16, the dividing wall 152 separates the common space 172 (e.g., partition, etc.) into a first ancillary space, shown as a galley space 180, and a second ancillary space, shown as a living space 190. According to an exemplary embodiment, living space 170 may be completely enclosed from the outside environment while utility space 172 is at least partially open to the outside environment. In some embodiments, the cementitious composite residence 100 does not include an inner wall 140 and/or a common space 172. In some embodiments, the cementitious composite residence 100 includes additional walls, fewer walls, and/or has a different floor design (e.g., additional rooms, fewer rooms, different shapes, multiple floors, etc.).

As shown in fig. 8-18, first side wall 110, second side wall 120, first end wall 130, inner wall 140, second end wall 150, partition walls 152, and roof 160 are constructed from a plurality of panels, shown as cementitious composite panel 200. Specifically, first sidewall 110 and second sidewall 120 are constructed from a first plurality of cementitious composite panels 200, shown as side panels 250; first end wall 130, inner wall 140, and second end wall 150 are constructed from a second plurality of cementitious composite panels 200, shown as end plates 252; and roof 160 is constructed from a third plurality of cementitious composite panels 200, shown as roof panels 254. In some embodiments, the side panels 250, the end panels 252, and/or the roof panels 254 have different dimensions (e.g., the side panels 250 are longer than the end panels 252, etc.). In some embodiments, the panels 250, end panels 252, and/or roof panels 252 have different dimensions (e.g., the side panels 250 are longer than the end panels 252, etc.). In some embodiments, the side panels 250, end panels 252, and/or roof panels 254 are the same size.

As shown in fig. 8-12 and 15-18, one or more side panels 250 and/or end panels 252 include a door (e.g., a lockable door), showing the door 210, disposed therein. As shown in fig. 8, 9, 11, 12, and 15-18, one or more of the side panels 250 includes a window (e.g., an openable window, a lockable window, etc.), shown as window 220 disposed therein. In some embodiments, one or more of the end panels 252 and/or the house panels 254 include a window 220. As shown in fig. 8, 9, 12 and 14, one or more of the roof panels 254 includes photovoltaic panels, shown as solar panels 230, disposed therein. The solar panel 230 may provide electrical power to a plurality of electrical devices (e.g., lights, heaters, air conditioners, refrigerators, water pumps, etc.) within and/or around the cementitious composite residence 100. In some embodiments, the cementitious composite residence 100 includes a battery storage to store electrical energy generated by the solar panels 230. In some embodiments, the cementitious composite residence 100 additionally or alternatively includes a solar generator and/or a combustion generator configured to generate electrical energy to power a plurality of power consumers.

As shown in fig. 9-11, 13, 15, 17 and 18, the top end of the end plate 252 is spaced a distance from the roof 160 such that a gap is formed between (i) the first end wall 130 and the roof 160, (ii) the inner wall 140 and the roof 160, and (iii) the second end wall 150 and the roof 160. The cementitious composite residence 100 includes a plurality of windows (e.g., Plexiglas panels, etc.), shown as windows 240, disposed between (i) the first end wall 130 and the roof 160 and (ii) the inner wall 140 and the roof 160 to isolate the living space 170 from the external environment. The gap 192 between the second end wall 150 and the roof 160 may remain open such that the utility space 172 is at least partially open to the outside environment. In some embodiments, the cementitious composite residence 100 includes a screen, fence, wire fence member, barbed wire, and/or other semi-open or permeable divider positioned to at least partially close the gap 192 between the second end wall 150 and the roof 160 to prevent or deter animals or humans from climbing through the second end wall 150 and into the cementitious composite residence 100.

In some embodiments, living space 190 is completely enclosed. For example, the outer wall of the living space 190 may extend along a roof or have a window. The windows may be identical triangles that separate living space 170 and utility space 172. There are two triangular transparent dividers between (i) living space 190, kitchen space 180 and living space 170, and (ii) living space 190, kitchen space 180 and the exterior. The exterior window may be open on both sides (kitchen and living room) and/or the partition wall 152 may extend all the way to the roof.

In some embodiments, the galley space 180 may be more completely enclosed to the living space 190 (e.g., the galley space 180 is completely enclosed from the exterior, etc.). In this embodiment, the galley space 180 may include a chimney that captures smoke and exhausts the smoke to a roof exhaust, which may be placed above the cooking location (e.g., stove). In some embodiments, the galley space 180 includes a powered fan and/or a window outside the galley space 180 to remove smoke from the galley space 180. In some embodiments, the divider wall 152 extends all the way to the roof, completely separating the galley space 180 from the living space 190.

As shown in fig. 8-18, cementitious composite panels 200 (e.g., side panels 250, end panels 252, roof panels 254, etc.) of cementitious composite residence 100 are aligned with (e.g., do not overlap, are adjacent to, etc.) one another. According to an exemplary embodiment, cementitious composite panels 200 are fused to one another as they hydrate (e.g., cementitious mixture 30 partially extends out of the sides of cementitious composite mat 10 to bond adjacent mats to one another, etc.) to effectively seal cementitious composite dwelling 100 from environmental elements (e.g., rain, wind, snow, debris, dust, etc.). In some embodiments, at least some of the cementitious composite panels 200 of the cementitious composite residence 100 may at least partially overlap. As shown in fig. 19 and 20, (i) adjacent edges of adjacent side panels 250 partially overlap each other, (ii) adjacent edges of adjacent roof panels 254 partially overlap each other, and (iii) adjacent edges of adjacent side panels 250 and roof panels 254 partially overlap each other. The overlapping of adjacent cementitious composite panels 200 may further isolate the cementitious composite dwelling 100 from environmental constituents. In some embodiments, overlapping ends of adjacent cementitious composite mats 10 form continuous or discrete (e.g., spaced, etc.) interlocking Z-channels.

In some embodiments, the bottom of the side plates 250 and end plates 252 can be secured (e.g., secured, anchored, etc.) to the ground 102 and/or ground surface. For example, the bottom of the side plates 250 and end plates 252 may be anchored to the ground, fixed to the ground 102, and/or otherwise secured. As shown in fig. 9-11, the bottom of the side panel 250 has a protrusion (e.g., a portion of the cementitious composite mat 10 extends beyond the length of the respective panel frame, etc.), shown as a curved portion 256, which is curved (e.g., 90 degrees relative to the first side wall 110, the second side wall 120, etc.), and extends from the cementitious composite dwelling 100. In some embodiments, the curved portion 256 is buried underground to anchor the first sidewall 110 and/or the second sidewall 120. In other embodiments, curved portion 256 may or may not be anchored in other ways and remain on the ground. In this embodiment, curved portion 256 may direct rainwater away from a footprint of the cementitious composite residence (e.g., to prevent water from forming a pool, etc. from the perimeter of cementitious composite residence 100). In some embodiments, the bottom of the end plate 252 is curved.

