Lightweight building component

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Patent issued

01/12/1993

Inventor(s):	Kakuk, Stefan
Application	No. 07/869,836 filed on 04/16/1992
Current US Class	52/606, 52/659, 52/DIG9
Field of search	52/659, 52/606, 52/DIG.9, 52/323, 52/322, 52/321, 52/100
International Classes:	E04C 500
Examiners
Primary	Raduazo Henry E.
Attorney, agent or firm:	Staas & Halsey
US patent references	1347146, 1414246, 1604097, 1921518, 1969402, 2087522, 2888819, 3418402, 3545155, 3562979, 3660214, 3664076, 3740909, 3874139, 3922832, 4085001, 4090884, 4123889, 4154030, 4229222, 4301198, 4307552, 4364979, 4378401, 4398378, 4433521, 4682458, 4690874, 4748777, 4947611
Foreign patents	8706757 (05/12/1987, DE), 8632320 (12/03/1987, DE), 9000238 (01/11/1990, DE), 250137 (02/29/1964, AU), 0269990 (10/31/1987, EP), 8536156 (01/31/1964, DE), 2081257 (02/28/1970, FR), 896408 (04/30/1962, GB), 2084212 (03/31/1982, GB)

A building kit including lightweight, extruded components made ofenvironmentally acceptable, i.e., organic and mineral, materials. Thelightweight components are made of: a) untreated chopped straw, grainchaff, rice husks, rock fibers and/or glass fibers, b) binders, namelycement, lime and/or gypsum, and c) mineral additives. The componentsinclude air chambers and reinforcing members and are connected usingI-beams, adhesives, nails, etc.
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This application is a continuation-in-part of application Ser. No.07/752,998, filed Sep. 3, 1991, now abandoned, which is a continuation ofapplication Ser. No. 07/497,025, filed Mar. 22, 1990, now abandoned, whichis a continuation-in-part of Ser. No. 07/320,820 filed Mar. 9, 1989, nowabandoned, which is a continuation of Ser. No. 07/128,200, filed Dec. 3,1987, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a kit consisting of lightweight componentsfor building walls, supports, ceilings and other structures.
With increasingly stringent sound, fire and heat insulation requirements,building components in use today must have characteristics higher thanthose required, and yet must be economically manufactured. Despitelarge-surface shapes, components also should not constrict architects andplanners to specific dimensions, grids or series. That is, the shape andstructure of the components should lend themselves to a variety ofapplications, and offer unlimited possibilities with respect to dimensionsand architectural design.
It would also be advantageous if building materials were absolutelyincombustible, even having a fire-retarding effect, and, in case of fire,produced no smoke or other impermissible gases.
The building materials must be able to breath, must be waterproof andshould be resistent to frost and aging. In addition, the buildingmaterials must retain their spatial shape over time, so that deformation,shrinkage or swelling does not occur, even under the most extremeconditions.
Preferably, it should be possible to assemble the components in a dryprocedure using screws, nails, brackets or adhesives with simple tools,such as saws, drills, grinding machines, etc., and not requiring hoistingtools or other heavy equipment, and the components should have a finishedsurface or be end-coated. In addition, the components must satisfynecessary static conditions.
The components and facing elements or shells in use today only satisfythese requirements in part, if at all.
SUMMARY OF THE INVENTION
Objects of the present invention are to provide a building kit consistingof lightweight components made of environmentally acceptable, i.e.,organic and mineral materials, are heat and sound insulating and, despitethe organic additives, are non-flammable, or even fire-retarding, areresistant to water and frost, actively breathe, retain their spatialshape, do not shrink or swell, may be adjusted to the static andarchitectural conditions in terms of their shape, and which are so lightthat they may be easily assembled without the use of hoisting tools andheavy equipment. In addition, the shape of these components, combined withthe capacity of easy separation into varying widths, gives them an almostunlimited variety of applications.
These objects are achieved by a building kit of lightweight components,including:
a) untreated chopped straw, grain, chaff, rice husks, rock fibers, and/orglass fibers;
b) binders, namely cement, lime and/or gypsum; and
c) mineral additives.
Other features and advantages of the present invention will be apparentfrom the following description taken in conjunction with the accompanyingdrawings, in which like reference characters designate the same or similarparts throughout the figures thereof.

