WO2017019786A1

WO2017019786A1 - System and method for standardized modular construction

Info

Publication number: WO2017019786A1
Application number: PCT/US2016/044295
Authority: WO
Inventors: Tarcisio TARCISIO MARCIO ALONSO
Original assignee: Colline Of Florida, Llc
Priority date: 2015-07-27
Filing date: 2016-07-27
Publication date: 2017-02-02
Also published as: EP3329059A4; CA2993960A1; EP3329059A1; US20180223527A1

Abstract

Construction systems and methods of the invention provide building constructions systems which may be assembled, such as for example, by stacking and interconnecting standardized modular blocks between standardized modular posts. The modular posts may be comprised of a sleeve of WPC or other composite material surrounding a reinforced concrete core. The blocks, posts and other components in accordance with the principles of the invention may have a variety of geometries and features. These components may together form the basis of a modular, standardized method and system of constructing dwellings or other buildings.

Description

UNITED STATES PROVISIONAL PATENT APPLICATION

FOR

SYSTEM AND METHOD FOR STANDARDIZED MODULAR CONSTRUCTION

Inventors: Tarcisio Marcio Alonso

Prepared by:

Allen F. Bennett

Reg. No. 50199

Bennett Intellectual Property

531 N. Ocean Blvd., Ste 905

Pompano Beach, FL 33062

Phone: 561-860-0654

Email: allen@afbip.com.

Attorney's Docket No. COLPCT1 TITLE OF INVENTION SYSTEM AND METHOD FOR STANDARDIZED MODULAR CONSTRUCTION

CROSS REFERENCE TO RELATED APPLICATIONS

Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM

LISTING APPENDIX SUBMITTED ON A COMPACT DISC AND INCORPORATION-BY- REFERENCE OF THE MATERIAL

Not Applicable.

COPYRIGHT NOTICE

Not Applicable

BACKGROUND OF THE INVENTION

Field of Endeavor:

[001] The present invention relates to systems and methods for construction of buildings. More particularly, the invention relates to systems and methods for constructing buildings using lightweight standardized modular blocks capable of withstanding extreme temperatures, weight and forces, are heat and flame retardant, easily transported and easily assembled.

Background Information:

[002] There are many conventional construction techniques currently in use. Prevalent techniques include wood frame construction, masonry frame construction, and light-gauge steel construction. Each of these construction techniques has its own advantages and disadvantages, taking into consideration various factors such as cost, energy efficiency, durability, aesthetics, difficulty of assembly, and reliance upon special tools or components which may be necessary for assembly.

[003] Wood frame construction is currently the most commonly used system for residential construction. Although wood as a construction material remains relatively inexpensive, there is growing concern over the quality and quantity of the world's dwindling wood supply. These concerns are particularly acute in countries where native forests have been depleted, and reforestation is not practiced. In terms of difficulty in assembly, wood frame construction requires a basic knowledge of the structural characteristics and capabilities of a variety of wood products and pieces. The carpenter must also have adequate skills and experience to employ the appropriate framing techniques for the structural project at hand. Further, the connection system for the wood components relies upon mechanical fasteners. These fasteners must be selected and assembled through the application of professional skills.

[004] Masonry frame construction is still used in many parts of the world, particularly in third- world countries. Masonry construction can be inexpensive if the raw materials are available locally and the components are manufactured close to the building site. Nevertheless, proper assembly of masonry blocks is labor intensive, time consuming, and requires a fairly high level of skill and experience. After the blocks have been assembled, a suitable roof system must still be constructed and structurally integrated with the upper layer of wall blocks. The point of connection between the walls and the roof is critical, as high winds may cause a catastrophic separation of the two, if the connection is defective or weak. Masonry construction is also subject to damage or complete failure as the result of earthquakes, prevalent in many areas where such construction is commonly undertaken.

[005] A third prior art construction technique which has become more popular in recent years for both commercial and residential structures, is light-gauge steel construction. One advantage of such steel construction is that is does not directly, at least, have a negative impact on the world's forests. Also, steel construction is relatively light weight, and pest-proof However, a disadvantage is that steel construction is structurally similar to wood frame construction, and requires an even higher level of construction knowledge and on-site training. The connection system for steel structural and panel components is based entirely upon mechanical fasteners. The assembly of components with such fasteners must be done properly, through the application of learned skills and the use of necessary tools.

[006] More recently, yet another building technique, using Structural Insulated Panels ("SIPS"), has emerged. In a standard SIPS system, a pre-manufactured panel replaces the framing, sheathing, and insulation used in prior art construction. Typically, a SIP includes either polystyrene foam or polyurethane foam as material for its core. This rigid and dense foam spans the entire thickness of each panel, and provides a desirably high R-factor. Consequently, structures made from SIPS are generally stronger, more energy efficient, and offer a higher and more consistent level of quality than structures employing wood frame construction. However, the fastening system used in the standard SIPS system is similar to that used in wood frame construction. Even though assembly of the standard SIPS system requires a lower degree of construction knowledge than that necessary for wood-stick framing, it still requires basic carpentry skills and the use of heavy equipment to move and locate the large panels which are usually employed.

[007] Wood-plastic composites (WPCs) have been proposed as new building materials for use in constructing homes, offices, factories, sheds, warehouses, or any other type of edifices, and walls, barriers, floors, decks, or other structure. As compared with wood, WPC profiles or planks 200 can have greater durability, lower maintenance costs, and favorable aesthetics, while preserving the use of natural resources. WPC offers improved dimensional stability, a lower moisture absorption, and resistance to fungi. Wood-plastic composites of the disclosure are recyclable, and can be used in traditional thermoplastics processing routes such as extrusion, injection molding, and calendaring.

