| WO/2005/093182 | METHOD FOR CONSTRUCTION OF A SUPPORTING WALL AND BLOCKS FOR CARRYING OUT SAID METHOD |
| WO/2006/075827 | A PREFAB BLOCK FOR USE MUCH |
| JP2002088945 | PILING-UP BRICK AND ITS PILING-UP METHOD |
QUERIDO, Daniel (Eerste Leliedwarsstraat 1, NL-Amsterdam 1015 Sz, NL)
| Claims 1. Method for manufacturing a building structure, such as a wall, comprising of: stacking foam construction elements on a substrate; - arranging a covering on the stacked construction elements; providing at least one feed channel extending with a vertical directional component through at least two stacked construction elements; and arranging a tensioner through the feed channel between the covering and the substrate; - arranging a stop for the covering in order to prevent the possibility of the covering being pulled too far into the foam construction elements; and applying to the construction elements a controlled tension directed toward the substrate by applying the tension on the tensioner. 2. Method as claimed in claim 1 , wherein arranging of the stop comprises of receiving in the feed channel a bush which encloses the tensioner and supports the covering. 3. Method as claimed in any of the foregoing claims, comprising of: - providing, prior to the stacking, at least one groove in a side of the construction elements for the purpose of placing a conduit, such as a water or electricity conduit. 4. Method as claimed in any of the foregoing claims, comprising of providing a finishing such as a plastering on an interior of the building structure and/or providing an outer wall cladding such as tiling on an exterior of the building structure. 5. Method as claimed in claim 4, comprising of arranging between two adjacent construction elements a substantially plate-like part of a holder for the tiling extending outside the construction elements, wherein the plate-like part is provided with an opening with a cross-section corresponding to the cross-section of the feed channel. 6. Method for forming a roof or floor of a building, comprising of - arranging at least two supports, such as beams, extending parallel in the plane of the roof to be formed; and - arranging a foam construction element between adjacent supports. 7. Method as claimed in claim 6, comprising of: - laying the supports and the construction elements against each other such that a construction element protrudes in each case above two supports adjacent to this construction element; and - arranging a foam filling element in the space between the construction elements and above the support so that the whole roof surface consists of foam on an upper side. 8. Method as claimed in claim 7, comprising of arranging a roof covering, such as a tarpaulin, or bitumen, over the foam. 9. Method as claimed in claim 7 or 8, comprising of: - arranging a clamping means such as a U-profile or a strip on the filling element, and - applying to the U-profile a clamping tension directed toward the support such that the filling element bulges outward and lies at least partially against the adjacent construction elements. 10. Method as claimed in any of the claims 6-9, comprising of: - arranging tensioning elements, such as threaded ends, transversely of the direction in which the supports and construction elements extend; - tightening the tensioning elements. 11. Construction element for use in a method as claimed in any of the foregoing claims, comprising: - a substantially beam-like body manufactured from a foam having a compression strength which is greater than or equal to 60 kN/m2 per 10% of deformation (EPS 60), and in particular greater than or equal to 100 kN/m2 per 10% deformation (EPS 100), - at least one feed channel for a tensioning means which extends from a side of the body intended as upper side during use to a side of the body intended as underside during use. 12. Construction element as claimed in claim 11 , wherein the body has - a length of between 50 cm and 200 cm, preferably between 90 cm and 150 cm, more preferably between 110 and 130 cm, and in particular 120 cm; - a height of between 10 cm and 60 cm, preferably between 20 cm and 50 cm, more preferably between 30 cm and 50 cm, and in particular 40 cm; and - a width of between 40 cm and 80 cm, preferably between 50 cm and 70 cm, and in particular 60 cm. 13. Construction element as claimed in claim 11 or 12, wherein the feed channel has a cross-section of between 5 and 25 cm, preferably between 10 and 20 cm, and in particular 15 cm. 14. Construction element as claimed in any of the claims 11-13, wherein a groove is provided in at least a surface intended as side during use for the purpose of receiving a conduit, in particular a groove wherein the width of the groove increases in width in a direction from the surface of the side to the interior of the construction element over at least part of the depth of the groove. 15. Holder for use in a method as claimed in claim 5 or for use in combination with a construction element according to any of the claims 10-14, comprising: - a substantially plate-like part provided with an opening having a cross-section corresponding to the cross-section of the feed channel, and - mounting means for an outer wall cladding such as a tile. 16. Building structure comprising at least one construction element as claimed in any of the claims 11-15. |
The present invention relates to a foam construction element and to the manufacture of a building structure with a foam construction element. The use of foam construction elements such as sheets or blocks as insulating means in building structures is per se known. Foam blocks or plates are here placed against a wall or between a plurality of walls and/or partitions. Foam is however less obvious as structural construction element due to the prevailing opinion that the material is too light or not strong enough. The present invention therefore has for its object to provide a construction element and a method for manufacturing a building structure with which cheaper and/or lighter construction is possible than with conventional building techniques, or to provide a usable alternative thereto.