I claim:
1. Lightweight elongated extruded structural component for walls, columnsand ceilings, comprising longitudinally split straw fragments which arebound by a binding agent, and impregnated with a water repellant agent,
wherein the lightweight component is provided with air chambers extendingin the longitudinal direction of the component.
2. Lightweight component according to claim 1, wherein the component is inthe form a rectangular board, a body of which is provided with the airchambers.
3. Lightweight component according to claim 1, wherein the component is inthe form of a rectangular board with a welt on three edges and a groove onthe remaining edge.
4. Lightweight component according to claim 1, wherein the component is inthe form of a rectangular board with welts on two opposing edges and agroove on another edge.
5. Lightweight component according to claim 1, wherein the component is inthe form of a rectangular board having a welt with one edged bevelled.
6. Lightweight component according to claim 1, wherein the component is inthe form of a tube having a rectangular cross-section.
7. Lightweight component according to claim 1 wherein the component isU-shaped.
8. Lightweight component according to claim 1 wherein the component is inthe form of a hollow trapezoid with a welt on two opposing longitudinaledges.
9. Lightweight component according to claim 1, wherein the component is inthe form of an angular cross-section.
10. Lightweight component according to claim 1, wherein the component hasan h-shaped cross-section.
11. Lightweight component according to claim 1, further comprising amaterial coated on at least one surface thereof.
12. Lightweight component according to claim 11, wherein the material isweather proof.
13. Lightweight component according to claim 11, wherein the material isplywood.
14. Lightweight component according to claim 11, wherein the material isveneer.
15. Lightweight component according to claim 11, wherein the material issheeting.
16. Lightweight component according to claim 11, wherein the material iscardboard.
17. Lightweight component according to claim 11, wherein the material ispaint.
18. Lightweight component according to claim 1, wherein the straw fragmentsare impregnated with a flame retarding material.

BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a partof the specification, illustrate embodiments of the invention and,together with the description, serve to explain the principles of theinvention.
FIG. 1 is a perspective view of a building component according to thepresent invention, with an exploded view of one side thereof.
FIG. 2 is a perspective view of a second embodiment of a building componentaccording to the present invention, with an exploded view of one sidethereof.
FIG. 3 is a third embodiment of a building component according to thepresent invention, with an exploded view of one side thereof.
FIG. 4 is a perspective view of a building component according to a fourthembodiment of the present invention.
FIG. 5 is a perspective view of a building component according to a fifthembodiment of the present invention.
FIG. 6 is a perspective view of building components assembled according toa sixth embodiment of the present
FIG. 6A is a perspective view of a separating wedge used to promoteadhesive flow in the component joints.
FIG. 7 is a perspective view of building components assembled according toa seventh embodiment of the present invention.
FIG. 8 is a perspective view of building components assembled according toan eighth embodiment of the present invention.
FIG. 9 is a perspective view of a double T section used to assemble thebuilding components of the present invention.
FIG. 10 is a side view of building components assembled according to thepresent invention.
FIG. 11 is a top view of building components assembled according to thepresent invention.
FIG. 11A is a top view of the notch details of FIG. 11.
FIG. 12 is a side view of building components assembled according to thepresent invention.
FIG. 13 is a front view of facing brinks to cover the building componentsassembled according to the present invention.
FIG. 14 is a side view of the facing brinks shown in FIG. 13.
FIG. 15 is a front view of tile to cover the building components assembledaccording to the present invention.
FIG. 16 is a side view of the tiles shown in FIG. 15.
FIG. 17 illustrates a hollow rectangular cross-section profile for thecomponent.
FIG. 18 illustrates a U-shaped cross-section profile for the component.
FIG. 19 illustrates a hollow trapezoidal cross-section profile for thecomponent.
FIG. 20 illustrates an angle cross-section profile for the component.
FIG. 21 illustrates an h-shaped cross-section profile for the component.
FIG. 22 is a perspective view of the component according to the presentinvention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In general, the lightweight components of the present invention are used tobuild walls, supports, ceilings and other structures, and are preferablyformed by extrusion.
Today's building materials must have economical properties in terms of use.
Therefore, it is advantageous for these building materials to havesound-deadening and thermally insulating properties, while beingnon-combustible and consisting of environmentally acceptable basematerial.
In terms of economy, the ease of handling and processing on theconstruction site cannot go unnoticed. Last but not least, the buildingcomponents must meet the necessary static demands. Today's buildingcomponents do not, or only partially, meet these demands.
