US4288962A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of forming structural walls and roofs
Assignee: Individual
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Filing: 1979-02-27
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Granted: 1981-09-15
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Expires: 1999-02-27
Abstract
Abstract The present invention contemplates a simple and inexpensive, but effective method for constructing straight walls at a building site without use of nails or other fastening means. Appropriately flanged metal I-beam studs are erected with the flanges in the direction of the wall, and expanded polyurethane foam is applied, such as by spraying, to a desired thickness between the I-beam flanges, thereby acting as a fastener and providing insulating properties. A fiberglass-cementitious mixture is then applied to provide a very hard, smooth, waterproof and durable surface of very high fire rating. The invention is equally applicable to interior walls, exterior walls, and roof panels.
Inventors
- 👤 Harvey H. Kavanaugh
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 13:07
CPC Classifications
E; E04; E04B; E04B2/00; E04B2/56; E04B2/562
Claims Analysis
Total Claims: 2
Claim 1
Independent Claim
299 words
The method of forming a structural wall in place comprising the following steps: (a) erecting vertically in spaced relation a plurality of support studs; (b) placing a section of plasterboard on the side of the support studs facing the interior side of the structural wall; (c) spraying a layer of high density expanded cellular foam to the plasterboard from the side exterior to the structural wall to substantially fill the space between the studs; (d) allowing the foam layer to cure to form a solid insulating layer; (e) spraying a layer of bonding agent over the exterior exposed surface of said insulating layer so that the inner surface of the bonding agent and stud are coplanar; (f) spraying a layer of cementitious material to said bonding agent and inner surface of the stud in a continuous thickness of at least one-half inch without including reinforcements; and (g) allowing said cementitious layer to cure to form a smooth, hard, durable exterior wall layer, said support stud being a metal I-beam having substantially parallel flanges in the plane of said structural wall, the flanges being joined by a web, the I-shaped beam being of unitary construction, said cementitious material being a mixture of Portland cement, hydrated lime, calcium chloride, calcium stearate, and alkali-resistant fiber glass filaments approximately one-half inch in length, and said expanded cellular foam is a polyurethane synthetic resin, said metal stud being aluminum and the outer flange having a width less than the width of the interior flange, the interior flange being perforated to facilitate bonding of the plasterboard with the foam layer, said inner perforated flange having a plurality of perforations in staggered configuration along the I-shaped beam, and the web of said beam is perforated to allow passage therethrough of electrical conduit, plumbing and the like.
Claim 2
Independent Claim
299 words
The method of forming a structural wall in place comprising the following steps: (a) erecting vertically in spaced relation a plurality of support studs; (b) placing a section of plasterboard on the side of the support studs facing the interior side of the structural wall; (c) spraying a layer of high density expanded cellular foam to the plasterboard from the side exterior to the structural wall to substantially fill the space between the studs; (d) allowing the foam layer to cure to form a solid insulating layer; (e) spraying a layer of bonding agent over the exterior exposed surface of said insulating layer so that the inner surface of the bonding agent and stud are coplanar; (f) spraying a layer of cementitious material to said bonding agent and inner surface of the stud in a continuous thickness of at least one-half inch without including reinforcements; and (g) allowing said cementitious layer to cure to form a smooth, hard, durable exterior wall layer, said support stud being a metal I-beam having substantially parallel flanges in the plane of said structural wall, the flanges being joined by a web, the I-shaped beam being of unitary construction, said cementitious material being a mixture of Portland cement, hydrated lime, calcium chloride, calcium stearate, and alkali-resistant fiber glass filaments approximately one-half inch in length, and said expanded cellular foam is a polyurethane synthetic resin, said metal stud being aluminum and the outer flange having a width less than the width of the interior flange, the interior flange being perforated to facilitate bonding of the plasterboard with the foam layer, said inner perforated flange having a plurality of perforations in staggered configuration along the I-shaped beam, and the web of said beam is perforated to allow passage therethrough of electrical conduit, plumbing and the like.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1984-09-14 | 1985-03-16 | 1985-09-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1988-09-14 | 1989-03-16 | 1989-09-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1992-09-14 | 1993-03-16 | 1993-09-15 | $7700.00 | Window Closed / Lapsed |