US20250146276A1

US20250146276A1 - Structural Composite Wall and Building System

Info

Publication number: US20250146276A1
Application number: US18/504,441
Authority: US
Inventors: Dieter Roland Krohmer
Original assignee: Individual
Current assignee: Individual
Priority date: 2023-11-08
Filing date: 2023-11-08
Publication date: 2025-05-08

Abstract

A composite wall and building system. The composite wall and building system provide a structural beam formed of fiberglass composite having one or more flanges that engage with an insulation member. The structural beam may be formed in a variety of dimensions and profiles. A plurality of structural beams is used together to form a wall or other parts of the building. A panel is used to cover the beams and insulation. The wall sections are joined together with interlocking beams and fasteners are used to secure the beams to each other and wall sections to other wall sections. The composite beams and insulation are coated with a fire-retardant material. A modified beam is used in certain applications for additional strength and connection points with other preexisting wood structures.

Description

BACKGROUND OF THE INVENTION

The present invention relates to a composite wall and building system. More specifically, the composite wall and building system comprises a structural beam formed of fiberglass composite, wherein the structural beam includes one or more flanges. The structural beam may be formed in a variety of dimensions and profiles as needed. A plurality of structural beams is used together to form a wall or other parts of the building. An insulator member is configured to abut the structural beam, wherein the insulator member comprises one or more channels sized to receive the one or more flanges.
The construction industry utilizes many different types of wall construction for buildings. Traditionally, buildings are constructed from wood frames and plywood/drywall sheathing that are assembled on site. While these methods have been effective in creating structures, they come with inherent limitations that impact efficiency, structural integrity, and ease of construction. For instance, engineering large spans with wood beams as supports can be challenging, requiring complex load distribution designs. Additionally, on-site construction processes tend to be labor-intensive, time-consuming, and may lead to inconsistencies in quality and precision.
Another type of residential or commercial construction utilizes a composite wall structure which can be quickly constructed into a completely unitary wall structure. Most of these prior composite wall structures have complicated arrangements using large precast panels, leading to challenges in handling and assembly without specialized equipment. Some utilize reinforcing rods that are placed within the space between these panels, necessitating spacer blocks and tie wires to hold them rigidly in position. However, this method of construction has several drawbacks. Handling these larger panels often requires heavy machinery and the assembly process can be complicated.
In view of these developments, there exists a need for a composite wall structure that can be utilized to replace conventional construction. The present invention includes a composite wall structure that incorporates fiberglass composite beams, insulation with cutouts, and magnesium oxide (MgO) boards that streamlines construction processes, enhances structural integrity, and improves energy efficiency. The insulation is also fire-resistant expanded polystyrene (EPS) foam insulation, making these wall structures not only energy-efficient but also significantly enhancing their safety and fire resistance. This insulation further contributes to the overall thermal performance of the system, reducing heat transfer and ensuring a comfortable indoor environment. This wall structure provides improvements over traditional building practices which require the need for plywood sheathing, are labor-intensive on-site assembly, and impose design limitations.
In light of the devices disclosed in the known art, it is submitted that the present invention substantially diverges in design elements and methods from the known art and consequently it is clear that there is a need in the art for an improvement for composite wall and building systems. In this regard the instant invention substantially fulfills these needs.

SUMMARY OF THE INVENTION

In view of the foregoing disadvantages inherent in the known types of walls and building systems. The present invention provides a new composite wall and building system for construction and transportation.
It is an objective of the present invention to provide an embodiment of the wall and building system comprising the composite wall and building system comprises a structural beam formed of fiberglass composite, wherein the structural beam includes one or more flanges. The structural beam may be formed in a variety of dimensions and profiles as needed. A plurality of structural beams is used together to form a wall or other parts of the building. An insulator member is configured to abut the structural beam, wherein the insulator member comprises one or more channels sized to receive the one or more flanges.
It is yet another objective of the present invention to provide an embodiment of the wall and building system that utilizes prefabricated materials that can be constructed in sections offsite and transported to the job site. This streamlines the construction process while minimizing the time and effort required for positioning the beams and panels.
It is yet another objective of the present invention to provide an embodiment of the wall and building system that utilizes the strength to weight ration of fiberglass, comparable to steel, and other materials. The relatively lightweight construction enables ease of handling and lower transportation costs. Additionally, the system eliminates concerns of warping, rotting, and susceptibility to chemical decay. The inert properties of the composite material contribute to its exceptional durability and longevity.
It is an objective of the present invention to provide an embodiment of the wall and building system having composite beams and insulated panels that are prefabricated to any custom dimensions and are tailored to specific project requirements. This made-to-order approach minimizes material waste and optimizes resource utilization.
Other objects, features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTIONS OF THE DRAWINGS

