CEMENTITIOUS COMPOSITE SHELTER

- Cortex Composites, Inc.

A kit for a structure includes a plurality of frame elements that facilitate constructing a frame structure of the structure and a plurality of cementitious composite mats. The plurality of frame elements and the plurality of cementitious composite mats are assemblable to provide the structure. In response to the plurality of cementitious composite mats being hydrated in-situ, the plurality of cementitious composite mats cure to provide cement panels for the structure.

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Description
CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application claims the benefit of and priority to U.S. Provisional Patent Application No. 62/726,627, filed Sep. 4, 2018, which is incorporated herein by reference in its entirety.

BACKGROUND

Long term housing solutions for refugee, disaster, and other low cost housing situations are often poorly constructed, include cheap materials, and can take an extended period of time to construct.

SUMMARY

One embodiment relates to a kit for a structure. The kit includes a plurality of frame elements that facilitate constructing a frame structure of the structure and a plurality of cementitious composite mats. The plurality of frame elements and the plurality of cementitious composite mats are assemblable to provide the structure. In response to the plurality of cementitious composite mats being hydrated in-situ, the plurality of cementitious composite mats cure to provide cement panels for the structure.

Another embodiment relates to a cementitious composite panel for a structure. The cementitious composite panel includes a frame and a cementitious composite mat coupled to the frame. The cementitious composite mat includes an inner layer disposed along the frame, an outer layer that is permeable to water, and a cementitious mixture disposed between the inner layer and the outer layer. The frame is configured to connect to adjacent frames of adjacent panels of the structure. In response to the cementitious composite mat being hydrated in-situ, the cementitious mixture cures to provide a cement panel for the structure.

Still another embodiment relates to a structure. The structure includes a plurality of cementitious composite panels coupled together. Each of the plurality of cementitious composite panels include a sub-frame assembly interconnected with sub-frame assemblies of adjacent cementitious composite panels to provide a frame structure of the structure; an inner, non-permeable layer disposed along the sub-frame assembly; an outer, water-permeable layer; and a cementitious mixture disposed between the inner, non-permeable layer and the outer, water-permeable layer. In response to the plurality of cementitious composite panels being hydrated in-situ, the cementitious mixture cures to provide cement panels of the structure.

This summary is illustrative only and is not intended to be in any way limiting. Other aspects, inventive features, and advantages of the devices or processes described herein will become apparent in the detailed description set forth herein, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a cementitious composite, according to an exemplary embodiment.

FIG. 2 is a perspective view of a rolled cementitious composite, according to an exemplary embodiment.

FIGS. 3-7 are various views of a cementitious composite shelter, according to an exemplary embodiment.

FIGS. 8-18 are various detailed views of a cementitious composite shelter, according to an exemplary embodiment.

FIGS. 19 and 20 are various views of a cementitious composite shelter having overlapping panels, according to an exemplary embodiment.

FIGS. 21-24 are various views of a panel for a cementitious composite shelter, according to an exemplary embodiment.

FIGS. 25A and 25B are various views of support members for the panel of FIGS. 21-24, according to an exemplary embodiment.

FIGS. 26-29 are various views of assembling a cementitious composite shelter using a prefabricated panel kit, according to an exemplary embodiment.

FIGS. 30-36 are various views of assembling a cementitious composite shelter using a prefabricated panel kit, according to another exemplary embodiment.

FIGS. 37 and 38 are various views of assembling a cementitious composite shelter using a completely deconstructed kit, according to an exemplary embodiment.

FIG. 39 is a perspective view of a cementitious composite and a frame of a panel having a coupling assembly, according to an exemplary embodiment.

FIGS. 40-44 are various views of a cementitious composite and a frame of a panel having a coupling assembly, according to another exemplary embodiment.

FIGS. 45-63 are various alternative ways of assembling a cementitious composite shelter, according to an exemplary embodiment.

FIG. 64 is a cross-sectional view of a cementitious composite shelter having a rain water collection basin, according to an exemplary embodiment.

FIG. 65 is a front view of a cementitious composite building, according to an exemplary embodiment.

FIG. 66 is a perspective exploded view of a panel for a cementitious composite building, according to an exemplary embodiment.

FIG. 67 is a perspective exploded view of a panel for a cementitious composite building, according to another exemplary embodiment.

FIG. 68 is a detailed view of an interface between conduits of adjacent panels, according to an exemplary embodiment.

FIGS. 69-71 are various views of a panel for a cementitious composite building having electronic components embedded therein, according to various exemplary embodiments.

 DETAILED DESCRIPTION

Before turning to the figures, which illustrate certain exemplary embodiments in detail, it should be understood that the present disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting.

Cementitious Composite Mat

Cementitious composite mats may include a dry cementitious mixture embedded in, and/or contained by, a structure layer. The structure layer may be positioned between an impermeable layer and a permeable layer. The cementitious mixture undergoes its normal setting and strength gain process after in-situ hydration to produce a rigid composite. The permeable layer may hold water (e.g., for a controlled period of time, etc.) for improved curing of the cementitious composite mat (e.g., facilitating the release of water into the cementitious mixture over a period of time, etc.). Unlike traditional concrete, cementitious composite mats do not require the cementitious portion to be mixed (e.g., in a standalone mixer, in a cement mixer truck, etc.). The cementitious mixture of the present application does not wash from the cementitious composite mat as easily (e.g., not at all, etc.) as traditional, non-formulated cementitious mixtures and remains secured within the cementitious composite mat such that it hardens in place without needing to be mixed. The cementitious mixture is disposed between the permeable and impermeable layers and may include accelerators, retarders, latex modifiers, curing modifiers, other modifiers, fibers, glass additives, metal additives, stone additives, organic additives, water reducing admixtures, shrinkage reducing admixtures, viscosity modifiers, absorbent materials (e.g., superabsorbent materials, superabsorbent polymers, superabsorbent clays, etc.), interconnection particles (e.g., beads, pellets, strands, etc.; made of a resin, a polymer, elastomeric polymer, PVC, polypropylene, polyethylene, a metal or metal alloy having a low melting point, etc.), adhesives, and/or other gel forming additives so the cementitious mixture remains stationary when hydrated. A cementitious mixture that remains stationary facilitates using a top layer (e.g., permeable layer, etc.) that dissolves upon hydration and/or that has apertures.