Cementitious composite panel

According to the exemplary embodiment shown in fig. 21-25B, each cementitious composite panel 200 (e.g., side panels 250, end panels 252, roof panels 254, etc.) includes a cementitious composite mat 10; a support structure, shown as frame 300; an insulating sheet, shown as insulating sheet 400; and/or an inner liner, shown as liner 500. In some embodiments, cementitious composite mat 10, frame 300, insulating sheet 400, and/or inner liner 500 of cementitious composite panel 200 are pre-fabricated and assembled prior to shipping such that pre-assembly or limited pre-assembly is not required at the hydrated location to form a cementitious composite dwelling 100 (e.g., cementitious composite mat 10 and frame 300 are pre-assembled prior to shipping; cementitious composite mat 10, frame 300 and insulating sheet 400 are pre-assembled prior to shipping; cementitious composite mat 10, frame 300, insulating sheet 400 and inner liner 500 are pre-assembled prior to shipping, etc.). In some embodiments, the cementitious composite panel 200 is shipped completely disassembled so that the cementitious composite mat 10, frame 300, insulating sheet 400, and liner 500 can be received as separate components and must be completely assembled to form the cementitious composite panel 200 and cementitious composite dwelling 100.

As shown in fig. 21-24, the cementitious composite mat 10, the frame 300, the insulating sheet 400, and the liner 500 are assembled in a stacked configuration to form a cementitious composite panel 200 having the cementitious composite mat 10 on the exterior of the cementitious composite panel 200, the frame 300 disposed along the interior side of the cementitious composite mat 10 (e.g., along the impermeable layer 50, etc.), the insulating sheet 400 disposed on the side of the frame 300 (e.g., the interior side, etc.) relative to the cementitious composite mat 10 (e.g., thereby sandwiching the frame 300 between the cementitious composite mat 10 and the insulating sheet 400, etc.), and the liner 500 disposed on the side of the insulating sheet 400 relative to the frame 300 (e.g., the interior side, etc.) (e.g., thereby sandwiching the insulating sheet 400 between the frame 300 and the liner 500, etc.). In further embodiments, insulating sheet 400 is disposed in the gaps between the frame members of frame 300. In further embodiments, insulating sheet 300 bounds a plurality of channels that receive frame members of frame 300, whereby frame 300 is at least partially embedded within insulating sheet 400.

As shown in FIG. 23, frame 300 includes a first plurality of frame members (e.g., rails, tubes, etc.), shown as longitudinal frame tubes 310, that extend along the longitudinal length of cementitious composite panel 200, and a second plurality of frame members (e.g., rails, tubes, etc.), shown as side frame tubes 320, that extend laterally through cementitious composite panel 200. According to an exemplary embodiment, the longitudinal frame tubes 310 and the lateral frame tubes 320 may be made of a metal material (e.g., aluminum metal, galvanized steel, etc.).

According to an exemplary embodiment, the longitudinal frame tubes 319 and the side frame tubes 320 may be interlocked to form a building support structure (e.g., frame 300, etc.) of the cementitious composite residence 100. In some embodiments, the longitudinal frame tubes 310 and/or the side frame tubes 320 are coupled to each other by a snap-fit connection. In some embodiments, the longitudinal frame tubes 310 and/or the side frame tubes 320 are fastened by fasteners (e.g., rivets, screws, bolts, pins, etc.). In some embodiments, the longitudinal frame tubes 310 and/or the side frame tubes 320 are coupled to each other by a snap-fit connection, and optionally, secured by fasteners. In some embodiments, the longitudinal frame tubes 310 and/or the side frame tubes 320 are coupled to each other by engaging the corresponding portions, then rotating the components relative to each other to snap into place and securing the two components to each other (e.g., rotating the snap connection, rotating into a predetermined position at a predetermined angle, etc.). In some embodiments, the longitudinal frame tubes 310 and/or the side frame tubes 320 are coupled to each other using an interference fit. It will be appreciated that any combination of the above-described coupling mechanisms and/or other suitable coupling mechanisms may be used.

As shown in fig. 23, 25A and 25B, each longitudinal frame tube 310 has a first end, shown as first end 312, and an opposite second end, shown as second end 314. According to an exemplary embodiment, (i) the first end 312 of the longitudinal frame tube 310 of the panel 250 of the first sidewall 110 is configured to be joined with the first end 312 of the longitudinal frame tube 310 of the roof panel 254 to couple the first sidewall 110 to the roof 160 and (ii) the first end 312 of the longitudinal frame tube 310 of the panel 250 of the second sidewall 120 is configured to be joined with the second end 314 of the longitudinal frame tube 310 of the roof panel 254 to couple the second sidewall to the roof 160. As shown in fig. 23, each side frame tube 320 has a first end, shown as first end 322, and an opposite second end, shown as second end 324. According to an exemplary embodiment, (i) the first ends 322 of the side frame tubes 320 of the panel 250 are configured to couple with the second ends 324 of the side frame tubes 320 of an adjacent second panel 250, (ii) the first ends 322 of the side frame tubes 320 of the end panel 252 are configured to couple with the second ends 325 of the side frame tubes 320 of the associated end panel 252 to form the first end wall 130, the inner wall 140, and the second end wall 150, and (iii) the first ends 322 of the side frame tubes 320 of the roof panel 254 are configured to couple with the second ends 324 of the side frame tubes 320 of the adjacent roof panel 254 to form the roof 160.

As shown in fig. 23, 25A and 25B, at least a portion of the longitudinal frame tube 310 defines a plurality of apertures (cutlets), shown as V-shaped notches 316 (notches). As shown in fig. 23 and 25B, the V-shaped notch 316 may facilitate bending the longitudinal frame tube 310 at an angle to create a bend, shown as bend 318, at a predetermined location along the length of the longitudinal frame tube 310. According to an exemplary embodiment, the V-shaped cut 316 facilitates manual bending of the longitudinal frame tube 310 using a hand (e.g., without the use of tools, hydraulic presses, etc.). As shown in fig. 25B, the support plate, shown as a curved plate 330, is optionally coupled to the longitudinal frame tube 310 proximate the V-shaped notch 316 with fasteners after the longitudinal frame tube 310 is bent to maintain the bend 318 within the longitudinal frame tube 310. In alternative embodiments, at least some of the side frame tubes 320 include V-shaped cutouts 316 to facilitate forming the bends 318 and/or at least some of the side frame tubes 320 are pre-completed during the manufacturing process (e.g., to provide curved side walls, curved end walls, etc.). In some embodiments, the longitudinal frame tubes 310 and/or side frame tubes 320 are not pre-bent or manually bendable, but rather the longitudinal frame tubes 310 and/or side frame tubes 320 are coupled in a vertical configuration (e.g., vertical side panels and vertical roof panels are coupled at an angle, etc.).

