Patent Description:
In many situations there is a need to raise buildings quickly and in an inexpensive manner, that being for temporary use or for permanent use. Such situations may be related to refugees' camps, major disaster situations like earthquakes or tsunamis, but also situations of less urgency, such as improving building quality in poor regions.

On the other hand, plastic waste material has become a large and growing environmental problem on shore and off shore. An ideal situation would be to solve the first mentioned problems by using the waste material constituting the second mentioned problem as a raw material.

The present invention sets out to do just that, to find use for plastic waste material as a raw material in a wall-building element system that allows buildings of a decent and reliable standard to be assembled in a minimum of time.

Many modular building systems are known, primarily based on conventional materials and suitable as permanent buildings like apartment buildings or residential houses of high standard. On the other end of the scale, tents and modular building systems based on standard containers have been suggested.

<CIT> teaches thermally insulated composite panels comprising layers of non-combustible, cement based material and a core of insulating material.

<CIT> describes a panel system of five layers, with a centre plate layer, insulating layers on both sides of the centre layer and outer plate layers again to cover the exterior sides of the insulating layers.

<CIT> teaches a wall or ceiling element comprising outer plate shaped layers of wood surrounding a layer of foamed polystyrene.

A more complex building block is described in <CIT>, comprising a centre insulating layer, plate layers and longitudinally extending reinforcement elements.

Korean document <CIT> discloses a wall-building element according to the preamble of claim <NUM>.

German utility model <CIT> discloses a complete wall-building element system.

The present invention is different from the prior art building elements in problem approach as well as with regard to the technicalities.

The present invention is a prefabricated basic wall-building element according to the subject-matter of claim <NUM>.

Preferred embodiments of the present invention are disclosed by the dependent claims.

With the wall-building element system according to a specific embodiment of the present invention, temporary or permanent buildings may be raised quickly and at a low cost on any flat surface. The main component of the building system is a wall-building element comprising a load bearing central core, typically made of a rigid synthetic material, preferably recycle or waste plastic material or a composite product including such plastic material, plywood or the like. The wall-building element further comprises form-stable layers of thermally insulating materials preferably made of foamed recycled or waste plastic material. These elements are adapted to be combined with similar elements horizontally and vertically to thereby construct a wall. 'Between each horizontal layer of these wall-building elements specially adapted H-profiled beams or rails are arranged to transfer load in a safe and reliable manner in a vertical direction. These H-beams are specifically adapted to the top side surface and the bottom side surface of the wall-building elements to ensure that the vertical forces are correctly transferred from level to level of the core member of each wall-building element and to ensure that there is no overload of the comparatively weaker, though substantially rigid, thermal insulation layer of the wall-building elements.

A complete building will always comprise at least one outer door and typically, but not necessarily, a number of windows. Windows and doors may generally be adapted to a building raised according to the principles of the present invention, in one of two alternative ways. One way is to cut out the required opening, typically using an electric sawing/ cutting machine and to put in a door or a window, including frame, more or less of a standard type. The frame of a window assembled in a basic wall-building element in such a manner, could be provided with a lower beam, in wood, metal or synthetic material, having a profile corresponding to the lowermost side edge of a wall-building element, adapted to be mounted on top of a section of an H-beam according to the present invention. Similarly, the uppermost side edge of the window frame may have profile like the top side edge of a wall-building element, hence being adapted to the lowermost part of the H-beam being part of the present system. In such a case, the lower and the upper sides of the cut out opening may be provided with an H-beam before assembly. This allows the window/ frame, once assembled in a wall, to become part of the load bearing structure of the wall, if the window frame has an adequate load bearing capacity.

Another way of adapting doors and windows to the present invention, is to include production elements with the same dimensions as any other basic wall-building elements, in which a door frame or a widow frame is included already as a prefabricated element, ensuring that the end user does neither need to perform any cutting nor any kind of adaptation during assembly of a building. On the other hand, this alternative requires a higher number of alternative building elements, in particular if the end user shall be allowed to choose between different window and/or door sizes. While assembly of doors and windows are required operations during assembly of a building, the manner in which it is made is not as such an element of the present invention and therefore not discussed in further detail herein.

The form-stable layer of insulation material will typically exhibit properties including UV resistance and moisture resistance, and may be supplied with a polymer coating of UV resistant and/ or moisture resistant material at the exterior side of the basic wall-building element to ensure long lasting properties with regard to resistance against moisture and sunlight.