The structure layer of the cementitious composite mat may be formed into, or include an independent, free-standing material. The structure layer may improve load bearing capabilities of the cementitious composite mat by distributing the energy of a load across the structure layer. The structure layer may also bridge crack faces in the cementitious phase to provide improved crack resistance and/or localize cracking to reduce crack propagation. The structure layer may be coupled to at least one of the permeable layer and the impermeable layer with an adhesive, a heat treatment process, and/or mechanically (e.g., barbs, fibers, etc.). In some embodiments, the structure layer is at least partially manufactured from an adhesive material. In some embodiments, the cementitious composite does not include the structure layer, but rather the adhesive layer functions as a structural layer. Cementitious composite mats having the structure layer may provide improved structural performance per unit of volume, have a lower cost, reduce labor costs, require less processing than other concrete or concrete composite, reduce the possibility of variation in specification compared to poured concrete, and/or eliminate the disadvantages of traditional wet mixing (e.g., range constraints for delivery with a concrete mixer vehicle, etc.), among having other advantages. In addition to holding the cementitious composite mat together and/or retaining the cementitious mixture (e.g., pre-hydration, etc.), the structure layer may structurally reinforce the cementitious layer and/or cementitious composite mat post-hydration. In some embodiments, the cementitious composite mat does not include the structure layer. In some embodiments, the cementitious composite mat includes a securing layer (e.g., formed through the cementitious composite mat using a quilting process, a needle punching process, etc.).

According to the exemplary embodiment shown in FIG. 1, a composite mat, shown as cementitious composite mat 10, includes a plurality of layers. As shown in FIG. 1, such layers include a containment layer, shown as permeable layer 20; a cementitious layer, shown as cementitious mixture 30; a three-dimensional volume layer (e.g., a securing layer, a bunching layer, a mesh layer, a grid layer, a nonwoven layer, a not woven layer, a nonfibrous layer, a fiberless layer, pins and/or connectors, interconnecting particle layer, a coiled layer, a tube layer, a 3D knitted and/or woven layer, a needle punched layer, a quilted layer, a plastic layer, a metal layer, a layer configured for integration with one or more snap-fit connections, etc.), shown as structure layer 40; an impermeable (e.g., sealing, etc.) layer, shown as impermeable layer 50; and one or more adhesive layers, shown as adhesive layer 60. According to an exemplary embodiment, permeable layer 20, cementitious mixture 30, structure layer 40, impermeable layer 50, and/or adhesive layer 60 are disposed adjacent to one another and assembled into a sheet to form cementitious composite mat 10. As shown in FIG. 1, structure layer 40 may be disposed between (e.g., sandwiched between, etc.) permeable layer 20, impermeable layer 50, and adhesive layer 60. In some embodiments, the cementitious composite mat 10 does not include structure layer 40. In such embodiments, adhesive layer 60 may function as a structure layer and/or cementitious composite mat 10 may include a securing layer formed via a needle punching or quilting process. According to an exemplary embodiment, cementitious composite mat 10 has a thickness of between five millimeters and one hundred millimeters pre-hydration. The thickness of cementitious composite mat 10 may exceed the pre-hydration thickness after hydration when, by way of example, additives are included in cementitious mixture 30 (e.g., expansive cement, etc.). It should be understood that reference to a structure layer, an adhesive layer, a securing layer, and/or a cementitious mixture may include any structure layer, adhesive layer, securing layer, and/or cementitious mixture disclosed herein or incorporated herein by reference.

According to an exemplary embodiment, cementitious composite mat 10 includes layers that are coupled together (e.g., adhesively coupled, sewn, using pins, using staples, using snap-fit connections, etc.). Such coupling may reduce the relative movement between the layers pre-hydration (e.g., during the manufacturing process, during transportation, during installation, etc.). By way of example, impermeable layer 50 may be coupled (e.g., selectively joined, etc.) with structure layer 40 and/or cementitious mixture 30 with or without adhesive layer 60. By way of another example, permeable layer 20 may be coupled (e.g., selectively joined, etc.) with structure layer 40 and/or cementitious mixture 30 with or without adhesive layer 60. By way of another example, impermeable layer 50 may be coupled to permeable layer 20 (e.g., sewn together, pinned together, stapled together, etc.). Such coupling may improve the structural characteristics of cementitious composite mat 10 by facilitating load transfer between permeable layer 20, structure layer 40, adhesive layer 60, and/or impermeable layer 50. Adhesive layer 60 and/or structure layer 40 may serve as a bonding medium. Various structure layers and/or adhesive layers may reduce the risk of delamination.

