SAFEDEK

Abstract

The SafeDEK product and composite assembly is used within the building industry and the materials, methods of product assembly, process and procedures are disclosed. The Safedek product combines rigid materials, supporting members and anchors that attach to concrete, other building materials or building systems. The SafeDEK product and assembly process not only replaces removable concrete forming materials and other building materials but, remains in place to form a storm resistant, and energy efficient structural building system.

Description

BACKGROUND OF MY INVENTION

Today, because of intense storms including tornados and hurricanes, not only The Federal Emergency Management Agency (FEMA) but, State agencies, and Insurance companies are encouraging people to place their families in homes that are safer and more sustainable. Evacuation that takes place in densely populated areas themselves can be dangerous due to traffic and weather.

The trends in energy conservation, global warming and escalating energy cost are mandating the general public to look for more realistic ways to control rising cost. Encouraging existing or new mitigation techniques will also help the rebuilding process in the event of any type of disaster. Energy Star, Sustainability, and Green Built construction are becoming a pyridine movement that is to lead the way for years to come.

It is desired to have a home that is construction to withstand significant wind velocities and other catastrophic damages that occur from hurricanes and tornadoes and being “Green” encompasses energy conservation, sustainability and conservation of natural resources.

The majority of new homes being built in the United States are constructed of wood and no considerations or provisions are being taken to construct any type of safe room or storm room within said new housing. Furthermore there are millions of homes built within the last 30 plus years that have no provisions to take shelter from any type of storms such as a tornado or a hurricane.

The building industry today is starting to address past concerns by building stronger, sustainable, and more energy efficient housing. The enacting of new codes concerning safety in construction and energy efficiency are being addressed throughout the country. Poured-in-place concrete wall systems using removable forms, Insulated concrete block (ICF), and panelized wall systems are being accepted today with market share growing every year.

A major concern today is the exterior wall and roof system that enclose the building structure making it safer, storm resistant, and more energy efficient. The process of continuing the wall systems to include the roof system to complete the structural envelop has been most challenging within the building industry. Today, little has been done to mitigate the damages of a structure if disasters do accrue without rendering said structures unusable for the occupants. The value of the SafeDEK product and composite assembly invention will complete the structural envelop and also simplify the economics of construction, not only in the residential building market, but also in many commercial applications. The following presentation of my SafeDEK product and composite assembly invention as referenced by the drawings will become evident in comparison to traditional and prior proposed approaches that have been available within the marketplace.

BRIEF SUMMARY OF MY INVENTION

The scope of my invention comprises of rigid materials which consist of mineral based Magnesium Oxide board which comprised of (MgO) Magnesium Oxide, (MgCi) Magnesium Chloride, Fibrous Reinforcement for strength and other proprietary fillers that is attached to expanded polystyrene and supporting members. Anchors are then used to permanently fasten the mineral based Magnesium Oxide board and supporting members to concrete or other materials. My invention has several major functions: the invention acts as a non removable form for the concrete that will remain in place as part of the structural floor, ceiling, or wall system. The mineral based bonded Magnesium Oxide board is sustainable, impact resistant, mold resistant, and fire resistant and covers the expanded polystyrene that is attached. The invention is then attached to concrete which now becomes a structural Thermal-Mass, energy efficient, and storm resistant assembly.

The advantages and novel features of my invention, as well as details of illustrated embodiments thereof, will be more fully understood from the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 are major component materials including supporting members, and anchors.

FIG. 2 are major component materials including alternate supporting members, and anchors.

FIG. 3 are assembly sequence section details and drawings showing rigid materials, support members, and attached anchors.

FIG. 4 are assembly sequence section details and drawings showing rigid materials, alternate support members, and attached anchors.

FIG. 5 are major component materials including support members, anchors, and safety cap.

FIG. 5a are major component materials including support members, anchors, and safety cap.

FIG. 5b are major component materials including support members, anchors, and safety cap.

FIG. 6 are major component materials including alternate support members, anchors, and safety cap.