The invention proposes for this purpose a method for manufacturing a building structure, such as a wall, a floor, roof or (other part of) a building, comprising of stacking foam construction elements on a substrate; and, in the case of a wall, applying to the construction elements a controlled tension directed toward the substrate and, in the case of a ceiling, floor or roof, arranging a foam construction element between at least two supports.
By applying the controlled tension directed toward the substrate to the stacked construction elements during the manufacture of a wall, the elements are able to withstand greater lateral forces, whereby the stacked construction elements are prevented from falling over, being blown over or pushed over. The applying of the tension in co-action with the compressibility of the foam used also provides for a good sealing between the construction elements stacked on each other, whereby use of adhesive such as mortar or glue is not necessary. A type of foam which has been found suitable is polystyrene foam. The construction elements can be stacked in offset manner, as is usual in normal brickwork, or be stacked in any other manner in which they wholly or partially overlap each other, or be arranged in any other optionally overlapping manner. The compression of the construction elements, and thereby the height of the building structure, is also determined by applying a controlled tension. Applying the tension comprises of arranging on the stacked construction elements a covering such as a plate, edge, beam or a profile part extending over a determined width of the construction element or plurality of construction elements, subsequently arranging a tensioner such as a steel wire or stud bolt between the covering and the substrate; and applying the tension on the tensioner. In an extreme case the height of the building structure corresponds here to a single (relatively high) construction element with the height of a whole wall. Because the covering at least partially covers the construction element, the force exerted on the construction element by the tensioner is distributed. The tensioner can be connected to the substrate by being cast into the substrate, or for instance be connected by means of a coupling piece to a threaded end connected to the substrate. The method according to the present invention preferably comprises of providing at least one feed channel extending with a vertical directional component through at least two stacked construction elements, and subsequently carrying the tensioner through the feed channel. Providing the feed channel can take place when the construction elements are stacked, for instance by means of drilling, perforating or piercing with the tensioner, optionally accommodated in a housing suitable for the drilling, perforating or piercing, although use is preferably made of mutually aligning feed channels arranged for this purpose in individual construction elements. Such construction elements prepared specially for use in the present invention will be discussed below. The method can further comprise of arranging a stop for the covering. The use of such a stop provides several advantages. First of all, the exact height of the covering can thereby be determined since further tightening of the tensioner no longer results in downward movement of the covering when the tensioning force is further increased. The stop can also prevent the covering being pulled too far into the foam construction elements, since damage or unacceptable deformation of the blocks could then occur.
Arranging of the stop can for instance take place by receiving in the feed channel a bush which encloses the tensioner and supports the covering, In this embodiment the tensioner can for instance comprise a threaded end which protrudes through the covering and is provided on the upper side with a nut, such as a locking nut, for determining the height and applying the tension, wherein the opening in the covering is smaller than the diameter of the nut and of the bush. The outer diameter of the bush more preferably corresponds substantially with an inner diameter of the feed channel, so that construction elements stacked on each other can be fixed relative to each other by means of placing of the feed channel.