As shown in fig. 24, insulating sheet 400 includes an insulating medium, shown as insulating material 420, and a cover, shown as insulating cover 410, to surround insulating material 420. According to an exemplary embodiment, insulating cover 410 is made of a waterproof fabric material that is easy to clean and maintain. According to an exemplary embodiment, the insulating material 420 facilitates waterproofing of the cementitious composite residence 100. For example, the insulation 420 may autonomously regulate the temperature of the living space 170 of the cementitious composite residence 100 in hot and/or cold weather. In one embodiment, the insulating sheet 400 is shipped pre-assembled with the frame 300. In another embodiment, the insulating sheet 400 is separate from the frame 300 and may be selectively coupled to the frame 300 at a hydrated location.

In some embodiments, the liner 500 is shipped pre-assembled with the insulating sheet 400. In further embodiments, the liner 500 is separate from the insulation sheet 400 and may be selectively coupled to the insulation sheet 400 at a hydration site. In one embodiment, the liner 500 is a fabric sheet coupled to the inside of the insulating sheet 400. The liner 500 may cover the gaps between adjacent insulating sheets 400 and/or have a decorative finish (e.g., color or pattern, etc.). In some embodiments, the liner 500 is a second, internally cementitious composite blanket. In some embodiments, the liner 500 is a drywall layer. In some embodiments, liner 500 includes a second, internally cementitious composite underlayment and a drywall disposed therein.

In some embodiments, cementitious composite panel 200 includes a fastener that extends at least partially through the thickness of cementitious composite panel 200 and secures two or more layers to one another. For example, the fasteners may extend between and bond the cementitious composite mat, insulating sheet 400 and/or liner 500 to one another in a stacked configuration. The fasteners may be placed at multiple frequencies (e.g., 1 per foot, one per 6 inches, etc.).

Prefabricated slab cementing composite material residence suite

According to the exemplary embodiment illustrated in FIGS. 26-29, the cementitious composite residence 100 is shipped as a partially prefabricated or assembled kit, shown as a prefabricated panel kit 600. As shown in fig. 26, the prefabricated panel kit 600 includes a side panel 250, the side panel 250 including a pre-installed door 210, the side panel 250 including a pre-installed window 220, an end panel 252, a roof panel 254, a base member, shown as a base longitudinal ground anchor 260, a first module, shown as an end module 270, and an installation sheet 400. In some embodiments, door 210 and/or window 220 are separate from each other and require installation. In this embodiment, the plate 250 may be pre-cut to receive the door 210 and/or window 220, or personnel may be required to cut out portions of the plate 250 for installation of the door 210 and/or window 220. In some embodiments, the mounting sheet 400 is pre-assembled with the plate 250, the end plate 252, and/or the roof plate 254. In some embodiments, the insulating sheet 400 is not pre-assembled with the panel 250, end panel 252, and/or roof panel 254.

As shown in fig. 26, 28 and 29, the end module 270 includes a plurality of supports, shown as a base lateral ground anchor 272, a first vertical support 274, an upper support 276, a second vertical support 278, a window 240 and an end plate 252. For example, the base lateral ground anchor 272 may be secured to a ground surface (e.g., the ground 102, the ground, etc.) with a first vertical support 274 extending therefrom and coupled to an opposite end thereof with an upper support 276. A second side support 278 may extend from the upper end side support 276. The end plate 252 may be inserted between the base-side ground anchor 272, the second vertical support 278 and the upper support 276. The window 240 may be interposed between the upper side support 276 and the second side support 278. The assembly may be inserted between a pair of interconnected side panels 250 through a roof panel 250.

As shown in fig. 27, the panels 250 and roof panels 254 may be bent from a flat panel, shipped in a bent-in-place installation configuration (e.g., via V-shaped cutouts 317, etc.). In some embodiments, the panels 250 and/or roof panels 254 may be unbent (e.g., joining a flat roof at a positive angle, etc.). As shown in fig. 28 and 29, the plurality of side panels 250 and roof panels 254 may be selectively assembled into a second module, shown as a standard module 280, a third module, shown as a door module 282, and a fourth module, shown as a window module 284. As shown in fig. 28, the standard module 280 comprises two side panels 250 coupled to each other by a roof panel 254, the door module 282 comprises two side panels 250 coupled to each other by a roof panel 252 having at least one of the two panels 250 comprising one door 210, and the window module 284 comprises two side panels 250 coupled to each other by a roof panel 254, at least one of the two side panels 250 having a window 220. In some embodiments, other mechanisms may be present.

As shown in fig. 29, one or more of the end modules 270, standard modules 280, door modules 282 and/or window modules 284 are coupled to the base longitudinal ground anchor 260 and to each other (e.g., in a particular contemplated order, etc.). Additionally, the insulating sheet 400 and/or the inner liner 500 may be installed (if not already coupled to the cementitious composite panel 200 at the time of shipping) and/or the cementitious composite residence 100 may be hydrated to allow the cementitious composite mat 10 to set and harden.

In some embodiments, two or more adjacent cementitious composite panels 200 are secured to one another with a reinforcing panel, rather than spanning two or more (e.g., two, three, four, five, etc.) cementitious composite panels 200 (e.g., reinforcing panels coupled through adjacent insulating sheets 400 and adjacent cementitious composite mats 10, adjacent inner liners 500, etc.). In some embodiments, two or more adjacent cementitious composite boards 200 are laminated into a sheet with an adhesive. In some embodiments, two or more (e.g., two, three, four, five, etc.) adjacent cementitious composite panels 200 are secured to one another using reinforcing rods, rather than spanning two or more cementitious composite panels 200 (e.g., reinforcing rods span adjacent insulating sheets 400, adjacent cementitious composite mats 10, adjacent inner liners 500, etc.). In some embodiments, cementitious composite panels 200 define a channel that receives a reinforcing rod, wherein adjacent cementitious composite panels 200 are aligned with one another. The channels are defined by the cementitious composite mat 10, the insulating sheet 400 and/or the inner liner 500. The reinforced pipe may include a nail pipe made from cut (Cutworks), metal rod, composite rod, lettered rod, and/or rod, tube, seal, plate, etc., made from a variety of suitable materials. The reinforcing plates and/or reinforcing rods may be mechanically and/or adhesively secured to adjacent plates.

