Abstract
A method and means to build an ecological house with enormous monolithic foam blocks is described here. The building structure is reinforced by liquid cement filled pipes or by glass fiber mesh. The building according to this disclosure may be 1-3 floor building. The building according to this disclosure is earthquake resistant.
Claims
1. A reinforced two story foam block building made of multiple monolithic foam blocks and comprising: a) at least two vault structures formed of a first and a second half vault, said first and second half vaults being mirror images to each other, each first and second half vault comprising: i. a wall block having a vertical wall axis, a horizontal wall axis, two flat sides, an upper wall end, a flat outer wall surface, and an inner wall surface having a bottom end and a top end, and the inner wall surface being curved perpendicularly with the wall vertical axis from the top end and being flat at the bottom end; ii. a roof block having a vertical roof axis, a horizontal roof axis, two flat sides, a lower roof end, a flat upper roof end, a flat outer roof surface, and an inner roof surface having a bottom end and top end, and the inner roof surface being curved perpendicularly with the vertical roof axis from the bottom and the top ends; the wall blocks and the roof blocks being attached to each other by fitting the lower roof ends of the roof blocks to the upper wall ends of the wall blocks thereby forming the first and the second half vaults; the first and the second half vaults being attached together to form the vault structure; two or more vault structures being attached together from the flat sides of the wall blocks and the flat sides of the roof blocks, thereby forming a foam core of the building; b) a second story floor attached to the wall blocks of each half vault; and c) a double layered fiberglass mesh coiled around the foam core, and having an inner layer and an outer layer, the outer layer having edges and said edges being wrapped under the foundation slab, and the inner layer having edges sandwiched between attaching elements, said attaching elements located in the wall blocks at the level the second story floor; wherein the vertical axis of the blocks is 5-7 meters and the thickness of the blocks is 30 to 60 cm.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) FIG. 1A shows vertical cross views of wall and roof blocks according to one preferred embodiment.
(2) FIG. 1B shows horizontal cross sections of wall, center or roof blocks according to one preferred embodiment.
(3) FIG. 2A is a vertical perspective front view of a building according to one embodiment of the invention.
(4) FIG. 2B is a vertical perspective front view of a building according to another embodiment of the invention.
(5) FIG. 3A shows a vertical cross section of one embodiment of the invention.
(6) FIG. 3B shows a detail of FIG. 3A.
(7) FIG. 4 shows a vertical cross section of another embodiment of the invention.
(8) FIG. 5A shows a vertical cross section of yet another embodiment of the invention.
(9) FIG. 5B shows a detail of FIG. 5A.
(10) FIG. 5C shows connection of reinforcing mesh according to further embodiments.
(11) FIG. 6A is vertical cross section of another embodiment of the invention.
(12) FIG. 6B shows a detail of FIG. 6A.
(13) FIG. 7 shows a vertical cross section of yet another embodiment of the invention.
(14) FIG. 8A shows a vertical cross section of yet another embodiment of the invention.
(15) FIG. 8B shows a vertical cross section of still another embodiment of the invention.
(16) FIG. 9A shows a vertical cross section of another embodiment, namely a floating house.
(17) FIG. 9B shows a vertical cross section of another embodiment of a floating house.
(18) FIG. 9C shows a vertical cross section of yet another embodiment of a floating house.
(19) FIG. 10 is a vertical perspective front view of a floating house according to one embodiment.
(20) FIG. 11A is a vertical cross section of an embodiment of a floating house.
(21) FIG. 11B is a vertical cross section of another embodiment of a floating house.
(22) FIG. 11C is a vertical cross section of yet another embodiment of a floating house.
(23) FIG. 11D is a vertical cross section of still another embodiment of a floating house.
(24) FIG. 12 is a vertical perspective front view of a floating house according to another embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
(25) The preferred embodiments of the present invention will now be described with reference to FIGS. 1-12. Identical elements in the various figures are identified with the same reference numerals.
