Hurricane resistant foam-concrete structural composite
AssigneeR-40 Homes, Inc.
InventorPaul K. Moore
Life of this patent
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Abstract
The present invention is directed toward a new method of building construction which eliminates traditional framed wall and trussed roof construction methods. The method of construction utilizes a polymer bonded foam-concrete structural composite building material formed from a styrene foam having a fiber reinforced, ethylene-vinyl acetate containing concrete emulsion integrally cured thereto, resulting in enhanced impact resistance and enhanced ability to withstand tensile load. The resultant structure has enhanced thermal insulation properties. The invention is further directed to a foam panel interface construction which renders the resultant structure impervious to wind damage at velocities in the range of about 155-310 mph.
Claims6
A method for manufacturing a wind resistant structure formed from a plurality of foam-concrete structural composite members comprising:
- providing a rigid base having a shape defining an outer perimeter of said structure and being constructed and arranged to support said plurality of foam-concrete structural composite members;
- affixing to said rigid base, a plurality of vertically oriented and adhesively engaged foam panels characterized as containing a plurality of channels adapted to contain a reinforcing post therein and whereby vertical wall portions of said structure are formed;
- providing a plurality of obliquely oriented and adhesively engaged foam panels characterized as containing a plurality of channels adapted to contain a reinforcing post therein and whereby oblique roof portions of said structure are formed, said roof portions being adhesively attached to said vertical wall portions and further fixedly engaging a central horizontal reinforcing member, whereby a roof structure is formed;
- inserting a plurality of reinforcing members within the channels of said vertical wall portions and said roof portions and further inserting a fiber reinforced, ethylene-vinyl acetate containing concrete emulsion within said channels whereby said reinforcing posts are formed in-situ;
- applying multiple thin layers of said fiber reinforced, ethylene-vinyl acetate containing concrete emulsion to inner and outer surfaces of said vertical wall portions and roof portions, and curing said emulsion to provide an integrally bonded cementitious layer;
- wherein a structure having enhanced tensile load characteristics is formed, said characteristics being effective to render said structure impervious to damage from winds in the range of about 155-310 mph.
A fiber reinforced, ethylene-vinyl acetate containing concrete emulsion produced by:
- 1) forming an ethylene-vinyl acetate reaction product by contacting vinyl acetate with gaseous ethylene until about a 3 wt. % ethylene concentration is reached;
- 2) adding water with constant agitation until an emulsion is formed containing about 55 wt. % of said ethylene-vinyl acetate reaction product;
- 3) further including about 2 wt. % propylene glycol and 1 wt. % ethylene-vinyl acetate copolymer and continuing agitation whereby a stable concentrate is formed;
- 4) diluting the resultant stable concentrate of step (3) by adding about 3 parts by weight concentrate to about 5 parts by weight of water to form a working solution;
- 5) admixing the working solution of step (4) with a Portland mix, to form an ethylene-vinyl acetate containing concrete emulsion;
- 6) further admixing said ethylene-vinyl acetate containing concrete emulsion with an amount of fine polymer fibers effective to increase the tensile load characteristics of the ethylene-vinyl acetate containing concrete emulsion so as to enable it to withstand winds in excess of about 155 mph;
- and
- 7) agitating the mixture until a homogeneously dispersed, fiber reinforced ethylene-vinyl acetate containing concrete emulsion is formed.
Dependencies are inferred from the claim text.