BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates generally to autoclaved aerated concrete panels, and methods of making and using such panels, and specifically to residential home construction using autoclaved aerated concrete panels.

[0003] 2. Prior Art

[0004] Autoclaved aerated concrete was discovered in the early 1900's and is a mixture of cement, aluminum powder, lime, water and finely ground sand. This mixture expands dramatically, and this “foamed” concrete is allowed to harden in a mold, and cure in a pressurized steam chamber, or autoclave.

[0005] Commercial production of autoclaved aerated concrete (AAC) began in the 1930's, and recently more than 31 million cubic meters were produced by over 50 factories worldwide. The construction industry has sought alternative building techniques in order to limit the traditional expenses of construction, including the high energy costs, increasingly expensive construction labor and equipment, and a higher environmental consciousness of home owners. These factors have forced home builders in particular to search for new construction materials. These new materials have to be versatile, easy to use, durable, and energy efficient. AAC appears to satisfy the demands of such a superior construction material.

[0006] AAC is used in a wide range of building construction with residential, commercial and industrial buildings being common applications. Autoclaved aerated concrete is as workable as wood, and can easily be cut, shaped or routed to accommodate almost any design criteria. Conventional uses of AAC are as small masonry-like units, or blocks. The walls, floors and roof of an AAC building are constructed with a plurality of these blocks.

[0007] There are several advantages to construction methods using autoclaved aerated concrete blocks as they have low weight per unit, beneficial insulative characteristics, are non-toxic, non-combustible and water resistant. Another advantage to AAC is its environmental friendliness.

[0008] AAC weighs 30% less than traditional concrete masonry units. Standard 8″ concrete masonry units weigh approximately 38 lbs./unit. Alternatively, 8″ AAC blocks weigh approximately 28 lbs./unit. Per square foot, standard 8″ concrete masonry units weigh 42.8 lbs./square foot as compared to 21 lbs./square foot for 8″ AAC blocks. Due to the light weight of AAC, reduced equipment demands also are realized.

[0009] AAC buildings are very energy efficient. This efficiency is due to a combination of high R-value, thermal mass and air-tightness. AAC is the only product currently available that meets Germany's stringent energy codes without added insulation. It is well documented that the R-value of a mass product need not be as high as that of light frame construction, to perform thermally efficient. A recent study in the U.S. shows that an 8″ AAC wall performs much better than a conventional wood stud wall system with R-30 insulation.

[0010] Due to AAC's excellent insulation qualities, energy consumption for the heating and cooling of buildings built from AAC is greatly reduced compared to most conventional wall and roof systems.

[0011] In the AAC manufacturing process, no pollutants or toxic by-products are produced. AAC is an inorganic material that contains no toxic substances. Due to its inorganic structure, AAC also eliminates the food source condition required to be present for microbial growth to occur.

[0012] Further, AAC is non-combustible, so in the case of fire it can help prevent the fire from spreading to other rooms. During a fire, no toxic gases or vapors are ever emitted from inorganic AAC.

[0013] AAC does not slowly decompose and off-gas. Thus, AAC is resistant to water penetration and decay.

[0014] AAC also is well known as an environmentally friendly construction material. Compared to the energy consumed in production of many other basic building materials, only a fraction of this energy is required to produce AAC. Raw material consumption is very low for the amount of finished product produced. Since AAC is both a structural and insulation material, it allows for the elimination of other materials both as an environmental benefit and as limiting any poor indoor air quality due to construction material other than AAC. AAC is also completely recyclable.

[0015] As another advantage, field mistakes easily can be corrected. Conventional screws and nails can be used with AAC. For heavy loads, fasteners similar to those used for concrete block are utilized.

[0016] AAC products are unfinished. Depending on the building use or the aesthetic requirements, AAC may be coated with an interior or exterior surface finish. On the exterior stone veneers, brick veneer, wood siding, vinyl siding or metal sidings may all be easily attached to AAC. In addition, an AAC interior usually has sheet rock installed, and may be wallpapered after a skim coat of plaster or gypsum-based material is applied.

[0017] Although AAC construction is superior to conventional systems, the current methods of use for AAC residential construction are self-defeating, and actually prevent AAC from becoming the residential industry standard.

[0018] Therefore, a need exists in the art for AAC panels, instead of blocks, and manufacturing and construction methods using AAC panels that not only overcome many of the problems of current AAC production and use, but also become such an assets in and of themselves that by their implementation alone (apart from all of AAC's inherit attributes), AAC could become the industry standard due solely to ease and time savings in construction. It is to the provision of such panels and manufacturing and construction methods that the present invention is primarily directed.