(26) FIG. 1A shows vertical cross sectional views of different blocks. The figure shows a wall block 3a and a roof block 3b. The figure shows the vertical axis 104 of the blocks. The wall blocks 3a have a flat lower end 112 and a shaped upper end 114. The wall blocks 3a have a flat outer surface 140 and an inner surface 130 that is curved perpendicularly to the vertical axis 104 from its top end 116. The roof block 3b has a flat upper end 122 and a shaped lower end 124. The roof block has a flat outer surface 140 and an inner surface 130 that is curved perpendicularly with the vertical axis 104 from its top end 116 and from its bottom end 118.
(27) FIG. 1B is a horizontal cross section of either a wall block, center block or a roof block according to one preferred embodiment. The figure shows the outer surface 140 and the inner surface 130 and two flat sides 106. The figure shows a half circle cross section of vertical grooves 135 at both flat sides of the block. The figure also shows a cross section of a reinforcing cement pipe 6 that snugly fits to a tubular tunnel formed by two vertical grooves 135 of adjacent blocks. FIG. 1B also shows connection protrusion 4 of the blocks where no reinforcing pipe is applied.
(28) FIG. 2A is a vertical perspective front view of a building according to one embodiment of the invention. The figure shows foam core 700 formed of wall blocks 3a and roof blocks 3 b and their mirror images made of expanded polystyrene and forming vault structures 119 when joined together, flat sides of the blocks 106, top ends 116, bottom ends 118, joints between the blocks 150, vault 200, radius of the vault 210, foundation slab 2.
(29) FIG. 2B shows a vertical perspective front view of a building according to another embodiment. The figure shows the foundation slab 2, the wall blocks 3a, the roof blocks 3b, an interior of the building 8, and a belt 12 securing the vault structures together.
(30) FIG. 3A is a vertical cross section of a building 1 according to one embodiment of the invention. The figure shows wall blocks 3a, roof blocks 3b and their mirror images made of expanded polystyrene and forming a vault structure 119 when joined together. The figure shows the interior of the building 8, the foundation slab 2, fiber glass mesh 9, and attachment elements 10 to attach the edge of the mesh.
(31) FIG. 3B is a detail of FIG. 3A and shows a wall block 3a, fiber glass mesh 9, foundation slab 2 and attachment element 10 to attach the edge of the mesh.
(32) FIG. 4 is a vertical cross section of a building according to one embodiment of the invention. The figure shows wall blocks 3a, roof blocks 3b, their mirror images, made of expanded polystyrene and forming a vault structure 119 when joined together. Mirror image in this disclosure means a structure that is a mirror image in a sense that the blocks and their mirror images are capable of forming a vault structure when attached together. Mirror image definition of this disclosure does not require that the structures have any other features common, such as windows, doors or other additional structures. The figure shows the foundation slab 2, the fiber glass mesh 9, the joints of the blocks 4, and a conduit for reinforcing pipe 5.
(33) FIG. 5A shows another vertical cross section of a building according to another embodiment of the invention. The figure shows wall blocks 3a, and roof blocks 3b made of expanded polystyrene. The figure shows bottom layer of fiber glass mesh 9a and outer layer of the mesh 9b. The figure shows the joints of the blocks 4, the conduit for the reinforcing pipe 5, interior of the building 8 and the foundation slab 2.
(34) FIG. 5B is a detail of FIG. 5A. The figure shows foundation slab 2, wall block 3a, inner layer of fiber glass mesh 9a, outer layer of fiber glass mesh 9b, attachment of the edge of the mesh 10, and vertical cross section of a reinforcing pipe 7.
(35) FIG. 5C is a detail of attachment of the fiber glass mesh according to another embodiment. The figure shows foundation slab 2, a wall block 3a, an inner surface of the block 130, an outer surface of the block 140. An inner layer of fiber glass mesh 9a, a outer layer of fiber glass mesh 9b, and a third layer of fiber glass mesh 9c.
(36) FIG. 6A is a vertical cross sectional view of a building according to one embodiment of the invention. The figure shows wall blocks 3a and roof blocks 3b, foundation slab 2, joints between the blocks 4, conduit for the reinforcing pipe 5, inner layer of the fiber glass mesh 9a, outer layer of the fiber glass mesh 9b, attachment element to attach the edge of the mesh 10, floor support 13, and a second story floor 14. Detail D is shown in FIG. 6B.