Prior to the stacking at least one groove can additionally be provided in a side of the construction elements for the purpose of placing a conduit, such as a water, heating or electricity conduit. In order to enable simple alignment of the grooves of different construction elements and still enable alignment of the feed channels, it is advantageous to make use of construction elements of substantially the same form, or geometrically at least partially corresponding construction elements.
After construction of the building structure a finishing such as a plastering can be arranged, or an outer wall cladding such as tiling. For this latter purpose a substantially plate-like part of a holder for the tiling extending outside the construction elements can be inserted between two adjacent construction elements, wherein the plate-like part is provided with an opening with a cross-section corresponding to the cross-section of the feed channel so that it is fixed in place when the tensioner and optionally the bush are arranged. A finishing such as a cladding or tiling can however be arranged on the construction elements by means of glueing. When applying the above described method for manufacturing a wall, use is preferably made of a construction element comprising a substantially beam-like body
manufactured from a foam having a compression strength which depends on the application, but which is preferably greater than or equal to 60 kN/m 2 per 10% of deformation (EPS 60), for instance for a separate wall or a shed. For heavier
applications EPS 60 can be used, although preferably more than EPS 80, and more preferably a minimum of 100 kN/m 2 10% deformation (EPS 100) for an outer wall of a dwelling, rising to for instance 250 kN/m 2 10% deformation (EPS 250) for an outer wall of a storey of a dwelling on which a further storey is built, and wherein at least one feed channel for a tensioner is provided which extends from a side of the body intended as upper side during use to a side of the body intended as underside during use.
Using such a construction element, which in an embodiment comprises a plurality of feed channels, and preferably a plurality of identical construction elements, a robust building structure can be erected quickly and easily by means of the method according to the present invention.
In an advantageous embodiment the body of the construction element preferably has a length between 50 cm and 300 cm, preferably between 90 cm and 150 cm, or in a second case between 210 and 270 cm, and particularly about 120 cm or about 240 cm, and a height of between 10 cm and 60 cm, preferably between 20 cm and 50 cm, in particular 30 cm. It is possible to opt to work with two different heights at the same time, for instance 30 and 50 cm, so that any desired height from 80 cm can be realized in steps of 10 cm. The width can differ depending on the application. A different insulating value can for instance be required for a house than for instance for a shed. In the first case the body can have a width between 40 cm and 80 cm, preferably between 50 cm and 70 cm, and in particular 60 cm, while in the second case it can suffice for the body to have a width of between 20 cm and 40 cm, and in particular 30 cm. In order to enable simple creation of building structures with varying structures and to enable the application of different stacking and building methods, it is advantageous when a side of a construction element intended to be the upper side during use can be divided into equal parts, wherein each part comprises one feed channel. These parts are preferably squares with a feed channel which is arranged centrally therein and which is preferably point, line or rotation-symmetrical so that it is possible to realize a connecting feed channel in different relative orientations of the construction elements. A highly suitable cross-section for the feed channel is therefore a round or square one. The feed channel preferably has a cross-section here of between 5 and 25 cm, preferably between 10 and 20 cm, and in particular 15 cm. In addition to the use of these channels for receiving a tensioner, other feed channels can be used particularly for for instance ventilation and air heating. It is also possible to arrange objects in feed channels on one determined side of the construction element for the purpose of exerting pressure on the construction element, and thereby realize a curvature of the construction element, A curved wall can for instance be made in this way. A groove can also be provided in at least a surface intended as side during use for the purpose of receiving a conduit. Conduits can be easily mounted in the building structure in this way without extra grinding or sawing work being necessary for this purpose. The groove can extend horizontally or vertically, or both, and a construction element can comprise a plurality of grooves. In the case where a plurality of feed channels are present, such grooves are preferably situated at the same centre-to-centre distance as the feed channels. The grooves can only be received in a side directed toward an interior of a building during use, or be provided in a plurality of or all walls. It is also possible to arrange recesses, for instance for wall sockets. It has been found that an appropriate method for arranging thereof is to press into the construction element a heated object the size of the object to be placed. In the case of a wall socket a cylindrical tin object can for instance be used for this purpose. In order to enable simple clamping of the conduit it is advantageous if the width of the groove increases in a direction from the surface of the side to the interior of the construction element over at least part of the depth of the groove. This results in for instance a keyhole-shaped cross-section of the groove. The narrowest part of the groove, which is adjacent to the surface of the construction element, must here have a slightly smaller diameter than that of the placed conduit so that the conduit, once placed, remains clamped in the groove.