According to various embodiments, cementitious composite mat 10 includes a different combination of layers. By way of example, cementitious composite mat 10 may include impermeable layer 50, structure layer 40, adhesive layer 60, cementitious mixture 30, permeable layer 20, and/or the securing layer. Such a composite may utilize the structure layer 40, the adhesive layer 60, and/or the securing layer to hold cementitious mixture 30, may include a removable layer to retain cementitious mixture 30 during transport and in the application of cementitious composite mat 10, and/or may include another system designed to retain cementitious mixture 30. According to various alternative embodiments, cementitious composite mat 10 includes permeable layer 20 and impermeable layer 50, only impermeable layer 50, only permeable layer 20, or neither permeable layer 20 nor impermeable layer 50. By way of example, cementitious composite mat 10 may include impermeable layer 50, structure layer 40, adhesive layer 60, cementitious mixture 30, and permeable layer 20. By way of another example, cementitious composite mat 10 may include impermeable layer 50, structure layer 40, adhesive layer 60, and cementitious mixture 30. By way of yet another example, cementitious composite mat 10 may include impermeable layer 50, adhesive layer 60, cementitious mixture 30, and permeable layer 20. Further, impermeable layer 50 may have one or more surface imperfections and/or a roughness (e.g., fibers, members, barbs, etc.) that are configured to facilitate holding cementitious mixture 30 prior to and/or after hydration, attach to the hardened concrete, and/or be embedded within the hardened concrete. Further details regarding the impermeable layer 50, structure layer 40, adhesive layer 60, cementitious mixture 30, permeable layer 20, and/or the securing layer may be found in (i) U.S. Pat. No. 9,187,902, (ii) U.S. patent application Ser. No. 15/767,191, and (iii) International Patent Application No. PCT/US2018/027984, all of which are incorporated herein by reference in their entireties.

Referring next to the exemplary embodiment shown in FIG. 2, cementitious composite mat 10 may be arranged into a flexible sheet. As shown in FIG. 2, permeable layer 20, structure layer 40, and impermeable layer 50 are each flexible and disposed adjacent to one another. According to an exemplary embodiment, such a combination of flexible layers facilitates rolling cementitious composite mat 10 to facilitate transportation and reduce the amount of cementitious mixture 30 that migrates through permeable layer 20. According to an alternative embodiment, cementitious composite mat 10 may be arranged in another configuration (e.g., various sheets that may be stacked, a sheet having a pre-formed shape, etc.).

Hydration of cementitious composite mat 10 may be initiated in-situ (e.g., in place, on a job site, etc.). The cementitious composite mat 10 may be transported to a location as a flexible composite material in a pre-packaged configuration (e.g., sheets, rolls, panels, etc.) and hydrated on-location. Cementitious composite mat 10 may provide commercial, water conservation, and operational benefits. By way of example, cementitious composite mat 10 may be used in the construction of a structure (e.g., a shed, a storage building or unit, a refugee shelter, a disaster shelter, a temporary living residence, a permanent living residence, a dwelling, a cabin, a shack, a cottage, a hut, etc.). Upon in-situ hydration, cementitious mixture 30 is configured to set and harden to form a durable, heavy-duty, long-term, self-built, low cost, just-add-water housing solution.

Cementitious Composite Shelter

According to the exemplary embodiment shown in FIGS. 3-20, cementitious composite mats 10 are configured to enable the assembly and construction of a temporary or more-permanent structure, shown a cementitious composite shelter 100. According to an exemplary embodiment, the materials for cementitious composite shelter 100 (e.g., frame members, doors, windows, solar panels, insulation, waterproof lining, cementitious composite mats 10, bathroom components, kitchen components, etc.) can be provided (e.g., shipped, etc.) as a kit (e.g., as a completely deconstructed kit, as a prefabricated panel kit, etc.) to a desired location (e.g., a refugee camp, a disaster camp, a homeowner's yard, etc.). The kit may then be assembled by the purchaser at the desired location to form the structure of cementitious composite shelter 100. Thereafter, cementitious composite shelter 100 may be hydrated in-situ (e.g., using a stored water source, through rainfall, etc.) to form a durable, heavy-duty, long-lasting shelter.

As shown in FIGS. 8-18, cementitious composite shelter 100 includes a base, shown floor 102; a first longitudinal wall, shown as first sidewall 110; a second longitudinal wall, shown as second sidewall 120, opposite and spaced from first sidewall 110; a first lateral wall, shown as first end wall 130, extending between first sidewall 110 and second sidewall 120; a second lateral wall, shown as interior wall 140, opposite and spaced from first end wall 130 and extending between first sidewall 110 and second sidewall 120; a third lateral wall, shown as second end wall 150, spaced from interior wall 140 and extending between first sidewall 110 and second sidewall 120; a divider, shown as dividing wall 152, extending between interior wall 140 and second end wall 150; and a roof, shown as roof 160, at least partially enclosing an interior space of cementitious composite shelter 100. Floor 102 may be or include a lining, a tarp, a platform (e.g., made of cementitious composite mats 10, a traditional concrete slab, a wood platform, a metal platform, etc.), and/or still another type of suitable base.

As shown in FIGS. 9 and 15-18, first sidewall 110, second sidewall 120, first end wall 130, and interior wall 140 define a main space, shown as living space 170, of cementitious composite shelter 100. As shown in FIGS. 8-11,15, and 16, first sidewall 110, second sidewall 120, interior wall 140, and second end wall 150 define a secondary space, shown as utility space 172. As shown in FIGS. 9-11 and 16, dividing wall 152 separates (e.g., divides, etc.) utility space 172 into a first secondary space, shown as kitchen space 180, and a second secondary space, shown as restroom space 190. According to an exemplary embodiment, living space 170 is completely enclosed from an external environment, while utility space 172 is at least partially open to the external environment. In some embodiments, cementitious composite shelter 100 does not include interior wall 140 and/or utility space 172. In some embodiments, cementitious composite shelter 100 includes additional walls, fewer walls, and/or has a different floor plan (e.g., additional rooms, fewer rooms, a different shape, multiple floors, etc.).