(37) FIG. 6B is a detail D of FIG. 6A. The figure shows second story floor 14, conduit for the reinforcing pipe 5, bottom layer of fiber glass mesh 9a, outer layer of fiber glass mesh 9b, and attachment element 10 to attach the edge of the mesh 10.
(38) FIG. 7 is a vertical cross sectional view of the building according to one embodiment of this invention. The figure shows, a foundation slab 2, a wall block 3a and roof block 3b and mirror images thereof. The figure shows the interior of the building 8, a vertical cross section of a reinforced pipe 7, a belt made of synthetic fiber 12 and connection of belt ends 15.
(39) FIG. 8A is a vertical cross sectional view of a building according to another embodiment of this invention. The figure shows, a foundation slab 2, wall blocks 3a, center blocks 3c, roof blocks 3b and a conduit for reinforcing pipe 7.
(40) FIG. 8B is a vertical cross sectional view of a building according to another embodiment of this invention. The figure shows, a foundation slab 2, wall blocks 3a, center blocks 3c, roof blocks 3b and a conduit for reinforcing pipe 7.
(41) FIG. 9A is a vertical cross sectional view of a floating house 21 according to one embodiment of the invention. The figure shows floating platform 22, reinforced slab or ballast 23, technical chamber 24, wall blocks 26a and roof blocks 26b, floor 37, fiber glass mesh 33, and floor slab 28.
(42) FIG. 9B is a vertical cross sectional view of another embodiment of a floating house 21 according to one embodiment of the invention. The figure shows floating platform 22, reinforced slab or ballast 23, technical chamber 24, wall blocks 26a and roof blocks 26b, floor 27, conduit for the reinforcing pipe 31, fiber glass mesh 33, and floor slab 28.
(43) FIG. 9C is a vertical cross sectional view of another embodiment of a floating house 21. The figure shows floating platform 22, reinforced slab or ballast 23, technical chamber 24, wall blocks 26a and roof blocks 26b, floor 37, conduit for the reinforcing pipe 31, belt to attach the blocks together 35, connection of the belt ends 36 and floor slab 28.
(44) FIG. 10 is a perspective vertical sectional view of the floating house of this invention. The figure shows the building 21, the roof blocks 26b, the wall blocks 26a, the floating platform 22, the belt 35, the connection of the belt ends 36, and the floor slab 28.
(45) FIG. 11A is a vertical cross section of the floating house of this invention. The figure shows a wall block 26a, roof block 26b, interior of the building 29, ballasts 25, floor slab 28, floating platform 22, reinforced slab-ballast 23, and reinforcing mesh 33.
(46) FIG. 11B is a vertical cross section of the floating house according to one embodiment of this invention. The figure shows a wall block 26a, roof block 26b, interior of the building 29, ballasts 25, floor slab 28, floating platform 22, reinforced slab-ballast 23, reinforcing mesh 33, and conduit for the reinforcing pipe 31.
(47) FIG. 11C is a vertical cross section of the floating house according to one embodiment of this invention. The figure shows a wall block 26a, roof block 26b, interior of the building 29, ballasts 25, floor slab 28, floating platform 22, reinforced slab-ballast 23, bottom layer mesh 33a, outer layer mesh 33b, and conduit for the reinforcing pipe 31.
(48) FIG. 11D is a vertical cross section of the floating house according to one embodiment of this invention. The figure shows a wall block 26a, roof block 26b, interior of the building 29, ballasts 25, floor slab 28, floating platform 22, reinforced slab-ballast 23, belt 35, connection of belt ends 36, and conduit for the reinforcing pipe 31.
(49) FIG. 12 is a perspective vertical sectional view of the floating house of this invention. The figure shows the building 21, the roof blocks 26b, the wall blocks 26a, the floating platform 22, the belt 35, the connection of the belt ends 36, and the floor slab 28.
(50) The present invention is now further described by way of example only with reference to accompanying drawings.
