Wall construction method using injected urethane foam between the wall and autoclaved concrete (AAC) blocks

Abstract

The present invention provides novel wall construction systems and materials for residential and commercial construction that incorporate grooved lightweight building material units (e.g., blocks, panels, and the like), a plurality of connection devices, a track system, and (injected) polyurethane structural foam. The wall construction system comprises building material units married to a building frame with a plurality of connection devices (e.g., clip fasteners) slidingly retained in a track system that is attached to the building's structural (e.g., load-bearing) framing. The building material units are joined to each other with a suitable binding agent. The cavity between the frame and the building material units is injected with an insulating structural polyurethane foam. The exterior of the wall is finished with a waterproof applied finish such as cementitious stucco. The interior of the wall is amenable to standard finish options.

Claims

1. A composite construction system comprising: a load-bearing frame and a lightweight concrete construction unit, and a cavity between the load-bearing frame and the lightweight concrete construction unit, wherein one side of the lightweight concrete construction unit faces towards the load-bearing frame, further wherein the load-bearing frame is adhered to the lightweight concrete construction unit using at least a single layer of polyurethane foam interposed between the load-bearing frame and the lightweight concrete construction unit to fill the cavity, and at least one clip fastener, wherein the clip fastener comprises a main body section having a first terminus and second terminus, further wherein the first terminus comprises two compressible leg sections emanating from the main body section and the second terminus comprises an upward interlock stub and a downward interlock stub, the clip fastener being positioned between the load-bearing frame and the lightweight concrete construction unit such that the clip fastener is slidingly retained in the track system section.

2. The composite construction system of claim 1, wherein the load-bearing frame is made out of at least one of a group of materials consisting of solid wood, timber materials, engineered wood products, wood composite materials, steel and aluminum.

3. The composite construction system of claim 1, wherein the compressible leg sections are separated by a gap.

4. The composite construction system of claim 1, wherein each compressible leg section ends in a semicircular hook.

5. The composite construction system of claim 1, wherein the upward interlock stub and the downward interlock stub of the clip fastener, each protrude at a right angle from the main body section of the clip fastener.

6. The composite construction system of claim 1, wherein the clip fastener is made out of at least one of a group of materials comprising metals and plastics.

7. The composite construction system of claim 6, wherein the plastics comprise ABS plastics.

8. The composite construction system of claim 1, wherein the clip fastener is thermally non-conductive.

9. The composite construction system of claim 1, wherein the track system section comprises a main body having opposed top and bottom edges comprising two short protrusions at a right angles from the axis of the main body, further wherein the protrusions terminate in two opposing inwardly semicircular sections.

10. The composite construction system of claim 9, wherein the track system section is made out of at least one of a group of materials comprising metals and plastics.

11. The composite construction system of claim 10, wherein the plastics comprise ABS plastics.

12. The composite construction system of claim 1, wherein the track system section is thermally non-conductive.

13. The composite construction system of claim 1, wherein the lightweight concrete construction unit comprises an autoclaved aerated concrete (AAC) block.

14. The composite construction system of claim 13, wherein the AAC block comprises at least one groove for attaching to the clip fastener.

15. The composite construction system of claim 1, wherein the distance between the load-bearing frame and the lightweight concrete construction unit comprises about 1″ to about 4″.

16. The composite construction system of claim 1, wherein the single layer of polyurethane foam comprises a width of about 2″ to about 8″.