Although the characteristic features of this invention will be particularly pointed out in the claims, the invention itself and manner in which it may be made and used may be better understood after a review of the following description, taken in connection with the accompanying drawings wherein like numeral annotations are provided throughout.

FIG. 1 shows a perspective view of an embodiment of the wall and building system.

FIG. 2 shows a cutaway view of an embodiment of a wall of the system.

FIG. 3 shows an exploded cross-sectional view of an embodiment of the wall of the system.

FIG. 4 shows a perspective view of an embodiment of the wall and building system wherein two adjacent prefabricated wall sections are being joined.

FIG. 5 shows a cutaway side view of an embodiment of a beam of the system.

FIG. 6 shows a cutaway side view of an embodiment of a modified beam of the system.

FIG. 7 shows a cutaway side view of a joint of a joist and an H-beam with wood blocking.

FIG. 8 shows a perspective view of a floor with wood blocking.

DETAILED DESCRIPTION OF THE INVENTION

Reference is made herein to the attached drawings. Like reference numerals are used throughout the drawings to depict like or similar elements of the system. For the purpose of presenting a brief and clear description of the present invention, the embodiment discussed will be used for constructing a wall with the respective elements of the wall and building system. The figures are intended for representative purposes only and should not be considered to be limiting in any respect. Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to give a thorough understanding of embodiments.
Reference will now be made in detail to the exemplary embodiment(s) of the invention. References to “one embodiment,” “at least one embodiment,” “an embodiment,” “one example,” “an example,” “for example,” and so on indicate that the embodiment(s) or example(s) may include a feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that feature, structure, characteristic, property, element, or limitation. Further, repeated use of the phrase “in an embodiment,” “first embodiment”, “second embodiment”, or “third embodiment” does not necessarily refer to the same embodiment.
Referring now to FIG. 1 , there is shown a perspective view of an embodiment of the wall and building system. The wall and building system provide several elements that are used in conjunction to build walls and buildings. The composite wall and building system 1000 utilize composite material that has superior strength and more desirable weight properties than conventional wood frame construction and other systems. The composite wall and building system 1000 comprise a structural beam 2000 formed of fiberglass composite, wherein the structural beam 1000 includes one or more flanges. In general, structural beam 2000 includes a web that connects to one or more flanges. The flanges are typically oriented to resist most of the bending moment and the web resists shearing forces. Depending on the particular wall and building constriction, the structural beam 2000 is constructed for the particular specifications desired.
As used herein, “structural beam” includes several variations of beams, such as I-beams, H-beams, W-beams, S-beams, C-beams, L-beams, girders, and the like. Additionally, other terms such as plate, joist, bar, and the like are used interchangeably with structural beam 2000. In one embodiment, the structural beams are constructed through pultrusion thereby forming specific integral elements. These elements are then cut to a desired size as needed. During or prior to the pultrusion, fibers, such as string, glass and/or webbing, are added to the composite to achieve desired structural properties. The composite beams have low conductivity thereby do not transfer heat easily. This assists with the insulation of the walls and does not expand or contract over time. In some embodiments, the edges of the structural beams, such as the H-beam, include ridges or hooks to increase structural strength, as the edges may deform under load. The ridges also assist with the interlocking of the insulation and flanges. Moreover, the ridges and/or hooks provide a mechanical connection when adhesives or sealants are applied during assembly, these hooks provide additional grip and strength to the joint.
In the shown embodiment, the structural beam 2000 comprise a top plate 2100 that forms an upper end of the wall 1500 and a base plate 2200 at the lower end of the wall. Both the top plate and base plate 2100, 2200 run generally horizontal and parallel to each other. An insulator member 3000 is configured to abut the top plate 2100. In the shown embodiment, the top plate 2100 comprises a C-beam with two flanges extending from a central web. The insulator member 3000 comprises a panel having perimeter edges with one or more channels sized to receive the one or more flanges of the structural beams 2000. In this way, the insulator member 3000 is coupled with the beams 2000, and do not require additional fasteners for securement. In some embodiments, fasteners are used in conjunction with the mating of the flanges and channels for securement.
