WO2003008727A1

WO2003008727A1 - Variable size panels for construction blocks and building system therewith

Info

Publication number: WO2003008727A1
Application number: PCT/CA2002/001121
Authority: WO
Inventors: Paul Bastien; Gerard Fyfe
Original assignee: 9105-6291 Québec Inc.
Priority date: 2001-07-18
Filing date: 2002-07-18
Publication date: 2003-01-30
Also published as: CA2353234A1

Abstract

A building block of light weight cement or other durable material capable of being of a variable size, comprising of means for engaging adjacent blocks with the integrity of the frame being assured by the tongue and groove of all the joints, and a brace track means for positioning and holding level and square a first row of said building blocks of a width substantially the same as the width of the brace track which can be of different width, comprising of a 'finish' fireproof interior wall face and a finish 'fireproof' exterior wall face, defining a block cavity brace means positioned at regular interval within the form cavity of the blocks and slots located at regular intervals of the interior wall face sides of the building blocks for the engagement of the PVC braces.

Description

Variable Size Panels for Construction Blocks and

Building System Therewith

Field of the Invention

The present invention relates to building panel components for the manufacture of variable design building blocks and to the method of use of such components for the manufacture of building structures.

Background of the Invention

Recent developments in residential, commercial, multi- unit and institutional building construction have included the use of rigid polymer components and forms to provide the form-work for the load bearing or non-load bearing walls. Typically, the material used in the form- work is concrete with the form-works remaining in place thereafter. In such modes of constructions, it may be required to finish the exterior and interior surfaces of the walls for the purpose of weather proofing and aesthetic design appearance. As a further disadvantage, there is the cost associated With concrete materials and the risk of damage to load bearing and non-load bearing walls made of this material associated with seismic activity. More traditional, wood frame type of construction, although generally economical, has certain disadvantages associated with it . Use of pressure treated wood is associated with the risk of harmful vapours.

Additionally, use of this traditional building material is associated with risks with respect to termite and fire hazards. Water proofing and insulation is also required to make such structures habitable to humans or satisfactory for the intended purpose. Accordingly, there is a need for structural components which are easy to manufacture and transport and to assemble into an edifice which will provide for a building without the above-referenced disadvantages.

In recent years, the use of prefabricated building panels have been increasingly in demand. Such panels generally take the form of a pair of spaced walls or skins having inserted there between some kind of insulting core such as polyethylene, expended plastic, wood chips and the like more for structural support than insulation primarily because these material are rigid and self supporting. However none of the above fillers would support and retain the spaced panel walls in their properly spaced position.

Therefore, unless the building panels or blocks is to be made stronger so that when the edges when joined will be structurally sound, some other type of blocks or panel need to be introduced to the home building market different enough to challenge the applied prior act.

It is therefore an object and 'feature of our invention to provide to the public such block panel structure of different width and length which is strong and durable and can be put together more quickly and more economically than is possible with structures of the same class provided by the prior act.

It will be apparent that we have invented a novel building block with improved and simplified mounting and connecting means which is such that it can be easily and economically mass-produced. The foregoing and other objects and features of our invention will be fully understood from the following detailed description contained- in the accompanying drawing.

Summary of the Invention

The present invention is one aspect provides for a building panel of polymer of other durable material and capable of being of a variable size, comprising of means for engaging adjacent panels, a brace track means for positioning and holding a first row of said building panels which, with end panels, form a block or row of blocks of a width substantially the same as the width of the _^braces track, comprising an interior wall ace and an exterior wall face, defining a block cavity, brace means positioned at regular intervals within the formed cavity of the blocks and slots located at regular intervals on the interior face sides of the building panels, within the cavity of the formed blocks for engagement of the braces.

I

In another aspect, the present invention provides for a block or wall formed as aforesaid into which is deposited polyurethane material .

In another aspect, the present invention provides for a method of manufacturing an edifice comprising the use of the building panels as aforesaid.

Other features and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples while indicating preferred embodiments of the invention are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to the skilled person in the art from this description. Brief description of the drawings

The invention will now be described in relational to the drawing in which:

Figures 1 to 8 are perspective and sectional views of wall sections made in accordance with the present invention.

Figure 9 is a side elevation of a building panel with ^rA inch bevel, 16 inch height and 36 inch length.

Figure 10 is a top view of a building block formed of the building panels of the present invention with structural braces positioned at 12 inch intervals.

Detailed Description of the Invention

Referring to figure 5, the building panel (10) of the present invention may be manufactured of any suitable durable material such as wood, polyethylene or cement. The exterior surface of these building panels may be of any colour or texture design as may be intended for the desired purpose. For example, for exterior wall purposes, the texture may be of stucco or of any resilient and durable exterior kind. The interior and exterior panel surfaces may be made or composed of suitable fire proof or resistant materials.