(51) EP 2273019 discloses a house structure made of foamed polystyrene or polyurethane blocks. Those structures may be large enough for being used as single story residential houses or storage or office buildings, but the material sets limits to the size of the buildings and can be used only for relatively small one floor buildings. The instant invention comprises a method and structures to extend the vertical dimension of the foam monoliths up to 12 meters and enables building of two or even three story buildings. However, one skilled in the art will realized that monoliths may have smaller dimensions and that such monoliths and buildings made of such monoliths are also within the scope of this invention. Buildings made of elements according to this invention can survive an earth quake of 7.5 on the Richter-scale.
(52) According to one preferred embodiment the structures of this invention are reinforced either by PVC tubes running inside the foam and containing liquid expansive cement to reinforce the structures. According to another preferred embodiment the structures are coiled by fiber glass mesh or mesh made of other material that has similar reinforcing properties.
(53) According to one embodiment the vault structures are secured by one or more belts made of synthetic fiber.
(54) According to one preferred embodiment the foam is lined with plaster board, spray plaster and/or intumescent paint thereby making the structure fire resistant for about 60 minutes.
(55) According to another preferred embodiment the foam is lined with poly-paraphenylene terephtalamide (Kevlar) to increase resistance of the foam material. A building constructed with such reinforced material is substantially bullet proof.
(56) According to yet another preferred embodiment the foam may be lined with graphite, which increases the thermal capacity of the foam. Alternatively polystyrene foam including graphite (e.g. Neopor) may be used.
(57) According to one preferred embodiment the building has more than one story.
(58) According to yet another preferred embodiment the building is a floating house.
(59) Now referring to FIG. 1A, one embodiment of this invention is a system having four types of blocks: the wall blocks 3a, the roof blocks 3b and mirror images of both of these types. All the monolithic blocks of the invention have a vertical axis 104. All the blocks have two flat ends 106 (one is shown in FIG. 1A). The monolithic blocks may be wall blocks 3a or roof blocks 3b. All of the blocks have a flat outer surface 140. The wall blocks have an inner surface 130 that is curved perpendicularly with the vertical axis 104 of the block at its top end 116. The roof blocks 3b have an inner surface 130 that is curved perpendicularly with the vertical axis 104 at its top end 116 and its bottom end 118. The wall blocks 3a have a flat lower end 112 and a shaped upper end 114. The roof blocks 3b have preferably a flat upper end 122 and a shaped lower end 124. The upper ends of the wall blocks are shaped such that it matches the shape of the shaped lower end of the roof block. According to one preferred embodiment the upper ends 122 of the roof blocks may also be shaped in a way that the shaped upper end of the roof block matches the shaped upper end of its mirror image roof block. The curvature of the inner surfaces of the blocks is such that by attaching a wall block to a roof block the inner surfaces create a half of a vault. Attaching the mirror image roof block to a mirror image wall block creates another half vault. Attaching the roof blocks of the half vaults together now creates a full vault 200 (not shown in FIG. 1A) that is a half circle with a radius 210 (not shown in FIG. 1A) determined by the dimensions of the blocks. According to a preferred embodiment the radius of the half circle is 6 to 12 meters.
(60) Referring now to FIG. 1B the wall blocks 3a (or roof blocks or center blocks) are attached together from their flat sides 106. According to one preferred embodiment the flat sides have vertical grooves 135 that have a half circle cross section. When the blocks are attached together the vertical grooves form a conduit for reinforcing cement pipe 6 to snugly fit in the formed conduit. FIG. 1B also shows blocks that have connection protrusion 4 which has a half circle cross section and which snugly fits into the groove 135 of adjacent block when a reinforcing pipe is not used.
(61) Referring to FIG. 2A, attaching the wall blocks 3a and roof blocks 3b and their mirror images together form a vault structure 119. One or more vault structures 119 form a foam core 700 of a building when attached together from their flat sides 106.
(62) Referring to FIG. 2B, according to one preferred embodiment the vault structures may be secured by use of a belt 12. The belt may be made of synthetic fiber and belt goes vertically around the building as is shown in FIG. 7. There may be one or more belts in a building.
(63) Referring now to FIG. 8A, one embodiment of the invention is a system comprising six different kinds of blocks: wall blocks 3a, center blocks 3c, roof blocks 3c and mirror images thereof.