A second structural beam 2000, the I-beam 2300, extends between the top plate 2100 and the base plate 2200. In the shown embodiment, the I-beam 2300 acts as a stud or vertical support member that connects the top plate 2100 and the base plate 2200. This I-beam 2300 acts as a vertical load-bearing member in the wall, supporting the weight of the structure, including the roof and other floors. It helps transfer these loads down to the floor below or to the foundation, ensuring the stability and integrity of the building. The spacing between the I-beam 2300 members is varied depending on several factors, including local regulations. Additionally, the particular structural properties of the I-beam 2300 also define the needed load bearing capacity in any given application.
Referring now to FIGS. 2 and 3 , there is shown a cutaway view of an embodiment of a wall of the system and an exploded cross-sectional view of an embodiment of the wall of the system, respectively. In the shown embodiment, a wall section 5000 is shown with a panel 4000 positioned on an interior side to cover the structural beams and the insulation member 3000. In this embodiment, structural beams comprise a first and second vertical beams 2310, 2320 each joined to the top plate 2100 and the base plate 2200, respectively. This configuration forms a rectangular wall section 5000 having an interior volume.
Referring specifically to FIG. 3 , the insulation 3000 is positioned within the interior volume such that the flanges 2050 of the first vertical beams 2310 on an interior side 2311 thereof protrude into the interior volume such that the insulation member 3000 is received within the interior volume and receives the flanges 2050 within channels 3100 thereof. These channels 3100 are sized and configured to receive the one or more flanges 2050 of the structural beam, ensuring a precise and efficient alignment within the wall. In some embodiments, one or more insulation members 3000 are positioned within a single interior volume. The panel 4000 is positioned on the interior side and exterior side to enclose the beams 2310, 2320, 2100, 2200. In one embodiment, the panel 4000 comprises magnesium oxide (MgO) boards. In the shown embodiment, the panels 4000 side flush against the insulation member 300. In other embodiments, the panel's 4000 side may form a gap between the insulation member 3000.
In one embodiment, the insulation comprises rockwool insulation. In one embodiment, the insulation is fire resistant. In one embodiment, a fire-retardant barrier is applied to the system. For example, a spray coating is applied to the insulation to increase the fire-resistant properties of insulation.
Referring now to FIGS. 4 and 5 , there is shown a perspective view of an embodiment of the wall and building system wherein two adjacent prefabricated wall sections are being joined and a cutaway side view of an embodiment of a beam of the system, respectively. In the shown embodiment, a first wall section 5000 and a second wall section 5100 are positioned next to each other. The first vertical beam and a second vertical beams 2310, 2320 of each respective wall section 5000, 5100 each comprises an exterior side 2312, 2322 opposite the interior side. At least one exterior side 2312 comprises a first exterior side flange 2410 wherein the first exterior side flange 2410 is adapted to correspond to an exterior side channel 2412 of the opposing wall section 5100.
Specifically referring to FIG. 5 , there is shown a first vertical beam 2310. When viewed from right to left in FIG. 5 , the first vertical beam 2310 comprises an exterior side web 2411, a first exterior side flange 2410 that protrudes from the exterior side web 2411, an interior web 2415, an exterior side channel 2412, and a second exterior side flange 2413. In one embodiment, the exterior side web 2411 and the first exterior side flange 2410 are inverse of the exterior side channel 2412 and the second exterior side flange 2413. In this way, an identical second beam 2320 is configured to be mated as shown in FIG. 4 .
In the show embodiment, the wall sections 5000, 5100 are prefabricated off site and transported to the site in sections. At the site, these wall sections 5000, 5100 are assembled according to the design specifications, with the wall sections 5000, 5100 being joined via any suitable fastener. Such fasteners include bolts and nuts, screws, nails, anchors, rivets, adhesive fasteners, snap connectors, and the like. In the shown embodiments, the H-beam is secured to the top plate and base plate via stainless steel screws.
Referring now to FIG. 6 , there is shown a cutaway side view of an embodiment of a modified beam of the system. In the shown embodiment, the modified beam 6000 is used particularly within wall, floor, and beam systems to provide structural reinforcement that significantly strengthens the rail system, effectively bolstering its load-bearing capacity and overall stability. Additionally, the increased thickness of the modified beam 6000 provides a greater amount of fiberglass material within the rail system for securely attaching fasteners, such as screws. In one use, the modified beam 6000 is used for long span supports that directly interfaces with conventional wood framing of a building.