The object of the invention is to provide an assembly kit consisting ofnon-combustible and environmentally acceptable building material, which isthermally insulating and can be adjusted in its shape to meet staticrequirements.
According to the invention, this object is achieved in that the assemblykit consists of lightweight building components such as pretreated strawand a binding agent, that the building component has the shape of a boardwhose body is provided with air chambers, that the building component hasthe shape of a board with a circumferential welt on three sides and agroove on one side, that the building component has the shape of a board,an opposite welt and a groove on one side.
Further preferred embodiments are characterized by the fact that thebuilding component has the shape of a board, the inner edge of whose welthas a chamfer, that the building component has the shape of a rectangulartube, that the building component has a U-shape, that the buildingcomponent is shaped like a hollow trapezoid, that the building componenthas the shape of an elbow, that the building component is h-shaped.
Another preferred embodiment is characterized by the fact that the buildingcomponent may be provided with a weather-resistant or decorative materialat its front face.
The rectangular profile 90 shown in FIG. 17, may be used vertically as acolumn or wall boarding for a construction or ventilation duct.
The U-profile 100 shown in FIG. 18 is well-suited for concrete chutes andducts, as well as for boardings of installations, but also forinstallation shafts.
FIG. 19 shows one embodiment of the invention in which the buildingcomponent takes the shape of a hollow trapezoid 110. This profile is usedfor constructing hollow beam ceilings.
FIG. 20 shows an angled or elbow profile 120 and is suitable for boardingon installations, boarding of concrete ceilings, or boarding of buildingcomponents such as roof beams.
FIG. 21 depicts an h-profile 130 suitable for use as revolving shuttercasing with ceilings.
All the aforementioned profile examples have excellent thermal insulatingand sound-deadening properties and can be shaped according to theirstructural demands.
It goes without saying that all of the building components have thepossibility of being provided on the corresponding fronts with materialsthat can cope with weather conditions or have an attractive appearance.
This invention provides an ideal assembly kit with economical propertiesthat do not require additional thermal insulating and sound-deadeningfeatures or, if required, changes in esthetic appearance.
In addition, the invention relates to a lightweight assembly kit whichconsists of pretreated straw and a binding agent.
The board as taught by the invention may be built as a sandwich board, astrip or a sound-deadening board.
In accordance with today's requirements, building materials shouldpreferably consist of biological raw materials in order to be ecologicallyacceptable. The building materials should also be flame-retardant,water-repellant, waterproof and possibly non-inflammable.
The building material, and therefore the building boards, should be easilyprocessable, preferably using dry procedures and simple hand tools. Thebuilding material should also be terminally coated or the surface shouldallow for or have further coating such as by means of plywood, veneer,foil, cardboard or paint.
The building materials known heretofore do not, or only partially, meetthese demands.
Therefore, the object of the invention is to provide a building material,i.e., a lightweight building board, which meets these demands andpossesses all of the properties described above.
This object is achieved according to the invention by providing alightweight building board consisting of pretreated straw and a bindingagent.
This lightweight building board embodying the invention can be used forerecting building components, sandwich boards and strips as well assound-deadening boards.
The novel lightweight building board is especially humidity-resistant. Itssurface has a final finish or is at least suitable for finish treatmentsuch as covering with wallpaper or paint.
The lightweight building board according to the invention is at the sametime hard and can be worked with hand tools such as saws and drills.
Due to its straw content, the lightweight building board has excellentheat-insulating and sound-deadening properties as well as superior tensilestrength.
The lightweight building board of the invention, because of its strawcontent, is a so-called biological building material and possessesexcellent heating properties.
Because the raw material is straw, which is found in relatively largequantities and accumulates as a waste product, the lightweight buildingboard has a great economic advantage as compared to the building materialsknown heretofore.
In addition, the lightweight building board has great environmentalacceptability.
The straw is pretreated with means that are known from the prior art andwhich provide the required properties such as flame retardation, waterinhibition, etc. These means are known to professionals active incellulose-containing products.
The joining of the pretreated straw or straw elements to the spatial formof the lightweight building board is carried out by means of per-se knownadhesives or binding agents suitable for this purpose in accordance withprocesses known from the prior art and possibly under application of heatand pressure.
The final coating of the lightweight building board is carried out withper-se known coating agents made of wood or plastics.
The subject of the present invention is shown in the accompanying FIG. 22.