As shown in FIGS. 8-18, first sidewall 110, second sidewall 120, first end wall 130, interior wall 140, second end wall 150, dividing wall 152, and roof 160 are constructed from a plurality of panels, shown as cementitious composite panels 200. Specifically, first sidewall 110 and second sidewall 120 are constructed of a first plurality of panels of cementitious composite panels 200, shown as side panels 250; first end wall 130, interior wall 140, and second end wall 150 are constructed from a second plurality of panels of cementitious composite panels 200, shown as end panels 252; and roof 160 is constructed from a third plurality of panels of cementitious composite panels 200, shown as roof panels 254. In some embodiments, side panels 250, end panels 252, and/or roof panels 254 have different dimensions (e.g., side panels 250 are longer than end panels 252, etc.). In some embodiments, side panels 250, end panels 252, and/or roof panels 254 have the same dimensions.

As shown in FIGS. 8-12 and 15-18, one or more of side panels 250 and/or end panels 252 include doors (e.g., lockable doors, etc.), shown as doors 210, disposed therein. As shown in FIGS. 8,9,11,12, and 15-18, one or more of side panels 250 include windows (e.g., openable windows, lockable windows, etc.), shown as windows 220, disposed therein. In some embodiments, one or more of end panels 252 and/or roof panels 254 includes windows 220. As shown in FIGS. 8,9,12, and 14, one or more of roof panels 254 includes photovoltaic panels, shown as solar panels 230, disposed thereon. The solar panels 230 may power various electrically powered devices (e.g., lights, a heater, an air conditioner, a refrigerator, a water pump, etc.) within and/or around cementitious composite shelter 100. In some embodiments, cementitious composite shelter 100 includes battery storage to store electricity generated by solar panels 230. In some embodiments, cementitious composite shelter 100 additionally or alternatively includes a solar generator and/or a combustion generator configured to generate electricity to power the various electrically powered devices.

As shown in FIGS. 9-11, 13, 15, 17, and 18, the top ends of end panels 252 are spaced a distance from the roof 160 such that gaps 192 are formed between (i) first end wall 130 and roof 160, (ii) interior wall 140 and roof 160, and (iii) second end wall 150 and roof 160. Cementitious composite shelter 100 include a plurality of windows (e.g., Plexiglas panels, etc.), shown as windows 240, positioned between (i) first end wall 130 and roof 160 and (ii) interior wall 140 and roof 160 to enclose the living space 170 from the external environment. Gap 192 between second end wall 150 and roof 160 may be left open such that utility space 172 is at least partially open to the external environment. In some embodiments, cementitious composite shelter 100 includes a screen, bars, a chain-link fence element, barbed wire, and/or still another semi-open or permeable divider positioned to at least partially block gap 192 between second end wall 150 and roof 160 to prevent or deter animals or persons from climbing over second end wall 150 and entering cementitious composite shelter 100.

In some embodiments, restroom space 190 is fully enclosed. By way of example, the exterior wall of restroom space 190 may extend the roof or has a window. The window could be the same triangle shape that divides living space 170 and utility space 172. There can be two triangle shaped transparent dividers between (i) the restroom space 190, kitchen space 180, and living space 170 and (ii) restroom space 190, kitchen space 180, and the exterior. The exterior window may be able to be opened on both sides (kitchen and bathroom), and/or dividing wall 152 may extend all the way to the roof

In some embodiments, kitchen space 180 is more fully enclosed than restroom space 190 (e.g., kitchen space 180 is fully enclosed from the exterior, etc.). In such embodiment, kitchen space 180 may include a smoke stack that captures internal smoke and vents the smoke to a roof vent that may be positioned over the cooking location (e.g., a stove). In some embodiments, kitchen space 180 includes an electric fan and/or a window on the exterior of kitchen space 180 that assists in removing smoke from kitchen space 180. In some embodiments, dividing wall 152 extends all the way to the roof, completely separating kitchen space 180 from restroom space 190.

As shown in FIGS. 8-18, cementitious composite panels 200 (e.g., side panels 250, end panels 252, roof panels 254, etc.) of cementitious composite shelter 100 are flush with one another (e.g., do not overlap, abut each other, etc.). According to an exemplary embodiment, cementitious composite panels 200 fuse together upon hydration (e.g., cementitious mixture 30 partially expands out the sides of cementitious composite mats 10 to join adjacent mats together, etc.) to effectively seal cementitious composite shelter 100 from the elements (e.g., rain, wind, snow, debris, dust, etc.). In some embodiments, at least some of cementitious composite panels 200 of cementitious composite shelter 100 at least partially overlap. As shown in FIGS. 19 and 20, (i) adjacent edges of adjacent side panels 250 partially overlap each other, (ii) adjacent edges of adjacent roof panels 254 partially overlap each other, and (iii) adjacent edges of adjacent side panels 250 and roof panels 254 partially overlap each other. Such partial overlap between adjacent cementitious composite panels 200 may further seal cementitious composite shelter 100 from the elements. In some embodiments, overlapping ends of adjacent cementitious composite mats 10 form continuous or discrete (e.g., spaced, etc.) interlocking Z-channels.

