Patent Publication Number: US-8991137-B2

Title: Method of making housing components

Description:
PRIORITY AND RELATED APPLICATION 
     This application claims priority to U.S. Provisional Patent Application Ser. No. 61/772,040, filed Mar. 4, 2013, entitled “Method of Making a Roof,” which is hereby incorporated by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a method of making parts of housing such as walls or roofs. 
     BACKGROUND OF THE INVENTION 
     Today many people in the world are without decent housing, or any housing at all. In addition, houses that are off-grid have no energy supply, beyond what can be obtained from primitive means, such as wood, kerosene, etc. A solar powered eco-friendly home or “solar bungalow” would be ideal for solving this need. In much of Africa, and in other parts of the world, families without access to electricity rely on kerosene lamps. Expensive, unsafe and unhealthy, they also provide only a dim light. But while solar alternatives are far cleaner and cheaper, widespread use of this technology will rely on innovative forms of payment and distribution. Inexpensive housing units that offer the possibility of simultaneously attaching solar panels will be of great benefit. Such housing units will have to be affordable and preferably eco-friendly. Housing units comprised of compressed earth bricks are an example of the kind of buildings needed. Corresponding inexpensive housing parts such as roofs for these housing units are of equal importance in order to bring down the overall price of the housing unit. 
     Accordingly, what is desired is a method of making inexpensive housing components that use fiberglass and concrete but does not use steel in any form. A method is desired that is a total structural housing part system. A method is desired that uses a single layer rigid fiberglass form potentially well-suited for a compressed earth brick (CEB) bungalow design. Also it is desired that the form be free of iron or wire meshes and be continuous without voids between a top and bottom panel of concrete. It is also desired to provide a method that imparts additional strength and creates a flat surface for a floor or roof for instance, on which a second story for living space or storage can be built. It is further desired that fiberglass resin be used as a form and be able to distort in two directions allowing a concrete shell to handle structural work. A method is desired that will produce a structure that is light and therefore less costly to ship. The method should provide a permanent housing component that is meant to span long distances. The method is further desired that will provide housing components that have internal strength. 
     BRIEF SUMMARY OF THE INVENTION 
     A housing component formed of a plurality of single rigid fiberglass arch forms secured in place with a binder such as cement or eco-bricks. The forms are placed parallel to each other and secured on or in an edifice with a temporary shore that receives and retains a binder. The temporary shore is removed once the binder cures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         FIG. 1  shows a housing component of the present invention, the housing component shown in  FIG. 1  is a roof system disposed on an edifice. 
         FIG. 2  is a side view of the roof system in  FIG. 1 . 
         FIG. 3  shows one housing component form as shown in  FIG. 1 . 
         FIG. 4  shows a plan view of  FIG. 3 . 
         FIGS. 5A and 5B  show end views of  FIG. 3 . 
         FIG. 6  shows a second embodiment of the housing component of the present invention, the housing component shown in  FIG. 6  is a roof system disposed on an edifice. 
         FIG. 7  is a side view of the roof system in  FIG. 6 . 
         FIG. 8  shows one housing component form as shown in  FIG. 6 . 
         FIG. 9  shows a plan view of  FIG. 6 . 
         FIG. 10  shows an end view of  FIG. 6 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  shows a thin-shelled roof system  100  on an edifice  50 . The roof  100  comprises arched forms  120  and cement, ferro-cement or concrete  110 . Forms  120  are placed parallel to each other on the edifice  50  and once in place cement  110  is poured on top and contained on top with a temporary perimeter that is removed once set. The form  120  may comprise a fiberglass concrete form that remains in place once the concrete  110  cures. See  FIG. 2 . The form  120  thus can become an integral part of the thin-shelled roof system. The form itself can take the shape of a trapezoid as shown in  FIGS. 3 and 4 . 
     Looking now to  FIGS. 3-5B  the form  120  is shown to have ends  122  and  124  and fins  126 . End  122  is narrower than end  124 . The fins  127  may be trapezoid shaped but could be any other shape as well. With a trapezoid shaped fin the form  120  deforms in two planes this gives the roof strength and also allow the components to fit together. The distorted configuration of the form  120  may also allow the roof  100  to be strong and avoid the need for any reinforcement components such as reinforcing bar (rebars) of metal mesh. Form  120  may have any dimension in one embodiment the form may be about 548 cm long, 96.8 cm at end  122  and 127.3 cm at end  124 . Form  120  can support a live load of 244 kilograms per square meter (50 PSF). 
       FIGS. 6-10  shows a thin-shelled roof system  200  that is another embodiment of system  100 .  FIG. 6  shows system  200  comprising forms  220  and cement, ferro-cement or concrete  110 . The forms  220  are placed next to each other on edifice  50  and, like system  100 , cement  110  is poured on top and contained on top with a temporary perimeter that is removed once set. Here too the form  220  may comprise a fiberglass concrete form that remains in place once the concrete  110  cures. Form  220  employ domes  220  that are either symmetrical  242  or asymmetrical  244 . The irregularity increases the deformation in two planes increasing strength. The ends  230  of the form  220  are uniform as they have the same dimension. Forms  220  can span 265 CM (12′) with an overhang for a total of 549 cm (18′) and support a live load of 244 kilograms per square meter (50 PSF). 
     As mentioned above, systems  100 ,  200  provide fiberglass-resin forms that once secured are made permanent by pouring cement  110  on the forms  120 ,  220  on site. Temporary shoring is required as the cement  110  cures. The forms  120 ,  220  are stackable and interlocking and can be packed in a container for shipping. Each form  120 ,  220  is a single rigid layer of fiberglass per arch. In an alternative embodiment, instead of using cement  110  eco-bricks (ecbs) may be used as filler material. The above-described systems  100 ,  200  may equally be used to form other housing components such as a floor or walls. 
     While the present invention has been described in conjunction with specific embodiments, those of normal skill in the art will appreciate the modifications and variations can be made without departing from the scope and the spirit of the present invention. Such modifications and variations are envisioned to be within the scope of the appended claims.