For formation of a wall referring to figures 1 and 2, a first block (12) is formed on the brace track means (14) which have been previously laid in any desired pattern to form the layout of the edifice to be raised. At an appropriate corner, a first or starter block (12) is prepared by the placing of a first panel which is a tongue and groove construction. The brace track means will be of a desired width for the formation of a block. For example, this may be of a 12 inch width for the formation of a wall of such thickness. For enhanced rigidity and bracing, the typical first block will be of a length substantially identical to the width of the brace track means, to thereby provide for overlapping interlocking securing as levels of blocks are superimposed in formation of a wall. Adjacent building panels are engaged by tongue and groove means (16) along the bracing trace to form a first block level of a wall in construction. The interiors of the building panels comprise of evenly positioned slot means (18) into which at regular intervals, such as 12 inches, are inserted for the first level of blocks half-brace means (20) , for the purpose of providing rigid bracing. The said brace means may be arcuate or channel-like in construction to provide means for the support of reinforcement or bracing bars as well as to provide for a conduit for the passage of electrical wiring, fibre cables, plumbing—-nd—the like and may be made of PVC or other plastic, metal and the like. End cap means (22) are also added, by again tongue and groove engagement, with the building panels at the end of a bracing track for enclosure and formation of the block row. The half-brace means engaged with the first block row are approximately half the height of the building panels.

On completion of a first row of blocks, one or more subsequent layers of panels may be engaged in the manner as above described for the creation of a wall of desired height. Referring to figures 3, 4 and full brace means (24) are inserted in the slots for engagement at regular intervals. The brace means are of a sufficient height, typically the same height as a building panel, such as to brace for support two panels, one on top of the other. Brace means in a superior row of wall panels will be in line with brace means for lower rows of panels.

During the construction of a building, at regular intervals any suitable polymer foam material, for example polyurethane may be blown into the block spaces, to fill the spaces therein and to provide a rigid wall structure.

Such a rigid wall structure will be of extremely high strength and durability with excellent acoustic and thermal insulation properties. This will nevertheless be of easy means of construction and inexpensive relative to the use of other materials and other means of construction.

At corners, referring to figures 3 and 4 overlapping first blocks or starter blocks will be engaged in overlapping contact as described above to assist in wall rigidity. For the construction of a corner using first starter blocks, a panel face will be included across the width of the brace track means', which panel will include an opening generally parallel to the brace means, to provide for a conduit for plumbing, electrical, wires, cables, reinforcement bars and the like.

For the placement and positioning of doors, windows, other openings and the like, referring to figures 6, 7 and 8, frames (26) of suitable size, conformation and material of construction for example PVC extruded material, may be positioned at the desired locations where blocks have been formed of the desired dimensions and shape from pre-placed panels of the present invention. Construction of the wall by adding the desired levels of building panels to form rows of blocks may be continued, to the required height around and above the frames positioned for doors and windows. Any usual means known to the skilled person may then be utilized for positioning and engaging doors and windows of conventional manufacture, which would be readily available for the purpose of such construction.

Both interior and exterior panels may be of 1 inch or 1/4 inch construction or of any other dimension in thickness as may be desired. Interior or exterior walls may be covered in stucco, wood, brick, cement or any other desired finish, including a finish which is fire resistant. This may be pre-applied to the panels prior to assembly for wall construction.

The bracing track means, may be of any suitable durable material such as non-corrosive metals or polymer and may be laid down in any suitable pattern desired by the , builder, including a T-form for the preparation of internal walls or at an L-angle.

Upon completion of the construction of a wall, the top row of blocks may be capped and suitable material applied for enclosure of the structure.

While the present invention has been described with reference to what are presently considered to be the preferred examples, it is to be understood that the invention is not limited to the disclosed example above. The invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of appended claims.

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A building panel pf polymer or other durable material and capable of- being of a variable size, comprising of means for_. engaging adjacent panels, a brace track means for positioning and holding a first row of said building panels, which, with end panels, form a block or row of blocks of a width substantially the same as the width of the brace track, comprising an interior wall face and an exterior wall face, defining a block cavity, brace means positioned at regular intervals within the formed cavity of the blocks and slots located at regular intervals on the interior face sides of the building panels, within the cavity of the formed blocks for engagement of the braces.

2. A block or wall formed of the panels of claim 1, into which is deposited polyurethane material.

3. A method of manufacturing an edif ce comprising the use of the building panels of claim 1.