In some embodiments, the bottoms of side panels 250 and end panels 252 are secured (e.g., fixed to, anchored, etc.) to floor 102 and/or the ground surface. By way of example, the bottoms of side panels 250 and end panels 252 may be anchored in the ground, fastened to floor 102, and/or still otherwise secured. As shown in FIGS. 9-11, the bottoms of side panels 250 have a protrusion (e.g., a portion of cementitious composite mat 10 that extends beyond the length of a frame of a respective panel, etc.), shown curved portions 256, that curve (e.g., ninety degrees relative to first sidewall 110, second sidewall 120, etc.) and extend away from cementitious composite shelter 100. In some embodiments, the curved portions 256 are buried underground to anchor first sidewall 110 and/or second sidewall 120. In other embodiments, curved portions 256 are otherwise anchored or unanchored and remain above ground. In such embodiments, curved portions 256 may direct rain water away from the footprint of cementitious composite shelter 100 (e.g., to prevent water from pooling around the perimeter of cementitious composite shelter 100, etc.). In some embodiments, the bottoms of end panels 252 are curved.

Cementitious Composite Panel

According to the exemplary embodiment shown in FIGS. 21-25B, each of cementitious composite panels 200 (e.g., side panels 250, end panels 252, roof panels 254, etc.) includes cementitious composite mat 10; a support structure, shown as frame 300; an insulation panel, shown as insulation sheet 400; and/or an interior liner, shown as liner 500. In some embodiments, cementitious composite mat 10, frame 300, insulation sheet 400, and/or liner 500 of cementitious composite panels 200 are prefabricated and assembled prior to shipping such that no or limited pre-assembly of the panels is required at the hydration location to form cementitious composite shelter 100 (e.g., cementitious composite mat 10 and frame 300 are pre-assembled prior to shipping; cementitious composite mat 10, frame 300, and insulation sheet 400 are pre-assembled prior to shipping; cementitious composite mat 10, frame 300, insulation sheet 400, and liner 500 are pre-assembled prior to shipping; etc.). In some embodiments, cementitious composite panels 200 are shipped completely deconstructed such that cementitious composite mat 10, frame 300, insulation sheet 400, and liner 500 are received as individual components and must be entirely assembled to form cementitious composite panels 200 and cementitious composite shelter 100.

As shown in FIGS. 21-24, cementitious composite mat 10, frame 300, insulation sheet 400, and liner 500 arranged in a staked configuration to form cementitious composite panel 200 with cementitious composite mat 10 on the exterior of cementitious composite panel 200, frame 300 disposed along an interior side of cementitious composite mat 10 (e.g., along impermeable layer 50, etc.), insulation sheet 400 disposed on a side of frame 300 (e.g., an interior side, etc.) opposite cementitious composite mat 10 (e.g., thereby sandwiching frame 300 between cementitious composite mat 10 and insulation sheet 400, etc.), and liner 500 disposed on a side of insulation sheet 400 (e.g., an interior side, etc.) opposite frame 300 (e.g., thereby sandwiching insulation sheet 400 between frame 300 and liner 500, etc.). In other embodiments, insulation sheet 400 is disposed within the gaps between frame members of frame 300. In still other embodiments, insulation sheet 400 defines various channels that receive the frame members of frame 300 such that frame 300 is at least partially recessed within insulation sheet 400.

As shown in FIG. 23, frame 300 includes a first plurality of frame members (e.g., rails, tubes, etc.), shown as longitudinal frame tubes 310, that extend along the longitudinal length of cementitious composite panels 200 and a second plurality of frame members (e.g., rails, tubes, etc.), shown as lateral frame tubes 320, that extend laterally across cementitious composite panels 200. According to an exemplary embodiment, longitudinal frame tubes 310 and lateral frame tubes 320 are manufactured from a metallic material (e.g., aluminum, galvanized steel, etc.).

According to an exemplary embodiment, longitudinal frame tubes 310 and lateral frame tubes 320 are locked together to form an architectural support structure (e.g., frame 300, etc.) of cementitious composite shelter 100. In some embodiments, longitudinal frame tubes 310 and/or lateral frame tubes 320 couple together with snap-fit connections. In some embodiments, longitudinal frame tubes 310 and/or lateral frame tubes 320 couple together with fasteners (e.g., rivets, screws, bolts, pins, etc.). In some embodiments, longitudinal frame tubes 310 and/or lateral frame tubes 320 couple together with snap-fit connections and are also, optionally, further securable using fasteners. In some embodiments, longitudinal frame tubes 310 and/or lateral frame tubes 320 couple together by interfacing corresponding parts and then rotating the members relative to one another to snap into place and secure the two components together (e.g., a rotational snap-fit, rotate into a pre-defined position at a predefined angle, etc.). In some embodiments, longitudinal frame tubes 310 and/or lateral frame tubes 320 couple together using an interference fit. It should be understood that any combination of the above coupling mechanisms may be used and/or other suitable coupling mechanisms may be employed.