The invention also relates to a holder for enabling the arrangement of an outer wall cladding, such as a tiling, on an outer side of the building structure. Such a holder is provided with a substantially plate-like part provided with an opening having a cross- section corresponding to the cross-section of the feed channel, and mounting means for an outer wall cladding such as a tile. The plate-like part can be placed between two adjacent construction elements, wherein the opening is aligned with the feed channel. The holder is fixed in place by placing the tensioner with a spacing bush placed therearound, the outer diameter of the bush corresponding to the inner diameter of the channel. The invention further relates to a method related to the above described method, or to be applied in combination with the above described method, for forming a horizontally extending surface such as a floor or roof. A foam construction element is here arranged between two supports. A complete floor or complete roof can then be made by alternately arranging a number of supports and construction elements adjacently of each other. Prior to arranging of the construction elements between the supports, it is possible to arrange under the supports a ceiling or other type of support for the construction elements, so that they do not fall down between the supports.
If no panelling is desired or deemed necessary on the underside, a controlled tension can be applied between the at least two supports and directed toward each other. The foam construction element is thus clamped between two supports, formed for instance by wooden beams resting on the walls or another support. Not only does the construction element remain in place (in vertical direction) between the supports due to the clamping tension, it also provides load-bearing capacity to objects or persons placed thereon, and can for this reason also be arranged in combination with a panelling on the underside or a different type of ceiling.
The clamping tension can be obtained by pulling the supports toward each other, for instance in that tensioning elements such as threaded ends are inserted, transversely of the direction in which the supports and construction elements extend, from the one outermost support to the other outermost support, these tensioning elements then being tightened. Holes can be arranged beforehand through the supports and the foam construction elements for this purpose.
When the clamping tension is applied, a construction element is compressed by a predetermined percentage, just as in the manufacture of walls. Because in the case of a lying surface such as a ceiling, floor or roof the direction of the force exerted on the construction element is perpendicular to the direction in which the construction element is tensioned, a percentage is preferably used here of between 0.5 and 1.5%, and in particular around 1% for a construction element manufactured from EPS 100, and between 0.20 and 0.80%, and in particular around 0.50% for a construction element manufactured from EPS 200. Use of an EPS 60 construction element is also possible in determined cases.
When the horizontally extending surface is a roof or other closed insulating surface with some water-inhibiting properties, it is also desirable to make the structure watertight. For this purpose the supports and the construction elements can be placed against each other such that a construction element protrudes in each case above two supports adjacent to this construction element and optionally clamping the construction element. A foam filling element can then also be arranged in the space between the construction elements and above the support so that the whole roof surface consists of foam on an upper side.
A further roof covering, such as a tarpaulin, or bitumen can then be arranged thereover. When the filling elements are dimensioned such that they protrude just above the construction elements, a U-profile can be mounted over the filling elements after the roof covering has been arranged. This U-profile herein clamps and tensions the roof covering and increases the load-bearing capacity of the supports. The U-profile can for instance be arranged on the support by being screwed fixedly onto a threaded end arranged for this purpose in the support. By tightening the U-profile the filling element bulges outward, whereby its width increases. A sealing is hereby obtained between the filling element and the construction elements which, depending on the application, can even be sufficient for a tarpaulin or bitumen to be omitted. The U-profile can also be used to tension, seal and clamp the roof covering at the edges of the roof in the transverse direction of the support structure.
If the filling elements are dimensioned such that they do not protrude above the construction elements, or only a little, but for instance lie substantially flush therewith, a flat cover strip can be used instead of a U-profile. Both the U-profiles and the strips can for instance be manufactured from metal or (reinforced) plastic.
