Patent Publication Number: US-2023137437-A1

Title: Column Insulated Beam System and Method of Use

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     Not Applicable 
     FIELD OF THE INVENTION 
     The present invention refers to a constructive system for living spaces based on a single surrounding element. Specifically, the present invention comprises a structural construction system with high thermal efficiency comprising of beams and columns with thermal insulation within in a single compound element that, by means of intersecting members, form a ridged structural frame between a series of columns and beams. 
     BACKGROUND 
     As construction costs increase, there is a correlating increasing need to reduce costs associated with the time it takes to complete a construction project, reduce the percentage of waste in said activity and increase thermal efficiency for a lower energy consumption, and change the construction processes of spaces habitable from an economic and sustainable point of view. Accordingly, a need exists for a novel construction system that reduces the percentage of construction waste while simultaneously increasing thermal efficiency for a lower energy consumption with a focus on component prefabrication constructive that are quick and easy to install and that meet usually more than one function. 
     Various attempts have been made, although unsuccessfully, to solve the drawbacks of the traditional construction process. One illustrative attempt can be seen with respect to U.S. Patent Application No. 2009/0293396 which discloses, generally, a structural insulated panel that is manufactured with a plastic foam core, a board of oriented members capped with a structural member on each side to construct a structural wall. While this disclosure addresses constructure prefabrication, it does not address the reduction of construction waste premised on the use of a single construction element. 
     Another example may be seen with respect to U.S. Pat. No. 6,599,621 which discloses a structural insulation panel system with improved resistance to loads and weathering and that offers greater flexibility in the installation of the panel in the structure of a building having a weather-resistant surface, a finished interior surface, and an insulating layer between the surfaces exteriors and interiors that can be economically produced in mass and install easily. This disclosure does not, however, address the reduction of construction waste premised on a single construction element. 
     In yet another example, U.S. Pat. No. 6,599,621 discloses a generally flat structural panel for building construction including an inner core of insulation such as plastic foam and a pair of opposite outer facings, or sheets, attached to the core panel insulation. Other construction components of this disclosure also include external walls made of a gypsum composite while the other exterior cladding is an oriented strand board impregnated with plastic, such as a polyisocyanurate or urethane resin. While this disclosure addresses constructure prefabrication and thermal efficiency, it does not address the reduction of construction waste premised on the use of a single construction element. 
     As can be seen, various attempts have been made to solve the problems which may be found in the related art but have been unsuccessful. Specifically, the prior art do not address a construction method and system for living spaces based on a single element constructive, conceived for the construction of beams and columns, which by means of rigid joints they form a structural framework without the need of internal reinforcements, with a resistance to deformation as well as with a high thermal insulation capacity. which by uniting with each other assemble a volume that ultimately constitutes a thermally isolated. Therefore, a need exists for a new and novel construction system that reduces the percentage of construction waste while simultaneously increasing thermal efficiency for a lower energy consumption with a focus on a single component construction prefabrication. 
     SUMMARY OF THE INVENTION 
     It is to be understood that in the present disclosure, all embodiments are provided as illustrative and non-limiting representatives of many possible embodiments. In addition, the terms “is,” “can,” “will,” and the like are herein used as synonyms for and interchangeable with terms such as “may,” “may provide for,” and “it is contemplated that the present invention may” and so forth. 
     Furthermore, all elements listed by name, such as beams, columns, joints, and structural framework encompass all equivalents for such elements. Such equivalents are contemplated for each element named herein. 
     For purposes of summarizing, certain aspects, advantages, and novel features of the present invention are provided herein. It is to be understood that not all aspects, advantages, or novel features may be provided in any one particular embodiment. Thus, the disclosed subject matter may be embodied or carried out in a manner that achieves or optimizes one aspect, advantages, or novel features or group of features without achieving all aspects, advantages, or novel features as may be taught or suggested. 
     In view of the foregoing disadvantages inherent in the known art, the present invention provides a novel solution for a construction system for living spaces based on a single constructive element. The present invention comprises a prefabrication construction system that utilizes components that can be recycled or reused, thereby eliminating construction waste. 
     The features of the invention, which are believed to be novel, are particularly pointed out and distinctly claimed in the concluding portion of the specification. These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings and detailed description. 
