Engineered building block modular construction

Abstract

The composite log module can have an elongated structural shell having a first set parallel walls rigidly interconnected with a second set of parallel walls perpendicular to the first set of parallel walls, the interconnected walls enclosing an elongated cavity housing a core having thermal insulation material, and two opposite mating outer surfaces associated with the first set of parallel walls for stacking identical ones of the composite log, and two sides associated with the second set of parallel walls, the walls each having a structural engineered material.

What is claimed is: 
     
         1 . A composite log having an elongated structural shell having a first set parallel walls rigidly extending between and interconnected to a second set of parallel walls, the interconnected walls enclosing an elongated cavity housing a core having thermal insulation material, and two opposite mating outer surfaces associated with one of the first set and second set of parallel walls for stacking identical ones of the composite log, and two sides associated with the other one of the first set and second set of parallel walls, the walls each having a structural engineered material. 
     
     
         2 . The composite log of  claim 1  wherein the thermal insulation material has a block of rigid plastic foam insulation adhered to inner faces of the walls on at least two of its faces by an adhesive. 
     
     
         3 . The composite log of  claim 2  further comprising a separator board interconnected between two of the parallel walls with the block on one side thereof, and an other block of rigid plastic foam insulation on an other side of the separator board. 
     
     
         4 . The composite log of  claim 3  wherein both the block and the other block of rigid plastic foam insulation are adhered to the separator board. 
     
     
         5 . The composite log of  claim 1  wherein both sets of parallel walls each include at least one board of manufactured wood as the structural engineered material. 
     
     
         6 . The composite log of  claim 1  wherein one of the first and second sets of parallel walls has grooves defined in an internal face thereof, and the other one of the first and second sets of parallel walls has ends engaged into said grooves. 
     
     
         7 . The composite log of  claim 1  wherein the first set of parallel walls are interconnected to the second set of parallel walls by adhesion. 
     
     
         8 . The composite log of  claim 1  wherein outer surfaces of the sides have a plurality of air space channels. 
     
     
         9 . The composite log of  claim 8  wherein the air space channels are oriented longitudinally relative to the composite log. 
     
     
         10 . The composite log of  claim 9  wherein the walls bearing the sides each include a panel of the structural engineered material, and at least three spacer boards adhered to the panel parallel to and interspaced from one another, forming the air space channels therebetween. 
     
     
         11 . The composite log of  claim 8  further comprising at least one of an interior finishing panel and an exterior facing panel mounted to a corresponding one of the sides, and enclosing the corresponding air space channels. 
     
     
         12 . The composite log of  claim 1  wherein a first one of the two opposite mating outer surfaces has at least one groove, and the second one of the two opposite mating outer surfaces has at least one corresponding tongue. 
     
     
         13 . The composite log of  claim 12  wherein the at least one groove has two interspaced grooves and the at least one corresponding tongue includes two interspaced corresponding tongues. 
     
     
         14 . The composite log of  claim 12  further comprising a weather strip positioned at a bottom of the at least one groove. 
     
     
         15 . The composite log of  claim 14  wherein the at least one groove has a depth equal to a thickness of the at least one tongue, the at least one groove further comprising a recess at the bottom thereof housing the weather strip. 
     
     
         16 . The composite log of  claim 1  wherein the thermal insulation material has a thermal insulation above 0.35 m 2 .K/(W.in). 
     
     
         17 . The composite log of  claim 1  wherein the cavity has a rectangular cross-section shape. 
     
     
         18 . The composite log of  claim 1  further comprising at least one separator board interconnecting the parallel walls of one of the first and second set, splitting the cavity into at least two cavity portions, the thermal insulation filling both cavity portions. 
     
     
         19 . The composite log of  claim 18  wherein the separator board is perpendicular to the two parallel walls it interconnects. 
     
     
         20 . A method of assembling a composite log having a first set of parallel walls having grooves with a second set of parallel walls perpendicular to the first set of parallel walls and interconnected therebetween and engaged into the grooves, and a core having at least one block of rigid plastic foam insulation; the method comprising in sequence:
 Stacking the core onto a first one of the parallel walls of the first set, with an adhesive applied therebetween;   Engaging a first end of the parallel walls of the second set into the grooves of the first one of the parallel walls of the first set, with an adhesive between the core and the parallel walls of the second set;   Folding the parallel walls of the second set against opposite sides of the core;   Lowering the second one of the parallel walls of the first set onto the core, thereby engaging the second end of the parallel walls of the second set into the grooves of the second one of the parallel walls of the first set; and   Applying a predetermined pressure in compression respectively between both sets of parallel walls and allowing the adhesive to set.   
     
     
         21 . A composite module having an elongated structural shell having a first set parallel walls rigidly interconnected with a second set of parallel walls perpendicular to the first set of parallel walls, the interconnected walls enclosing an elongated cavity housing a core having at least one block of rigid plastic foam insulation adhered to inner faces of the walls by an adhesive, and two opposite mating outer surfaces associated with the first set of parallel walls for stacking identical ones of the composite log, and two sides associated with the second set of parallel walls, the walls each having at least one board of manufactured wood. 
     
     
         22 . The composite module of  claim 21  wherein the core further comprises a separator board interconnected between two of the parallel walls with the block on one side thereof, and an other block of rigid plastic foam insulation on an other side of the separator board. 
     
     
         23 . The composite module of  claim 21  wherein outer surfaces of the second set of parallel walls have a plurality of air space channels. 
     
     
         24 . The composite module of  claim 23  further comprising at least one of an inner building facing panel and an outer building facing panel mounted to a corresponding one of the walls of the second set of parallel walls, and enclosing the corresponding air space channels.