SUMMARY OF THE INVENTION

[0019] Accordingly, the present invention includes novel AAC panels, a method of manufacturing these AAC panels, and a method of construction using the AAC panels. The AAC panel and methods of manufacturing and construction necessitate the production and use of novel tools and related equipment and subsystems, which themselves are further parts of the present invention.

[0020] The present invention provides a radically new use for AAC in residential construction, which system is far superior to prior art and conventional wood and steel frame construction in many ways. The present invention requires a new manufacturing process and a completely new installation process for residential construction, and certain commercial applications. From the initial and long term environmental impact, through the entire construction process, to the end user and home owner, the present system eradicates many, if not all, the current obstacles in the prior art of AAC blocks, and the use of AAC, which are preventing AAC from replacing wood/steel and becoming the home construction industry's standard material.

[0021] Panels

[0022] One aspect of the present invention is a monolithic panel of AAC, instead of the conventional small block, for residential applications, or conventional 2′ blocks for commercial constructions. The present AAC panels are monolithic walls, floors and roofs, so initially there are no more than one joint/seam per panel, and ultimately by fully implementing current methods of manufacture and construction, there are no seams/joints in the present panel of AAC measuring 8′ by 10′+.

[0023] The present invention also provides a new two- to three-story monolithic wall panel. The present invention incorporates numerous new design principles and concepts. For example, novel floor panel supports, self-supporting roof subsystems and whole panel exterior walls from which all openings are cut are provided, beyond just a new panel design.

[0024] No one has ever manufactured and constructed a residential/commercial structure which is truly habitable by modern standards and economically viable using monolithic structural panels of the present invention from which openings for windows and doors are cut after installation.

[0025] Manufacture

[0026] The present method of manufacture comprises the manufacture of new dimensional panels (for walls, roofs and floors) instead of the current 2′ wide blocks, the panels being monolithic AAC walls measuring 8′ tall and 10′+ wide, and further having no seams. By modifying current manufacturing systems, the same wall has no more than one seam.

[0027] Construction

[0028] Use of the present panels necessitates novel construction methods. A residential home of the present system does not require insulation, roofing materials, sheet-rock, exterior sheathing or gutters. The present construction system preferably uses only one material to build nearly the entire structural and insulation part of a building, AAC, which offers many advantages, including allowing excellent design flexibility, quick construction and reduced waste.

[0029] Further, the present construction system includes a roofing subsystem that incorporates a unique self-supporting ridge beam thus requiring no truss system, wherein conventional truss systems leave unusable attic space.

[0030] The present construction system produces an entire house from the foundation up (including, but not limited to, exterior and interior walls, basements, roof, interior floors, cam levered decks and fireplaces). The house is built solely of AAC panels in such a manner that an average 1,800 square foot house using the present construction method can be completely constructed on site within two long working days using a small crew (depending on size and design of home), instead of the several months and myriad of specialized crews that are currently required.

[0031] The present construction system is much more than just modular construction AAC, as the entire current system is unique in details and the overall symmetry creates a distinct product which prior art forms of block could not have combined to make. The prior art forms of commercial blocks can require the use of cranes, but have never approached anything remotely similar to present invention despite 70 years of manufacture and construction of AAC! For one thing, the prior art never recognized the problem of competing with conventional residential construction using AAC in another form, namely panels. Manufactures and builders using prior art blocks used solely in commercial construction never recognized the problem that the blocks were not monolithic, although the blocks were, in fact, used to construct what in the end result was similar to a monolithic structure.

[0032] The concept of a present house is that it can almost be completely prepared at the factory in terms of walls, floors, and roof system. This is how Solomon built the temple in Biblical records 1 Kings 6:7. It is then shipped by semi tractor-trailer that has a crane unit. Foundation at the site is prepared. The driver is also crane operator and simply erects the house with licensed crew. A 2,000 square foot house is completely set up, and the roof waterproofed.

[0033] The next day, all exterior finishes are applied, and door and window openings are cut. Windows and doors can be set immediately. There are no mechanical reasons once the slab/foundation is prepared that an entire 2,500 square foot house cannot be built and finished (except for interior such as H/A, plumbing, kitchen cabinets, bath fixtures, floors as hardwood, tile, carpet, etc.) within one week.

[0034] All exterior and interior finishes are still possible so that each home can have a custom look and “home” feel. Brick, stone and even wood treatments are possible on the exterior. On interior finish all standard materials can be used so that no one will know difference except for lower mortgage payments, quietness, lower utility bills and no fear of termites or fire destroying the home.

[0035] There is also no waste material from the construction as all panels and parts of panels are reused in applications for site improvement and other environmentally friendly uses.