     The present invention relates to a construction system for habitable spaces, where the structural element of the Column Insulated Beam System (“CIB” or “CIB System”) constitutes a single constructive element unique conceived for the materialization of structures based on the addition simplified layout of elements both horizontally and vertically, forming rigid joints that allow the construction of a frame structural, whose repetition defines the main structure. The use of a single construction element further allows for the reduction in construction waste. The frame is comprised of an upper beam, a lower beam, and columns. The structure of the frame offers high resistance to deformation, lateral thrust, and in turn of vertical loads. In a preferred embodiment, the frame structure allows for interior spaces to be free of secondary elements and annexes, dispensing with partitions or forced divisions to give resistance to the set of elements that make up a living space. 
     In a preferred embodiment of the present invention, the structure is built from the rigid connection between the beam and column elements and are comprised of plywood plates, plywood and expanded polystyrene (“EPS”), which may collectively or individually be referred to as “modules”. In some embodiments, the modules are joined by means of a structural adhesive to form a rigid frame, which contains a portion of floor, walls, and roof where the connecting repetition constructs the volume structure and thermal insulation of the habitable space. 
     The structural strength and resistance of the CIB System is afforded by the integration of beams that may be comprised of (1) plywood plates, laminated wood beams, or laminated wood veneer (or other wooden element) aligned on a longitudinal axis and (2) a thermal insulation block of EPS or other insulating foams such as polyurethane foam, styrene foam extrudate, or foams of polyisocyanurates. When joined, the wooden element and the EPS, adhered throughout the width and length of the wooden elements, allows for greater load capacity and resistance throughout the wooden elements. By adhering to the width of the wooden elements, the EPS provided an insulation thickness that exceeds currently known thermal energy saving requirements. The CIB System further offers an interior space with high thermal efficiency and an insulated envelope. 
     In other embodiments, the CIB System weighs less than traditional construction system, prefabricated or manually constructed, which allows for assembly to be completed easily, quicky, and without the need for specialized workers. 
     In some embodiments, the frames of the CIB System are composed of the same joining system of the beans and columns. By way of non-limiting example, a frame may be constructed from a 30 mm plywood plate, a 240 mm column and beam, and at least 32 screws per side whereby at least 16 screws are arranged every 30 mm. The frames may be further comprised of only two materials and a structural adhesive that may be derived from polyurethan, resin adhesives, synthetic elastomer, hot-melt adhesives, and other adhesives such as polyvinyl acetate that have a heightened resistance to humidity. 
     The CIB System may have measures of a wood element (thickness and height) and EPS based on the structural requirements of the construction build. By way of further non-limiting example, a CIB System may be comprised of 18 mm plywood (36 mm total of the plate reconstituted) that is divided into sections of 300 mm which provides an optimal measure for the EPS. Other measurements may include 300 mm thick blocks along with medium and high-density EPS (i.e., 15 kg/m3). With such measurements, waste from EPS products may be reduced by 90% as the EPS products are recyclable. 
     In other configurations, and by way of a non-limiting example, the CIB System may be arranged where two plywood elements measuring 2440×240×15 mm, and a third plywood element measuring 1220×240×15 mm in order to make maximum use of the structural plate of plywood and to form one of the sides of the wooden element plywood that is six (6) meters long, contained in the CIB System. Notwithstanding the measurements, the arrangement of the plywood pieces in these sheets are structurally adhered together in such a way horizontally that the cuts never coincide of the remaining elements. 
     The embodiment of the invention described herein are exemplary and numerous modifications, variations, and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. Furthermore, while the preferred embodiment of the invention has been described in terms of the components and configurations, it is understood that the invention is not limited to those specific dimensions or configurations but is to be accorded the full breadth of the spirit of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features, aspects and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying figures. 
         FIG.  1    shows a perspective view of a plurality of CIB System frames in accordance with a preferred embodiment of the present invention. 
         FIGS.  2 A,  2 B, and  2 C  show an illustrative view of plywood elements integrated with ESP elements in accordance with a preferred embodiment of the present invention. 
         FIGS.  3 A and  3 B  show a front, side, top, and perspective view of the CIB System frame. 
         FIG.  4 A  shows a perspective view of the joining members of the CIB System framework.  FIG.  4 B  shows solidification of the beam structure of the CIB System.  FIG.  4 C  shows a perspective view of the joint pillar creating the joining corners of the CIB System. 