[008] Thermoplastics which can be combined with wood in the manufacture of WPCs, which in turn are usable in accordance with the disclosure, can include, but are not limited to, High Density Polyethylene (HDPE); Polyvinyl Chloride (PVC); Polypropylene (PP), and Polystyrene (PS). In comparison to lumber, which shows apparent density of 0.35 g/cc for pines and 0.54 g/cc for red maple, wood-plastic composites typically range within 1 and 1.4 g/cc, depending on the formulation, lending to greater strength and durability.

[009] To reduce weight, WPC can be foamed during production. Provided a requisite amount of strength is retained for a particular application of the disclosure, such foamed materials can also be used herein. While plastic lumber formulations of the disclosure can make use of almost 100% of post-consumer recycled plastics, care must be taken with regard to the total amount of recycled resin used, in order to retain the requisite strength, processability and aesthetics of the final product.

[0010] Plastic extrusions can be used to form wall and ceiling panels, and modular building systems, such as are described in U.S. Patent 6,931,803.

[0011] WPC can be fabricated with cellulosic fillers melt compounded with polyolefins and vinyl resins, or other thermoplastic material, taking care to avoid overheating and damaging the cellulosic material. Wood-plastic composites (WPC) have been used to construct decking and fences, furniture, car parts, and applicances.

[0012] The extrusion of WPC is described, for example, in U.S. Patents 5,938,994 and 6,066,680. Reference may further be had to www.strandex.com.

[0013] Log homes, such as are popular in Scandanavian countries and North America, are constructed using interlocking wooden planks. BRIEF SUMMARY OF THE INVENTION

[0014] Accordingly, the primary object of the present invention is to provide an improved system and method of building construction utilizing standardized modular units or components that may be rapidly and easily transported and assembled

[0015] In accordance with an embodiment of the disclosure, one type of modular unit or component for building construction comprises an elongate plank defining a longitudinal axis and having upper, lower, front and back surfaces. The upper and lower surfaces may have mechanisms for interconnecting two or more stacked planks which extend substantially parallel to the longitudinal axes of the units. The interconnectable mechanisms of an upper surface of a lower unitmay be configured to mate with corresponding interconnectable mechanisms on a lower surface of a upper unit. The units or components of the invention may be comprised of WPC, such as a fabricated composite or aggregate mixture if cellulosic material and plastic.

[0016] In various embodiments thereof, the cellulosic material may be 15 to 85 wt% of the mixture, 25 to 75% of the mixture, 35 to 65 wt% of the mixture or 45 to 55 wt% of the mixture.

[0017] In some embodiments, one or more surfaces of the unit may be concave. The concave surface includes an overhanging ledge extending along the longitudinal axis; the plank further comprises an interior extruded with a honeycomb configuration; the plank further comprises interior walls extending from a front of the plank to a back of the plank, and from a top of the plank to a bottom of the plank, the walls mutually intersecting; the interior walls intersect at 90 degree angles; and/or a plurality of planks are stacked to mate the interconnectable shapes of upper and lower surfaces of successively vertically stacked planks.

[0018] In further variations thereof, the front surfaces of a plank are sloped with respect to the back surfaces of the plank; an interior of the plank includes one or more hollow channels extending along the longitudinal axis filled with an insulating foam; the foam is produced by a reaction of reagents within the one or more hollow channels; the reagents include a soy based material and vegetable oil; the mixture further includes one or more chemicals which retard degradation of the plank due to sunlight; and/or the mixture further includes one or more chemicals which retard a flammable combustion of the plank. [0019] In another embodiment of the disclosure, a method of building structures comprises providing an extruded plank defining a longitudinal axis and having upper, lower, front and back surfaces, the upper and lower surfaces having an interconnectable shape extending along the longitudinal axis, the interconnectable shape of an upper surface of a first plank shaped to mateably interconnect with the interconnectable shape of a lower surface of a second plank, the plank fabricated with a melted mixture if cellulosic material and plastic.

[0020] These and other objects and advantages of the present invention will become apparent from a reading of the attached specification and appended claims. There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

[0022] Figure 1 is a top cross-sectional view of an extrusion die in accordance with the principles of the invention;

[0023] Figure 2 is a front view of the die of Figure 1 in accordance with the principles of the invention;

[0024] Figure 3 is a perspective view of a plank in accordance with the principles of the invention;

[0025] Figure 4 is a side view of the plank of Figure 3 in accordance with the principles of the invention;

[0026] Figure 5 is a side view of two adjacent connecting walls of planks of Figs. 3 and 4 in accordance with the principles of the invention;

[0027] Figure 6 is a side view of two adjacent alternative embodiments of connecting walls of planks in accordance with the principles of the invention;

[0028] Figure 7 is a perspective view of intersecting perpendicular walls formed from planks in accordance with the principles of the invention;

[0029] Figure 8 is another perspective view of intersecting perpendicular walls formed from planks in accordance with the principles of the invention;

[0030] Figure 9 is an enlarged perspective view of a notch cut into a plank in accordance with the principles of the invention;

[0031] Figure 10 is a perspective view of an end Of a wall formed from planks in accordance with the principles of the invention; [0032] Figure 11 is a perspective view of an alternative embodiment of a plank in accordance with the principles of the invention;

[0033] Figure 12 is a partial perspective view of an end of a post in accordance with the principles of the invention;

[0034] Figure 13 is a top plan view of a post in accordance with the principles of the invention;

[0035] Figure 14 is a perspective view of an alternative embodiment of a wall constructed from planks in accordance with the principles of the invention;

[0036] Figure 15 is an enlarged perspective view of section "A" of Figure 14;

[0037] Figure 16 is an enlarged perspective view of section "B" of Figure 14;

[0038] Figure 17 is a top plan view of an alternative embodiment of a post and a plank in accordance with the principles of the invention;