As shown in FIGS. 23, 25A, and 25B, each of longitudinal frame tubes 310 has a first end, shown as first end 312, and an opposing second end, shown as second end 314. According to an exemplary embodiment, (i) first ends 312 of longitudinal frame tubes 310 of side panels 250 of first sidewall 110 are configured to interface with first ends 312 of longitudinal frame tubes 310 of roof panels 254 to couple first sidewall 110 to roof 160 and (ii) first ends 312 of longitudinal frame tubes 310 of side panels 250 of second sidewall 120 are configured to interface with second ends 314 of longitudinal frame tubes 310 of roof panels 254 to couple second sidewall 120 to roof 160. As shown in FIGS. 23, each of lateral frame tubes 320 has a first end, shown as first end 322, and an opposing second end, shown as second end 324. According to an exemplary embodiment, (i) first ends 322 of lateral frame tubes 320 of side panels 250 are configured to interface with second ends 324 of lateral frame tubes 320 of adjacent side panels 250 to form first sidewall 110 and second sidewall 120, (ii) first ends 322 of lateral frame tubes 320 of end panels 252 are configured to interface with second ends 324 of lateral frame tubes 320 of adjacent end panels 252 to form first end wall 130, interior wall 140, and second end wall 150, and (iii) first ends 322 of lateral frame tubes 320 of roof panels 254 are configured to interface with second ends 324 of lateral frame tubes 320 of adjacent roof panels 254 to form roof 160.

As shown in FIGS. 23, 25A, and 25B, at least a portion of longitudinal frame tubes 310 define a plurality of cutouts, shown as notches 316. As shown in FIGS. 23 and 25B, notches 316 facilitate bending longitudinal frame tubes 310 to a predetermined angle to create a bent portion, shown as bend 318, at a predetermined location along the length of longitudinal frame tubes 310. According to an exemplary embodiment, notches 316 facilitate manually bending longitudinal frame tubes 310 by hand (e.g., without the use of tools, a hydraulic press, etc.). As shown in FIGS. 25B, a support plate, shown as curved plate 330, is optionally couplable to longitudinal frame tubes 310 proximate notches 316 using fasteners after longitudinal frame tubes 310 has been bent to maintain bend 318 within longitudinal frame tubes 310. In an alternative embodiment, longitudinal frame tubes 310 are pre-bent during manufacturing. In some embodiments, at least some of lateral frame tubes 320 include notches 316 to facilitate forming bends 318 and/or at least some of lateral frame tubes 320 are pre-bent during manufacturing (e.g., to provide curved sidewalls, curved end walls, etc.). In some embodiments, longitudinal frame tubes 310 and/or lateral frame tubes 320 are not pre-bent or manually bendable, rather longitudinal frame tubes 310 and/or lateral frame tubes 320 couple together in a straight configuration (e.g., straight side panels and straight roof panels coupled together at an angle, etc.).

As shown in FIG. 24, insulation sheet 400 includes an insulating medium, shown as insulation 420, and a covering, shown as insulation cover 410, that surrounds insulation 420. According to an exemplary embodiment, insulation cover 410 is manufactured from a waterproof fabric material that is easy to wash and maintain. According to an exemplary embodiment, the insulation 420 facilitates weatherproofing cementitious composite shelter 100. By way of example, insulation 420 may self-regulate the temperature within living space 170 of cementitious composite shelter 100 in hot and/or cold weather climates. In one embodiment, insulation sheet 400 is shipped pre-assembled with frame 300. In another embodiment, insulation sheet 400 is separate from frame 300 and is selectively couplable to frame 300 at the hydration site.

In some embodiments, liner 500 is shipped pre-assembled with insulation sheet 400. In another embodiment, liner 500 is separate from insulation sheet 400 and is selectively couplable to insulation sheet 400 at the hydration site. In one embodiment, liner 500 is a fabric sheet that couples to the interior side of insulation sheets 400. Liner 500 may cover seams between adjacent insulation sheets 400 and/or have a decorative finish (e.g., a color, a pattern, etc.). In some embodiments, liner 500 is a second, interior cementitious composite mat layer. In some embodiments, liner 500 is a drywall sheet. In some embodiments, liner 500 includes a second, interior cementitious composite mat layer and a drywall layer disposed thereon.

In some embodiments, cementitious composite panel 200 includes securing elements that extend at least partially through the thickness of cementitious composite panel 200 and secure two or more layers thereof together. By way of example, the securing elements may extend between and secure cementitious composite mat, insulation sheet 400, and/or liner 500 together in the stacked arrangement. The securing elements may be positioned at various frequencies (e.g., one every foot, one every six inches, etc.).

Prefabricated Panel Cementitious Composite Shelter Kit

According to the exemplary embodiment shown in FIGS. 26-29, cementitious composite shelter 100 is shipped as a partially prefabricated or assembled kit, shown as prefabricated panel kit 600. As shown in FIG. 26, prefabricated panel kit 600 includes side panels 250, side panels 250 including pre-installed doors 210, side panels 250 including pre-installed windows 220, end panels 252, roof panels 254, a base member, shown as base longitudinal ground anchor 260, a first module, shown as end module 270, and insulation sheets 400. In some embodiments, doors 210 and/or windows 220 are separate and require installation. In such embodiments, side panels 250 may be pre-cut to receive doors 210 and/or windows 220, or may require someone to cut out a portion of side panels 250 for installation of doors 210 and/or windows 220. In some embodiments, insulation sheets 400 are pre-assembled with side panels 250, end panels 252, and/or roof panels 254. In some embodiments, insulation sheets 400 are not pre-assembled with side panels 250, end panels 252, and/or roof panels 254.

As shown in FIGS. 26, 28, and 29, end module 270 includes various support members, shown as base lateral ground anchors 272, first vertical supports 274, upper lateral supports 276, second vertical supports 278, windows 240, and end panels 252. By way of example, base lateral ground anchors 272 may be secured to a ground surface (e.g., floor 102, the ground, etc.) with first vertical supports 274 extending therefrom with upper lateral support 276 coupled to the opposing ends thereof. Second vertical supports 278 may extend from upper lateral support 276. End panels 252 may be inserted between base lateral ground anchor 272, second vertical supports 278, and upper lateral support 276. Windows 240 may be inserted between upper lateral support 276 and second vertical supports 278. The assembly may be inserted between a pair of side panels 250 connected together by a roof panel 254.