         FIG.  5    shows an exploded view of the joining members of the CIB System framework. 
         FIG.  6    shows an illustrative view of the CIB System constructed into a two-story structure. 
         FIG.  7    shows a perspective view of a CIB System constructed as a one-story structure. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention overcomes the limitations of the prior art by providing a novel construction system for living spaces based on a single constructive element conceived for the construction of beams and columns, which through rigid joints constitute a structural framework with resistance to deformation and with a high thermal insulation capacity. 
     It is essential to understand that the drawings and the associated descriptions are provided to illustrate potential embodiments of the invention and not to limit the scope of the invention. Reference in the specification to “one embodiment” or “an embodiment” is intended to indicate that a particular feature, structure, or characteristics described in connection with the embodiment is included in at least an embodiment of the invention. The appearances of the phrases “in one embodiment” or “an embodiment” in various places in the specification are not necessarily all referring to the same embodiment. 
     As used in this disclosure, except where the context requires otherwise, the term “comprise” and various of the term, such as “comprising”, “comprises” and “comprised” are not intended to exclude other additives, components, integers or steps. 
     In the following description, specific details are given to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. Well-known features, elements or techniques may be shown in detail in order not to obscure the embodiments. 
     The system of the present invention is a construction system suitable for living spaces based on a single constructive element conceived for the construction of beams and columns which, through rigid joints, constitute a structural framework with resistance to deformation and with a high thermal insulation capacity. The design of the CIB System focuses on the optimization of arrangements to optimize how the materials are used materials. For this reason, the measurement of the adhesion of two frames may be equivalent to the standard measure of coating products such as the plates of plasterboard, fiber cement boards, and wood panel chipboards. By way of non-limiting example, the measurement of the adhesion of two frames may be 1200 mm. The repetition of this process forms a volume of frames, which has a structural resistance to deformation and is thermally insulated. 
       FIG.  1    shows a perspective view of a plurality of  100  CIB System frames adhered together in accordance with a preferred embodiment of the present invention. A viewer may perceive that the  100  CIB System frames comprise of a  101  vertical beam element and a  102  horizontal column. In a non-limiting example, the wood element may be the length of 240×6000×30 mm with an ESP block of 15 Kg/m3 with measurements of 240×540×6000 mm which, when joined provides a single construction element. In another non-limiting example, the wood element may be the length of ×30 mm with an ESP block of 15 Kg/m3 with measurements of 200×500×600 mm, 240×550×600 mm, or 200×550×600 mm, where when joined provides a single construction element. 
       FIGS.  2 A,  2 B, and  2 C  show an illustrative view of plywood elements integrated with ESP elements in accordance with a preferred embodiment of the present invention. The repetitive adhesion of the plywood elements to the ESP elements provides for a structure that is thermally insolated. In  FIG.  2 A , a viewer may perceive that a  201   a ,  201   b  wood member may be adhered to a  203  block of EPS by and through a  202   a ,  202   b  structural adhesive. When fully constructed, the  201   a ,  201   b  wood member may be adhered to a  203  block of EPS by and through a  202   a ,  202   b  structural adhesive form a  204  single structural element. 
     As may be seen in  FIG.  2 C , the  204  single structural element may be modified in length by removing a block  206   a ,  206   b ,  207   a ,  207   b  which in turn forms the  101  vertical beam element and a  102  horizontal column element of the  100  CIB System frame. 
       FIG.  3 A  shows a  301  front,  302  side, and  303  top, and view of a single  100  CIB System frame, while  FIG.  3 B  shows a  304  perspective view of a single  100  CIB System frame. 
     A viewer may perceive that the  100  CIB System framework is comprises of beam and column elements whereby by joining beams to beams and columns to columns with metal-coated screws (such as zinc-coated screws) that may be of 10.16 cm (4 inches) or similar, which are regularly spaced every 600 mm for both edges of the beam and column elements. The corners are also used for the union of two frames and prior to placing the loose block of EPS, zinc plated 6×4 inches screws (or similar) are inserted perpendicular to the plane all layers of wood element. 
