PCT INTERNATIONAL APPLICATION

of

Guy L. Marker

and

Grant Golightly

for

COLUMN AND BEAM CONSTRUCTION

Column and Beam Construction

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application corresponds to a prior U.S. national application entitled, "Column and Beam Construction," filed May 29, 2007, and having attorney docket number 1006.U04, which claims priority to U.S. Provisional Patent Application No. 60/809,515, filed May 30, 2006, entitled, "Column and Beam Systems," which is incorporated herein by reference. In addition, the present application is related to three co-pending PCT International Applications also filed May 30, 2007: "Exterior Wall Construction," attorney docket no. 1006.N02; "Interior Wall Construction," attorney docket no. 1006.N02; and "Floor and Roof Construction," attorney docket no. 1006.N05.

TECHNICAL FIELD

[0002] This invention relates generally to construction materials. More particularly, embodiments of the present invention relate to construction using foam materials as concrete forms.

BACKGROUND ART

[0003] Polystyrene, a polymer discovered in the nineteenth century, is a highly useful material having a wide variety of applications that is manufactured for use in numerous commercial enterprises. One of the most common uses of polystyrene, however, is expanded polystyrene, which is used for making such products as packing material, craft and model materials, and take-away food cups and containers. [0004] In addition to these uses, expanded polystyrene is one of several foams used in making insulated panel building materials. These building materials, also referred to as insulated concrete forms, are used to form molds for use in constructing walls of buildings. Most commonly, an insulated concrete form for a portion of wall is set in place and the concrete is then poured into the insulated concrete form. The form then remains in place, where it acts as insulation both for curing the concrete and as general insulation for the building or structure being constructed. [0005] Using foams for building construction provides numerous benefits. For example, foams serve as excellent insulators helping to reduce energy costs. Foams also provide superior sound absorption and their use contributes to fast construction of

buildings, thereby creating competitive costs for using foams when compared to conventional building methods such as wood framing. These benefits have led to increased use of foams in building certain portions of buildings, such as exterior walls built using insulated concrete forms.

[0006] Although foams are used extensively in manufacturing insulated concrete forms for exterior walls of buildings and other structures, use of foams for other building systems and materials is not widespread. What is needed are systems and methods for configuring expanded polystyrene for interior walls of buildings and other structures.

DISCLOSURE OF INVENTION

[0007] Embodiments of the present invention include construction systems for columns and beams, construction system forms for columns and beams, and methods of constructing column and beam systems. In one embodiment of the invention a construction system form includes panels configured on top of, adjacent to, and opposite each other to form a construction system having any length, width, height, and shape. A connector .system connects opposite panels while fasteners secure adjacent panels. When the concrete form is completed, concrete is poured into the cavity defined by the form to create one distinct monolithic unit. Thus, embodiments of the present invention provide column and beam systems configured of concrete having minimal structural discontinuities.

[0008] These and other aspects of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.

BRIEF DESCRIPTION OF DRAWINGS

[0009] To further clarify the above and other aspects of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The drawings are not drawn to scale. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which: [0010] Figure 1 shows an isometric view of a configuration of panels of a construction system;

[0011] Figure 2 shows embodiments of a connector system; [0012] Figure 3 shows an isometric view of a construction system form for columns;

[0013] Figure 4 shows embodiments of a rebar stand;

[0014] Figure 5 shows an isometric view of a construction system for beams; and [0015] Figure 6 shows a method for constructing a column and/or beam system.

MODES FORCARRYINGOUTTHE INVENTION

[0016] Embodiments of the present invention include systems and methods for building concrete columns and beams using foam forms, such as, for example, expanded polystyrene forms. Column and beam systems of the present invention include panels, a connector system, and fasteners. Panels are configured on top of, adjacent to, and opposite each other in any arrangement to create a column or beam having any specified length, width, and height. The connector system engages interior sides of panels that are positioned opposite each other, thus securing the position of the panels and enhancing the stability of the panels. In addition, fasteners, placed on top of adjacent panels, also secure the position of adjacent panels and enhance the stability of the panels. When the concrete form for the column or beam has been completed, concrete is poured into the form creating one distinct monolithic unit.