According to the exemplary embodiment shown in fig. 30-36, the preformed sheet assembly 600 comprises a coiled cementitious composite sheet 200, rather than a flat cementitious composite sheet 200. As shown in fig. 30 and 31, cementitious composite sheet 200 is transported in a rolled configuration and longitudinal frame tube 310 coupled to cementitious composite mat 10. As shown in fig. 32, the coiled cementitious composite panel 200 is uncoiled in the hydrated position to form a planar structure. According to the exemplary embodiment shown in fig. 32, a portion of each end of the cementitious composite mat 10 is free and fixed to the longitudinal frame tube 310. As shown in fig. 33-36, the cementitious composite panel 200 is bent (e.g., due to V-shaped cuts 316 in the longitudinal frame tubes 130, etc.) to form the side panels 250 and roof panels 254. As shown in fig. 34-36, the longitudinal frame tubes 310 of the non-crimped side panels 250 and the roof panels are interlocked with one another with the free ends of the side panels 250 tucked under the free ends of the roof panels 254. The other free end of the non-curled side panel 250 may form a curled portion 256.

Disassembled cementitious composite dwelling kit

According to the exemplary embodiment shown in fig. 37 and 38, the cementitious composite residence 100 may be shipped as an entire disassembly kit, shown as a construction kit 37. In this embodiment, shown in FIG. 37, the frame 300 may be constructed for the first time entirely by connecting the base longitudinal ground anchor 260, the base lateral ground anchor 272, the first vertical support 274, the upper lateral support 276, the second vertical support 278, the longitudinal frame tubes 310, and the lateral frame tubes 320, and bending as needed to build the base support structure for the cementitious composite residence 100. Thus, as shown in fig. 38, a plurality of cementitious composite panels 200 (e.g., cementitious composite mat 10, side panels 250, end panels 252, roof panels 254, etc.) and window 240 are coupled to frame 300. The door 210 and the window 220 may be pre-installed or installed before or after the cementitious composite mat 10 is coupled to the frame 300. Accordingly, the insulating sheet 400 and/or the liner 500 may be installed and/or the cementitious composite dwelling 100 may be hydrated to allow the cementitious composite mat 10 to set and harden.

Coupling system

As shown in FIG. 39, cementitious composite panel 200 includes a coupling system, shown as coupling system 800. The coupling system 800 includes a first coupling assembly, shown as a pad coupling assembly 820, and a second coupling assembly, shown as a frame coupling assembly 840. The pad coupling assembly 820 includes a first coupler, shown as a center coupler 822, a second coupler, shown as a right coupler 824, and a third coupler, shown as a left coupler 826, that are coupled to the trailing side of the cementitious composite pad 10 (e.g., to the impermeable layer 50, etc.). In some embodiments, the pad coupling assembly 820 includes a plurality or fewer couplers. In one embodiment, center coupling 822, right coupling 824, and/or left coupling 826 are different types of couplings. Further, the pad coupling assembly 820 may include additional coupler assemblies spaced along the longitudinal length of the cementitious composite pad 10. The additional coupling assemblies may include the same type of coupling or different types of couplings (e.g., hooks on the top and magnets/Velcro on the middle and/or bottom ends).

As shown in fig. 39, the frame coupling assembly 840 includes a first coupling, shown as a center coupling 842, a second coupling, shown as a right coupling 844, and a third coupling, shown as a left coupling 846, coupled to the outside of the side frame tubes 320 of the respective cementitious composite panel 200. In some embodiments, the frame coupling assembly 840 includes more or fewer couplers (e.g., corresponding to the number of couplers of the pad coupling assembly 820, etc.). According to an exemplary embodiment, center coupler 842, right coupler 844, and left coupler 846 are positioned and configured to correspond to the associated couplers of mat coupling assembly 820 to releasably couple cementitious composite 10 to frame 300. Still further, the frame coupling assembly 840 may include additional coupling assemblies spaced along the longitudinal length of the frame 300 (e.g., along the length of the frame tubes 310, along different side frame tubes 320, etc.). The additional coupler sets may include the same type of coupler or different types of couplers.

According to various embodiments, center coupling 822, right coupling 824, left coupling 826, center coupling 842, right coupling 844, and left coupling 846 may be or include hook and loop fasteners (e.g., Velcro, etc.), magnets, hooks, snap-fit connections, protrusions and corresponding V-shaped cutouts or apertures, cables (e.g., for fastening to one another, etc.), and/or other releasable coupling mechanisms. In alternative embodiments, cementitious composite mat 10 may be fixedly coupled to frame 300 using an adhesive. Insulating sheet 400 may be coupled to the interior of frame 300 with respect to cementitious composite mat 10 and frame 300 using similar coupling mechanisms described herein.

According to the exemplary embodiment shown in fig. 40-44, the side frame tube 320 defines a first cutout, shown as a center cutout 342, a second cutout, shown as a right cutout 344, and a third cutout, shown as a left cutout 346. As shown in fig. 41-44, the central cutout 342, the right cutout 344, and the left cutout 346 are positioned to receive a central coupler 822, a right coupler 824, and a left coupler 826, respectively, to couple the cementitious composite mat 10 to the frame 300.

Alternative embodiments

In some embodiments, the disclosed dwelling kit additionally includes a solar panel, an electric cooking surface/appliance, a waterless toilet, a water purification system, a water storage system, a gravity shower, a light tube, a cord, a battery (e.g., for storing electrical energy generated by the solar panel, etc.), a bed, a mattress, a power outlet, a cell phone charger, and the like.

As shown in fig. 45 and 46, cementitious composite mat 10 includes a plurality of strips, shown as side strips 900, defining a plurality of cutouts, shown as notches 902, positioned to contact the plurality of notches, shown as notches 904, defined along longitudinal frame tube 310 (e.g., side strips 900 in place of side frame tube 320, etc.). According to an exemplary embodiment, side bars 900 facilitate crimping of cementitious composite mat 10 (e.g., for shipping, etc.) and prevent cementitious composite mat 10 from bending about its longitudinal axis.

As shown in fig. 47-49, cementitious composite mat 10 includes a plurality of rods, shown as vertical rods 910, and frame 300 includes a support, shown as support 350, that circumscribes a plurality of holes, shown as holes 352. As shown in fig. 49, the vertical rods 910 of cementitious composite mat 10 extend between the supports 350 and have ends that are received by the apertures 352 of the supports 350 (e.g., the vertical rods 910 replace the longitudinal frame tubes 310, etc.). According to an exemplary embodiment, vertical rods 910 facilitate crimping of cementitious composite 10 (e.g., for shipping, etc.) and placing cementitious composite mat 10 in a bend about a longitudinal axis.

As shown in fig. 50-53, the cementitious composite residence 100 includes walls that may be pre-assembled for shipping, but folded in an accordion-type style. At the desired hydration site, the wall may expand and hydrate. 54-58, the cementitious composite residence 100 includes a frame structure or frame 300 and a single, cementitious composite mat 10; a cementitious composite mat 10 is laid over the frame structure to form a cementitious composite dwelling 100. As shown in FIGS. 59-62, cementitious composite panel 200 is arranged to produce a structure having an open top and an open inlet, but the interior of the structure is not visible through the inlet. The structure can be used for public rest rooms of outer houses, shower rooms and the like. FIG. 63 shows an alternative configuration for cementitious composite residence 100. As shown in fig. 64, cementitious composite residence 100 may have a collector, shown as a rainwater collection basin 1000 (e.g., defined within cementitious composite panel 200, etc.), that will collect rainwater for use in a shower, sink, etc. of cementitious composite residence 100.