17. A method for constructing a wall of a building, comprising the steps of: a) erecting a load-bearing frame having an interior facing surface and an exterior facing surface on a support such as a conventional foundation or slab; b) placing at least one shelf angle on top of the foundation on the exterior surface of the load-bearing frame, wherein the shelf angle comprises an upwardly projecting interlock stub, further wherein the shelf angle is placed such that the interlock stub extends in an upward direction from the foundation distal from the load-bearing frame; c) placing a first lightweight concrete construction unit having a top groove and a bottom groove on top of the shelf angle by inserting the interlock stub of the shelf angle into the bottom groove of the lightweight concrete construction unit, such that a cavity is created between the load-bearing frame and the lightweight concrete construction unit, further wherein the lightweight concrete construction unit has an interior facing surface facing the load-bearing frame and an opposite exterior facing surface and a top facing surface and an opposite bottom facing surface; d) attaching at least one track support section to the exterior surface of the load-bearing frame; e) attaching at least one track system section to the track support section; f) providing at least one clip fastener, wherein the clip fastener comprises a main body section having a first terminus and second terminus, and further wherein the first terminus comprises two compressible leg sections emanating from the main body section and the second terminus comprises a downward interlock stub and an upward interlock stub; g) compressing the leg sections of the clip fastener to compressively insert the first terminus of the clip fastener into the track system section such that the clip fastener is slidingly retained in the track system section, wherein the clip fastener is placed such that the downward interlock stub is inserted into the top groove of the first lightweight concrete construction unit; h) applying a layer of adhesive to the top surface of the lightweight concrete construction unit; i) placing a second lightweight concrete construction unit on top of the first lightweight concrete construction unit such that the top interlock stub of the clip fastener is inserted into the bottom groove of the second lightweight concrete construction unit; j) repeating steps (d) through (i) until a desired exterior wall height and cavity separating the lightweight concrete construction units and the load-bearing frame are achieved; and k) injecting a polyurethane foam into the cavity.

18. The method for constructing a wall of a building of claim 17, wherein the compressible leg sections of the clip fastener are separated by a gap.

19. The method for constructing a wall of a building of claim 17, wherein each compressible leg section ends in a semicircular hook.

20. The method for constructing a wall of a building of claim 17, wherein the upward interlock stub and the downward interlock stub of the clip fastener, each protrude at a right angle from the main body section of the clip fastener.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1A illustrates an isometric view of a typical section of the wall system assembly. FIG. 1B illustrates a typical elevation of the wall system assembly from the exterior of the building. FIG. 1C illustrates a typical elevation of the wall system assembly from the interior of the building. FIG. 1D illustrates a sectional elevation of the wall system assembly from the interior of the building.

(2) FIG. 2 illustrates a typical section of the wall system assembly at the foundation.

(3) FIG. 3 illustrates a plan view of a typical section of the wall system assembly at a corner wall and window jamb.

(4) FIG. 4 illustrates a typical section of the wall system assembly at an intermediate floor.

(5) FIG. 5 illustrates a typical section of the wall system assembly at a window head and window sill.

(6) FIG. 6 illustrates a typical section of the wall system assembly at a slab foundation with exterior plaza.

(7) FIG. 7 illustrates a typical sectional view of the wall system assembly from the interior of the building at a stem wall.

(8) FIG. 8 illustrates cross sections of a typical track system and a clip fastener of the wall system assembly.

(9) FIG. 9 illustrates a cross section of a typical shelf angle of the wall system assembly.

DETAILED DESCRIPTION

(10) While several variations of the present invention have been illustrated by way of example in preferred or particular embodiments, it is apparent that further embodiments could be developed within the spirit and scope of the present invention, or the inventive concept thereof.

(11) The invention comprises a novel wall system for residential and light commercial construction that incorporates lightweight construction material units such as AAC blocks. This wall system comprises an exterior wall composed of AAC blocks married to an interior wood or metal load-bearing (structural) framing. The AAC blocks would be anchored to the framing using novel construction clips. Furthermore, a cavity or space between the framing and the interior surface of the exterior wall comprising AAC blocks is injected with structural polyurethane foam insulation to adhere the framing and the walls together and to provide insulation, air-sealing, and vapor-proofing. The exterior of the AAC walls further comprises an exterior cementitious stucco finish that is waterproof. The interior of the load-bearing framing receives a typical interior finish.

(12) FIGS. 1-7 generally illustrate isometric, plan, and section views of certain typical embodiments of the construction materials and construction methods of the present invention for constructing a novel wall system. In these embodiments, as is shown in the representative Figures a load-bearing frame (non-sheathed) 2 of wood and/or metal (e.g., steel) is erected with wind bracing 3 (See, FIG. 1B) (e.g., steel wind bracing) on a conventional concrete foundation 1. No sheathing is applied.

(13) In particular, FIG. 1A shows a detailed isometric view of a section of track system 10 having slidingly retained therein clip fasteners 8 with interlock stubs 8c and 8d engaging/set to engage groove(s) 7 in AAC block 5. Track section 10 is attached by attachment devices 9 (e.g., screws) to track support section 16. Track support section 16 (girt) is attached to load-bearing frame 2. Further, FIG. 1A shows a first course of AAC blocks 5 supporting a second course of AAC blocks 5 with a (leveling) layer of thin-bed mortar 6 in between the courses.

