Structural elements and method for fabricating structural elements

Abstract

A composite panel structure includes a flange beam assembly including: a web assembly; and a first flange assembly attached in an essentially perpendicular fashion to the web assembly. The composite panel structure further includes at least two panel assemblies. Each panel assembly includes: a foam layer; a first high-density material layer secured to the foam layer; and at least one recess configured to receive at least a portion of the first flange assembly.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the priority of U.S. Provisional Application No. 60 / 594,948, entitled APPARATUS AND METHOD FOR FABRICATING STRUCTURAL ELEMENTS FOR BUILDINGS, which was filed on 21 May 2005; the entire contents of which are herein incorporated by reference.FIELD OF DISCLOSURE [0002] The present invention relates to structural elements and methods for fabricating structural elements for buildings and more specifically to insulating foam-concrete structural elements. BACKGROUND [0003] Many types of fabrication techniques are used in the construction industry. The types of materials and systems used depend on several factors. For example, the size of the building will require different types of construction material based on the number of floors and other considerations. Local building codes also dictate specific types of construction materials. This will vary from area to area depending on the nature of local factors such as climat...

AI Technical Summary

Benefits of technology

[0013] The invention can be implemented to realize one or more of the following advantages. The composite system provides building structures with lighter weight, superior sound and thermal insulation, improved strength and improved fire safety. The structure may be fabricated on site or pre-fabricated at a factory.

[0015] An advantage of using a laminar structure is that the resulting structure exhibits many of the desired qualities of each of the laminate's components. In particular, the structure disclosed herein provides lightweight structural elements having the strength of concrete, and, in addition, structural elements that have superior insulation qualities for both sound and thermal insulation.

[0016] In building walls, the outer shell provides substantial structural strength which will satisfy local building codes for factors such as wind resistance, fire resistance, and the ability to support the weight which may be applied by floors above. In addition, the inner core provides a substantial increase in the insulating characteristics of the wall segments. The resulting laminated wall structure produces a wall structure with high strength and excellent insulating characteristics. Further, since the inner foam core of the wall structure weigh substantially less than the outer concrete shell, the wall segments will be lighter and easier to maneuver into place.

[0017] Further, all of these elements can be combined into prefabricated units to rapidly assemble a dwelling. Likewise, due to the reduced weight of the structural elements that comes as a result of the foam's light weight, substantial sections of a building or other construction project can be fabricated at factory locations under controlled conditions, and then shipped to the job site for assembly.

[0018] Also, the foam layer provides thermal insulation, provide some flexibility which may prevent cracking of the concrete, and also creates a vapor barrier. In addition, the foam is a fire retardant. As a result, in the event of a fire the foam would, at a minimum, slow down the spread of the fire and potentially reduce the extent of fire damage.

Problems solved by technology

Of course, this can drastically affect the types of materials selected for construction from one area of the country to another.

Due to a concern for environmental issues such as fuel conservation, proper insulation of homes has become a significant issue nationwide.

In addition to conservation issues, fuel conservation is also an important issue for individual family finances as well as for national policy / security reasons.

While many materials work very well in terms of providing insulation, some have been known to have one or more drawbacks.

For example, the cost of adding insulation to buildings and other structures may be expensive.

Likewise, some insulation materials, such as formaldehyde foam, which was originally found to be very effective as an insulation material, was later found to be toxic and its use was banned.

Another issue related to building construction is the use of multiple technologies.

While the prior art has provided numerous construction techniques and numerous construction materials, it has failed to provide a single construction technique that can be used across a variety of structural entities, such as roof trusses, sub-flooring, building walls, seawall bulkheads, highway privacy walls, and other like structures, and thereby allow construction projects to be completed with the benefit of redundant and easy to use materials.

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