[0036] Tools

[0037] Use of the present panels also necessitates new tools. New custom tools designed strictly for the present AAC panels and methods are used, including routers that catch all the dust for electrical (which boxes will be round), wiring installation (where panels do not use present manufacturing of conduit in panels or run in joints and then covered with mortar), AAC connector wall plates and a special design reciprocating saw used in conjunction with template guide for cutting openings in solid wall panels.

[0038] To join AAC panels together, mortar joints are used in addition to uniquely designed screws that are large and have a thread flange that is very wide and with distance between so they do not crush AAC but go deep and anchor well.

[0039] Benefits

[0040] No one has ever manufactured and constructed a residential/commercial structure which is truly habitable by modem standards and economically viable using monolithic structural walls from which openings for windows and doors are cut after installation.

[0041] One advantage never before appreciated is the fact a 2,000 square foot home can be constructed in less than half the current time at a greatly reduced labor cost of prior art AAC construction methods.

[0042] The present methods of construction using autoclaved aerated concrete overcomes numerous problems in the conventional residential construction market. The producers of AAC have had failure in breaking into the residential market due to current manufacturing and installation methods. One such problem is that there exists no installation method for AAC that is cost-effective, as producers heretofore have not recognized that construction revolutions dictate changing present manufacturing processes, designs, and construction systems for residential construction. Producers simply implement various improvements upon the prior art AAC “block” method.

[0043] The present system solves a problem that historically all companies in AAC (i.e.: Hebel, YTONG, Matrix and ACCO) have not successfully overcome, even after monumental investments. So much so that a Mr. Angelo Coduto of ACCO, an expert in AAC and responsible for bringing two AAC producers to America, said in November 1999, “We only do commercial because residential is too difficult to be successfil.”

[0044] Other experts in AAC construction identify the very problems the present invention overcomes. Mr. Roger Babb of Babb International said on Jan. 18, 2000, “the problem of expense lies in the required finish of interior and exterior walls.” Babb International's new “state of the art plant”, consists of prior art “block” designs, (though “trying new block ideas”), not large panels.

[0045] The present invention further reduces costs by eliminating blocks and the required extra surface coats of heavy stucco and sheet-rock. For example, the present construction method incorporates the use of spray paint-type coatings and paints that are water proof but allow beading action on the roof panels, in order to replace costly and environmentally unfriendly industry standard asphalt shingles.

[0046] The construction system of the present invention also removes the dependence on huge elements of blocks, wood and/or steel roof systems, interior walls and floors, while actually increasing capability.

[0047] The desire for a quality home that has the inherent advantages of AAC has not been financially feasible and competitive until the present invention of large panels, and the method of construction using such panels and the related synergism of all the various components. Now it is available to everyone, not just the rich. The present invention solves the long-felt, long-existing and unsolved need for affordable, economically feasible mass marketing of durable, insulate, termite proof housing that is extremely environmentally friendly in view of materials used, waste of materials and when current materials exhaust themselves the problem of landfills (roof shingles, etc.).

[0048] The present construction system is completely contrary to teachings of the prior art in that even the most innovative and yet-to-be-built AAC plants are still based on block systems instead of larger panels, and conventional construction methods.

[0049] Synergism exists in the present invention for numerous reasons. First, the present invention has never been expressly suggested or implied by previous art. Why else would every modem and yet-to-be-built plant costing $10,000,000's advertise the use of use prior art “block” manufacturing? Further, the prior-art references could never be combined physically to achieve same idea. The references alone or in combination do not teach or suggest the invention. The prior art references do not operate if combined in a manner remotely similar to the present system, for example lentils/headers are required above windows and doors in previous art uses of blocks, but in the present form none are required.

[0050] For residential applications, a YTONG engineer was quoted that “Roof panels are not used with block walls (as in residential, panel walls are not known to be used by anyone now) due cost issues and breakage. Only on an expensive custom home.” In addition, YTONG's anchoring system of floor and roof panels to block walls are completely different an the present construction, and YTONG details require prior art steel truss systems.

[0051] The prior art method of construction of a residential home is awkward, separate and involves numerous steps as the use of many blocks using manual labor, the roof system being wood or steel, and floor systems requires a different, inferior method. The present system transcends the whole field in current usage and application, and requires an entirely new approach distinct and separate from current construction techniques.

[0052] The present approach is from the opposite end of the spectrum and only practical and feasible by the invention of manufacturing large panels and/or the new unique construction methods and tools.

[0053] AAC is a superior material to conventional wood, concrete and steel, and the only reason AAC has not replaced other building materials is because no one thought of the current ideas for panels, manufacturing and constructing.

[0054] These and other objects, features, and advantages of the present invention will be more apparent upon reading the following specification in conjunction with the accompanying drawing figures.