[0039] Figure 18 is a perspective view of the alternative embodiment of a post of Figure 17 in accordance with the principles of the invention;

[0040] Figure 19 is a perspective view of an alternative embodiment of a plank in accordance with the principles of the invention;

[0041] Figure 20 is a side elevational view of an alternative embodiment of a wall constructed from the alternative embodiments of planks of Figure 19 in accordance with the principles of the invention;

[0042] Figure 21 is a perspective view of the wall of Figure 20 and accordance with the principles of the invention;

[0043] Figure 22 is a perspective view of an alternative embodiment of a plank in accordance with the principles of the invention;

[0044] Figure 23 is a side elevational view of an alternative embodiment of a wall constructed from the planks of Figure 23 in accordance with the principles of the invention; [0045] Figure 24 is another perspective view of the alternative embodiment of a plank shown in Figure 22;

[0046] Figure 25 is an enlarged perspective view of two adjacent alternative embodiments of a plank in accordance with the principles of the invention;

[0047] Figure 26 is an enlarged perspective view of an alternative embodiment of a plank and a header in accordance with the principles of the invention;

[0048] Figure 27 is a side elevational view of an alternative embodiment of a plank in accordance with principles of the invention;

[0049] Figure 28 is a side elevational view of a header of a wall in accordance with the principles of the invention;

[0050] Figure 29 is a perspective view of an alternative embodiment of a wall constructed from the alternative embodiments of planks of Figure 27 aligned consecutively and connected by means of an alternative embodiment of a post in accordance with principles of the invention;

[0051] Figure 30 is a perspective view of an alternative embodiment of a wall constructed from the alternative embodiments of planks of Figure 27 arranged perpendicularly and connected by an alternative embodiment of a post in accordance with the principles of the invention;

[0052] Figure 31 is an enlarged perspective view of "A" of Figure 30;

[0053] Figure 32 is an enlarged perspective view of the alternative embodiment of the post of Figure 30;

[0054] Figure 33 is a top plan view of the alternative embodiment of the post of Figure 30 in accordance with the principles of the invention;

[0055] Figure 34 is a perspective view of an alternative embodiment of a wall or cladding constructed from an alternative embodiment of planks in accordance with principles of the invention; [0056] Figure 35 is a perspective view of a series of alternative embodiments of planks in accordance with principles of the invention;

[0057] Figure 36 is an enlarged perspective view of the end of an alternative embodiment of a plank of Figure 35 in accordance with the principles of the invention;

[0058] Figure 37 is a side elevational view of an alternative embodiment of a plank of Figure 35 in accordance with the principles of the invention;

[0059] Figure 38 is an enlarged perspective view of two adjacent connected alternative embodiments of planks of Figure 35 in accordance with the principles of the invention;

[0060] Figure 39 is a side elevational view of two adjacent connected alternative embodiments of planks of Figure 35 in accordance with the principles of the invention;

[0061] Figure 40 is an enlarged side view of the interconnection of two adjacent alternative embodiments of planks of Figure 35 including a seal and a bolt in accordance with the principles of the invention;

[0062] Figure 41 is an alternative embodiment of a wall constructed from alternative embodiments of planks in accordance with the principles of the invention;

[0063] Figure 42 is an enlarged perspective view of an alternative embodiment of a plank used in constructing the wall of Figure 41;

[0064] Figure 43 is a side elevational view of an alternative embodiment of a plank of Figure 42; [0065] Figure 44 is an enlarged view of section "A" of Figure 41;

[0066] Figure 45 is a side elevational view of an alternative embodiment of a plank in accordance with principles of the invention;

[0067] Figure 46 is a perspective view of an alternative embodiment of a plank in accordance with principles of the invention; [0068] Figure 47 is a perspective view of an alternative embodiment of a header in accordance with principles of the invention;

[0069] Figure 48 is a perspective view of an alternative embodiment of a post in accordance with principles of the invention;

[0070] Figure 49 is an alternative embodiment of a plank in accordance with the principles of the invention;

[0071] Figure 50 is a perspective view of an alternative embodiment of a plank in accordance with the principles of the invention;

[0072] Figure 51 is a perspective view of a partial building frame constructed in accordance with the principles of the invention.

DETAILED DESCRIPTION

[0073] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

[0074] As required, detailed embodiments are disclosed herein; however, it is to be understood that the disclosed embodiments are merely examples and that the systems and methods described below can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present subject matter in virtually any appropriately detailed structure and function. Further, the terms and phrases used herein are not intended to be limiting, but rather, to provide an understandable description of the concepts.

[0075] The terms "a" or "an", as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms "including" and "having," as used herein, are defined as comprising (i.e., open language). The term "coupled," as used herein, is defined as "connected," although not necessarily directly, and not necessarily mechanically.

[0076] The term "WPC" as used here in refers to a wood plastic composite material. Wood plastic composite materials may be formed from many different materials in various combinations and in various different ratios. They may also include many different additives that may affect the materials' durability, appearance, flame retardancy, tensile strength, rigidity, flexibility, melting point change in volume in response to change in temperature and other parameters or factors. Unless indicated otherwise, either expressly or by implication, a different material may be used in place of WPC so long as the replacement material has suitable qualities.

[0077] As used herein, "components" and "units" are generally used interchangeably and refer to individual pieces that when used together facilitate and are incorporated into a system of constructing buildings as described herein. The components of a system in accordance with the principles of the invention may be further categorized into panels, blocks, posts, planks, plates, platforms, lintels and other components commonly found in building construction. These various components may be described as modules or as module blocks to indicate that they are discrete units which may be combined to form a single building or structure. The components may be considered standardized because each type of components generally has similar geometries and have standard sized and shaped interconnection mechanisms.

[0078] A system of building construction in accordance with the principles of the invention may utilize several different interconnected components having standardized connection means. The various components may be connected to one another, i.e. interconnected, and less time and with less effort than in any conventional building construction methods.