Cementitious composite building

According to the exemplary embodiment shown in fig. 65-71, cementitious composite panel 200 is configured to enable the assembly and construction of a fixed structure (e.g., a personal residence, a house, a commercial building, etc.), shown as cementitious composite building 1100. For example, cementitious composite panel 200 may be provided as a kit with a plurality of other items that facilitate the construction of a single-story house, a multi-story house, an apartment building, a commercial building (e.g., a retail space, a corporate office, a warehouse, a living room, a restaurant, etc.) and/or other possible buildings or structures.

As shown in FIG. 65, a cementitious composite building 1100 is constructed using cementitious composite panels 200, which are similar to cementitious composite dwelling 100. For example, cementitious composite building 1100 may be constructed using cementitious composite panels 200 having doors 210, windows 220, and the like. However, unlike cementitious composite residence 100, cementitious composite building 1100 may include cementitious composite panels 200 that include additional features that may provide a more suitable long-term residential or commercial space (e.g., water connections, air connections, electrical connections, HVAC connections, drywall interior surfaces, etc.).

For example, liner 500 of cementitious composite panel 200 may be a drywall. Liner 500 may be provided as a protective sheet or covering to prevent damage during installation (e.g., during construction of cementitious composite building 1100, stripping protective plastic off of drywall and placing it dustless to provide a dust-free painted surface, drywall may be coated with a desired color prior to shipping, etc.). In some embodiments, some of the cementitious composite panels 200 used in cementitious composite building 1100 (e.g., for interior walls of cementitious composite building 1100, etc.) do not include cementitious composite mat 10. In this embodiment, cementitious composite mat 10 may be replaced with a second liner 500 (e.g., a second drywall board, etc.). In some embodiments, insulation panel 400 and/or liner 500 comprise an acoustic insulation material.

As shown in fig. 66 and 67, cementitious composite panel 200 for use in cementitious composite building 1100 includes a pipe assembly, shown as pipe assembly 1200. According to the exemplary embodiment shown in fig. 66 and 67, duct assembly 1200 extends within insulating sheet 400 and/or across insulating sheet 400. In some embodiments, duct assembly 1200 additionally or alternatively extends within and/or through cementitious composite mat 10 (e.g., for an exterior wall of cementitious composite building 1100 having lights attached thereto; to facilitate connection of gas lines, water lines, electrical lines, etc. outside or below cementitious composite building 1100). In some embodiments, the tubing assembly 1200 is placed between (e.g., sandwiched between) the insulation sheet 400 and the liner 500. In some embodiments, insulating sheet 400 extends only through a portion of the thickness of cementitious composite panel 200. For example, insulation layer 400 may extend (i) to cover only half of the thickness of tubing assembly 1200, (ii) to cover all of tubing assembly 1200, (iii) only partially from inner liner 500 to cementitious composite mat 10, (iv) partially from cementitious composite mat 10 to inner liner 500, or (v) between the entire inner liner 500 and cementitious composite mat 10.

As shown in fig. 66 and 67, conduit assembly 1200 of cementitious composite panel 200 includes (i) a first conduit, shown as electrical conduit 1210, configured to facilitate the transport of wires through cementitious composite panel 200 to provide electrical power (e.g., lights, microphones, TVs, fans, electrical appliances, HVAC systems, etc.) to electrical components of cementitious composite building 1100, (ii) a second conduit, shown as water conduit 1220, configured to facilitate the transport of water through cementitious composite panel 200 to facilitate the provision of moisture to water appliances of cementitious composite building 1100 (e.g., dishwashers, washing machines, ice makers, sinks, showers, bathtubs, toilets, water heaters, etc.), and (iii) a third conduit, shown as air conduit 1230, configured to transport gas through cementitious composite panel 200 to facilitate the provision of gas to gas appliances of cementitious composite building 1100 (e.g., gas furnaces, gas ovens, gas water heaters, HVAC systems, etc.). As shown in fig. 67, the conduit assembly 1200 additionally includes a fourth conduit, shown as a gas conduit 1240 through which the electrical conduit 1210, the water conduit 1220 and/or the gas conduit 1230 are positioned and extended. The air conduit 1240 may provide protection for the appliance conduit 1210, the water conduit 1220, and/or the gas conduit 1230. In some embodiments, gas conduit 1240 does not receive electrical conduit 1210, water conduit 1220, and/or gas conduit 1230. Air duct 1240 may be configured to facilitate the transport of air conditioning gas through cementitious composite panel 200 to facilitate the provision of air conditioning gas from an HVAC system across the entire cementitious composite building 1100 to thermally condition the spaces and houses of cementitious composite building 1100. In some embodiments, conduit assembly 1200 additionally or alternatively includes a fourth conduit or waste conduit configured to transport waste through cementitious composite panel 200 to facilitate transporting waste from the living room within cementitious composite building to a waste collection system (e.g., septic tank, sewer, etc.) associated with cementitious composite building 1100.

In some embodiments, one or more cementitious composite panels 200 of cementitious composite building 1100 do not include conduit assembly 1200. In some embodiments, one or more cementitious composite panels 200 of cementitious composite building 1100 includes only one of electrical conduit 1210, water conduit 1220, gas conduit 1230, air conduit, or waste conduit. In some embodiments, one or more cementitious composite panels 200 of cementitious composite building 1100 includes only two of electrical conduit 1210, water conduit 1220, gas conduit 1230, air conduit 1240, or waste conduit. In some embodiments, one or more cementitious composite panels 200 of cementitious composite building 1100 includes only three of electrical conduit 1210, water conduit 1220, gas conduit 1230, air conduit 1240, or waste conduit. In some embodiments, one or more cementitious composite panels 200 of cementitious composite building 1100 includes only four of electrical conduit 1210, water conduit 1220, gas conduit 1230, air conduit 1240, or waste conduit. In some embodiments, cementitious composite panel 200 of cementitious composite building 1100 includes two or more electrical conduits 1210, two or more water conduits 1220, two or more gas conduits 1230, two or more air conduits 1240, and/or two or more waste conduits. The plurality of conduits of conduit assembly 1200 may extend in multiple directions to extend all the way through cementitious composite panel 200, exit from the side and/or longitudinal edges of cementitious composite panel 200 and/or extend from inner liner 500 and/or cementitious composite mat 10 to facilitate connection of the plurality of assemblies (e.g., sockets, switches, vents, electrical interfaces, lights, etc.) and conduits of adjacent cementitious composite panels 200.

