Construction assemblies or modules comprising headers, wall sections and beams, are formed of end-to-end arrays of plastic foam blocks and steel studs extending above and below the foam blocks, with flanges thereof extending into the blocks. Steel studs are disposed between each pair of adjacent blocks with flanges thereof extending may be utilized for strength and durable surfaces.

BACKGROUND AND SUMMARY OF THE INVENTION  
         [0001]    In the construction industry, particularly with respect to house construction, there has long been a need for reduced costs of construction, shortened time period for construction, and improved insulation with minimum heat transfer between the exterior and interior of a constructed house.  
           [0002]    The present invention provides construction assemblies or modules, improved components and improved methods for rapid construction, excellent insulation, and durability. A construction module comprises foam blocks, preferably formed of polystyrene in end-to-end array, with adjacent blocks separated by back-to-back studs secured together, as by welding, and with flanges thereof extending oppositely into the adjacent blocks. Elongate studs, preferably of steel, extend above and below the array of blocks with flanges thereof extending into the blocks.  
           [0003]    The term “studs” with respect to steel components, is used herein because the term has long been used in the construction art to denote studs, typically of wood, which have been widely used for vertical members, etc., in building and home construction.  
           [0004]    A construction assembly or module, typically for use as a beam, comprises a plurality of foam blocks disposed end-to-end, with elongate studs along the upper and lower surfaces of the plurality of blocks with flanges extending into the foam blocks. Between each adjacent pair of blocks are two studs secured back-to-back and extending oppositely into the adjacent blocks.  
           [0005]    In a construction module typically for use as a wall section, the end-to-end array of blocks, longitudinally extending studs above and below the blocks with flanges extending into the blocks, are utilized. Between each pair of adjacent blocks are back-to-back studs secured together by welding with flanges extending oppositely into the adjacent blocks.  
           [0006]    A construction module for use as a header above a door or window opening, has a first row of end-to-end blocks, and elongated studs extending along the upper and lower surfaces of the end-to-end blocks. Both studs have edge flanges extending into the blocks. A second row of end-to-end blocks is disposed normally below the first array of blocks. Elongated studs extend along the upper surfaces and the bottom surfaces of the blocks. The second or lower row of blocks may be narrower than the blocks of the upper row and a relatively narrower row of end-to-end blocks may be disposed on either side of the lower array of blocks.  
           [0007]    The construction assemblies or modules according to the invention provides great structural strength, and excellent insulation with respect to heat transfer between the interior and exterior of a house built utilizing the modules of the invention.  
           [0008]    The steel studs, etc., utilized according to the invention, provide substantially greater strength than structures comprised of wooden members, and have the highest strength-to-weight ratio among building materials. Outer surfaces of the construction modules, typically wall and header modules, preferably have applied thereto an adhesive coating, a matting layer applied atop the adhesive coating, and a second adhesive coating applied atop the matting. A hard, cementous coating and tough fire barriers are thus provided. The present invention enables the erection of a house in a single day, with an additional day or longer required for finish work and details. A house structure is preferably secured to a slab by appropriate metal foundation straps together with other securement arrangements.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]    [0009]FIG. 1 is an elevational view of a house wall frame structure including vertical studs and defining a door opening and a window opening;  
         [0010]    [0010]FIG. 2 is a perspective view of a construction section or module according to the invention which is adapted as a header for mounting above a door or window;  
         [0011]    [0011]FIG. 3 is an enlarged sectional view taken at line  3 - 3  in FIG. 1;  
         [0012]    [0012]FIG. 4 is an enlarged sectional view taken at line  4 - 4  in FIG. 1;  
         [0013]    [0013]FIG. 5 is an elevational view of a construction module for use typically as a beam; and  
         [0014]    [0014]FIG. 6 is an enlarged perspective view of the construction module of FIG. 5, showing structural features thereof.  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0015]    Referring to the drawings, FIGS. 1 and 3 show an embodiment of the present invention which may typically be used, as in house construction, as a header associated with doors and windows. FIGS. 4 and 1 show an embodiment of the invention which serves as a wall portion or section in such construction. FIGS. 5 and 6 illustrate an embodiment in the form of a beam.  