[0079] Formation of a component for use in accordance with the principles of the invention from WPC formulation into a desired final geometry may be accomplished using various techniques. For example, molten WPC may be extruded through a die section to form various components. During optimization of the process, the concentrations of cellulosic material and other materials forming the WPC mixture may be adjusted as required.

[0080] Construction systems and methods in accordance with the principles of the invention provide building constructions systems which may be assembled, such as for example, by stacking and interconnecting standardized modular blocks between standardized modular posts. The modular posts may be comprised of a sleeve of WPC or other composite material surrounding a reinforced concrete core. The blocks, posts and other components in accordance with the principles of the invention may have a variety of geometries and features. These components may together form the basis of a modular, standardized method and system of constructing dwellings or other buildings.

[0081] In an embodiment of the disclosure, the units of the modular standardized building system may have interior cavities such that may include a plurality of hollow spaces within the units. These cavities may be filled with insulating foam or other material, such as for example foam which is produced by a chemical reaction of two agents, for example in a Reaction Injection Molding (RIM) process, while the agents are injected into the hollow spaces. The inclusion of insulating foam may provide a thermal and/or acoustic barrier.

[0082] In one embodment, the WPC used in the manufacture of the components or units of the system may be a blend of polyolefinic thermoplastics, woodflour, and additives which combine to provide structural integrity, flame resistance, and sound and weather shielding, and which can comply with acceptance criteria of applicable building codes.

[0083] The following examples, which are exemplary and non-limiting, illustrate some suitable materials for use in some embodiments of the invention for use in forming the units or components of the modular, standardized construction system.

Example Formulations

[0084] One WPC formulation which may be used for manufacturing extruded WPC profiles of the disclosure, can include a composition of: from 35 to 65 wt% of a polyolefin, for example a virgin or newly produced High Density Polyethylene (HDPE) and/or a blend of virgin HDPE; up to 10 wt% of recycled post-consumer HDPE, for example recycled bottles; up to 10 wt% of a mineral filler, for example calcium carbonate or talc; from 0.5 to 2.0 wt% of a non-metallic stearate lubricant; from 1.0 to 3.0 wt% of a maleic coupling agent; from 0.1 to 0.5 wt% of a thermal stabilizer comprising a blend of an organophosphate and a hindered phenolic antioxidant, the amount of thermal stabilizer dependent on the amount of post- consumer recycled content; from 0.1 to 0.5 wt% of an ultraviolet stabilizer comprising a blend of an ultraviolet absorber and a hindered amine light stabilizer (HALS); and

5 to 15% Halogen-free flame retardants based on monoammonium and diammonium phosphate.

[0085] The foregoing ingredients may be blended, for example in a dryblender, then melt compounded with 35 to 65 wt% of a controlled moisture content powdered wood flour. The composition is advantageously formed into pellets in a manner known in the art, for extrusion as planks 200 in a subsequent step. If PVC is used instead of HDPE, a lower percentage of wood flour or other natural fiber may be advantageous, for example up to 30 to 50 wt%. It should further be understood that about 30-75% natural fiber can be used in various embodiments. It should be understood that the foregoing example is a representative formulation that is advantageously used in carrying out the disclosure, and that there are many different possible formulations which can be used, depending upon the particular requirements of the application.

[0086] In one embodiment, the wood flour, which may be from either or both of soft and hard woods, may have a mesh size of between 40 and 100 mesh, and a moisture content lower than 1%. This may reduce processing fluctuations and equipment wear. Less than about 10 wt% of post- consumer polyethylene may be sourced from bottle scrap, in order to obtain highly predictable strength, durability, and appearance attributes for the final extruded product.

[0087] The above composition may be modified in order to advantageously produce a desired melting flow index suitable for extrusion. In accordance with the disclosure, to produce the disclosed profile geometries, flow indexes ranging from 0.1 to 2.0 g/lOmin (ASTM D-1038) can be achieved with the disclosed formulation of dry blended ingredients which are then melt compounded with treated woodflour in a twin screw extruder. Without being bound to any particular theory, respective roles of various constituents of the formulation are detailed as follows.

[0088] The addition of 5 to 15% mineral filler, for example precipitated calcium carbonate (CaC03) and/or talc may provide improved structural strength of the extruded profiles, while improving their appearance improving the smoothness of the finish Cellulose degradation typically occurs at 200-220 degrees C, and this may be a constraint on WPC processing, as cellulose degradation can release volatiles, cause wood bleaching and colour fading, produce unstable flow and output fluctuations, which may impair the mechanical properties of the WPC product. In accordance with the disclosure, the formulation may include specific chemical additives, including primary and secondary antioxidants, which can retard thermo-oxidative degradation of cellulosic materials during extrusion of the WPC formulation. These may include, for example, synergistic blends of organophosphites and hindered phenolic antioxidants which have low volatility and high resistance to hydrolysis. The use of antioxidant additives may promote proper extrudability of the profiles while avoiding damage due to degradation, which may include discoloration and yellowness.

[0089] A light stabilizing additive may protect from damage due to ambient light, including UV light, and resultant fading and reduced integrity of the matrix resin. In an embodiment, the additive can include any or all of the pigment titanium dioxide, for example from 0.5-3wt%, and light or UV stabilizers, such as UV absorbers (UVAs), that act by shielding the polymer from ultraviolet light, and hindered amine light stabilizers (HALS), that act by scavenging the radical intermediates formed in the photo -oxidation process. Examples include benzophenones and benzotriazoles, or blends of these, as described in U.S. Patent 8,901,209.