The reference numeral 111 denotes the subject of the invention, i.e., thelightweight building board in the form of a rectangular board.
The reference numeral 222 denotes the longitudinally split straw elementswhich are held together by the binding agent 333 which consolidates in theinterstices between the straw elements.
Very light mineral substances, such as perlites, pumice, expanded clay,fine sand and mineral dust, and organic substances such as untreated andchopped straw, grain, chaff, rice husks is even peanut shells, are used asadditives or fillers. For the purposes of reinforcement, rock or glassfibers may be used, as well as straw.
To facilitate extrusion, conventional lubricants are used, as areretardants. The lightweight components are pressed in a pore-tight mannerby means of extruders and have very closely packed through air chambersand a relatively thin cross section. The components can have a relativelylarge surface area and can act as walls or facing shells for walls.
In one embodiment, the lightweight components include:
a) 20 to 30% of untreated and chopped straw, chaff and/or rice husks;
b) 10 to 15% of fine sand and/or mineral dust;
c) 20 to 25% of cement, lime, mortar and/or gypsum binder;
d) 40 to 50% of perlites, pumice powder and/or expanded clay filler;
e) 10 to 15% of water;
f) lubricants for extrusion; and
g) retardants for extrusion.
In another embodiment, the components include:
a) 20 to 30% of chopped rock and/or glass fibers;
b) 10 to 15% of fine sand and/or mineral dust;
c) 20 to 25% of cement, lime, mortar and/or gypsum binder;
d) 40 to 50% of perlites, pumice powder and/or expanded clay filler;
e) 5 to 10% of water;
f) lubricants for extrusion; and
g) retardants for extrusion.
In still another embodiment, the components include:
a) 10 to 15% of untreated and chopped straw, chaff and/or rice husks;
b) 10 to 15% of chopped rock and/or glasses;
c) 10 to 15% of fine sand and/or mineral dust;
d) 20 to 25% of cement, lime, mortar and/or gypsum binders;
e) 40 to 50% of perlites, pumice powder and/or expanded clay filler;
f) 5 to 10% of water;
g) lubricants for extrusion; and
h) retardants for extrusion.
The organic additives should be admixed in quantities which prevent, in theevent of a fire or high temperature, the development of smoke or gaseswhich are impermissible according to fire regulations.
In addition, the water absorption should be low and the building materialabsolutely resistant to water, frost and aging, despite the partialcontent of organic substances.
The lightweight components may be furnished with air chambers which provideintrinsic reinforcement, enable easy separation of the components alongtheir lengths at "weak points" spaced at certain intervals, and save onweight and material.
Another preferred embodiment is characterized by the fact that thecomponent can be in a U shape interwoven with air chambers, and can beused as a lintel, header, ceiling, wall or support board. This componentcan be readily separated into two angles at weak points, and assembledwith other components or facing shells into the most varied of structures.
Another preferred embodiment is characterized by the fact that a coveringfor walls of these components is provided, in which a backfill consistingof the building material described above is made out of small rocks ortiles, and the backfill is continuous in terms of thickness or isperforated with air chambers.
The components are preferably joined together by means of adhesive, screws,nails, brackets, or I beam sections used for alignment and attachmentprior to bonding and smoothing. Grooves in opposing notches and bevellingon an outside edge of each notch can be provided in order to achieve aflawless bonding of the components. For this reason, the bonding points,which are held by I beam sections, are temporarily separated as far aspossible with wedges in order to obtain as wide as possible a joint, sothat the adhesive can be continuously pressed in.
After the adhesive has dried, the wedges are removed, and the joints aresmoothed in a fine and flush manner. The hollow spaces or the air chambersreceiving the I beam sections are not filled. Rather, the I beam sectionis, if desired, pulled out and reused at another location.
Detailed descriptions of various embodiments are described hereinafter withreference to the figures.
FIG. 1 shows a lightweight building component A or facing shell with aconnecting slit 1, air chambers 2, a reinforcement member 3 made out ofmetal or wood, and "weak" or separation points 4. The separation points 4are placed at certain longitudinal intervals to facilitate separating thecomponents along its length into smaller widths.
FIG. 2 shows a lightweight component A' or facing shell with a groove 5, aprojection 6, air chambers 2' in the groove 5 and the projection 6, an airchamber 7, a reinforcement member 8 made out of wood or metal inserted inthe chamber 7, and a separation point 4.