       FIG.  4 A  shows a perspective view of the joining members of the  100  CIB System framework. A viewer may perceive that the  102  horizontal beam element may be joined to the  101  vertical column element by a  401  joint pillar. When joined, as seen in  FIG.  4 C , the  401  joint pillar creates the joining comers of the  100  CIB System frame. To form a straight and resistant frame it is necessary to join columns and beams through linear type comer plywood. Each linear comer plywood measures the same width as the wood elements of a beam or pillar of the CIB System, of preferably 240 mm for a length of 480 mm, a length that allows joining a beam with a column, the linear comer wood element allows continuity to the remaining wooden elements, being joined, fixed, with a preferred size of 7×50.8 mm (or similar) zinc plated screws per connection, that is, 32 screws per comer joint, about 252 screws per frame corresponding to 8 linear wood elements of 240 mm×480 mm and 30 mm thick. The joint between frames is fixed as well as at the comers as by the interior and exterior perimeter contour between frames, in the joints of the continuous wooden elements, along and at the height of the frames. The joints in the comers between frames are made by means of 6×100 mm or similar screws that secure a sequence of layers preferably of structural plywood, and the linear joints are attached using 6×100 mm lancer screws. inches (or similar), on both sides of the wooden elements of CIB System, placed at an angle of 45°, arranged every 600 mm. 
     As shown in  FIG.  4 B , and to further solidify the beam structure, the wood sheets may be screwed together around each perimeter and point of connection between the plywood sheets by zinc-plated screws, or other metal-plated screws, of an inch or 6×100 mm, thus achieving the necessary pressure between the layers so that the plywood sheets and the ESP are joined and work as a single element allowing the final thickness of each beam to be 60 mm. In another embodiment, the wood sheets may be screwed together around each perimeter and point of connection between the plywood sheets by zinc-plated screws, or other metal-plated screws, of an inch or 2.54 cm, thus achieving the necessary pressure between the layers so that the plywood sheets and the ESP are joined and work as a single element allowing the final thickness of each beam to be 30 mm. 
       FIG.  5    shows an exploded view of the connectors for the corner joints in accordance with a preferred embodiment of the present invention, which provide additional support to the  401  joint pillars. By way of non-limiting example, this includes a  501  45-degree corner joint as seen in  FIG.  5 A , a  502  120-degree corner joint as seen in  FIG.  5 B , a  503  180-degree horizontal corner joint as seen in  FIG.  5 C , a  504  180-degree vertical corner joint as seen in  FIG.  5 D , and a  505  90-degree corner joint as seen in  FIG.  5 E . 
       FIG.  6    shows an illustrative view of the  100  CIB System constructed into a  601  two-story structure. A viewer may perceive that the embodiment that the illustration shows a constructed  601  two-story frame with a single interior space, without divisions. 
       FIG.  7    shows a perspective view of a  100  CIB System constructed as a one-story structure. By way of non-limiting example, a viewer may perceive that the  100  CIB System may comprises of beams that are 2440 mm high, 1220 mm wide, and 60 mm thick to comprise a standard  100  CIB System construction. For such a configuration, each column comprises of a beam that is 6 m long by 600 mm wide, using two plywood sheets that are 15 mm wide×2440 mm high×1220 mm long, and block of EPS that is 6000 mm long×540 mm high, which a density of 15 Kg/m3. 
     Structural Examples 
     The varying types of structural partitions must have the integrity to resist different loads. These loads are determined in accordance with construction regulations in the applicable jurisdiction. The purpose of this invention is to provide a common power of resistance on horizonal loads. 
     The  100  CIB System may be materially constituted by two pieces of 30 mm plywood having an EPS foam member of medium density that is 240 mm thick, 540 mm wide, and 6000 mm long thereby becoming a single structural element for construction purposes. In another embodiment, the EPS foam member may have a medium density that is 200 mm thick, 540 mm wide, and 6000 mm. In another embodiment, the EPS foam member may have a medium density that is 240 mm thick, 550 mm wide, and 6000 mm. In another embodiment, the EPS foam member may have a medium density that is 200 mm thick, 550 mm wide, and 6000 mm. 
