US2009113829A1PendingUtilityA1

Three dimensional building element

60
Individually held — no corporate assignee on recordPriority: May 14, 2007Filed: May 11, 2008Published: May 7, 2009
Est. expiryMay 14, 2027(~0.8 yrs left)· nominal 20-yr term from priority
Inventors:Franz Meier
E04C 2/044
60
PatentIndex Score
0
Cited by
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References
0
Claims

Abstract

Disclosed is a three dimensional building element having outer shells formed from cementitious compositions having different densities. The outer shell forming the exterior portion of the building element has a density greater than the interior shell to provide structure strength. The interior shell is formed from a lower density cementitious compound to provide an interior wall portion of a structure with a smooth finished appearance. The lower density of the interior cementitious compound enables the interior shell to obtain a smooth finished appearance without the need to apply various secondary coatings such as plaster or drywall.

Claims

exact text as granted — not AI-modified
1 . A three dimensional building element comprising:
 two parallel welded wire mesh mats and individual web wires joined at each end to the mats for keeping the mats at a predetermined distance from each other, the individual web wires being arranged in rows connecting the two wire mesh mats;   an insulating body spanning more than two of the rows of web wires and defining two opposite surfaces arranged parallel to and positioned between the wire mesh mats and at a predetermined distance therefrom, the insulating body being pierced by the web wires; and   an exterior cementitious outer shell in communication with one of the two wire mesh mats and an interior cementitious outer shell in communication with the other of the two wire mesh mats, wherein the exterior cementitious outer shell has a density greater than the density of the an interior cementitious outer shell.   
     
     
         2 . The three dimensional building element of  claim 1 , wherein the ratio of the density of the exterior cementitious outer shell to the density of the interior cementitious outer shell is greater than 1.1 to 1. 
     
     
         3 . The three dimensional building element of  claim 1 , wherein the ratio of the density of the exterior cementitious outer shell to the density of the interior cementitious outer shell is greater than 1.5 to 1. 
     
     
         4 . The three dimensional building element of  claim 1 , wherein the density of the exterior cementitious outer shell is between about 100 pcf to about 145 pcf. 
     
     
         5 . The three dimensional building element of  claim 1 , wherein the density of the interior cementitious outer shell is between about 55 pcf to about 110 pcf. 
     
     
         6 . The three dimensional building element of  claim 1 , wherein the compressive strength of the exterior cementitious outer shell is between about 2,500 psi to about 8,800 psi. 
     
     
         7 . The three dimensional building element of  claim 1 , wherein the compressive strength of the interior cementitious outer shell is between about 2,000 psi to about 5000 psi. 
     
     
         8 . The three dimensional building element of  claim 1 , wherein the interior cementitious outer shell includes a foam admixture. 
     
     
         9 . The three dimensional building element of  claim 8 , wherein the interior cementitious outer shell further includes fly ash. 
     
     
         10 . A three dimensional building element comprising:
 two parallel welded wire mesh mats and individual web wires joined at each end to the mats for keeping the mats at a predetermined distance from each other, the individual web wires being arranged in rows connecting the two wire mesh mats;   an insulating body spanning more than two of the rows of web wires and defining two opposite surfaces arranged parallel to and positioned between the wire mesh mats and at a predetermined distance therefrom, the insulating body being pierced by the web wires;   an exterior cementitious outer shell in communication with one of the two wire mesh mats and an interior cementitious outer shell in communication with the other of the two wire mesh mats, wherein the exterior cementitious outer shell has a density greater than the density of the an interior cementitious outer shell; and   wherein the ratio of the density of the exterior cementitious outer shell to the density of the interior cementitious outer shell is greater than 1.2 to 1 and wherein the density of the exterior cementitious outer shell is between about 100 pcf to about 150 pcf and the density of the interior cementitious outer shell is between about 50 pcf to about 110 pcf.   
     
     
         11 . The three dimensional building element of  claim 10 , wherein the compressive strength of the exterior cementitious outer shell is between about 2,500 psi to about 8,800 psi. 
     
     
         12 . The three dimensional building element of  claim 10 , wherein the compressive strength of the interior cementitious outer shell is between about 2,000 psi to about 5000 psi. 
     
     
         13 . The three dimensional building element of  claim 10 , wherein the interior cementitious outer shell includes a foam admixture. 
     
     
         14 . The three dimensional building element of  claim 13 , wherein the interior cementitious outer shell further includes fly ash. 
     
     
         15 . A three dimensional building element comprising:
 two parallel welded wire mesh mats and individual web wires joined at each end to the mats for keeping the mats at a predetermined distance from each other, the individual web wires being arranged in rows connecting the two wire mesh mats;   an insulating body spanning more than two of the rows of web wires and defining two opposite surfaces arranged parallel to and positioned between the wire mesh mats and at a predetermined distance therefrom, the insulating body being pierced by the web wires;   an exterior cementitious outer shell in communication with one of the two wire mesh mats and an interior cementitious outer shell in communication with the other of the two wire mesh mats, wherein the exterior cementitious outer shell has a density greater than the density of the an interior cementitious outer shell;   wherein the ratio of the density of the exterior cementitious outer shell to the density of the interior cementitious outer shell is greater than 1.2 to 1 and wherein the ratio of the compressive strength of the exterior cementitious outer shell to the compressive strength of the interior cementitious outer shell is greater than 1.2 to 1; and   wherein the interior cementitious outer shell includes a foam admixture.   
     
     
         16 . The three dimensional building element of  claim 15 , wherein the interior cementitious outer shell further includes fly ash. 
     
     
         17 . The three dimensional building element of  claim 15 , wherein the compressive strength of the exterior cementitious outer shell is between about 2,500 psi to about 8,800 psi. 
     
     
         17 . The three dimensional building element of  claim 15 , wherein the compressive strength of the interior cementitious outer shell is between about 2,000 psi to about 5000 psi. 
     
     
         18 . A method of forming a three dimensional building element comprising the steps of:
 providing two parallel welded wire mesh mats and individual web wires joined at each end to the mats for keeping the mats at a predetermined distance from each other, the individual web wires being arranged in rows connecting the two wire mesh mats;   providing an insulating body spanning more than two of the rows of web wires and defining two opposite surfaces arranged parallel to and positioned between the wire mesh mats and at a predetermined distance therefrom, the insulating body being pierced by the web wires;   applying a first cementitious composition to one of the two wire mesh mats to form an exterior outer shell;   applying a second cementitious composition to the other of the two wire mesh mats to form an interior outer shell; and   wherein the ratio of the density of the first cementitious composition applied to the exterior cementitious outer shell to the density of second cementitious composition applied to the interior cementitious outer shell is greater than 1.1 to 1.   
     
     
         19 . The method of  claim 18 , wherein the ratio of the density of the exterior cementitious outer shell to the density of the interior cementitious outer shell is greater than 1.2 to 1 and wherein the ratio of the compressive strength of the exterior cementitious outer shell to the compressive strength of the interior cementitious outer shell is greater than 1.2 to 1. 
     
     
         20 . The method of  claim 18 , wherein the applied cementitious composition applied to the other of the two wire mesh mates to form an interior outer shell includes a foam admixture. 
     
     
         21 . The method of  claim 20 , wherein the applied cementitious composition applied to the other of the two wire mesh mates to form an interior outer shell includes fly ash. 
     
     
         22 . The method of  claim 19 , further includes applying to the interior cementitious outer shell a composition comprising a drywall powder and primer based paint. 
     
     
         22 . The method of  claim 22 , further including sanding the applied composition comprising a drywall powder and primer based paint to a level wall finish of between about 4 to about 5 of ASTM C 840 standard.

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