[0017] With attention now the Figure 1, a configuration of panels 100 of a column construction system are shown. Panels 102, 104, 106, 108, 110, and 112, having any length, width, and height, include interior sides and exterior sides. For example, panels 102 and 104 include interior sides (not shown) and exterior sides 114 and 116, respectively. Similarly, panels 106 and 108 include interior sides 118 and 120, respectively, and exterior sides (not shown). In one embodiment of the invention panels 102, 104, 106, 108, 110, and 112 are made of foam material, such as, for example, a cement-foam composite, polyurethane foam polystyrene foam, expanded polystyrene, and extruded polystyrene.

[0018] In addition, each of panels 102, 104, 106, 108, 110, and 112 includes a top, such as top 122 of panel 112, and a bottom (not shown). Each top of panels 102, 104, 106, 108, 110, and 112 includes protrusions 124. Likewise, each bottom of panels 102, 104, 106, 108, 110, and 112 includes openings configured to engage protrusions 124 when panels are positioned on top of each other. Finally, panels 102, 104, 106, 108, 110, and 112 include openings 126 on the interior sides of the panels. [0019] In operation, panels 102, 104, 106, 108, 110, and 112 are configured in any arrangement. For example, in one embodiment of the invention panels 102 and 104 and configured adjacent to each other, while panels 102 and 106 are configured opposite each other. In addition, panel 112 is configured on top of panels 106 and 108 and adjacent to panel 110. Protrusions 124 of panel 106 engage openings located

on the bottom (not shown) of panel 112. Further, in one embodiment of the invention anchor base plates 128 are configured to engage panels 102 and 104, thus attaching panels 102 and 104 to a base structure 130. Base plates 128 may be fabricated from steel, galvanized steel, or any other metal or other suitable material. [0020] Although the configuration of panels 100, shown in Figure 1, is substantially cubical in shape, it is to be appreciated that embodiments of the present invention anticipate any variety of shapes of the configuration of panels 100, such as, for example, triangular, circular, polygonal, and any other shapes. Further, embodiments of the present invention include configurations of any number of panels to form a column system having any length, width, and height. Configuration of panels 100 is discussed in further detail below with reference to Figures 3 and 5. [0021] Directing attention now to Figure 2, a connector system 200 for connecting panels is shown. Connector system 200 includes one or more end pieces 202, one or more receptacles 204, and one or more connectors 206. In one embodiment of the invention connectors 206 ^• are plastic wall chains and may include couplers (not shown) to connect multiple plastic wall chain sections to form a longer section of plastic wall chain. Further, in another embodiment of the invention the end pieces 202, receptacles 204, and connectors 206 are made of plastic, acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), metal, or any other material. [0022] In addition, in one embodiment of the invention shown in Figure 2, connector system 200 includes a first end piece 208 and a second end piece 210. Receptacles 212 are mounted onto first end piece 208, while receptacles 214 are mounted onto second end piece 210. Receptacles 214 are configured to engage connectors 216 and may be configured of any shape and/or size depending on the shape and size of connectors 216.

[0023] In operation, end piece 208 engages an opening on the interior side of a first panel (not shown), while end piece 210 engages an opening on the interior side of a second panel (not shown), with the second panel configured opposite the first panel. Connectors 216 traverse the distance between the first panel and the second panel, attaching to receptacles 212 of end piece 208 and receptacles 214 of end piece 210. In this way the connector system 200 secures and stabilizes the first and second panels configured opposite each other. Moreover, in one embodiment the connector system 200 reinforces concrete that will be poured into the form created using the connector

system, panels, and other components. Connector system 200 is discussed in further detail below with reference to Figures 3 and 5.

[0024] As suggested by the preceding discussion, the connector system 200 is an exemplary structural implementation of a means for connecting panels. Generally, such means serve to connect, stabilize, and secure panels positioned opposite each other. Other examples of a means for connecting panels include any other part of, or attachment to, a construction system form for columns or beams that engages opposite panels and helps to maintain the position of the panels and to enhance the stability of the panels.