While the specific materials for the load bearing core member and for the thermal insulation layers may vary, typically both are comprised by recycle plastic materials. The material for the thermal insulation layers is foamed to a desired density without jeopardizing its form stability. In commercial buildings it is estimated that about <NUM> % of the materials used will be recycle plastic materials.

The thermally insulating material is typically rich in polyethylene (PE). Other plastic materials may also be used but the ones mentioned are preferred also due to their availability in vast amounts. The thermal insulation layers are foamed to a high degree and may have a density about <NUM>/ m<NUM> (less than <NUM> % of the density of water). The expanded - or foamed - polyethylene of such a density still is form-stable and well functioning for the purpose of the present invention.

Materials of polyvinyl chloride (PVC) may also be useful in relation to the present invention, such as for rooftops and the like, not however as such covered by the present invention.

The load bearing core member may typically be comprised by a material selected from the group consisting of honeycomb polymer structure, preferably including recycled polymer material, composite materials, plywood, or a combination thereof and having a density typically around <NUM>-<NUM>/m<NUM>, i.e. still a density in the range <NUM>-<NUM> % of the density of water. The load bearing capacity in terms of compressive modulus as defined by ASTM C365-<NUM> has been found to be about 20MPa (about <NUM> atm). The polymers for the load bearing core member typically comprises at least one of polyethylene (PE), polypropylene (PP) and polyethylene terephthalate (PET), the latter typically used just as a coating material.

With a convenient element thickness, the specific weight of the basic wall-building element according to the present invention typically is in the range <NUM> - <NUM>/m<NUM>. While it might be assumed that such a light construction would be vulnerable for damage in strong winds, tests have shown that buildings raised in accordance with the present invention are surprisingly stable. This is believed to be due to way in which all the elements engage with other elements. In addition, the buildings are stabilized by the roof structure that closes the building and binds the walls together, preventing winds from getting inside. The roof structure is, however, not part of the present invention and therefore not described in any detail here. Any conventional roof structure may be used for providing a roof for the wall-building elements of the present invention.

The square dimensions of the basic wall-building elements according to the present invention may vary within wide limits dependent upon type of building, location, available means for transportation and assembly etc. For instance, in situations where cranes or the like are not available for lifting and positioning the elements to their intended positions and orientations, the elements should preferably not be larger than allowing manual handling by two people. One element could have a height corresponding to a floor, e.g. <NUM> meters. If such an element has a width of <NUM> meter, its square dimension is <NUM> meters and its weight near <NUM> (assuming a specific weight of <NUM>/ m<NUM>. Two people would quite easily be able to raise and assemble elements of such a weight.

<FIG> shows schematically end sections of two wall-building elements <NUM> wherein the right-most part of one element and the left-most part of an adjacent similar element. Each element has a core member <NUM>, which is the load-carrying element, and on both sides thereof, a thermal insulation layer <NUM>. The core member is made in a material with a compressive strength sufficient to take up all vertical forces applied when the elements are assembled to complete walls and a roof being put on top of the walls. The thermal insulation layer <NUM> is preferably made from recycled plastic materials, which are subsequently foamed to a density beyond a minimum density level. The thermal insulation layer exhibits integrity in the sense that it is rigid and dimensionally stable.

At one short side of the wall-building element, shown as the right part of the left-most element in <FIG>, the core members protrudes from the thermal insulation layer, thereby forming a tongue 12a. At the other side of the wall-building element, shown as the left part of the right-most element in <FIG>, the core member <NUM> is recessed as compared to the thermal insulation layer <NUM>, thereby forming a groove 12b of a width adapted to the width of the load bearing core member <NUM>.

As illustrated by <FIG>, the elements may be assembled in accordance with s tongue and groove principle in the lateral direction, due also to the inherent rigidity and dimension stability of the thermal insulation layer.

<FIG> shows schematically a top view of a wall-building element which is rather similar to the one shown in <FIG>, the sole difference being that the thermal insulation layer <NUM> at both sides of the groove 12b, is tapered 13b to allow easy assembly of the wall-building elements.

<FIG> shows schematically a side view of parts of two wall-building similar with or equal to the one shown in <FIG>. The view is from the short end of each element, which is with the largest horizontal extension of the elements perpendicular to the paper plane.