(64) Referring now to FIG. 8B, another embodiment of the invention is a system comprising eight different kinds of blocks: wall blocks 3a, center blocks 3c, two roof blocks 3b and mirror images thereof. One skilled in the art would understand that the number of different blocks may be changed and each such variation is within the scope of this invention.
(65) According to this invention the monolith blocks 3a or 3b preferably have a length along the vertical axis 104 of 5 to 12 meters, more preferably 6 to 11 meters and most preferably 6.10 to 10.40 meters. The dimension along horizontal axis 102 of the blocks is preferably 100 and 200 centimeters, more preferably between 120 and 150 centimeters and most preferably 123 centimeters. The thickness of the blocks varies between 25 and 70 centimeters, preferably 30 and 60 centimeters. When the blocks are assembled together the inner surfaces of the blocks 130 form a vault 200. Due to the enforcement structures discussed below, the vault according to the present invention can have vaults substantially larger than have been possible to make with the previously known methods. According to a preferred embodiment the vault 200 is defined as a half circle having a radius 210 between 4 and 15 meters, more preferably 6 and 12 meters. This again allows construction of much larger buildings with same cost effective and fast method.
(66) The building as shown in FIGS. 2A and 2B is constructed by attaching a desired number of the above described vault structures 119 together from their flat sides 106 to form a foam core 700.
(67) According to a preferred embodiment the blocks are put together with glue. However, one skilled in the art would understand that other methods may also be used, such as staples. As is discussed above and shown in FIG. 1B the flat sides 106 of the blocks may be attached by fitting a connection protrusion 4 in the groove 135. Furthermore the attachment of the vault structures 119 may be secured by a belt 12.
(68) Now referring to FIGS. 3A and 3B a preferred embodiment of the invention is described. In order to improve the stability of the structure and especially in order to enable use of monolithic blocks that have a size larger than disclosed in the prior art, the monolithic structures are reinforced by wrapping the structures in reinforcing mesh, preferably a fiber glass mesh 9. The edges of the mesh may be secured under the foundation slab 2 or they may be secured by separate attaching elements 10 to attach the edges. FIG. 3B shows the separate elements 10 and how the edges is attached between the elements. The elements may be made of concrete.
(69) Referring now to FIG. 4, the stability of the structure may be reinforced by liquid cement pipes. FIG. 4 shows the conduit for the reinforcing pipe 5. The pipes according to this invention are preferably PVC pipes having a cross section between 5 to 30 centimeters, and more preferably between 10 to 25 centimeters. As is shown in FIG. 4 the reinforcing pipes may be used in addition to the reinforcing fiber mesh 9.
(70) According to one preferred embodiment, the foam blocks have prefabricated tunnels for inserting the liquid cement pipes. Referring now again to FIG. 1 B, according to a preferred embodiment the wall, roof and optional center blocks have vertical grooves 135 preferably with a cross section of a half circle on both of their flat sides 106. When two blocks are attached together the adjacent grooves form a tunnel to fit an enforcing liquid cement filled pipe 6 snugly inside the tunnel.
(71) According to a preferred embodiment the pipes 6 are installed so that the distance between two pipes is 100 to 200 centimeters, preferably 120 centimeters. According to one preferred embodiment of the invention there is one pipe in each vault structure 119 unit formed by a wall block 3a, a roof block 3b and their mirror images or by a wall block 3a, a center block 3c and a roof block 3b and their mirror images.
(72) Now referring to FIGS. 5A and 5B, according to another preferred embodiment the building according to this invention is reinforced by a double layered fiber glass mesh 9. According to a preferred embodiment the mesh size is 4 mm times 4 mm, but other mesh size can also be used.
(73) According to one preferred embodiment the fiber mesh coils the whole building structure. According to another preferred embodiment the fiber mesh coils only a bottom section of the building structure. According to one preferred embodiment the fiber mesh coils about 20 to 100 centimeters of the building structure when measured from the ground, preferably about 50 cm of the building structure is covered.