[0025] With attention now to Figure 3, Figure 3 shows a cut-away view of construction system form 300 for columns. Construction system form 300 includes multiple panels, such as panels 302, 304, 306, 308, 310, and 312. Each panel may include two or more sub-panels configured together as a panel. Further, panels 302, 304, 306, 308, 310, and 312 may be configured in an arrangement having any length, width, and height. Coordinate system 314 shows x, y, and z-axes corresponding to the length, width, and height dimensions, respectively, of construction system form 300. More particularly, panels 302, 304, 306, 308, 310, and 312 maybe configured in an arrangement on top of, adjacent to, and opposite each other, forming a construction system form having any length, width, height, and shape.

[0026] In addition to having the capability of being arranged to have any length, width, and height, panels 302, 304, 306, 308, 310, and 312 may be configured to have any shape. For example, in one embodiment of the invention panels 302, 304, 306, 308, 310, and 312 are configured in a rectangular prism arrangement, as shown in Figure 3. In other embodiments of the invention panels 302, 304, 306, 308, 310, and 312 may be configured in other shapes, such as, for example, cubical shapes, pyramid shapes, and any other three dimensional polygonal shapes. Moreover, in one embodiment of the invention panels 302, 304, 306, 308, 310, and 312 are configured of a foam material, such as, for example, a cement-foam composite, polyurethane foam polystyrene foam, expanded polystyrene, and extruded polystyrene. [0027] While panels 302, 304, 306, 308, 310, and 312 shown in Figure 3 may be configured of a foam material, each of panels 302, 304, 306, 308, 310, and 312 further includes an interior side and an exterior side. For example, interior sides 316 of panel 306 and 318 of panel 308 are shown in Figure 3. In addition, exterior sides 320 of

panel 302 and 322 of panel 304 are also shown in Figure 3. Interior sides 316 and 318 face the interior portion of construction system form 300. In other words, interior sides 316 and 318 face the cavity, or the space surrounded by panels 302, 304, 306, 308, 310, and 312, created by construction system form 300. In contrast, exterior sides 320 and 322 face the away from the cavity created by construction system form 300. In other words, exterior sides 320 and 322 are located on the outside surface of construction system form 300.

[00281 In addition to interior and exterior sides, panels 302, 304, 306, 308, 310, and 312 also include openings 324. In one embodiment of the invention openings 324 may be a channel, a groove, a furrow, or any other elongated opening extending along the height of the interior sides of panels 302, 304, 306, 308, 310, and 312. [0029] Moreover, each of panels 302, 304, 306, 308, 310, and 312 further includes a top, as shown by top 326 of panels 310 and top 328 of panels 312, and a bottom (not shown). Top 326 and top 328 include protrusions 330. Protrusions 330 may be configured of any shape, such as, for example, a substantially cubical shape. Bottom of panels 302, 304, 306, 308, 310, and 312 include openings configured to engage protrusions 330 when one panel is positioned on top of another panel. The openings located on the bottom of panels 302, 304, 306, 308, 310, and 312 are configured of any size and shape corresponding to the size and shape of protrusions 330.

[0030] In addition to panels 302, 304, 306, 308, 310, and 312, construction system form 300 further includes a fastener 332. In one embodiment of the invention fastener 332 is manufactured of one or more of plastic, PVC, ABS, or metal. Also, fastener 332 may be configured to have any number of configurations. For example, in one embodiment of the invention shown in Figure 3, fastener 332 is configured to have two substantially straight ends forming a 90° angle. In other embodiments of the invention fastener 332 is configured to be substantially straight, while in another embodiment of the invention fastener 332 is configured to be adjustable such that a first and a second end of fastener 332 are capable of forming an acute, orthogonal, or obtuse angle. Finally, fastener 332 includes openings 334 configured to engage protrusions 330.