FIG. 6a are major multiple support members and details.

FIG. 6b are major support members and showing interlocking system in rigid polystyrene.

FIG. 7 are rigid material splicing technique details.

FIG. 8 are final installation example details no. 1

FIG. 9 are final installation example details no. 2

FIG. 10 are final installation example details no. 3

FIG. 11 are final installation example details no. 4

FIG. 12 are final installation example details no. 5

FIG. 13 are assembled panels showing clarification

DRAWINGS—REFERENCE NUMBERS

1	expanded polystyrene board	2	metal elongated support member
3	Rigid material based magnesium	4	mechanical metal anchor
	oxide board
5	elongated support member made of	7	saw cutting for specified supporting
	rigid recyclable material		members
8	guide for future saw cutting	9	cut out for element 2
10	none edge safety cap covering a	13	cut out for element 5
	double metal supporting member
14	Finished product with rigid recyclable	18	safety cap covering element 5
	material installed
19	Showing connection of panels of	21	Finished product with metal supports
	invention using elongated rigid		installed
	recyclable material to concrete by
	mechanical anchors
23	elongated supporting member T	24	safety cap covering element 2
25	Showing connection of invention	26	structural concrete
	using elongated metal members to
	concrete by several methods
27	metal elongated supporting member	28	Splice cut into element 1 for spicing
	lip		Rigid recyclable material elongated
			support members together
29	interlocking system connecting to	30	female end of interlocking system in
	multiple element 1		element 1
31	male end of interlocking system in	32	Finished product with element 1
	element 1		interlocking system and metal supports
			installed
33	Finished product with additional rigid	34	Showing connection of invention using
	recyclable material installed		non edge elongated rigid recyclable
			material to concrete by mechanical
			anchors
35	none edge safety cap covering a	36	Finished product with additional rigid
	none edge rigid elongated recyclable		recyclable material installed including
	supporting member		interlocking system in element 1
37	Splice cut into element 1 for spicing	39	shows the product and assembly on
	Rigid material based magnesium		ceilings and floors
	oxide board together
40	shows the product and assembly on	41	Finished product with additional metal
	interior and exterior walls		supports installed

DETAILED DESCRIPTION OF MY INVENTION

With reference now to the drawings in which like elements are denoted with the same numeral throughout the several views. Some of the unique features of my invention are that (a) the composite assembly is used as the forming system that holds in place the liquid concrete until setting and remains in place as part of a composite system, (b) the rigid expanded polystyrene with R value is combined with the concrete to form a monolithic structural thermal mass energy system, (c) the invention is combined with concrete to form a structural safe and storm resistant composite system, and (d) the invention has a mineral based magnesium oxide board which is bonded to rigid expanded polystyrene to make a finished product that can be a cosmetic finished product on the interior or exterior exposed surface for home and commercial buildings. The embodiments, structural cast-in-place concrete including all attachments to elements comprises a complete poured-in-place wall, floor, and ceiling system invention. Additional system elements, which are described within the drawings 1 through 13 are included.

The product and assembly elements consist of five (5) pre-manufactured items 1 thru 5 as shown in FIGS. 1 and 2. Element 1 is rigid expanded polystyrene, element 2 is metal elongated support member, element 3 is a rigid material based magnesium oxide board, element 4 is mechanical metal anchor, and element 5 is an elongated support member made of rigid recyclable material.

All five elements 1 thru 5 can be used in various thicknesses, sizes, gages, lengths, densities, and may be modified to fit different types of constructions heights, spans, widths, cross-sectional shapes and other structural and engineering requirements. Element 2 and 5 as showed in FIGS. 1 and 2 are interchangeable and may vary in use depending on project specifications. Another item that is critical to the product assembly that is not shown in FIGS. 1 and 2 is a moisture and fireproof adhesive cementing agent that bonds elements 3 to element 1, 2, and 5.