As shown in FIG. 68, a first tube of tube assembly 1200 (e.g., electrical tube 1210, water tube 1220, gas tube 1230, air tube 1240, waste tube, etc.) of a first cementitious composite sheet 200 is shown as tube 1202 configured to join a second tube of tube assembly 1200 of a second, adjacent cementitious composite sheet 200. The conduit 1202 includes a first interface, shown as interface 1206, and the conduit 1204 includes a second interface, shown as interface 1208. According to the exemplary embodiment shown in fig. 68, the interface 1208 has a first diameter and the interface 1206 has a projection of a second diameter that is smaller than the first diameter such that the interface 1206 is received by the interface 1208 to facilitate coupling the conduit 1202 to the conduit 1204.

In some embodiments, interface 1206 and interface 1208 are coupled with an interface kit. In some embodiments, the interface 1206 and/or interface 1208 may be manually covered with an adhesive (e.g., light, heat, etc. activated cement; epoxy, etc.) before coupling the plates to each other to provide an adhesive seal (e.g., air seal, water seal, etc.) between the conduit 1202 and the conduit 1204. According to the exemplary embodiment shown in fig. 68, interface 1206 and/or interface 1208 include a seal, shown as seal 1209, disposed therein. In some embodiments, seal 1209 is or includes a resilient element (e.g., a circle, an O-ring, etc.). In some embodiments, the seal 1209 additionally or alternatively comprises a rupturable adhesive element configured to rupture upon engagement of the conduit 1202 with the conduit 1204 to adhesively seal the interface 1206 and the interface 1208. In some embodiments, the

interfaces

1206 and 1208 additionally or alternatively include mechanical retention elements (e.g., clips, snap-fit interfaces, external latches, etc.) that mechanically secure the

conduits

1202 and 1204 to one another. In some embodiments, the interface 1206 and the interface 1208 are welded to each other by heat treatment and/or ultrasonic welding methods. In some embodiments, the liner 500 is optionally movable to attach a pipe disposed therein to an adjacent plate pipe or to service on a pipe. In some embodiments, the conduits are loose within cementitious composite panel 200 and, thus, may be manually pushed out from a free end, whereby an opposite end may be pushed (e.g., pushed, etc.) to bond with an adjacent plate conduit.

As shown in fig. 69-71, cementitious composite panel 200 includes a plurality of electrical components, shown as electronic components 1300, embedded within and/or disposed along liner 500. In some embodiments, electrical component 1300 is additionally or alternatively impregnated within cementitious composite mat 10 and/or disposed along cementitious composite mat 10. In an alternative embodiment, electrical assembly 1300 may be used separate from cementitious composite board 200 and mounted in place. According to an exemplary embodiment, the electrical assembly 1300 connects electrical wires within the electrical conduit 1210 of the cementitious composite panel 200. As shown in fig. 69, the electrical assembly 1300 includes a first electrical assembly, shown as a recessed can or the like 1310. As shown in fig. 70, the electronic assembly 1300 includes a second electrical assembly, shown as an electrical receptacle 1320, a third electrical assembly, shown as a light switch, and a fourth electrical assembly, shown as a speaker 1340. As shown in fig. 71, electrical assembly 1300 includes a fifth electrical assembly, shown as electrical interface 1350, configured to facilitate coupling the electrical assembly of the installer in the field proximate cementitious composite board 200 (e.g., ceiling fan, monitoring camera, light, chandelier, thermostat, etc.). It is to be understood that the construction, combination, and selection of the electrical assembly 1300 shown in fig. 69-71 is for illustrative purposes and is not to be construed as limiting. The cementitious composite panel 200 may include any combination of any suitable electrical components embedded therein or disposed therealong.

As shown in FIG. 71, cementitious composite panel 200 includes an outlet, shown as air outlet 1250, disposed along liner 500. According to an exemplary embodiment, air outlet 1250 is positioned to cover an air outlet in liner 500 that would connect with air conduit 1240. Thus, conditioned air (e.g., heated, cooled) may be provided by an HVAC system connecting air inlets of respective cementitious composite panels 200 and passing through air ducts 1240 of cementitious composite panels 200 to facilitate providing conditioned air through connected cementitious composite panels 200 to thermally condition a space or room with air outlets 1250 of respective cementitious composite panels 200, the air outlets 1250 being located within cementitious composite building 1100. Similarly, water may be provided to the water inlet of a respective cementitious composite panel 200 from a source of water located outside cementitious composite building 1100 and through the water inlet of the attached cementitious composite panel 200 providing water to the respective cementitious composite panel 200, the cementitious composite panel 200 attaching a water appliance within cementitious composite building 1100. Similarly, a combustion gas (e.g., natural gas, propane, etc.) may be provided from a combustion gas source external to cementitious composite building 1100 to a combustion gas inlet of a respective cementitious composite panel 200 and through combustion gas conduit 1230 of the connected cementitious composite panels 200 to facilitate providing the combustion gas through a combustion gas outlet of a respective cementitious composite panel 200 of cementitious composite panels 200 to which cementitious composite panels 200 are connected to a combustion gas appliance within cementitious composite building 1100.

Following assembly of the plurality of cementitious composite panels 200, the cementitious composite building 1100 is hydrated. The gaps between cementitious composite mats 10 outside cementitious composite building 1100 and/or the gaps between liners inside cementitious composite building 1100 can be filled with mud and sanded smooth to hide the gaps. The cured cementitious composite mat 10 is then painted, covered with gypsum, covered with bricks, covered with stone, covered with siding, etc. to provide the desired exterior aesthetics. Alternatively, cementitious mixture 30 may include a color additive that will change the exterior color of cementitious composite slab 200 to a desired color for cementitious composite building 1100 upon curing. The liner 500 may also be painted, covered with wallpaper, etc. The floor may be added to a poured concrete slab before the cementitious composite building 1100 is constructed, or the floor may be added to the floor of the cementitious composite slab 200 to create a concrete slab. As shown in fig. 65, roof tiles 1400 may be assembled to project exposed hooks from a roof deck or have snap connectors (which engage the interface of the roof deck). The roof panel may include brackets or flanges that engage the wall panel to secure the cross panel to the wall panel. Alternatively, the frame and wall panels of the roof deck are joined to one another, as described with respect to cementitious composite dwelling 100.