At both sides of the top edge of the core member <NUM> and adjacent thereto, the thermal insulation layer <NUM> exhibits recessed regions 13a. In these recessed regions 13a, the thermal insulation layer is recessed as compared to the level of the insulation layer farther away from the core member <NUM> and it is recessed also when compared with the core member <NUM>.

A similar recessed region 13c is shown at the bottom of the upper element. <FIG> also illustrates the fact that the load bearing core member <NUM> extends vertically above the recessed region 13a but not quite to the top level of the thermal insulation layer <NUM>.

An H-shaped beam <NUM> is used to connect the upper wall building element to the one below.

<FIG> is an enlargement of details encircled in <FIG>. The level differences mentioned above are seen more clearly in <FIG>. The three levels at the top of the wall-building elements are shown namely the top level L13 of the thermal insulation layer, the top level L12 of the load bearing core member <NUM> and the level L13a of the recessed region 13a of the thermal insulation layer <NUM>. It is understood that the horizontal part of the H shaped beam <NUM> has a width or thickness that is about twice the level difference between levels L13 and L12 while the vertical extension of the H shaped beam is about twice the difference between the levels L13 and L13a.

Similarly, at the bottom of each wall-building element <NUM>, the load bearing core member <NUM> extends below the recessed region 13c of the thermal insulation layer <NUM> but not quite to the lowermost level of the thermal insulation layer.

The wall-building element system comprises two additional components one being an H-shaped beam or rail <NUM> adapted to fit between different vertical layers of wall-building elements <NUM>. The dimension of the H-shaped beam are adapted to the dimensions of the recessed regions 13a, 13c, and to the level difference between the top of the load bearing core member <NUM> and the top level of the thermal insulation layer <NUM>.

<FIG> is a side view of the elements shown in <FIG> in assembled position, using the H-beam <NUM> as a stabilizing and load-transferring member between the layers. The H beam may be made in any strong, stable material. Typically, the H shaped beam <NUM> is made of light metal, composite materials or compact plastic material, with a density and compressive strength much higher than the thermal insulation layer and at least comparable with the density and compressive strength of the core member <NUM>. The length of each H beam <NUM> may be different from the horizontal extension of the wall-building elements and the joints between the different H beam elements are typically positioned so as not to coincide with the joints between the wall-building elements. While the thermal insulation layer has an integrity and dimension stability in itself, the presence of the H shaped beams between each layer of wall-building elements still significantly enhances the stability of the complete, assembled building structure.

<FIG> shows a top view of an entire wall-building element similar to the ones shown in part in <FIG>.

<FIG> shows schematically a top view of an embodiment of a wall-building element according to the present invention. The difference from <FIG> is that the core member <NUM> exhibits lateral ribs <NUM> extending from both sides of the plate shaped main body <NUM> of the core member <NUM>. The main body <NUM> and the ribs are typically casted as a single integrated structure and the vertical extension thereof is typically the same as the main body <NUM> with the exception that in the recessed region 13c of the thermal insulation, the vertical level of the ribs <NUM> typically coincide with the vertical level L13a of the thermal insulation layer <NUM> in the recessed region. Thereby the ribs <NUM> are allowed to support the beams <NUM> directly from underneath.

<FIG> shows schematically a slightly different variant of the wall-building element compared to the one shown in <FIG>, the only difference being an increased number of ribs <NUM> extending from the main body <NUM> of the core member.

<FIG> shows yet another variant in which the ribs are arranged symmetrically on both sides of the main body <NUM> of the core member.

The ribs shown in Figures ¤b-4c have several functions. They serve to make the core members <NUM> more rigid and twist-resistant, they serve to support and stabilize the thermal insulation layer and, in interaction with the H-shaped beams <NUM>, they serve to distribute the forces transferred between the vertical layers of the structure over a larger area. In addition, as elaborated below, they serve to stabilize the different vertical layers of an assembled wall structure even with regard to lateral forces.

Preferably, the ribs <NUM> are arranged in a fixed pattern, equally spaced and all ribs arranged in parallel with one another. The longitudinal direction is typically vertical and perpendicular to the main body <NUM> of the core member <NUM>. The lateral extension is typically a little less than the thickness of the thermal insulation layer <NUM>, thereby allowing the thermal insulation layer to fully cover the ribs and at the same time allowing the thermal insulation layer to be applied as one continuous element rather than a number of smaller elements separated by ribs.