[0090] To improve interface properties between the cellulosic filler and the polyethylene copolymer, a maleic coupling agent, for example maleic anhydride with a melt flow index within the range of 20 to 100 grams/10 min, may be added. This may produce, for example, maleic anhydride grafted polyolefins with a melt flow index ranging from 100 to 120g/10min). (ASTM D 1238 - 190°C/2.16kg) with maleic graft index ranging from 1 to 3.0%. The coupling agent may improve wettability of the cellulose filler by reducing the surface tension at the wood-plastic interface, improving mechanical strength and resistance to delamination and moisture uptake by the composite. This may result in improved dimensional stability of the extruded profile embodiments by reducing moisture uptake during a service life of the planks 200, posts 240, or other extruded WPC components of the disclosure.

[0091] Improved filler dispersion, and wetting of the filler surface may be achieved by using a lubricant, for example a non-metallic stearic lubricant. The result is improved processability and rheology for higher extrusion throughput. Lubricants can also include a blend of complex modified fatty acid esters.

[0092] Fire retardancy, for example to meet IBS standards, can be improved by the addition of halogen-free flame retardants and smoke suppressants, such as zinc borate or a molybdenum derivatives. [0093] Organic or other pigments may be added for improved aesthetics and long-term proof resistance to colour fading.

[0094] Resistance to degredation by insects may be improved by the addition of a biocide, for example zinc borate, advantageously with proven resistance to termites, mildew and fungus.

Example Processing

[0095] Using the foregoing example formulation, or other suitable WPC compositions, components cmay be produced in accordance with the disclosure using the following process. Processing of pelletized wood plastic composite is performed using a counter-rotating conical twin screw extruder, having a screw diameter front and rear of 92 and 188 mm, respectively. Five heating zones are provided in the barrel, and degassing means are positioned at half of the length of the screws. The counter-rotating twin screw extruder used in the invention was designed to meet throughput rates up to 2,600 lbs/hr. The screws have three distinct zones: feeding, conveying, and metering, which are designed to provide high head pressure capabilities and high torque for gentle plastification of the melt to feed the die shown in FIG. 1. The equipment is selected for heat and shear sensitive materials such as WPC. More particularly, it is desired to have a narrow residence time in order to produce optimal melt conditions for feeding the die with a homogeneous and continuous flow melt.

[0096] In accordance with the disclosure, it may be advantageous to have a melt temperature of about 150 to 170 degrees C, and a die temperature of 130 to 180 degrees C. Screw speed may be between about 10 and 20 rpm, with a melt pressure of between 5 and 15 Mpa.

[0097] An embodiment of tooling to provide the final geometry of a profile of the disclosure is shown in FIG. 1. Dual cavity extrusion dies may be used for manufacturing the extruded profile geometries depicted in some of the Figures. Flow channels 112 may be designed to promoting a balanced and evenly distributed flow throughout the cross section of the tool, with a homogeneous heating distribution within the die. This promotes controlled viscosity and a balanced downstream molten flow into die, to accurately produce the final profile geometry of the extruded plank.

[0098] Referring now to FIG. 1, a transverse cross-section of an extrusion die 110 of the disclosure reveals two cavities 108 for simultaneously producing two extruded plancks 200. In this example, the plancks 200 formed using die 110 may have a convex external geometry, as can be seen in FIG. 2. Runners or flow channels 112 are designed to promote a balanced, even flow through and out of die 110. Heaters 114 maintain an optimal temperature distribution of the composition as it moves through channels 112 and past the die lips 118, in order to control a viscosity of the composite melt to balance a downstream flow to produce a correct final geometry of the extruded profile plank.

[0099] The plank 200 shown in Figures 3 and 4 provides one type of component that may be useful for a system of construction in accordance with the present invention. A plank 200 may have a facing surface 203, a rear surface 205 and two opposite connecting surfaces 210 and 211. The facing surface 203 may typically be the surface of the plank positioned on the outside of a wall or other surface built from planks and may be the most aesthetically pleasing. In this embodiment, the facing surface 203 is slightly convex. If several planks 200 are aligned parallel to one another and engaged by means of their connecting surfaces to 10, it may give the appearance of several logs or other rounded objects aligned or stacked. Planks 200 may be used to form walls, ceilings, roofing, floors or other surfaces. Planks 200 may also be formed sufficiently thick that they may be used to serve simultaneously as the framing for a wall as well as its cladding, insulation and other components. Optionally, the rear surface 205 may also serve as a facing surface for the interior of a building or other structure. The connecting surfaces 210 and 211 may include complementary attachment mechanisms.

[00100] Figure 5 shows an enlarged view of corresponding complementary connecting surfaces 210 and 211. Connecting surface 211 may include two ridges 224. Each of the ridges 224 may include a small rib 228 on each side. The ridges 224 and their ribs 228 may extend all or part of the longitudinal length of a plank 200. The connecting surface 210 may have two channels 229 corresponding to the two ridges 224. Each of the channels 229 may include a small groove 229 on either side corresponding to the ribs 228. The ridges 224 and channels 226 may be sized such that they are surfaces lies substantially flush when the ridges 224 are inserted into the channels 226. The ribs 228 and the grooves 229 may be slightly angled such that the ribs 228 may be securely snapped into place. This may secure two adjacent planks 200 securely to one another.

[00101] Figure 6 shows alternative embodiments of two connecting surfaces 240 and 241. The connecting surface 241 may include two ridges 244 and the connecting surface 240 may include two channels 246. The two channels 246 may include two grooves 250. In this embodiment, the ridges 244 may also have two grooves 248 instead of ribs like the one shown in Figure 12. The ridges 244 may be sized slightly smaller than the channels 246 to provide a small space between the two structures when the ridges 244 are inserted into the channels 246. A glue, which may have elastomeric properties when dry, may be used along the connecting surfaces 240 and 241. The grooves 248 and 250 along both the ridges 244 and channels 246 may retain some of the adhesive to better secure two adjacent planks 200 together.