As shown in FIG. 27, side panels 250 and roof panels 254 are bendable from a flat, shipping configuration to a bent, installation configuration on-site (e.g., facilitated by notches 316, etc.). In some embodiments, side panels 250 and/or roof panels 254 are not bendable (e.g., engage at a right angle, a flat roof, etc.). As shown in FIGS. 28 and 29, the various side panels 250 and roof panels 254 are selectively assemblable into a second module, shown as standard module 280, a third module, shown as door module 282, and a fourth module, shown as window module 284. As shown in FIG. 28, standard module 280 includes two side panels 250 coupled together by a roof panel 254, door module 282 includes two side panels 250 coupled together by a roof panel 254 with at least one of the two side panels 250 having a door 210, and window module 284 includes two side panels 250 coupled together by a roof panel 254 with at least one of the two side panels 250 having a window 220. In some embodiments, other arrangements are possible.

As shown in FIG. 29, one or more end modules 270, standard modules 280, door modules 282, and/or window modules 284 are couplable to base longitudinal ground anchor 260 and each other (e.g., in any particular order desired, etc.). Thereafter, insulation sheets 400 and/or liner 500 may be installed (if not already coupled to cementitious composite panels 200 at the time of shipping) and/or cementitious composite shelter 100 may be hydrated such that cementitious composite mats 10 set and harden.

In some embodiments, two or more adjacent cementitious composite panels 200 are secured together using reinforcement panels than span across the two or more (e.g., two, three, four, five, etc.) cementitious composite panels 200 (e.g., reinforcement panels coupled across adjacent insulation sheets 400, adjacent cementitious composite mats 10, adjacent liners 500, etc.). In some embodiments, two or more adjacent cementitious composite panels 200 are laminated together using adhesive. In some embodiments, two or more (e.g., two, three, four, five, etc.) adjacent cementitious composite panels 200 are secured together using reinforcement rods than span across the two or more cementitious composite panels 200 (e.g., reinforcement rods coupled across adjacent insulation sheets 400, adjacent cementitious composite mats 10, adjacent liners 500, etc.). In some embodiments, cementitious composite panels 200 define channels that receive the reinforcement rods where the channels of adjacent cementitious composite panels 200 align. The channels may be defined by cementitious composite mats 10, insulation sheets 400, and/or liner 500. The reinforcement tubes may include staple tubes manufactured by Cutworks, metal rods, composite rods, word rods, and/or rods, tubes, bars, boards, etc. manufactured from various suitable materials. The reinforcement panels and/or the reinforcement tubes may be mechanically and/or adhesively secured to adjacent panels.

According to the exemplary embodiment shown in FIGS. 30-36, prefabricated panel kit 600 includes rolled cementitious composite panels 200, rather than flat cementitious composite panels 200. As shown in FIGS. 30 and 31, cementitious composite panels 200 are shipped in a rolled configuration with longitudinal frame tubes 310 coupled to cementitious composite mats 10. As shown in FIG. 32, rolled cementitious composite panels 200 are unrollable at the hydration location into a flat configuration. According to the exemplary embodiment shown in FIG. 32, a portion of each of the ends of cementitious composite mats 10 are free and not secured to longitudinal frame tubes 310. As shown in FIGS. 33-36, cementitious composite panels 200 are bendable (e.g., because of notches 316 within longitudinal frame tubes 310, etc.) to form side panels 250 and roof panels 254. As shown in FIGS. 34-36, longitudinal frame tubes 310 of the unrolled side panels 250 and roof panels 254 can be interlocked and the free end of side panels 250 tucked underneath the fee end of roof panels 254. The other free end of the unrolled side panels 250 may form curved portion 256.

Deconstructed Cementitious Composite Shelter Kit

According to the exemplary embodiment shown in FIGS. 37 and 38, cementitious composite shelter 100 is shipped as a completely deconstructed kit, shown as deconstructed kit 700. In such an embodiment, as shown in FIG. 37, frame 300 may be completely constructed first by connecting base longitudinal ground anchors 260, base lateral ground anchors 272, first vertical supports 274, upper lateral supports 276, second vertical supports 278, longitudinal frame tubes 310, and lateral frame tubes 320 together and bent as needed to construct the base support structure for cementitious composite shelter 100. Thereafter, as shown in FIG. 38, the various cementitious composite panels 200 (e.g., cementitious composite mats 10, side panels 250, end panels 252, roof panels 254, etc.) and windows 240 are coupled to frame 300. Doors 210 and windows 220 may be pre-installed or require installation prior to or after cementitious composite mats 10 are coupled to frame 300. Thereafter, insulation sheets 400 and/or liner 500 may be installed and/or cementitious composite shelter 100 may be hydrated such that cementitious composite mats 10 set and harden.

