US4280974A — Process and apparatus for making a plurality of b…

Claim 1

Independent Claim 329 words

Process for making a plurality of building modules each having at least one insulating foam core encased in a shell of fiber reinforced cementitious material which comprises: (a) providing a continuous longitudinal casting zone having continuous side rails along a base having transverse division members thereon positioned so as to correspond to the lengths of the modules being formed; (b) continuously casting a bottom layer of wet cementitious material between the side rails and over the base and division members along the length of the casting zone and leveling said bottom layer so as to be even with the top of the division members; (c) adding fiber reinforcement to the bottom layer formed in step (b) by applying fibers in discrete lengths in one or more passes over the casting zone and incorporating the fibers into the bottom layer; (d) dividing said casting zone into lengths corresponding to the lengths of the modules being formed by inserting end members on top of the division members between the side rails; (e) placing foam core members on each length of the bottom layer between end members, said foam core members having a peripheral shape smaller than the surface of the bottom lengths so as to leave a free space between the core member, the side rails and the end members, said core member having a height less than the height of the said side rails; (f) applying wet cementitious material to the entire length of the casting zone so as to fill the free space surrounding each core member and to form a top layer which covers each core member thereby separately encasing each core member; (g) applying fiber reinforcement to the top layer formed in step (f) by applying fibers in discrete lengths in one or more passes over the casting zone and incorporating the fibers into the top layer; and (h) curing the cementitious material encasing each core and removing a plurality of cured modules from the casting zone.

Claim 2

Dependent Claim 329 words

Process for making a plurality of building modules each having at least one insulating foam core encased in a shell of fiber reinforced cementitious material which comprises: (a) providing a continuous longitudinal casting zone having continuous side rails along a base having transverse division members thereon positioned so as to correspond to the lengths of the modules being formed; (b) continuously casting a bottom layer of wet cementitious material between the side rails and over the base and division members along the length of the casting zone and leveling said bottom layer so as to be even with the top of the division members; (c) adding fiber reinforcement to the bottom layer formed in step (b) by applying fibers in discrete lengths in one or more passes over the casting zone and incorporating the fibers into the bottom layer; (d) dividing said casting zone into lengths corresponding to the lengths of the modules being formed by inserting end members on top of the division members between the side rails; (e) placing foam core members on each length of the bottom layer between end members, said foam core members having a peripheral shape smaller than the surface of the bottom lengths so as to leave a free space between the core member, the side rails and the end members, said core member having a height less than the height of the said side rails; (f) applying wet cementitious material to the entire length of the casting zone so as to fill the free space surrounding each core member and to form a top layer which covers each core member thereby separately encasing each core member; (g) applying fiber reinforcement to the top layer formed in step (f) by applying fibers in discrete lengths in one or more passes over the casting zone and incorporating the fibers into the top layer; and (h) curing the cementitious material encasing each core and removing a plurality of cured modules from the casting zone.

Claim 3

Dependent Claim 31 words

Process of claim 1 which includes the step of premixing the wet cementitious material with from about one to two percent by weight fiber reinforcement prior to steps (b) and (f).

Claim 4

Dependent Claim 58 words

Process of claim 1 wherein fiber reinforcement is added to the bottom and top layers by chopping and spraying continuous rolls of fiber reinforcement in a plurality of passes over the casting zone and the fibers are incorporated into the layers after each pass by rolling so as to substantially completely wet the fibers with the cementitious material.

Claim 5

Dependent Claim 20 words

Process of claim 1 wherein a scrim reinforcing material is positioned at least around the edges of the core members.

Claim 6

Dependent Claim 38 words

Process of claim 4 wherein scrim is imbedded at least around the edges of the bottom layer with excess scrim extending up and over the side rails, said excess being folded in and imbedded in the top layer.

Claim 7

Dependent Claim 57 words

Process of claim 1 further comprising providing a cement deflecting screed movable along the longitudinal length of the casting zone and wherein step (b) includes leveling the bottom layer by movement of the screed and step (f) includes filling the free spaces surrounding each core member and leveling the top layer by the movement of the screed.

Claim 8

Dependent Claim 16 words

Process of claim 6 wherein the screed is vibrated as it moves along the casting zone.

Claim 9

Dependent Claim 30 words

Process of claim 1 further comprising after step (e), inserting spacing members between the foam core and both the side rails and the end members to insure uniform shell thickness.

Claim 10

Dependent Claim 23 words

Process of claim 1 further comprising providing retainers along the side rails to maintain the division members and the end members in position.

Claim 11

Dependent Claim 17 words

Process of claim 1 wherein steps (c) and (g) include needling the fibers into the cementitious material.

Claim 12

Dependent Claim 15 words

Process of claim 3 wherein the fibers are needled into the cementitious material after rolling.

Claim 13

Dependent Claim 19 words

Process of claim 1 wherein at least two foam core members are placed between each pair of end members.

Claim 14

Dependent Claim 23 words

Process of claim 12 wherein the cores are spaced apart and the free space therebetween is filled with cementitious material in step (f).

Claim 15

Dependent Claim 13 words

Process of claim 13 wherein the cores have a reinforcing member between them.

Claim 16

Dependent Claim 25 words

Process of claim 1 wherein at least one core has reinforcing slots therein and the process further comprises filling the slots with wet cementitious material.

Claim 17

Dependent Claim 150 words

Process for making a plurality of fiber reinforced discrete unconnected cementitious building modules which comprises: (a) providing a continuous longitudinal casting zone having continuous side rails along a base having transverse division members thereon positioned so as to correspond to the lengths of the modules being formed; (b) continuously casting a layer of wet cementitious material between the side rails and over the base and division members along the length of the casting zone and leveling said bottom layer so as to be even with the top of the division members such that adjoining modules are unconnected and discrete; (c) adding fiber reinforcement to the layer formed in step (b) by applying fibers in discrete lengths in one or more passes over the casting zone and incorporating the fibers into the bottom layer; and (d) curing the cementitious material and removing a plurality of cured modules from the casting zone.

Claim 18

Dependent Claim 150 words

Process for making a plurality of fiber reinforced discrete unconnected cementitious building modules which comprises: (a) providing a continuous longitudinal casting zone having continuous side rails along a base having transverse division members thereon positioned so as to correspond to the lengths of the modules being formed; (b) continuously casting a layer of wet cementitious material between the side rails and over the base and division members along the length of the casting zone and leveling said bottom layer so as to be even with the top of the division members such that adjoining modules are unconnected and discrete; (c) adding fiber reinforcement to the layer formed in step (b) by applying fibers in discrete lengths in one or more passes over the casting zone and incorporating the fibers into the bottom layer; and (d) curing the cementitious material and removing a plurality of cured modules from the casting zone.

Claim 19

Dependent Claim 29 words

Process of claim 16 which includes the step of premixing the wet cementitious material with from about one to two percent by weight fiber reinforcement prior to step (b).

Claim 20

Dependent Claim 52 words

Process of claim 16 wherein fiber reinforcement is added by chopping and spraying continuous rolls of fiber reinforcement in a plurality of passes over the casting zone and the fibers are incorporated into the layers after each pass by rolling so as to substantially completely wet the fibers with the cementitious material.

Claim 21

Dependent Claim 15 words

Process of claim 16 wherein the fibers are needled into the cementitious material after rolling.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1984-07-27	1985-01-26	1985-07-28	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1988-07-27	1989-01-26	1989-07-28	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1992-07-27	1993-01-26	1993-07-28	$7700.00	Window Closed / Lapsed

Process and apparatus for making a plurality of building modules having a foam core and a cementitious shell

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