<FIG> is a side sectional view along the line V-V in <FIG>, and generally illustrates the extension of the ribs <NUM> in relation to or comparison with the thermal insulation layer <NUM>. In the recessed region 13a, it I essential that the ribs allow room for the H-shaped beam <NUM> and therefore exhibit flat areas corresponding to (at least) the width of the recessed region 13a of the thermal insulation layer <NUM>. By following the upwards <NUM> degrees angle of the thermal insulation layer <NUM> at the imaginary line along the outermost side of the recessed region 13a, the ribs provide support for the H-beam even laterally, thereby contributing to the stability of the assembled structure also with regard to lateral forces between the vertical layers thereof.

<FIG> shows a slightly different variant from the one shown in <FIG>, the difference being that the upwards angle of the ribs <NUM> at the bending line along the outer side of the recessed region 13a, is somewhat larger than <NUM> degrees, making it slightly easier to fit the H-beam into the recessed region 13a while still providing lateral support.

While the profiles of the ribs <NUM> shown in <FIG> are based on <FIG>, the ribs indicated in <FIG> will typically have similar profiles, contributing to the stabilization of the complete structure when assembled with H-shaped beams <NUM> between each vertical layer of the wall structure.

Reference is now made to <FIG>. Beneath the lowermost vertical row of wall-building element <NUM>, a particular sole element <NUM> is used, the top of which being provided with a profile adapted to the bottom surface of the wall-building elements. The upper surface of the sole element <NUM> thus exhibits extending flanges 15a, which fits into the recessed region 13c of wall-building element with a groove 15b there-between to allow space for the lower end of the core member, or more specifically, the main body thereof. The width of the sole element is adapted to the width of the wall-building elements, i.e. the sole element is typically as wide as - or somewhat wider than - the wall-building elements.

<FIG> shows a variant of the sole element <NUM>, the difference being that the lower surface is corrugated to slightly penetrate the ground on which it is placed. <FIG> shows yet a variant where the lower surface is provided with long spikes to more deeply penetrate the ground.

<FIG> shows a view an assembled wall structure as seen from the short end of the wall-building elements. The wall structure consists of a bottom sole element <NUM> and three layers of wall-building elements <NUM> joined via H-shaped beams <NUM>. <FIG> illustrates the fact that the ribs (shaded area) surrounds the H-beams from below and from above, thereby stabilizing the wall structure laterally while transferring the weight load via the H-beams vertically.

<FIG> also indicates the presence of a roof which, however is not part of the present invention.

The number of floors are not indicated in <FIG>. The height covered by the three elements on top of one another may correspond to one or more floors. When more than one floor is encountered, floor supporting elements (not shown) such as pillars, bars and/ or beams (not shown) would typically be present since the wall structure according to the present invention is not designed to support floors.

<FIG> shows a variation of the wall shown in <FIG>, the differences being that the wall elements are relatively higher but also that the upper and lower edges of the exterior side of the thermal insulation layer <NUM> are designed with an inclination <NUM> preventing water from penetrating the wall during rainfall.

The basic wall-building elements are typically symmetrical around the central load-bearing core, with the possible exception of a particular layer of UV resistant and/ or moisture resistant material at its exterior side. In the drawings <NUM>-<NUM>, all basic wall-building elements are shown as symmetrical in this respect.

While the exterior and the interior side of the wall-building elements may be identical to one another, there is also the possibility of providing at least one extra layer on the exterior side, to better protect against humidity and/ or deterioration by sunlight.

While the wall-building elements according to the present invention is suitable for assembly of complete buildings, with the exception of a roof, the elements may also be used for providing thermal insulation in existing buildings.

Claim 1:
Prefabricated basic wall-building element (<NUM>) comprising a load bearing core member (<NUM>) comprising a plate shape main body (<NUM>) having a vertical orientation in its assembled position, said main body (<NUM>) being covered by and attached to, directly or indirectly, a form-stable thermal insulation layer (<NUM>) at both sides thereof, wherein
along one vertical side of each basic wall-building element the core member (<NUM>) protrudes to constitute a tongue (12a) while along the opposite side of the basic wall-building element, the core member (<NUM>) is recessed to constitute a groove (12b) adapted to receive the tongue (12a) of an adjacent wall-building element, and wherein
the core member (<NUM>) further comprises ribs (<NUM>) extending laterally from both sides of the main body (<NUM>), with a vertical orientation, their lateral extension being less than the thickness of the thermal insulation layer (<NUM>).