FIG. 3 represents the element assembly process and sequence of my invention. Item 1 in FIG. 3 is properly sized and saw cutting is determined 7 on the type of supporting members that is to be used. An additional saw cut 8 is made as a future guide to remove safety cap 24 in FIG. 5 and 18 in FIG. 6. The cut out section 9 is then removed from element 1 to prepare for the insertion of the supporting members 2 into the prepared opening. Element 1 and element 3 is then compressed together by an adhesive or cement agent that forms a bond. A properly sized Element 4 which is a metal type anchor is then properly spaced and installed into the invention anchoring the rigid mineral based magnesium oxide board 3, the supporting members 2 and into the rigid expanded polystyrene 1 for embedment and anchoring into the concrete 26 in FIGS. 5, 5a, 5b, 6, 6a, 6b, and 7.

FIG. 4 represents another element assembly process using element 5 in place of element 2 of my invention. Item 1 in FIG. 4 is properly sized and saw cutting is determined 7 on the type of recyclable supporting member that is to be used. An additional saw cut 8 is made as a future guide to remove safety cap 24 in FIGS. 5 and 18 in FIG. 6. The cut out section 13 in FIG. 4 is then removed from element 1 to prepare for the insertion of the recyclable supporting member 5 into the prepared opening. Element 1 and element 3 in FIG. 4 is then compressed together by an adhesive cementing agent that forms a bond. A properly sized Element 4 which is a metal type anchor is then properly spaced and installed into the invention anchoring the mineral based magnesium oxide board 3, the supporting member 5 and into the rigid expanded polystyrene 1 for embedment and anchoring into the concrete 26 in. FIGS. 5, 5a, 5b, 6, 6a, 6b, and 7.

FIG. 5 Element 21 is the finished product that is shipped to the jobsite. The width and length of the product will vary depending on specifications and requirements on each job. The width of the product will usually be 24 inches but, may be as wide as 48 inches with the lengths of the product depending on acceptable engineered concrete spans. The product contains a safety shipping block out 24 that will be removed after unloading or installation in place on the jobsite. The block out will protect the product from shipping damages and any OSHA concerns to safety. Item 25 FIG. 5 shows the connection of the invention to the concrete by four methods. (a) the metal anchor 4, (b) the supporting member T 23, (c) the supporting member lip behind the rigid expanded polystyrene 27, and (d) by bonding of the rigid expanded polystyrene board to the concrete by chemical reaction within the concrete during hydration.

FIG. 5a is showing the use of additional supports within the invention. Element 41 is the finished product that is shipped to the jobsite. The width and length of the product will vary depending on specifications and requirements on each job. The width of the product will usually be 24 inches but, may be as wide as 48 inches with the lengths of the product depending on acceptable engineered concrete spans. The product contains a safety shipping block out 26 that will be removed after unloading or installation in place on the jobsite. The block out will protect the product from shipping damages and any OSHA concerns to safety. Item 25 FIGS. 5, 5a, and 5b shows the connection of the invention to the concrete by four methods. (a) the metal anchor 4, (b) the supporting member T 23, (c) the supporting member lip behind the rigid expanded polystyrene 27, and (d) by bonding of the rigid expanded polystyrene board to the concrete by chemical reaction within the concrete during hydration.

FIG. 5b is showing the use of additional supports built within element 1 which include an interlocking system as shown in FIG. 5b element 29 and shown in FIG. 5b as element 30 female end and 31 male end within the invention. Element 32 is the finished product that is shipped to the jobsite. The width and length of the product will vary depending on specifications and requirements on each job. The width of the product will usually be 24 inches but, may be as wide as 48 inches with the lengths of the product that spans as long as 50 feet depending on acceptable engineered concrete spans. The product contains a safety shipping block out 10 covering a none edged metal supporting member that will be removed after unloading or installation in place on the jobsite. The block out will protect the product from shipping damages and any OSHA concerns to safety. Item 25 FIGS. 5, 5a, and 5b shows the connection of the invention to the concrete in FIGS. 5, 5a, 5b, 6, 6a, 6b, and 7. by four methods. (a) the metal anchor 4, (b) the supporting member T 23, (c) the supporting member lip behind the rigid expanded polystyrene 27, and (d) by bonding of the rigid expanded polystyrene board to the concrete by chemical reaction within the concrete during hydration.