The invention will now be elucidated with reference to the following non-limitative figures. Herein: Figure Ia shows a top view of a foam construction element according to the present invention;
Figure 1 b shows a side view of the construction element of figure 1 a;
Figure Ic shows a number of forms of grooves;
- Figure 2a shows the manufacture of a building structure according to the present invention;
Figure 2b shows in detail how the coupling takes place between the threaded ends connected to the substrate and the threaded end forming the tensioner;
Figure 2c shows the covering and the tensioner received in the spacer;
- Figure 3 shows a holder for an outer wall cladding element; and
Figure 4 shows a cross-section of a building structure;
Figure 5 shows a perspective view of a roof according to the present invention; and
Figure 6 shows a first cross-section of a roof according to the present invention; - Figure 7 shows a second cross-section of a roof according to the present
invention.
Figure Ia shows a top view of a foam construction element 1 according to the present invention. The construction element has a substantially beam-like body 1 manufactured from a foam with a compression strength greater than or equal to 250 kN/m 2 per 10% deformation, in which are arranged feed channels 2 for a tensioner which extend from a side of the body intended as upper side during use to a side of the body intended as underside during use. Also arranged in the side walls of the body are grooves 3 in which conduits such as water or electricity conduits can be arranged. Construction element 1 can be deemed constructed from a plurality of parts 4 of the same form, whereby the erection of building structures with varying forms is simplified.
Figure Ib shows a side view of construction element 1 of figures Ia, in which grooves 3 are shown. The length 6, width 7 and height 8 of the construction elements are indicated in figures Ia and Ib. In an embodiment the length lies between 50 cm and 200 cm, preferably between 90 cm and 150 cm, more preferably between 110 cm and 130 cm, and is in particular 120 cm, and the height lies between 10 cm and 60 cm, preferably between 20 cm and 50 cm, more preferably between 30 cm and 50 cm, and is in particular 40 cm. The width can for instance lie between 40 cm and 80 cm, preferably between 50 cm and 70 cm, and be in particular 60 cm, or between 20 cm and 40 cm, and be in particular 30 cm. Other forms and dimensions of the construction element can of course be provided for specific applications. In addition, the form of a construction element can be adapted to specific wishes or requirements of a determined building structure by means of for instance cutting or sawing.
Figure Ic shows a number of forms of grooves 3, 3% 3" in which a conduit 30 is arranged. Groove 3 has a keyhole-shaped cross-section which has a width 31 on the outside of the construction element of about 13 mm and an internal cross-section 32 of about 17 mm. Groove 3' has a trapezium-shaped cross-section and groove 3" a substantially rectangular cross-section.
In addition to holding conduits, grooves 3 can also be used to mutually connect construction elements 1, 1', 1" during construction by means of a connecting clamp 21 as shown in figure 2a, or after construction, particularly on the outside, for arranging against the building structure a fabric or mesh 33 which can be attached to the building structure by means of a clamping tube or clamps 34.
Figure 2a shows the manufacture of a (simplified) building structure 100 by means of the method according to the present invention. The figure shows how a construction element 1 is stacked onto two construction elements 1' and 1" placed on a substrate. It is not necessary here, as shown, to make use of identical construction elements 1, 1', 1".
Tensioners formed by threaded ends 10, 11 are arranged through feed channels 2, 2\ 2" of respective construction elements 1, 1 ', 1". Threaded ends 10 and 11 are connected by means of coupling pieces 16 and 17 to threaded ends 14 and 15 which are fixed in or on the substrate and which are for instance cast in during pouring of a concrete floor.
Placed round threaded ends 10, 14 and 11, 15 are respective spacers formed by bushes 12, 13, the outer periphery of which substantially corresponds to the inner periphery of channels 2, 2', 2". The relative orientation of construction elements 2, 2', 2" in vertical direction is secured by placing bushes 12, 13. The bushes have a length 22 (not shown to scale) which is slightly smaller than the overall height of the building structure before tensioning of the tensioners. During tensioning the building structure is drawn together over a controlled distance. This takes place by arranging a covering formed by plate 18 on the upper construction element. Plate 18 is provided with openings 23, which have a cross-section such that tensioners 10, 11, but not spacers 12, 13, can be placed therethrough. In the shown embodiment tensioners 10, 11 can be provided with a nut 19, 20. Through tightening of the nut the plate 18 is urged toward the substrate while clamping construction elements 1 , 1 ', 1 ". The construction elements are preferably compressed in the height here by between 0 and 2%, and more preferably by about 1%.