(74) According to one preferred embodiment the fiber mesh is attached to the building structure with plaster. One layer of plaster is spread on the foam structure, the fiber glass mesh is attached to the plaster and another layer of plaster is spread on top of the foam structure. According to another embodiment, the foam blocks have notches where the fiber mesh is attached.
(75) As is shown in FIGS. 5A and 5B a double layered fiberglass mesh 9a and 9b is coiled around the whole building. The double layered fiberglass mesh consists of an inner layer 9a and an outer layer 9b. The loose edges of the outer layer of the fiber glass mesh 9b are wrapped under the foundation slab 2. The loose edges of the inner layer of the fiber glass mesh 9a are sandwiched between the foundation slab 2 and flat lower ends of the 112 of the wall blocks. According to a preferred embodiment the loose edges sandwiched between the foundation slab and the flat lower ends of the wall block is about 20-50 cm long, more preferably about 30 cm. According to a preferred embodiment the loose edges of the outer layer of the fiber glass mesh are wrapped under the foundation slab throughout the breadth of the building. According to another preferred embodiment the loose ends of the outer layer are wrapped under the foundation slab at least for a length of 60 centimeters.
(76) According to one preferred embodiment the loose edges of the outer layer of the fiber glass mesh is set on the foundation slab when the slab concrete is still wet and the fiber glass mesh sticks on the slab that.
(77) Now referring to FIG. 5C, in addition to the double layered fiber glass mesh 9a, 9b, the structure may be enforced with a third layer of fiber glass mesh 9c. According to this embodiment the third layer 9c may not wrap the full structure but only 30 to 100 cm from the bottom of the building. The loose edges of the third layer are sandwiched between the ground and the foundation slab 3. This embodiment is specifically preferred when the building is erected in area where temperatures drop below 0 C.
(78) An advantage of this invention is that buildings with more than one story may be built with the foam structures. FIGS. 6A and B show such embodiment. The double layered fiber glass mesh may now be used to wrap only the upper story of the building and the inner layer of the mesh 9a is sandwiched between attaching elements 10 locating at the level of the second story floor 14. The outer layer of the mesh 9b is wrapped over the first floor and sandwiched under the foundation slab 2.
(79) Now referring to FIG. 7, according to one embodiment of the invention the vault structures may be secured by a belt 12 that is preferably made of synthetic fiber and wrapped around the building. The ends of the belt are attached with a connection 15 under the foundation slab 2. There may be one or more belts in a building.
(80) Another embodiment of the instant invention is a floating building or floating home. Such floating building is shown in FIGS. 9-12. Even if the numbering of the elements in FIGS. 9-12 is not equal with the numbering of FIGS. 1-11, the elements are substantially similar. The floating building has wall blocks 26a and roof blocks 26b attached to each other similarly as described above. All the variations described in relation to FIGS. 1-8 apply here also. A fiber glass mesh 33 and/or reinforcing pipes 31 may be used similarly as described above. Instead of foundation slab the floating building has floating platform 22 and a floor slab 28. As is shown in FIGS. 9A and B, the loose edges of the fiber mesh 33 may be sandwiched between the floating platform 22 and the floor slab 28. FIG. 9C shows how the fiber belt 35 may be used similarly as described above to secure the vault structures. The belt connection 36 is now under the floating platform 22. FIG. 11C shows use of double layered mesh 33a, 33b and how the edges of the inner mesh are sandwiched between the floating slab 22 and the floor slab 28, and the outer mesh edges are sandwiched between the ends of the wall blocks 3a ends and the floor slab 28.
(81) An advantage of this invention in addition to the easy transport and erection of the buildings is the low energy demand. The total demand for energy needed for warming a house with 100 square meters living area and heating water is about one third of the demand of traditional building. For example a traditional building may use 180 Wh/m2 in a year while a building with same size made of monolithic blocks according to this invention may use 50 kWh/m.sup.2 per year. The technology also enables achieving standards of passive house: by using mechanical ventilation with recuperation, a soil heat exchanger and heat pumps a final energy demand of a building according to this description may be 15 kWH/m.sup.2.
(82) One skilled in the art would recognize that in addition to residential buildings, the method and materials of this invention can be used for office buildings, storage buildings, and even for boat homes.
(83) Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention.