[0031] As suggested by the preceding discussion, fastener 332 is an exemplary structural implementation of a means for fastening two or more panels in a secure

position. Generally, such means serve to fasten two or more panels configured adjacent to each other. Moreover, such means serve to maintain and secure the configuration of panels configured adjacent to each other. Other examples of a means for fastening include any other part of, or attachment to, the construction system form 300 that maintains and/or secures panels adjacent to each other. [0032] Construction system form 300 not only includes panels 302, 304, 306, 208, 310, and 312, and fastener 332, construction system form 300 also includes connector system 336, configured in the interior of the construction system form 300. As noted above with reference to Figure 2, connector system 336 includes end pieces 338, receptacles 340, and connectors 342. Each of end pieces 338, receptacles 340, and connectors 342, are, in one embodiment of the invention, made of one or more of plastic, ABS, PVC, and metal.

[0033] In operation, construction system form 300 is constructed as panels 302, 304, 306, 308, 310, and 312 are configured in an arrangement such that panels 302, 304, 306, 308, 310, and 312 are positioned on top of, adjacent to, and opposite each other. Panels 302 and 304, positioned as the bottom-most panels of construction system form 300, are engaged by anchor base plates 344. Anchor base plates 344, which, in one embodiment of the invention are configured of steel, galvanized steel, or any other metal, attach panels 302 and 304 to a floor or other base structure of a building.

[0034] Further, fasteners, such as fastener 332, are configured on the top of adjacent panels, such as tops 326 and 328 of panels 310 and 312. Openings 334 of fastener 332 engage protrusions 330. In this way, fastener 332 provides security and stability to adjacent panels 310 and 312.

[0035] The security and stability of construction system form 300 is further enhanced by connector system 336. End pieces 338 of connector system 336 are placed in openings 324 located on the interior sides of panels 302, 304, 306, 308, 310, and 312. Receptacles 340, attached to end pieces 338, engage connectors 342. Connectors 342 thus traverse substantially the entire length and/or width of the cavity created by construction system form 300, engaging connectors 342 that are attached to end pieces 338 configured on opposite panels, such as panels 302 and 306. Stated differently, two end pieces 338 positioned on opposite panels, such as panels 302 and 206, are attached to receptacles 340 that further engage connectors 342, the

connectors extending from an end piece 338 located on a first panel 302, to an end piece 338 Ideated on an opposite panel 306. Finally, rebar 344 may be placed within the cavity created by construction system form 300.

[0036] When construction system form 300 is completed, concrete is poured into the cavity of the form. Rebar 346 positioned within the cavity of the form, as well as the connector system 336, reinforce the concrete. In one embodiment of the invention, the concrete is poured in one continuous pour, thus creating a distinct monolithic unit. By providing a system whereby concrete can be poured into a form to create a distinct monolithic unit, embodiments of the present invention provide ways to minimize structural discontinuities in concrete structures. Embodiments of the present invention also substantially increase the efficiency and ease with which concrete forms can be constructed, while at the same time providing a secure and stable form that can be configured to meet any design and/or construction needs. Moreover, embodiments of the present invention may be used in conjunction with other construction systems to create structures wherein concrete deposited in the structures is one distinct monolithic unit having minimal structural discontinuities. [0037] Directing attention now to Figures 4A and 4B, a side view and a top view, respectively, of a rebar stand 400 is shown. Rebar stand 400 is an example of an additional component of construction system form 300 that may be used in embodiments of the present invention. The side view of rebar stand 400, as shown in Figure 4A, shows bottom portion 402 and top portion 404 of rebar stand 400. Bottom portion 402 is configured to attach to a base structure, or bottom of a construction system. For example, when the construction system is a construction system for columns the bottom portion 402 may attach to the base structure onto which the anchor base plates of the construction system are also attached. Ih another embodiment of the invention where the construction system is a beam, the bottom portion 402 may attach to a base or bottom side of the beam. As for top portion 404, top portion 404 includes depression 406. In one embodiment of the invention depression 406 is configured to engage rebar.