According to an exemplary embodiment, cementitious composite panel 200 facilitates providing a modular and fully personalized building. For example, a user may be able to design a plan view and the appliance, lights, speakers, windows, doors, water inlets, gas inlets, HVAC locations, etc., should be located. Cementitious composite panel 200 may be designed and manufactured to meet. The kit may be shipped to a user that includes cementitious composite panels 200, which would simply need to be assembled to build cementitious composite building 1100, with all of the electrical, water, gas, and air conduits and connections within the containment panels. The kit also provides a plurality of appliances (e.g., fans, lights, washing machines, dryers, dishwashers, ovens, microwave ovens, HVAC systems, stoves (furnaces), stoves (stows), grills, water heaters, sinks, toilets, showers, bathtubs, barbecues, massage bathtubs (Jacuzzi), garage door systems, etc.), furniture (e.g., sofas, tables, chairs, etc., beds, desks, gas meters, electricity meters, etc.), electronics (e.g., TVs, sound systems, alarms, thermostats, cameras, internet routers/modems, solar panels, battery storage, etc.), upholstery (e.g., roof tiles 1400, carpets, shapes, screens, paint, bricks, stones, wallpaper, wall panels, etc.), accessories (e.g., shutters, towels, pillows, cookers, etc.) and/or other household or commercial goods of choice by the customer. Accordingly, a kit is a kit that includes all of the contents, including all of the goods and items that a user may want or need for building and providing a suitable living or working space.

The kit may include a plurality of cementitious composite mats 10 to facilitate the construction of a plurality of external living convenience facilities. Such as driveways, sidewalks, walkways, terraces, swimming pools, whirlpools (Jacuzzis), fire scenes/pits, etc., in the property in which cementitious composite building 1100 is located. External life amenities can be similarly designed and manufactured according to the user's personalization and shipped within the kit. Alternatively, brick pavers, stones, etc. may be attached to the kit to facilitate construction of driveways, walkways, terraces, swimming pools, massage baths, fire/fire pits, etc. The kit may also include various horticultural and yard materials (e.g., turf, vegetation, seeds, sprinkler systems, etc.) according to the customer's instructions and according to yard and garden design.

In some embodiments, cementitious composite building 1100 may be configured as a smart home having a plurality of sensors, connection devices, and/or home automation systems that facilitate seamless control of a plurality of features of cementitious composite building 1100 while present or absent. For example, a kit for cementitious composite building 1100 may have a central control system to connect a plurality of electrically operated components of cementitious composite building 1100. For example, the electrically-operated components may include security systems (e.g., cameras, alarms, sensors, etc.), lights, coffee makers, electric ovens, pool heaters, whirlpool showers, TVs, TV recording systems, sound systems, water heaters, fans, solar panels and/or electrical energy storage, garage doors, refrigerators, home intercom systems, trash compactors, sprinkler systems, letter box sensors/cameras, storage and/or refrigerator cameras/sensors, humidifiers/dehumidif iotaers, water filtration systems, showers, bathtubs, floor heating systems, and the like.

The plurality of electrically operated components are configured to be controllable locally (e.g., via Wi-Fi, bluetooth, radio, NFC, etc.) or remotely (e.g., internet, cellular network, etc.) by a central control system using a port installed in cementitious composite building 1100 and/or using a user portable device (e.g., a smartphone, a portable controller, a smartwatch, a tablet, a laptop, a computer, etc.). Various directories of point-of-operation components can be provided through an application and/or using voice commands (e.g., through a port, a portable device, directly to a central control system handset, etc.). The user may also be able to view real-time and/or recorded footage from a camera (e.g., a food store camera, a refrigerator camera, a mailbox camera, a security camera, etc.). The central control system may be adapted to provide the following capabilities: if smoke is detected by the smoke detector, the fire department is notified and/or the police is notified when an alarm is triggered. The timed action may be set and initiated by the user. For example, the central control system may automatically attend a routine activity in the morning, turn on a shower, turn on shutters, adjust temperature, turn on multiple lights, cook coffee, etc., as a function of time or upon user command. As an additional example, the central control system may use the geographic location track to determine an estimated arrival time for the user and initiate an arrival operation (e.g., open an air conditioner, open a garage door, open a light, open music, etc.) based on the user's location relative to cementitious composite building 1100.

As used herein, the terms "proximate," "about," "substantially," and the like are intended to have a broad meaning consistent with the use of the public and accepted by those skilled in the art. Those skilled in the art who review this application will appreciate that these terms are intended to allow for the description of the specific technical features described and claimed without necessarily limiting these features to the detailed numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or variations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the claims appended hereto.

It should be noted that the term "exemplary" as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, expressions, and/or interpretations (and that such term does not imply that the embodiment is necessarily the only or the best example).

The term "coupled" and the like as used herein means that two components are directly or indirectly connected to each other. The connection may be fixed (e.g., permanent) or movable (e.g., removable or releasable, etc.). This connection may be achieved by the two components or the two components and any additional intermediate components being integrally formed with the other one or both components as a single unitary body or the two components and the additional intermediate components being attached to each other. If "coupled" or variations are modified by additional terms (e.g., directly coupled) the ordinary definition of "coupled" is used as the ordinary linguistic meaning of the additional terms (e.g., "directly coupled" means the joining of two components without any intervening components), resulting in the ordinary definition of "coupled" provided above. This coupling may be mechanical, electronic or fluidic.

Reference to component positions (e.g., "top," "bottom," "upper," "lower") is used only for the positioning of various components of the figures. It is understood that the positioning of the various elements may differ according to other exemplary embodiments, and that such variations are encompassed by the present disclosure.

Although the figures and description may depict a particular order of method steps, the order of the steps may be different from that depicted and described, unless otherwise indicated above. Also, two or more steps may be performed simultaneously or partially simultaneously, as indicated otherwise above. This variation may be based on the software and hardware systems selected and the user's choice, for example. All such variations are within the scope of the disclosure herein. Similarly, software implementations of the methods described herein can utilize standard programming techniques with regular base logic and other logic to perform the various connection steps, processing steps, comparison steps and decision steps.

Importantly, the construction and arrangement of cementitious composite mat 10, cementitious composite dwelling 100, and the components shown in the various exemplary embodiments are for illustration only. Additionally, any element described in an embodiment can be incorporated into or used with any other embodiment. While only one example of elements from one embodiment that may be combined or utilized in another embodiment has been described above, it should be understood that other elements of the various embodiments may be combined or utilized with any other embodiment disclosed herein.

Claims

1. A kit for a structure, the kit comprising:

a plurality of frame members for facilitating the construction of a frame structure of the structure;

a plurality of cementitious composite mats;

wherein a plurality of frame members and a plurality of cementitious composite mats are assemblable to provide the structure, and,

wherein, in response to in situ hydration of the cementitious composite mat, the plurality of cementitious composite mats cure to provide a cementitious panel for the structure.

2. The kit of claim 1, wherein a plurality of frame members and a plurality of cementitious composite mats are provided in the form of a knock-down kit, wherein the plurality of frame members are selectively connectable to provide a frame structure, and each of the plurality of cementitious composite mats is selectively coupled to one or more frame members of the plurality of frame members.

3. The kit of claim 2, further comprising at least one of a door or a window, wherein the at least one of a door or a window is pre-installed in or within a respective one of the plurality of cementitious composite mats.