FIG. 3 shows a lightweight component A" or facing shell with diagonallyopposed projecting notches B, which are bevelled on an outside edge 12 andinclude interwoven air chambers 9. The component A" also includes areinforcement chamber 10, a reinforcement member 11 made out of metal orwood, grooves 13, 14 arranged in each notch B, and a separation point 4.
Thus, the lightweight components A, A' and A" are shaped like a plate withtightly interwoven air chambers, wherein the edges of the componentsinclude a slit 1, a groove 5, a projection 6, or notches B, for speciallyreinforcing the plate, and several air chambers 2 have a metal or woodmember, which is inserted in the chambers.
FIG. 4 shows a U section building component C according to the presentinvention, which is suitable for use as beams, lintels, supports and wallforms or other revetments. The component C includes connecting slits 15,19, lateral grooves 16, a metal reinforcement 17 and, optionally, a woodreinforcement 18.
FIG. 5 shows a U section component C like the one shown in FIG. 4, but alsoincluding a central weak or separation point 20.
The U-shaped component or shell C is interwoven with air chambers 2". Theexternal air chambers 2" are continuous with the slits 15, 19 on bothlegs. The external surfaces of the legs may have grooves 16. Several airchambers have metal members or wood members 17, 18 inserted into thechambers for reinforcement. The middle of the shell has the weak point 20for easier separation into two angled components 23, if desired.
FIG. 6 shows opposing U section components C held with an I beam section21, to form a beam or lintel. The enlargement shows a bonding point 22,which is separated with a wedge 33.
FIG. 7 shows a U shaped section formed by two angle components 23, whichare connected by I beam sections 21 with facing shell strips 24. Thiscombination forms a relatively wide and tall lintel or beam.
FIG. 8 shows a combination of the lightweight components A" of FIG. 3connected to the U section components C of FIG. 4, which together form aceiling component.
FIG. 9 shows an I beam section 21, which is mounted to the connecting slits1, 15, 19 to hold the components.
FIG. 10 shows two joined U shaped lightweight components C shown in FIG. 4,which form a box pipe used as a support, support form, wall part, wallform, shaft or air channel. The supports or wall parts assembled in thisway may be used on, e.g., a floor by means of a keyed or grooved base 26for receiving mortar 25.
FIG. 11 shows a hollow wall made out of components A", as shown in FIG. 3,with opposing notches B. The enlargement shows the grooves 13, 14 arrangedin the notch B, and the bevelled outside edge 12 of the notch B.Insulation 28 is fit into the hollow.
FIG. 12 shows a hollow wall consisting of two components A and metalbrackets 27, which are attached to the floor and to the ceiling, andinsulation 28 lying in between the metal brackets 27 for better heat orsound qualities. Connection to the ceiling and floor is established by theformation of a grooved base or joint 29.
Tiles or facing bricks can be imbedded in mortar on the assembledcomponents discussed above, and thereby form large, interlocked surfaces,and the back of the tiles or facing bricks may be perforated.
More particularly, FIG. 13 and 14 show interlocked members made out offacing bricks 31, behind which is backfill 30 and a hollow chamber 33.Mortar finish joints 32 are also shown.
FIGS. 15 and 16 similarly show tiles 34 with finish joints 35 and backfill36.
The elements shown in FIGS. 13-16 are a cover layer for the buildingcomponents shown in FIGS. 1-12. They generally serve a decorativefunction. The cover layer can be attached to the lightweight componentsduring manufacturer or after the lightweight components are assembled at asite.
FIG. 1 also shows a similar cover member 50 for the lightwieght buildingcomponents according to the present invention. The cover 50 can be, e.g.,plywood, veneer, sheeting, cardboard, paint or a weatherproof covering.
All of the embodiment described above have excellent heat and soundinsulating properties, and may be altered in terms of shape depending onthe static requirements. Of course, all components may be coated orjacketed on the external faces with other materials, such as wallpaper,depending upon weather conditions and visual concepts. Further, thepresent invention provides lightweight components, e.g., facing shells,which satisfy and will continue to satisfy the most stringent requirementsof sound, heat and fire protection in the most economic way.
The foregoing is considered illustrative only of the principles of theinvention. Further, since numerous modifications and changes will readilyoccur to those skilled in the art, it is not desired to limit theinvention to the exact construction and operation shown and described.Accordingly, all suitable modifications and equivalents may be resorted tothat fall within the scope of the invention and the appended claims.