In one embodiment, the modified beam 6000 is adapted to receive a foam gasket thereagainst. The foam gasket, when placed between the subfloor and the wall, eliminates drafts and enhances the energy efficiency of the structure. In the shown embodiment, the modified beam 6000 includes an upper beam 6100 and a lower beam 6200 used to stiffen the modified beam 6000. The lower beam 6200 may be positioned under a wood plate on the top portion of the wall such that the wood plate rests on the flange 6150 of the upper beam 6100. The wood plate is used to assist in spreading the load of floor joist over the wall system and to make it easier to fasten conventional buildings, for example wood trusses, to the present invention. In one embodiment, the lower beam 6200 is not used should the load and/or span required does not require the additional strength.
In the shown embodiment, the beam 6000 is formed from a shell with support members therein that forms sub-compartments that decreases the weight of the beam 6000. However, in other embodiments, the beam 6000 may be filled or have a different arrangement of support structures. In one embodiment, the beams 6100, 6200 are completely filled and integral and/or monolithic with each other.
Referring now to FIGS. 7 and 8 , there is shown a cutaway side view of a joint of a joist and an H-beam with wood blocking and a perspective view of a floor with wood blocking, respectively. In the shown embodiment, a joist 7000 (also known as a header joist) is fastened to floor joist, such as an H-beam 2000 (structural beam) at an angle. The joist and H- beam 7000, 2000 are fiberglass composite having a relatively thin cross-sectional area. Wood blocking 8000 serves as a substrate and is used to secure threaded fasteners, such as screws, to provide a member that easily receives the threaded fasteners 7100. Generally, threaded fasteners 7100 resist pullout forces by engaging the threads along their length. These threads provide a mechanical advantage and are employed in combination with a fastener head to secure two elements together. In this configuration, the fiberglass composite joist 7000 and H-beam 2000 have a thickness of less than 1 inch, offering some area for threaded engagement. However, depending on the desired engineering specifications, additional threaded engagement length may be necessary. Wood blocking 8000 acts as an intermediary component connecting the joist 7000 and the H-beam 2000. Furthermore, wood blocking 8000 allows for the connection of the joist 7000 and the H-beam 2000 at various angles by utilizing wood blocks 8000 that are shaped to match the desired angle.
In the shown embodiment, a vapor permeable underlayment 7200 forms a layer around an exterior of the joist. A continuous sealant is used at each side of the wood blocking and floor/roof panel to ensure a tight and durable seal, preventing any moisture or air infiltration, and promoting the long-term structural integrity of the building.
Specifically referring to FIG. 8 , the area beneath the floor is removed for a clear view of the joist 7000 and I-beam 2000. In the shown embodiment, wood blocking 8000 is positioned on the joist 7000 at the point of intersection with the I-beam 2000. Blocking is positioned between the web and flange of the I-beam 2000, and fastened to the beam 2000. The wood blocking 8000 is similarly fastened to the joist 7000. The wood blocking 8000 of the joist 7000 is correspondingly fastened to the wood blocking of the beam 2000. In this way, the floor is formed by joining multiple beams perpendicular to the joist 7000 at an interval, wherein wood blocking 8000 is utilized to join the joists 7000 and beams 2000.
In the shown embodiment, a drained and ventilated cladding system 9000 is applied to the H-beam 2000 as a protective outer layer. This cladding 9000 is adapted to provide a a safeguard against the elements while also allowing for effective ventilation and drainage. The combination of these features helps to prevent moisture accumulation and promotes the long-term durability of the building's exterior envelope. The wood blocking 8000 utilized in this assembly is fabricated from dimensional lumber, for example 2″×8″ lumber, which is readily aalibale and provides support for the threaded fasteners. This choice of lumber dimensions ensures that there is ample surface area for securely anchoring the screws. In the embodiment described, 3-inch screws are employed for fastening, offering substantial holding power and stability in the joint connections.
The design of this system allows for versatility in construction, accommodating variations in angles and dimensions while maintaining structural integrity. The use of wood blocking in combination with the fiberglass composite joists and H-beams not only facilitates secure fastening but also simplifies the process of adapting to different project requirements. Additionally, the use of drained and ventilated cladding on the H-stud plays a pivotal role in the overall building envelope's performance. This cladding system effectively manages moisture and ventilation, reducing the risk of water damage and allowing the structure to ‘breathe,’ thereby enhancing energy efficiency and prolonging the life of the building.
It is therefore submitted that the instant invention has been shown and described in what is considered to be the most practical and preferred embodiments. It is recognized, however, that departures may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Claims