(14) FIG. 2 illustrates the grade of the building surface (not numbered) exterior to the concrete foundation 1. In one embodiment of the invention, the load-bearing frame 2 may be anchored to the concrete foundation 1 through bolts (not shown) about 7″ to about 9″ inwards from the exterior edge of the concrete foundation 1.

(15) The shelf angle 4 or starter piece is a continuous pultruded fiberglass shelf angle 4 that is attached 9 (e.g., screwed) to the load-bearing frame 2 at a level plane to create a level starter. Leveling grout 6 may be added underneath the shelf angles 4 at any gaps between the shelf angles 4 and the foundation 1. The shelf angles 4 have a continuous interlock stub 4d which fits into a bottom groove 7 of AAC blocks 5. The shelf angles 4 also comprise a vertical leg 4c that contains a traversing screw hole 4b for affixing the shelf angle 4 to the load-bearing framing system 2 using screws or bolts 9.

(16) Shelf angle 4 is affixed continuously around the base of the load-bearing frame 2 at a level plane on top of the concrete foundation 1. The interlock stubs 4d of the shelf angles 4 form a level starter track. A thin-bed mortar 6 with a thickness of about 1/16″ to about ⅛″ or more is placed over the starter track and AAC blocks 5 are laid on the level starter track. The AAC blocks 5 each have two grooves 7 on the top and the bottom which may be approximately ½″ deep and ⅛″ wide. As the AAC block 5 is laid down onto the starter track, the interlock stubs 4d of the shelf angles 4 are inserted into the bottom grooves 7 of AAC blocks 5.

(17) In another embodiment of the invention, an adhesive may be added to the grooves 7 to provide additional attachment of the AAC blocks 5 to the shelf angles and the various clip fasteners 8 disclosed in the invention.

(18) In one embodiment of the invention, the AAC blocks are insect-proof, lightweight and insulating. In another embodiment of the invention, the AAC blocks 5 may have a thickness of from about 2″ to about 6″ or more, a height of from about 8″ to about 24″ or more and a length of from about 24″ to about 48″ or more, although, the present invention is not limited to particular lightweight construction units and/or AAC block dimensions. In the preferred embodiment of the invention, the AAC blocks 5 comprise a thickness of 3″ and a face of 24″×24″.

(19) In particular embodiments, after the initial set of AAC blocks 5 are placed over the interlock stubs 4d of the shelf angles through bottom grooves 7, a plurality of track support sections 16 are horizontally (level) attached to the load-bearing framing with attachment devices 9 (e.g., screws) such that the track system sections 10 subsequently, or previously, attached thereto with attachment devices 9 (e.g., screws) are positioned to slidingly retain a plurality of clip fasteners 8 having upward projecting interlock stubs 8c and downward projecting interlock stubs 8d positioned to engage grooves 7 on one or more surfaces (e.g., top, bottom, sides, ends) of a plurality of AAC blocks 5 on a first, second, third, fourth, etc., course(s) of AAC blocks 5 during wall construction.

(20) As illustrated in FIG. 8, clip fastener 8 comprises a main body section 8a that defines the horizontal axis of clip fastener 8, and four protrusions therefrom: first, sliding anchorage portion 8b that in turn comprises two legs in a “Y” shaped configuration emanating from main body section 8a of clip fastener 8; second, an upward interlock stub 8c; and, third, a downward interlock stub 8d. The sliding anchorage portion 8b forms a first terminus of the clip fastener 8. The upward interlock stub 8c and the downward interlock stub 8d, respectively, emanate from the main body 8a of clip fastener 8. The upward interlock stub 8c and the downward interlock stub 8d, respectively, forms a second terminus of clip fastener 8. Each of legs of the sliding anchorage portion 8b of clip fastener 8 ends in a semicircular inward curving hook shaped terminus. FIG. 8 also illustrates a cross section of a section of track system 10. Track system 10 comprises main channel body 10a and two perpendicular protrusions 10b from the main body at the respective top and bottom of track system section 10. In preferred embodiments, each of protrusions 10b in turn terminate in inward facing beveled (or semicircular) ridge 10c that is optimized to slidingly retain the mated semicircular ends of each of the legs of sliding anchorage portion 8b of clip fastener 8. FIG. 1A shows the semicircular ends of each of the legs of sliding anchorage portion 8b of clip fastener 8 accepted by and slidingly mated with the corresponding protrusions 10b of track system 10. Each section of track system section 10 preferably further comprise a plurality of holes (not shown) that traverse main channel body section 10a for receiving attachment devices 9 to thus secure the track system section 10 to the track support section 16 (girt) or secure it directly to the load-bearing fame 2.