[00102] Numerous other complementary connecting surfaces are known in the art and many may be suitable. For example ridges and channels without ribs or grooves may be used. Connecting mechanisms may utilize interference fit, snapping into place, nuts, bolts, screws, rivets and other devices.

[00103] Planks 200 of any length may be extruded, but may typically be about 20 feet long for convenience in storage, packaging, and/or distribution. The longitudinal length of the plank 200 may be defined by the end surfaces 209. As may be seen from viewing and in surface 209, the interior 207 of the plank 200 has been shaped to form a plurality of cavities 220 parallel to the longitudinal axis of the plank. These cavities 220 may be defined by interior walls 222 that are parallel to the connecting surfaces 210 and several interior walls 223 that may be substantially perpendicular to interior walls 222. The perpendicular relationship of interior walls 222 and interior walls 223 results in the cavities 220 having a substantially rectangular cross-section and having a substantially parallelepiped shape. The cavities 220 may generally extend the entire longitudinal length of the plank 200. When as here one of the surfaces is convex or other shape, some of the channels may be rectangular or curved or have other geometries. The placement of cavities 220 with in the planks 200 may reduce their weight and the amount of material required to form them. The honeycomb structure may allow this reduction in weight and materials without sacrificing strength.

[00104] Planks may have any length, and that the lengths illustrated in the Figures of this disclosure are not to be construed as limiting. Further, planks may have any length and width, subject to applicable constraints of production and use.

[00105] Referring now to FIGS. 7 -10 it may be seen that the planks 200 may be connected in a configuration providing a building resembling a log home. As explained above, planks 200 may have a facing surface 203 which is convex. A notch 282 may be removed from plank 200, for example by cutting or stamping. In the partly exploded view of Figure 7, it may be seen that notch 282 of plank 200 may receive an upper portion, for example about one half, of a plank 200 positioned perpendicularly. This plank 200 may be similarly notched to receive a similar portion of a successive plank 200. The lower portion of Figure 7 illustrates several planks 200 thus interconnected to form two walls and a corner of a building. Any of a variety of means can be used to more fixedly connect the planks interwoven and interconnected in this manner, including adhesive, screws, bolts, rivets, straps, braces, ultrasonic welding, melting, or any other known or hereinafter developed method. In the illustration, planks 200 are interconnected to form perpendicular walls 230. Notches 282 can be cut on a bias angle to enable any particular angular disposition of planks 200. In this manner, a building may be constructed relatively easily, but also securely and having desirable properties.

[00106] A series of walls 230 formed by interconnected planks 200 may form a dwelling with the appearance of a log home, or any other structure, including a shed or barn, or any other building, or an open structure, such as a fence, corral, or barrier, for example using planks 200 to form walls disposed in alternating directions.

[00107] End caps 284 are shown in Figures 8 - 10 and may serve, in part, to cover and conceal the interior of the planks 200, which may include an interior honeycomb structure. This may form a more finished appearance, and may further protect the interior of the planks 200. End caps 284 may prevent plants, animals, rain and water, fire, debris and other things from entering into an interior of planks 200. End caps 284 may be sized and dimensioned to cover the ends of any of the plank 200 alternative embodiments disclosed herein. In Figures 8 - 10, it may be seen that end caps 284 may have a scalloped shape to conform to and seal an intersection of the notched and nested planks 200. The embodiment shown in Figure 10 may include rounded profiles on opposing sides thereof, to better mimic the appearance of a log on protruding ends of planks 200, particularly where plank 200 is flat on a side opposite a rounded, log-like side.

[00108] Figure 11 shows an alternative embodiment of a plank 300. The plank 300 may be constructed in a manner similar to plank 200 above. It may include interior walls 322 perpendicular to interior walls 323, which may thereby form cavities 320. The plank 300 may also include a facing surface 303, rear surface 305 and two connecting surfaces 310 and 312. The facing surface 303 may be textured or otherwise designed to be as aesthetically pleasing. Each of the planks 300 may have a length defined by two end surfaces 309. The end surfaces 309 may be substantially flat.

[00109] Figures 12 and 13 show a modular standardized post 350. The post 350 may include one or more flat facing surfaces 352 and one or more interconnecting surfaces 354. Facing surfaces 354 may include a connecting bed 342 defined by one or more connecting lips 340. The connecting surfaces 310 and 312 may have connecting mechanisms similar to those shown in Figures 5 - 6. During construction of a building or other structure, the planks 300 may be attached side-by-side and there end surfaces 309 may be placed within connecting beds 342 of two posts 350, as shown in Figures 13 - 15.

[00110] Figure 14 shows planks 300 stacked vertically to form two wall sections 332 and 334 joined by a connecting post 350. Each wall 332 and 334 are shown as constructed using six planks 300 for clarity in the illustration. It may be noted that for practical, design flexibility, and strength considerations, the height of the planks 300 may result in stacking 13-14, or more planks 300, in order to form a wall, depending upon the height of each plank 300. Another plurality of planks 300 may be inserted into the connecting bed 342 of a post 350 on an adjacent side of the first post 350. The posts 350 may have other configurations which form different angles, and different numbers of connections. Aplurality of posts 350 may join walls 330 to form an enclosing perimeter or other structure.