FIG. 6 Element 14 is an alternate finished product that is shipped to the jobsite. The width and length of the product will vary depending on specifications and requirements on each job. The width of the product will usually be 24 inches but, may be as wide as 48 inches with the lengths of the product depending on acceptable engineered concrete spans. The product contains a safety shipping block out 18 that will be removed after unloading or installation in place on the jobsite. The block out will protect the product from shipping damages and any OSHA concerns to safety. Item 19 FIG. 6 shows the connection of the invention to the concrete by a screw anchor 4 to meet code regulations. This screw anchor by design holds the rigid expanded polystyrene 1, mineral based magnesium oxide board 3 and recyclable material support member 5 in place permanently.

FIG. 6a is showing the use of additional supports built within element 3. Element 33 is an alternate finished product that is shipped to the jobsite. The width and length of the product will vary depending on specifications and requirements on each job. The width of the product will usually be 24 inches but, may be as wide as 48 inches with the lengths of the product depending on acceptable engineered concrete spans. The product contains an additional safety shipping block out 35 that will be removed after unloading or installation in place on the jobsite. The block out will protect the product from shipping damages and any OSHA concerns to safety. Item 19 FIGS. 6 and 6a shows the connection of the invention to the concrete by a screw anchor 4 to meet code regulations. This screw anchor by design holds the rigid expanded polystyrene 1, mineral based magnesium oxide board 3 and recyclable material support member 5 in place permanently.

FIG. 6b is showing an interlocking system as shown in FIG. 5b element 29 and shown in FIG. 5b as element 30 and 31 within the invention. Element 36 is the finished product that is shipped to the jobsite. The width and length of the product will vary depending on specifications and requirements on each job. The width of the product will usually be 24 inches but, may be as wide as 48 inches with the lengths of the product depending on acceptable engineered concrete spans. The product contains a safety shipping block out 26 that will be removed after unloading or installation in place on the jobsite. The block out will protect the product from shipping damages and any OSHA concerns to safety. Item 25 FIG. 5, 5a, 5b and item 19 and 34 in FIGS. 6, 6a, and 6b shows the connection of the invention to the concrete in FIGS. 5, 5a, 5b, 6, 6a, 6b, and 7. by three methods. (a) the metal anchor 4, (b) the supporting member T 23, and (c) the supporting member lip behind the rigid expanded polystyrene 27 in FIGS. 5 and 5a.

FIG. 7 represents the splicing techniques of our product. Splice plates 37 and 28 will be staggered and cut into the rigid expanded polystyrene 1 prior to adhesive cementing agent being applied to bond the supporting member 2 or 5 and mineral based magnesium oxide board to the rigid expanded polystyrene 1. The supporting member 2 which is not shown within this FIG. 7 may require no splicing together because the support member may be made to specified lengths without any splicing.

FIG. 8 thru 12 represents different installation examples that simplifies and clarifies the process and use of my invention. All connections, shoring and concrete reinforcement details have been removed in order to show clarification. This product and assembly is not restricted to any specific type of construction and may be used in residential building, multifamily building and commercial construction. FIG. 8 shows the product and assembly on the exterior 40 of the building and on the bottom of the second floor 39 and on the ceiling 39 of the second story. FIG. 9 shows the product and assembly on the exterior 40 and the ceiling 39 of a single story building. FIG. 10 shows the product and assembly on the interior 40 of the building and the second floor 39 and ceiling of a 2 story building. FIG. 11 shows the product and assembly on the interior 40 and on the ceiling 39 of a one story building. FIG. 12 shows the product and assembly on the second floor 39 and the ceiling 39 of a two story building. FIG. 13 shows two assembled panel examples.

