US4233787A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Composite building module and method for making same
Assignee: Maso-Therm Corp
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Filing: 1978-07-17
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Granted: 1980-11-18
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Expires: 1998-07-17
Abstract
Abstract A composite building module and method for making same including forming a bottom layer of fiber reinforced wet cementitious material, placing at least two rigid foam cores side by side on the bottom layer with the adjoining edges configured to define a channel around adjoining cores and encapsulating the cores in a fiber reinforced wet cementitious shell by depositing fibers on cementitious material around the sides of the cores and on the top thereof, wherein each channel is filled in to form a rib around the interior of the cementitious shell.
Inventors
- 👤 Matthew R. Piazza
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 22:55
CPC Classifications
B; B28; B28B; B28B19/00; B28B19/003; E; E04; E04C; E04C2/00; E04C2/02; E04C2/26; E04C2/284; E04C2/288; E04C2/2885
Claims Analysis
Total Claims: 23
Claim 1
Independent Claim
120 words
A method for making composite building modules comprising: a. forming a bottom layer of fiber reinforced wet cementitious material; b. forming a core by placing at least two rigid hollow foam box members each comprising a hollow tubular central portion and two flat end covers connected thereto side-by-side in a single layer on the bottom layer with all the adjoining edges forming at least one continuous channel completely around the core solely at the exterior thereof; and c. encapsulating the core in a fiber reinforced wet cementitious shell by depositing fibers and cementitious material around the sides of the core members and on the top thereof, filling each channel forming a rib completely around the interior of the cementitious shell.
Claim 2
Independent Claim
120 words
A method for making composite building modules comprising: a. forming a bottom layer of fiber reinforced wet cementitious material; b. forming a core by placing at least two rigid hollow foam box members each comprising a hollow tubular central portion and two flat end covers connected thereto side-by-side in a single layer on the bottom layer with all the adjoining edges forming at least one continuous channel completely around the core solely at the exterior thereof; and c. encapsulating the core in a fiber reinforced wet cementitious shell by depositing fibers and cementitious material around the sides of the core members and on the top thereof, filling each channel forming a rib completely around the interior of the cementitious shell.
Claim 3
Dependent Claim
26 words
A method according to claim 1, further comprising inserting lifting inserts into the top layer for effecting the lifting of the module by external lifting means.
Claim 4
Dependent Claim
18 words
A method according to claim 1, wherein the boxes are provided by connecting together individual planar foam members.
Claim 5
Dependent Claim
16 words
A method according to claim 1, wherein the boxes are connected by wrapping scrim material therearound.
Claim 6
Dependent Claim
15 words
A method according to claim 1, wherein the boxes are connected by tying bands therearound.
Claim 7
Dependent Claim
16 words
A method according to claim 1, wherein the boxes are connected by interlocking the adjoining sides.
Claim 8
Dependent Claim
24 words
A method according to claim 6, wherein the boxes comprise hollow rectangular solids having male and female interlocking elements on opposite longitudinal sides thereof.
Claim 9
Dependent Claim
38 words
A method according to claim 1, wherein the bottom layer is formed by providing a mold having bottom and side walls and depositing a layer of wet cementitious material and premixed fibers in the bottom of the mold.
Claim 10
Dependent Claim
21 words
A method according to claim 8, further comprising distributing lengths of fiber longer than the premixed fibers in the bottom layer.
Claim 11
Dependent Claim
17 words
A method according to claim 9, wherein the distributing step is carried out while vibrating the mold.
Claim 12
Dependent Claim
14 words
A method according to claim 10, wherein the boxes are wrapped in scrim material.
Claim 13
Dependent Claim
105 words
A composite building module comprising: a. a core comprising at least two rigid hollow foam box members each comprising a hollow tubular central portion and two flat end covers connected thereto disposed side-by-side in a single layer and each including channel forming means at all adjoining edges forming at least one continuous channel completely around the core solely at the exterior thereof when the cores are disposed side-by-side; b. means connecting the cores to maintaining same in the side-by-side relationship; and c. a fiber reinforced cementitious shell encapsulating the core and filling in each channel defining a rib completely around the interior of the shell.
Claim 14
Dependent Claim
105 words
A composite building module comprising: a. a core comprising at least two rigid hollow foam box members each comprising a hollow tubular central portion and two flat end covers connected thereto disposed side-by-side in a single layer and each including channel forming means at all adjoining edges forming at least one continuous channel completely around the core solely at the exterior thereof when the cores are disposed side-by-side; b. means connecting the cores to maintaining same in the side-by-side relationship; and c. a fiber reinforced cementitious shell encapsulating the core and filling in each channel defining a rib completely around the interior of the shell.
Claim 15
Dependent Claim
13 words
A module according to claim 12, wherein the cores are hollow rectangular solids.
Claim 16
Dependent Claim
17 words
A module according to claim 12, wherein the connecting means comprises scrim material wrapped around the boxes.
Claim 17
Dependent Claim
16 words
A module according to claim 12, wherein the connecting means comprises bands tied around the boxes.
Claim 18
Dependent Claim
42 words
A module according to claim 12, wherein the connecting means for each box comprises a male interlocking element on one side and a female interlocking element on the opposite side configured to interlock with the male interlocking element on the adjoining box.
Claim 19
Dependent Claim
27 words
A module according to claim 12, wherein the channel forming means comprises a bevel on the adjoinable edges having one of a concave, slanted or stepped cross-section.
Claim 20
Dependent Claim
21 words
A module according to claim 16, wherein the male and female interlocking elements have one of a rectangle or semicircular cross-section.
Claim 21
Dependent Claim
26 words
A module according to claim 12, further comprising a plurality of lifting inserts each having a portion thereof embedded in the top layer of the shell.
Claim 22
Dependent Claim
46 words
A module according to claim 19, wherein each lifting member comprises an internally threaded portion having the top thereof flush with the outer surface of the shell and a plurality of load bearing arms embedded in the shell and attached to threaded portion and projecting therefrom.
Claim 23
Dependent Claim
44 words
A module according to claim 19, wherein each lifting insert comprises an I-shaped member and means defining a semi-spherical indent in the shell, wherein the lower portion of the member is embedded in the shell and the upper portion thereof projects into the indent.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1983-11-18 | 1984-05-19 | 1984-11-18 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-11-18 | 1988-05-19 | 1988-11-18 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-11-18 | 1992-05-19 | 1992-11-18 | $7700.00 | Window Closed / Lapsed |