[00111] Figure 15 shows in detail section "A" which includes an end portion of plank 300 inserted into a connecting bed 342 of a post 350. In one embodiment, plank 300 may be retained within a connecting bed 342 by an interference fit between planks 300 and the lips 340. In another embodiment, an adhesive may be used to connect post 350 to plank 300. Other methods of connection may also be used. Post 350 may include any number of connecting beds adapted to join any number of wall sections 230. Figure 16 shows in detail section "B" which shows connecting surfaces 310 and 312 of adjacent stacked planks 300 having there end surfaces 309 flush so that they may be inserted into a connecting bed 342. [00112] The post 350 may include a hollow exterior comprised of WPC or a similar material and may include one or more aesthetically pleasing surfaces such as facing surfaces 352. In other embodiments, post 350 may be made of another material, and may have increased strength relative to planks 200. The posts 350 may be constructed to support a load, such as a roof, or to provide additional strength to connected walls, for example to bear forces imparted by a high wind load. For example, a post 350 may be formed with steel reinforced concrete, or metallic tubing or channels. Post 350 may be larger or smaller than depicted. Post 350 may optionally have a triangular profile, or a partly circular profile.

[00113] During construction, it may be desirable to first erect one or more posts 350 at a desired location and fill the post 350 with reinforced concrete, for example including rebar. Planks may then be successively stacked on top of one another as they are slid down the connecting beds of the posts.

[00114] Figures 17 and 18 show an alternative embodiment of a post 380 for use in the present invention. Post 380 may include one or more facing surfaces 382 and 384 and two or more connecting surfaces 386. Each connecting surface may include a connecting bed 388 defined by a short lip 390 and a complex lip 391. The complex lip 391 may include an interior groove 392. This post may be utilized to form a more secure engagement with a plank 394 having a bulge 396. In this embodiment, the plank 394 only includes one bulge 396. Optionally, the post 380 may include two complex lips 391, each having an interior groove 392 for connection to a plank having a bald on each side.

[00115] Figure 19 shows an alternative embodiment of a plank 400. As with the other planks, plank 400 may include a facing surface 403, a rear surface 405 and two connecting surfaces 410 and 412. Plank 400 may also include an interior honeycomb structure and may have a length defined by two end surfaces 409. In this embodiment, plank 400 includes a facing surface 403 that is concave rather than convex.

[00116] Figure 20 shows two of the planks 400 of Figure 19 connected by engagement of their respective connecting surfaces 410 and 412. Figure 21 shows a wall 430 formed by connecting several planks 400. The wall 430 may be placed between two posts to secure it in place in a structure. [00117] Figures 22 - 24 show planks 500 individually and interconnect. Plank 500 may have a facing surface 503 that may give the appearance of cladding. A lower lip 515 may extend partially over the upper connecting surface 512 of a lower plank 500 win it engages the lower connecting surface 510 of the upper plank 500.

[00118] Planks 500 are interconnected along top connecting surface 510 and bottom connecting surface. Plank 500 may include a slanted surface 503 from which a lip 515 extends downward covering the interface between the bottom connecting surface 510 and the top connecting surface 512 of the plank 500 below it.

[00119] Ridges 513 on top connecting surface 512 may be partially compressed during an interference fit into the channels 514 on the lower connecting surface 510 and 514, to form a water tight seal. Additionally or alternatively, a resilient gasket may be intercalated between the connecting surfaces 510 and 512 or at another location to form a watertight and/or gas tight seal between connected planks 500. In all embodiments, a connection between planks, a wall and/or a post may be carried out using clips, screws, bolts, adhesive, or other methods.

[00120] Figures 25 - 33 show alternative embodiments of planks 600 and posts 650 in accordance with the principles of the invention. Like other planks, planks 600 and have a first connecting surface 610 having one or more ridges 613, and a second connecting surface 612 having one or more channels 614 configured to interface with the ridges 613. As with other embodiments, the ridges 613 and channels 614 may engage by means of an interference fit and/or the use of glue or adhesives and may include additional structures as explained in Figures 5 and 6.

[00121] Multiple stacked planks 600 may be used to form a wall 630. A wall 630 may include a header 690. A header 690 may include ridges 692 such that it may securely engage a connecting surface 610 of a plank 600. The header 690 may also include flat facing surfaces 694 and a planar, flat upper surface 691.

[00122] Walls 630 may be joined consecutively using a post 650, or may be joined in a perpendicular configuration using a post 670. A post 670 may include connecting beds 674 between facing surfaces 673. The post 670 may also define one or more interior cavities 672 that may be filled with concrete, reinforced concrete or other material. [00123] Figures 37 - 40 show another alternative embodiment of planks 700 designed to imitate cladding. Plank 700 may be used to construct a wall 730, or alternatively may be used to form a facade over another wall. The plank 700 may include a slanted facing surface 703 that may include a pattern such as for example a series of parallel horizontal lines. The plank 700 I also include one or more interior cavities 720 that may run longitudinally along the width of the plank. The plank 700 may have a top connecting surface 710 and a bottom connecting surface 715. The top connecting surface may include a ridge 711 complementary to a channel 718 in the bottom connecting surface 715 of the plank 700. The channel 718 may also include a groove 719 in which a gasket or seal 750 may be housed. The use of seal 750 may result in the wall being impermeable. Optionally, a screw or bolt 752 may be placed through the plank 700 and extends out the back surface 708 and into a wall covered by the planks 700.

[00124] Figures 41 - 44 show another alternative embodiment of planks 800 that may be used as a facade on another wall or for a similar purpose. A plank 800 may include a facing surface 803, a top connecting service 810 and a bottom connecting surface 812. The top connecting surface 810 may include a ridge 818 configured to fit within a channel 815 on the bottom connecting surface 812. Optionally, a seal 850 may be incorporated into the connection between the ridge 818 and the channel 815. The top connecting surface 810 may optionally include a cover 817 designed to be flush with the back portion of bottom connecting surface 812.

Compression Test Loading

[00125] Planks in accordance with the principles of the invention may be tested for resistance to compression loading. A WPC composition suitable for use in the present invention may include 30-50% natural fibers, up to 10% mineral filler, 3-8% lubricants, no coupling agent, 2-6% color and U/V protection, 1-3% heat stabilizer, and up to 2% biocide, with the remainder comprising a PVC polymer.