While my invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of my invention without departing from its scope. Therefore, it is intended that my invention not be limited to the particular embodiment disclosed, but that my invention will include all embodiments falling within the scope of the appended claims and their legal equivalents.

Claims

1. A method comprising:

(a) includes a plurality of contiguous sheets of rigid materials of predetermined size, weight, and density,

(b) includes a plurality of elongated supporting members having a predetermined size, weight, density, strength, and cross-sectional shape,

(c) includes a plurality of mechanical anchors of predetermined size,

(d) includes an adhesive bonding agent of predetermined composition and properties,

(e) includes a first means for attaching said sheets of rigid materials to each other,

(f) includes a second means for attaching said elongated supporting members to said plurality of sheets,

(g) includes a third means by providing support of said sheets and said elongated supporting members to other materials having a predetermined size, weight, density, strength, and composition,

(h) includes a forth means for installing mechanical anchors of predetermined size, whereby this assembly not only replaces removable forming materials and other building materials but, remains in place to make building structures safer, storm resistant and more energy efficient.

2. The method of claim 1 wherein the contiguous sheets of rigid materials are made up of mineral based magnesium oxide board with fibrous reinforcement, and expanded polystyrene,

3. The method of claim 1 wherein the contiguous sheets of materials enhances the integrity of my invention in regards to adding support and strength to the invention and a reduction in damages do to severe weather conditions including hurricanes and tornadoes,

4. The method of claim 1, further including an adhesive cementing agent to bond the contiguous sheets of materials together,

5. The method of claim 1, further including mechanical metal anchors that connect rigid materials and elongated supporting members to other materials,

6. The method of claim 5 wherein other materials are rigid materials,

7. The method of claim 6 wherein rigid materials is concrete,

8. The method of claim 1 wherein elongated supporting members are made of metal,

9. The method of claim 8 wherein the metal is coated with a noncorrosive coating,

10. The method of claim 1 wherein a portion of elongated supporting members are encased into liquid concrete prior to hardening forming an embedment into the finished composite system,

11. A method comprising:

(a) includes a plurality of contiguous different types of rigid materials of predetermined dimension, thickness, mass, density, and structure composition,

(b) includes a plurality of extended supporting members having a predetermined size, weight, gage, strength, and cross-sectional shape,

(c) includes a plurality of mechanical anchors of predetermined size,

(d) includes a adhesive bonding agent of predetermined composition and properties,

(e) includes a first means for attaching said different types of rigid materials to each other,

(f) includes a second means for attaching said extended supporting members to said plurality of contiguous different types of rigid materials,

(g) includes a third means by providing support of said rigid materials and said extended supporting members to other materials having a predetermined dimension, liquidity, mass, concreteness, strength, and structure,

(h) includes a forth means for installing mechanical anchors of predetermined size, whereby this assembly not only reduces installation cost significantly and adds substantial labor savings versus other types of systems but, remains in place to make building structures safer, energy efficient, more sustainable, and storm resistant.

12. The method of claim 11 wherein the contiguous different types of rigid materials are made up of mineral based magnesium oxide board, fibrous reinforcement for strength, and rigid expanded polystyrene,

13. The method of claim 11 wherein the contiguous types of rigid materials enhances the integrity of my invention in regards to being insect, mold or fungus resistant, water and high-impact resistant therefore reducing damages done by severe weather conditions including hurricanes and tornadoes,

14. The method of claim 11, wherein the adhesive cement sandwiched between the different types of rigid materials bonding them together,

15. The method of claim 11 wherein elongated supporting members are made of rigid recyclable materials,

16. The method of claim 15 wherein the recyclable materials is treated with a noncorrosive coating,

17. The method of claim 11, further including mechanical metal anchors that connect rigid materials and extended supporting members to other materials,

18. The method of claim 17 wherein other materials is rigid materials,

19. The method of claim 18 wherein rigid materials is concrete,

20. The method of claim 11 wherein a portion of mechanical metal anchors are encased into liquid concrete prior to hardening forming an embedment into the finished composite system.