I claim:

1. A composite wall and building system, comprising:

a structural beam formed of fiberglass composite;

wherein the structural beam includes one or more flanges;

an insulator member configured to abut the structural beam, wherein the insulator member comprises one or more channels sized to receive the one or more flanges.

2. The composite wall and building system of claim 1, wherein the structural beam comprises an I-beam or H-beam.

3. The composite wall and building system of claim 2, wherein the insulator member comprises rockwool insulation.

4. The composite wall and building system of claim 2, wherein the structural beam comprises a top plate forming a C-beam with two flanges extending from a central web, wherein a first I-beam or H-beam is configured to be received within the top plate.

5. The composite wall and building system of claim 4, further comprising a panel configured to secure to the structural beam.

6. The composite wall and building system of claim 5, wherein the panel comprises a magnesium oxide board.

7. The composite wall and building system of claim 1, wherein the structural beam comprises:

a plurality of beams including a first vertical beam, a second vertical beam, a top plate, and a base plate;

wherein the top plate and base plate each forms a C-shape with two flanges extending from a central web.

8. The composite wall and building system of claim 7, further comprising a wall section, the wall section comprising:

the first and second vertical beams each joined to the top plate and base plate respectively, forming an interior volume;

wherein the flanges of the and second vertical beams protrude into the interior volume;

wherein the insulation member is received within the interior volume and receives the flanges within channels thereof.

9. The composite wall and building system of claim 8, wherein the insulator member comprises rockwool insulation.

10. The composite wall and building system of claim 8, wherein the first vertical beam and a second vertical beams each comprises an I-beam or H-beam.

11. The composite wall and building system of claim 8, wherein the first vertical beam and a second vertical beams each comprises an exterior side, opposite an interior side, wherein at least one exterior side comprises a first exterior side flange that protrudes from an exterior side web, an exterior side channel, and a second exterior side flange.

12. The composite wall and building system of claim 11, wherein the exterior side is configured to interlock with a corresponding with a mating second exterior side such that the mating exterior sides join two or more wall sections.

13. The composite wall and building system of claim 7, wherein the structural beam is a modified structural beam having a reinforcing member running along a longitudinal length thereof.

14. The composite wall and building system of claim 13, wherein the reinforcing member comprises a tapered flange adapted to decrease deflection of the structural beam when a loading force is applied thereto.

15. The composite wall and building system of claim 1, wherein the structural beam comprises a header joist joined to a floor joist via a fastener to form a floor.

16. The composite wall and building system of claim 15, wherein the floor joist comprises an H-beam or an I-beam.

17. The composite wall and building system of claim 16, wherein the header joist is fastened to the floor joist with wood blocking, wherein the wood blocking is configured to receive the fasteners for fastening the header joist to the floor joist.

18. The composite wall and building system of claim 17, wherein the H-beam used as the floor joist is composed of a fiberglass composite having a thickness of less than 1 inch.

19. The composite wall and building system of claim 18, wherein the wood blocking employed to secure the header joist to the H-beam is correspondingly fastened to wood blocking on the floor joist, thereby joining multiple H-beams and header joists perpendicular to one another to create a floor structure.

20. The composite wall and building system of claim 1, further comprising a vapor permeable underlayment positioned around an exterior of the joist and a continuous sealant applied to the wood blocking and floor/roof panel, the sealant configured to prevent moisture and air infiltration.