     Example 1 
     This structural example provides the description of detail of the joints of a residential structure having two floors with a roof in accordance with a CIB System. By way of non-limiting example, the joints between the roof beams are visible, preferably at a 45-degree angle, with cuts of the beam element at 45-degrees and the inclusion of “L” corner plywood joints having zinc-plated or galvanized screws that are at least 7×50.8 mm (7#×2 inches) or similar. There may also be joints between roof beams and columns, with cuts in the beam at 45 degrees and straight cuts at 90 degrees in the column. In another embodiment, the zinc-plated or galvanized screws that are at least (6#×2 inches) or similar. 
     Each linear corner plywood measures the same width as the wood elements of a beam or pillar of the CIB System, of preferably 240 mm for a length of 480 mm, a length that allows joining a beam with a column, the linear corner wood element allows continuity to the remaining wooden elements, being joined, fixed, with a preferential size of 7#×50.8 mm (7#×2 inches) or similar zinc plated screws per connection, that is, 32 screws per corner joint, about 252 screws per frame corresponding to 8 linear wood elements of 240 mm×480 mm and 15 mm thick. In another embodiment, the liner corner wood element allowing continuity to the remaining wooden elements may be joined, fixed, with a preferential size of 16×6×1.5 in or similar zinc plated screws per connection, that is, 32 screws per corner joint, about 252 screws per farm corresponding to 8 liner wood elements of 240 mm×480 mm and 30 mm. In another embodiment, the 8 liner wood elements may each have a dimension of 240 mm×480 mm and 30 mm. 
     For the second floor, the union between the column and the beam may be presented by straight cuts in the beam and the continuous column plus the corner plywood. 
     By way of non-limiting example, the joint between the column and the beam is required for the second floor with straight cut in the column and straight cut beam of a linear type corner plywood with a preferential size of 7#×50.8 mm. (7×2 inches) or similar zinc plated screws per connection, that is, 32 screws per corner joint, about 252 screws per frame corresponding to 8 linear wood elements of 240 mm×480 mm and 15 mm thick. In another embodiment, the joint between the column and the beam is required for the second floor with straight cut in the column and straight cut beam of a linear type corner plywood with a preferential size of 16×6×1.5 inches or similar zinc plated screws per connection, that is, 32 screws per corner joint, about 252 screws per frame corresponding to 8 linear wood elements of 240 mm×480 mm and 15 mm thick. In another embodiment, the 8 liner wood elements may each have a dimension of 240 mm×480 mm and 30 mm. 
     The joint between the column and the lower beam in the case of a residential construction would require a straight cut and the column and the lower beam linear type and with a preferential size of 7#×50.8 mm. (7#×2 inches) or similar zinc plated screws per connection, that is, 32 screws per corner joint, about 252 screws per frame corresponding to 8 linear wood elements of 240 mm×480 mm and 15 mm thick. In another embodiment, the joint between the column and the lower beam in the case of a residential construction would require a straight cut and the column and the lower beam linear type and with a preferential size of 6×2 inches or similar zinc plated screws per connection, that is, 32 screws per corner joint, about 252 screws per frame corresponding to 8 linear wood elements of 240 mm×480 mm and 15 mm thick. In another embodiment, the 8 liner wood elements may each have a dimension of 240 mm×480 mm and 30 mm. 
     Example 2 
     A sequence of eight (8) system frames of the CIB System comprises of 16 beam elements that are 6 m long and 16 column elements that are 3 m long, thereby providing for a constructed area of 29.5 square meters with 3.48 m of exterior height. The total weight of the volume may be 1,440 kg. The thickness of the walls, bottom slab and upper slab is 24 cm, a measure that corresponds to the thickness of the volume thermal insulation. The configuration of the plywood and the EPS stiffen the structure by means of the plywood plates having the same thickness inserted at each vertex joining beam elements and column elements, forming frames that are capable of resisting vertical loads and lateral thrusts without the need for interior partitions. 
     Although the present invention has been described with a degree of particularity, it is understood that the present disclosure has been made by way of example and that other versions are possible. As various changes could be made in the above description without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be illustrative and not used in a limiting sense. The spirit and scope of the appended claims should not be limited to the description of the preferred versions contained in the disclosure. 
     All features disclosed in the specification, including the claims, abstracts, and drawings, and all steps in any method or process disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in the specification, including the claims, abstract, and drawings, can be replaced by alternative features serving the same, equivalent or some similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. 
     While the present invention generally described herein has been disclosed in connection with a number of embodiments shown and described in detail, various modifications should be readily apparent to those of skill in the art.