(21) A plurality of clip fasteners 8 are slidingly retained in track system sections 10 setting the AAC blocks 5 away from the load-bearing frame 2 by from about 1″ to about 3½″ or more. Downward interlock stub 8d is inserted into the top grooves 7 of the AAC blocks 5 and the upward interlock stub 8c is inserted into the bottom groove 7 of the next layer of AAC blocks 5.

(22) In this embodiment of the invention, layers of clip fasteners 8 and AAC blocks 5 are placed on top of one another and married to the framing. In the preferred embodiment of the invention, the offset between the load-bearing frame 2 and the AAC blocks 5 is about 3½′.

(23) In preferred embodiments, once the AAC blocks 5 have been set, the windows 13 (e.g., FIGS. 3 and 5), doors, electrical wiring and plumbing systems, and other systems and sub subsystems of the building structure may be installed.

(24) In the present invention, the vertical cavity between the load-bearing framing 2 and the wall of AAC blocks 5 is injected with foamed-in-place medium-density closed-cell polyurethane foam 14. Because the polyurethane foam 14 is adhesive and structural, all components of the wall and wall construction system are bonded into a unified composite construction of great strength. In one embodiment of the invention, the polyurethane foam 14 may be waterproof, vapor-proof and non-toxic with high thermal resistance. In a further embodiment of the present invention, the polyurethane foam 14 may have a water-vapor permeability of less than one perm and thermal performance of about R-5 per inch or greater. Conventional finishes such as plaster may be applied to the interior of the wall 15 (See, FIG. 2).

(25) The exterior of the AAC blocks 5 receive a cementitious stucco finish 12. In one embodiment of the present invention, the stucco finish 12 may be impact-resistant, waterproof and decorative in a variety of colors.

(26) FIG. 3 illustrates a plan view of a typical section of the wall system assembly at a corner wall and window jamb. In this embodiment, incorporation of a window 13 into the wall structure is shown. The exterior of window 13 is sealed with siliconized caulk 17. Similarly, FIG. 5 illustrates a sectional view of a typical section of the wall system assembly at a window head and sill. In this embodiment of the present invention, incorporation of a window 13 into the wall structure is shown. Lintels are created with a shelf angle 4 screwed to the lintel beam 11 of the load-bearing frame 2.

(27) FIG. 4 illustrates one embodiment of a sectional view at an intermediate floor of the wall system assembly. In this embodiment, a frame joist may separate the floors in the structure as known to those skilled in the art.

(28) FIG. 6 illustrates a section view of a typical section of the wall system assembly at a slab foundation. In this embodiment, pavers 18 are shown as part of the exterior surface treatment on the slab foundation 1.

(29) FIG. 7 illustrates a typical sectional elevation of the wall system assembly from the interior of the building at a stem wall foundation. In this embodiment, one partial below grade 19 application of the wall construction materials and systems of the present invention is shown. In this embodiment, a drainage system 20 is optionally provided as known to those skilled in the art.

(30) FIG. 9 illustrates a cross section view of the shelf angle 4 of the wall system assembly. In this embodiment, a horizontal base section 4a and a hole 4b traversing the vertical leg 4c for attachment by an attachment device 9 to the load-bearing frame 2 as well as the continuous interlock stub 4d are illustrated.

(31) In one embodiment, the clip fasteners of the present invention may comprise lengths of 3″ to 10″. In another embodiment, the base surfaces of the clip fasteners of the present invention may comprise heights of ⅛″ to 4″ and widths of ⅛″ to 4″. In a further embodiment, the protrusions of the clip fasteners of the present invention may comprise heights of from about ⅛″ to about 4″ and widths of from about ⅛″ to about 4″. In one embodiment of the present invention, the resulting total wall thickness is from about 8″ to about 16″ or more.