[0038] More particularly, with attention to the top view of rebar stand 400 shown in Figure 4B, depression 406 may, in one embodiment of the invention, be configured to extend along a diameter of top portion 404 of rebar stand 400. In other words, depression 406 may be configured in an x- or cross-like configuration, with portions

of depression 406 traversing top portion 404 along two diameters of top portion 404, the diameters being orthogonal to each other. Thus, depression 406 may hold rebar positioned in two orientations, the orientations being orthogonal to each other. Rebar stand 400 is shown in further detail with reference to Figure 5 below. [0039] Directing attention now to Figure 5, a cut-away view of construction system form 500 for beams is shown. Construction system form 500 includes panels 502, 504, 506, 508, and 510, that may be configured to form a construction system form 500 having any length, width, height, and shape. Further, panels 502, 504, 056, 508, and 510 may be configured in any arrangement on top of, adjacent to, and opposite each other to create construction system form 500. Panels 502, 504, 506, 508, and 510, define a cavity in construction system form 500 into which concrete may be poured. In one embodiment of the invention panels 502, 504, 506, 508, and 510 are made of a foam material, such as, for example, a cement-foam composite, polyurethane foam, polystyrene foam, expanded polystyrene, and extruded polystyrene. Finally, panels 502, 504, 506, and 508 include openings (not shown) located on interior sides of panels 502, 504, 506, and 508.

[0040] In addition to panels 502, 504, 506, 508, and 510, construction system form 500 includes connector systems 512. Li one embodiment of the invention connector system 500 includes end pieces (not shown), receptacles 514 attached to end pieces, and connectors 516. Connectors 516 substantially traverse the width of construction system form 500 and are engaged by receptacles 514, which are configured in any size or shape as needed to engage connectors 516. In one embodiment of the invention where connectors 516 are chains, connector system 512 further includes couplers 518 that connect multiple chain sections to form a longer chain.

[0041] Finally, construction system form 500 also includes rebar 520 and 522, which, in one embodiment of the invention rests in rebar stands 524. Rebar 520 rests in rebar stand 524 in a position orthogonal to rebar 522.

[0042] When construction system form 500 is completed, concrete is poured into the cavity created by construction system form 500. Rebar 520 and 522, as well as connector system 512, reinforces the concrete. In one embodiment of the invention, the concrete is poured in one continuous pour, thus creating a distinct monolithic unit. By providing a system whereby concrete can be poured into a form to create a distinct

monolithic unit, embodiments of the present invention provide ways to minimize structural discontinuities in concrete structures. Embodiments of the present invention also substantially increase the efficiency and ease with which concrete ^• forms can be constructed, while at the same time providing a secure and stable form that can be configured to meet any design and/or construction needs. [0043] With attention now to Figure 6, a method 600 for constructing a column and/or beam system is shown. At stage 602, a form for a column and/or beam construction system is constructed. Stages 604, 606, 608, and 610 show how the construction system form of stage 602 is built. First, as shown at stage 604, panels are configured adjacent to, on top of, and opposite each other. Next, opposite panels are connected, as shown at stage 606. Adjacent panels are then fastened together, as shown at stage 608. Stage 610 then shows that panels configured on top of other panels are secured. With the construction system form completed, concrete is poured into the form to create one distinct monolithic unit, as shown at stage 612. [0044] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

INDUSTRIAL APPLICABILITY

[0045] Embodiments of the present invention are capable of exploitation in the industry by the way in which concrete structures can be built using modes of the present invention. The construction systems as described in the present invention allow forms for a large section, such as an entire floor of a large building, to be assembled at one time. Concrete then can be poured for the entire floor at one time. Not only do embodiments of the present invention provide a way for efficiently setting up concrete forms and building a concrete structure in a relatively short amount of time, embodiments of the invention also provide a way to enhance the structural integrity of the concrete structure by pouring concrete to create one distinct monolithic unit. Thus, embodiments of the present invention minimize structural discontinuities in buildings. Further, concrete structures built using systems of the present invention contain the many advantages of using foam forms in building construction. For example, foam forms used in modes of the present invention create insulating layers built into the wall system that minimize sound, retard fire, and insulate not only to increase energy efficiency. Moreover, foam forms also insulate freshly poured concrete thereby improving the quality of the concrete by providing an environment in which the concrete can properly cure.