         [0016]    The beam  10  of FIGS. 5 and 6 comprises a plurality of foam blocks  12  disposed in end-to-end relation, and an elongate steel stud  14  extending along the first or upper side of the foam blocks, and a second elongate stud  16  extending along a second or bottom side of the plurality of blocks, as shown.  
         [0017]    Between each respective adjacent pair of the end-to-end foam blocks is a pair of transverse steel studs  18 ,  20 , each having a pair of flanges therebetween, with flange portions  22  thereof extending oppositely into respective foam blocks, the flange portions being spaced inwardly from the outer side surfaces of the foam blocks, as shown. Slots are preferably cut or machined into the foam blocks to receive the flanges of the studs.  
         [0018]    The construction module of FIGS. 5 and 6 typically serves as a beam in construction, such as in a house. Such a beam may be secured to other construction members or components as by threaded fasteners and end components  24  and  26  (FIG. 5).  
         [0019]    Referring to FIGS. 1 and 4, wherein FIG. 4 is a sectional view taken at line  4 - 4  in FIG. 1, there is shown an embodiment  30  of the invention which may typically serve as a wall section. As in the embodiment of FIGS. 5 and 6, the construction module includes the plurality of foam blocks  31  disposed end-to-end with a pair of steel studs  32 ,  34  disposed between each adjacent pair of foam blocks, and having oppositely extending edge flanges  36 ,  38  extending oppositely into respective adjacent blocks. As shown, the flanges extend normally at right angles to, the flat body surfaces of the respective studs.  
         [0020]    A layer of adhesive  40  may preferably be applied to the outer side walls of the module, and a layer of matting  42  may preferably be applied atop the adhesive. A second layer of adhesive  44  is applied. The coatings provide structural strength and strong solid surfaces.  
         [0021]    Referring to FIGS. 1 and 3, wherein FIG. 3 is a sectional view taken at line  3 - 3  in FIG. 1, there is shown a construction module  50 , typically utilized as a header above a door or window, as indicated in the drawings.  
         [0022]    The construction module  50 , like the earlier-described construction modules, has a plurality of foam blocks  52  with an elongate stud  54  extending along a first or upper side and a second elongate stud  56  extending along a second or lower side of the plurality of blocks.  
         [0023]    The elongate stud  54  extends atop the end-to-end array of foam blocks  52 , and a second elongate stud  56  extends along the bottom sides of the plurality of foam blocks  52 , as shown. Both the upper stud  54  and the lower stud  56  have edge flanges  58  extending into the end-to-end foam blocks and spaced inwardly from the outer side surfaces of the blocks, as shown.  
         [0024]    A second plurality of foam blocks  59  is disposed below the array of foam blocks  52 . An elongate steel stud  60  extends above the lower stud array and has edge flanges  62  extending into the foam blocks  59 . A lower stud  64  extends along the lower surfaces of the foam blocks, and has flanges  66  extending into the foam blocks and spaced inwardly of side surfaces of the blocks, as shown.  
         [0025]    Both end portions  68  of the lower stud  64  are bent downwardly, as by cutting the flanges  66 , thus to provide panels for securement of the header to other structural members, as by means of threaded fasteners or other means.  
         [0026]    Relatively narrower pluralities of foam blocks  70  are mounted on respective sides of the lower array of the end-to-end foam blocks  59 , as best shown in FIG. 3, and are secured to the foam blocks, preferably by threaded fasteners  72  (FIG. 3).  
         [0027]    As with the embodiment of FIGS. 4 and 1, the construction module may preferably have on its outer surfaces a layer of adhesive  80 , a layer of matting  82  disposed atop said adhesive layer, and a second layer of adhesive  84  applied atop the layer of matting, thus to provide a strong, rugged, durable structure.  
         [0028]    It will be understood that various changes and modifications may be made from the preferred embodiments discussed above without departing from the scope of the present invention, which is established by the following claims and equivalents thereof.