[00126] A plank 900 shown in Figure 45, measuring 15.5 cm wide, 19 cm tall, and having one half to 1 cm thick walls and constructed of the material described immediately above may be compression tested in all three cardinal directions. Speed for the test may be conducted according to ASTM methods D695-10 Standard Test Method for Compressive Properties of Rigid Plastics at 1.3 mm/min. The segment was fully covered at the top and bottom, and loaded to failure at a constant crosshead speed per ASTM D 695-10 Section 9. Load-deflection data was recorded at 0.5 sec intervals during testing.

[00127] In addition to testing, Euler buckling loads were calculated as shown in Table 2, using the thickness of the column sections and their lengths. The moment of inertia was calculated using the formula I=(Lt³/12). Euler buckling load for a single column was determined using the equation Ρ=Νπ²ΕΜι², where where: I = the moment of inertia for the column section, L = the length of the test specimen, t = the thickness of the individual column section, P=the Euler buckling load for the individual column, E=Material modulus of elasticity, and h=the height of the column section.

[00128] The total cross section buckling capacity was calculated as the sum of the column capacities. A modulus of elasticity of 4140 MPa (about 600,000 psi) was estimated for a PVC based wood-plastic composite, and 2070 MPa (about 300,000 psi) for a polyethylene based wood- plastic composite. These figures were used for calculations of the ultimate buckling load if the structure failure occurs in a brittle manner, as observed during the test performance. Test results are shown in Table 1.

Table 1 - Compression Test Results

Table 2 - Euler Buckling Analysis

X-Direction kN Type Note

Ptotal = 4864.0 PVC for fixed-fixed end conditions

Ptotal = 1216.0 PVC for fixed-fixed with side

Ptotal = 2432.0 Polyethylene for fixed-fixed end conditions Ptotal = 608.0 Polyethylene for fixed-fixed with side

Y-Direction

Ptotal = 2299.2 PVC for fixed-fixed end conditions

Ptotal = 574.8 PVC for fixed-fixed with side

Ptotal = 1149.6 Polyethylene for fixed-fixed end conditions

Ptotal = 287.4 Polyethylene for fixed-fixed with side

[00129] Comparison of the test results with the Euler Buckling analysis illustrate that much greater strength is available within the design of plank 900. The plank segment 900 of FIG. 45 is a pre- production prototype. The planks described in Figures 1-44 may be suitable for use in construction if they exhibit the same results using the test methods described herein. Such planks may have more than enough strength to serve as wall members for dwellings, offices, storage facilities or other structures. More particularly, the results show that the planks are capable of supporting more than their own stacked weight, and can even be used as load bearing members of such structures, and that they have sufficient strength for many other applications.

[00130] The use of planks and posts in accordance with principles of the invention may have advantages in terms of assembling simplicity, reduced scrap in construction sites, and uses renewable resources in its manufacturing process that qualifies for green building certification LEEDS - Leadership in Energy & Environmental Design. The disclosure can provide modular building systems that are produced from renewable resources, and which contain renewable and recycled materials, in compliance with existing building construction recommendations, such as the International Code Council (ICC) and International Building Code (IBC). Furthermore, the proposed building systems contribute to substantial reduction of materials used in construction sites, and are eligible for points and verifiable attributes within the Green Building Standards, in accordance to ICC-ES Evaluation services.

[00131] Figure 46 shows an alternative embodiment of a plank 910 similar to infer use with planks 500. Figure 47 shows an alternative header 920 that may be used on top of or below walls constructed of planks in accordance with the invention. Optionally, a header 920 may also be used for the ends of walls. Figure 48 provides an alternative embodiment of a post 930 that may engage ridges or channels on the ends of or on top of walls constructed from planks as disclosed herein.

[00132] Figure 49 shows a plank 940 similar to the planks shown in figures 5 - 10 but does not include an interior honeycomb structure. Plank 940 may be useful for creating a facade over an existing wall. Optionally, plank 940 may be used as a post or as a header for a wall. Figure 50 shows a plank 950 that may include a few channels 952 but otherwise be more solid than the other planks or posts shown herein.

[00133] Figure 50 shows an initial stage of construction of a frame 1000 for a building in accordance with the principles of the invention. First, pilings 1006 are inserted into the grounds in accordance with typical construction practices. The pilings 1006 may be concrete, reinforced concrete or other materials used in the art. Next, posts 1010 are fitted over the pilings 1006 by sheathing the pilings 1006 using posts as described herein. Footers 1004 may be placed between the posts 1010 after the posts 1010 have been erected. The headers 1008 may be incorporated into the frame before or after planks have been inserted to form walls.

[00134] All references cited herein are expressly incorporated by reference in their entirety. It will be appreciated by persons skilled in the art that the present disclosure is not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. There are many different features to the present disclosure and it is contemplated that these features may be used together or separately. Thus, the disclosure should not be limited to any particular combination of features or to a particular application of the disclosure. Further, it should be understood that variations and modifications within the spirit and scope of the disclosure might occur to those skilled in the art to which the disclosure pertains. Accordingly, all expedient modifications readily attainable by one versed in the art from the disclosure set forth herein that are within the scope and spirit of the present disclosure are to be included as further embodiments of the present disclosure.

[00135] Whereas, the present invention has been described in relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention. Descriptions of the embodiments shown in the drawings should not be construed as limiting or defining the ordinary and plain meanings of the terms of the claims unless such is explicitly indicated.

[00136] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

Claims

1. A modular standardized system for building construction comprising:

One or more planks having a facing surface, a rear surface, and two connecting surfaces, wherein the connecting surfaces are configured to engage one another and may form a wall;

Optionally including one or more posts between walls that are parallel or perpendicular to each other.