4. A kit according to claim 1, wherein a plurality of frame members are pre-arranged within a plurality of subframe assemblies, wherein each of the plurality of cementitious composite mats is pre-coupled to a respective one of the plurality of subframe assemblies, such that the kit comprises a plurality of pre-fabricated cementitious composite panels, and wherein the plurality of subframe assemblies are selectively connectable to provide the frame structure.

5. A kit according to claim 4 wherein a plurality of pre-fabricated cementitious composite boards are shipped in a planar configuration.

6. A kit according to claim 4, wherein a plurality of pre-fabricated cementitious composite boards are shipped in a rolled configuration.

7. The kit of claim 3, wherein the plurality of pre-fabricated cementitious composite panels comprises a first type of panel and a second type of panel different from the first type of panel.

8. The kit of claim 7, wherein the first type of plate is provided in a planar configuration and the subframe is non-curved, and wherein the second type of plate is provided in a pre-curved configuration.

9. The kit of claim 7, wherein the first type of panel is provided in a planar configuration and the frame is non-curved, wherein the second type of panel is provided in a planar configuration and the sub-frame is selectively hand-curved, and wherein the frame members of the second type of panel define a plurality of adjacent cut-outs; the cut-outs facilitate selective bending from a planar, shipping configuration to a bent, installed configuration prior to hydration of the cementitious composite mat of the second type of board.

10. A kit according to claim 4, wherein a plurality of cementitious composite mats extend beyond at least one of the side or longitudinal ends of a plurality of subframe assemblies such that adjacent cementitious composite mats of adjacent cementitious composite panels at least partially overlap when the structure is assembled.

11. The kit of claim 4, wherein at least one of the plurality of preformed cementitious composite panels comprises a door embedded within a cementitious composite mat, and wherein at least one of the plurality of preformed cementitious composite panels comprises a window embedded within a cementitious composite mat.

12. The kit of claim 1, wherein at least one frame member of the plurality of frame members defines a plurality of adjacent cutouts facilitating selective manual bending of the planar, transport structure into the curved, mounting structure.

13. The kit of claim 1, wherein each of the plurality of cementitious composite mats includes a coupling system disposed externally and configured to facilitate removably coupling the plurality of cementitious composite mats to the plurality of frame members.

14. The kit of claim 1, comprising an insulating layer, wherein insulating layer is coupled inside the frame structure, and wherein a plurality of cementitious composite pads are coupled outside the frame structure.

15. The kit of claim 15, comprising one or more conduits embedded within the insulation, wherein the one or more conduits include at least one of (i) an electrical conduit configured to facilitate passage of electrical wiring through the insulation to facilitate powering of electrical components of the structure, (ii) a water conduit configured to facilitate passage of water through the insulation to facilitate providing water to water appliances of the structure, (iii) a gas conduit configured to facilitate passage of gas through the insulation to facilitate providing gas to gas appliances of the structure, (iv) an air conduit configured to facilitate passage of air through the insulation to facilitate providing air conditioning gas from the HVAC system through the entire structure, or (v) a waste conduit configured to facilitate passage of waste through the insulation to facilitate providing waste to a waste collection system external to the structure.

16. A cementitious composite panel for a structure, the cementitious composite panel comprising:

a frame, and,

a cementitious composite mat coupled to the frame, the cementitious composite mat comprising:

an inner layer disposed along the frame;

an outer layer permeable to water; and the combination of (a) and (b),

a cementitious mixture disposed between the inner layer and the outer layer;

wherein the frame is configured to be connected to an adjacent frame of an adjacent panel of the structure; and the combination of (a) and (b),

wherein, in response to in situ hydration of the cementitious composite mat, the cementitious mixture cures to provide a cementitious panel for the structure.

17. The cementitious composite panel of claim 16, wherein the cementitious composite mat has a longer longitudinal length relative to a frame such that the cementitious composite mat extends along at least one end of the frame.

18. The cementitious composite panel of claim 16, wherein at least one frame piece of the frame defines a plurality of adjacent cuts that facilitate bending the at least one frame piece of the frame from a planar, transport configuration to a curved, mounting configuration prior to hydration of the cementitious composite mat.

19. The cementitious composite panel of claim 16, further comprising an insulation layer, wherein the cementitious composite mat is disposed along a first side of the frame, and wherein the insulation layer is at least one of (i) disposed along an opposing second side of the frame such that the frame is sandwiched between the insulation layer and the cementitious composite mat or (ii) disposed within a gap between frame members of the frame.

20. The cementitious composite panel of claim 19, further comprising one or more conduits extending within the cementitious composite panel, wherein the one or more conduits include at least one of (i) an electrical conduit configured to pass electrical wiring through the cementitious composite material panel to facilitate providing electrical power to electrical components of the structure, (ii) a water conduit configured to pass water through the cementitious composite material panel to facilitate providing water to water appliances of the structure, (iii) a gas conduit configured to pass gas through the cementitious composite material panel to facilitate providing gas to gas appliances of the structure, (iv) an air conduit configured to pass air conditioning gas through the cementitious composite material panel to facilitate passing air from the HVAC system through the structure, or (v) a waste conduit configured to facilitate passage of waste through the sheet of cementitious composite material to facilitate providing of the waste through the sheet of cementitious composite material to a waste collection system external to the structure.

21. The cementitious composite panel of claim 20, wherein the one or more conduits are one or more first conduits, wherein the one or more first conduits are configured to join one or more second conduits of adjacent panels.

22. The cementitious composite panel of claim 21, wherein an interface between the one or more first conduits and one or more second conduits includes a seal or mechanical retainer to secure the interface.

23. The cementitious composite panel of claim 22, wherein the seal includes an adhesive member configured to rupture to adhesively seal the interface when the one or more first conduits are bonded to the one or more conduits.

24. The cementitious composite panel as claimed in claim 20, further comprising an inner liner disposed along a side of the insulating layer opposite the frame.

25. The cementitious composite panel of claim 24, wherein the liner is drywall.

26. The cementitious composite panel of claim 24, wherein the one or more conduits comprise an electrical conduit, further comprising an electrical component embedded within or disposed along a liner or cementitious composite mat, wherein the electrical component connects wires within the electrical conduit.

27. The structure comprises the following components in percentage by weight,

a plurality of interconnected cementitious composite boards, each of the plurality of composite cementitious boards comprising:

a sub-frame assembly interconnected with sub-frame assemblies of adjacent sheets of cementitious composite material to provide a frame structure for the structure;

an inner, impermeable layer disposed along the sub-frame assembly;

an outer, water permeable layer, and

a cementitious mixture disposed between the inner, impermeable layer and the outer, water permeable layer;

wherein, in response to in situ hydration of the cementitious composite mat, the cementitious mixture cures to provide a cementitious panel of the structure.