During stacking of construction elements 1, 1 ', 1" they can be held together by placing in grooves 3 a connecting clamp 21 which has an S-shaped cross-section in the shown embodiment. Other embodiments are possible, specifically adjusted to the form of the groove. A particularly advantageous embodiment is a foam strip which extends over the full height of a construction element and fits closely into two adjacent grooves, and which further increases the heat-insulating properties of the thus formed building structure.
Figure 2b shows in detail how the coupling takes place between the threaded ends 15 connected to the substrate and the threaded end 11 forming the tensioner. Used for this purpose is coupling element 17 consisting of a bush with internal screw thread in which a stop is provided.
Figure 2c shows covering 18 and tensioner 11 which is received in spacer 13. Spacer 13 extends through construction element 1 and supports covering 18, which is urged against construction element 1 by the nut 20 mounted on tensioner 11. The figure shows the fully tensioned position in which covering 18 lies against spacer 13, which can for instance comprise a PVC pipe.
Figure 3 shows a holder 40 for an outer wall cladding element, comprising a substantially flat plate 41 in which an opening is provided with a diameter
corresponding to the diameter of feed channel 2 in construction element 1. Holder 40 is held in place by a spacer to be carried through opening 2, and is further provided with a support 42 for an outer wall cladding element such as a tile or brick.
Figure 4 shows a cross-section of a building structure 51 placed on a substrate 50, on which a plurality of construction elements 1 according to the present invention are placed. The figure shows how covering 18 holds the stacked construction elements 1 together by means of tensioner 11 and nut 20, while bush 13 prevents a relative displacement of the construction elements occurring in horizontal direction. It can be seen how the construction elements according to the present invention provide the freedom of design to construct a sloping outer wall. It will be evident that many other embodiments can be envisaged, all falling within the scope of protection of the present invention as laid down in the following claims. Particularly envisaged are construction elements provided with an imprint or print or other finish, construction elements with tongues and grooves for mutual co-action during stacking, or construction elements with shapes suitable for forming for instance a round or half-round wall. Throughfeed holes can also be particularly situated in the vicinity of one side of the construction element for the purpose of working the construction elements by means of sculpting.
Figure 5 shows a perspective view of a roof 52 manufactured according to the present invention. The roof is constructed from supports 53 formed by wooden beams, between which foam construction elements 54 are arranged. Arranged transversely of the direction in which the beams and the foam construction elements extend are tensioning elements 55 (optional for the method according to the present invention), which are provided through holes prearranged in supports 53 and foam construction elements 54. Construction elements 54 protrude in the height above supports 53. In the shown case this is because they are higher than the supports, although if this is not the case the same effect can be achieved by the relative placing. Foam filling elements 56 are placed in the resulting spaces between the construction elements and above the supports. A tarpaulin 57 is arranged over the construction elements and the filling elements in order to obtain a watertight seal. Arranged over filling elements 56 are U-profiles which serve to clamp and cause the filling elements to bulge outward in order to obtain a connection to construction elements 54. The U-profiles are arranged over tarpaulin 57 and are attached to supports 53 with nuts by means of threaded ends 59 arranged therein. Figure 6 shows a cross-section of a part of the roof of figure 5, wherein part A shows the situation during the mounting of the U-profile and part B shows the situation after mounting, wherein it can be seen that the filling element has bulged outward and thus provides for a seal between the construction elements. Figure 7 shows a side view of a placed roof 52 as shown in figure 5. It can be seen that the roof is arranged at an incline on walls 60 and 61 in order to enhance drainage.
In addition to the shown embodiments, the invention can be embodied in many ways, all of which must be deemed as lying within the scope of protection of the following claims.
Next Patent: SAMPLING DEVICE AND METHOD FOR PREPARING THE SAME