Coupling System

As shown in FIG. 39, cementitious composite panel 200 includes a coupling system, shown as coupling system 800. Coupling system 800 includes a first coupling assembly, shown as mat coupling assembly 820, and a second coupling assembly, shown as frame coupling assembly 840. Mat coupling assembly 820 includes a first coupler, shown as center coupler 822, a second coupler, shown as right coupler 824, and a third coupler, shown as left coupler 826, coupled to a rear side of cementitious composite mat 10 (e.g., to impermeable layer 50, etc.). In some embodiments, mat coupling assembly 820 includes more or fewer couplers. In one embodiment, center coupler 822, right coupler 824, and left coupler 826 are the same type of coupler. In another embodiment, center coupler 822, right coupler 824, and/or left coupler 826 are different types of couplers. Further, mat coupling assembly 820 may include additional coupler sets spaced along the longitudinal length of cementitious composite mat 10. The additional coupler sets may include the same type of couplers or a different type of couplers (e.g., hooks at the top end and magnets/Velcro at the middle and/or bottom end, etc.).

As shown in FIG. 39, frame coupling assembly 840 includes a first coupler, shown as center coupler 842, a second coupler, shown as right coupler 844, and a third coupler, shown as left coupler 846, coupled to an exterior side of one of lateral frame tubes 320 of a respective cementitious composite panel 200. In some embodiments, frame coupling assembly 840 includes more or fewer couplers (e.g., to correspond with the number of couplers of mat coupling assembly 820, etc.). According to an exemplary embodiment, center coupler 842, right coupler 844, and left coupler 846 are positioned and configured to correspond with its associated coupler of mat coupling assembly 820 to facilitate releasably coupling cementitious composite mat 10 to frame 300. Further, frame coupling assembly 840 may include additional coupler sets spaced along the longitudinal length of frame 300 (e.g., along longitudinal frame tubes 310, along different lateral frame tubes 320, etc.). The additional coupler sets may include the same type of couplers or a different type of couplers.

According to various embodiments, center coupler 822, right coupler 824, left coupler 826, center coupler 842, right coupler 844, and left coupler 846 are or include hook and loop fasteners (e.g., Velcro, etc.), magnets, hooks, snap-fit connections, protrusions and corresponding notches or apertures, cables (e.g., for tying together, etc.), and/or other releasable coupling mechanisms. In an alternative embodiment, cementitious composite mats 10 are fixedly coupled to frame 300 using adhesive. Insulation sheets 400 may be coupled to the interior of frame 300 using similar coupling mechanisms as described herein with regard to cementitious composite mats 10 and frame 300.

According to the exemplary embodiment shown in FIGS. 40-44, lateral frame tubes 320 define a first cutout, shown as center cutout 342, a second cutout, shown as right cutout 344, and a third cutout, shown as left cutout 346. As shown in FIGS. 41-44, center cutout 342, right cutout 344, and left cutout 346 are positioned to receive center coupler 822, right coupler 824, and left coupler 826, respectively, to couple cementitious composite mat 10 to frame 300.

Alternative Embodiments

In some embodiments, the shelter kits disclosed herein additionally include solar panels, electric cooking surfaces/appliances, a waterless toilet, a water purification system, a water storage system, a gravity shower, lighting, electrical wiring, batteries (e.g., for storing energy generated by the solar panels, etc.), bedding, sleeping mats, electrical outlets, phone chargers, etc.

As shown in FIGS. 45 and 46, cementitious composite mat 10 includes a plurality of bars, shown as lateral bars 900, that defines a first plurality of cutouts, shown as notches 902, that are positioned to interface with a second plurality of notches, shown as notches 904, defined along longitudinal frame tubes 310 (e.g., lateral bars 900 replace lateral frame tubes 320, etc.). According to an exemplary embodiments, lateral bars 900 facilitate rolling cementitious composite mat 10 (e.g., for shipping, etc.) and prevent twisting of cementitious composite mat 10 about the longitudinal axis thereof.

As shown in FIGS. 47-49, cementitious composite mat 10 includes a plurality of rods, shown as vertical rods 910, and frame 300 includes supports, shown as supports 350, that define a plurality of apertures, shown as apertures 352. As shown in FIG. 49, vertical rods 910 of cementitious composite mat 10 extend between respective supports 350, with the ends thereof received by apertures 352 of supports 350 (e.g., vertical rods 910 replace longitudinal frame tubes 310, etc.). According to an exemplary embodiments, vertical rods 910 facilitate rolling cementitious composite mat 10 (e.g., for shipping, etc.) and prevent twisting of cementitious composite mat 10 about the longitudinal axis thereof.

As shown in FIGS. 50-53, cementitious composite shelter 100 includes walls that can be shipped preassembled, but folded in an accordion style fashion. At the desired hydration location, the walls can be expanded and hydrated. As shown in FIGS. 54-58, cementitious composite shelter 100 includes a frame structure or frame 300 and a single, cementitious composite mat 10 that is draped over the frame structure to form cementitious composite shelter 100. As shown in FIGS. 59-62, cementitious composite panels 200 are arranged to create a structure having an open top and an open entryway, but the interior of the structure is not visible through the entryway. Such a structure may be used for outdoor public restrooms, showers, etc. FIG. 63 shows another alternative structure for cementitious composite shelter 100. As shown in FIG. 64, cementitious composite shelter 100 may have a collector, shown as rain water collection basin 1000 (e.g., defined within one of cementitious composite panels 200, etc.), that collects rain water for use with a shower, sink, etc. of cementitious composite shelter 100.

Cementitious Composite Building

According to the exemplary embodiment shown in FIGS. 65-71, cementitious composite panels 200 are configured to enable the assembly and construction of a permanent structure (e.g., a personal residence, a home, a commercial building, etc.), shown a cementitious composite building 1100. For example, cementitious composite panels 200 may be provided as a kit with various other items that facilitate constructing a single-story home, a multi-story home, an apartment building, a commercial building (e.g., retail space, corporate office, a warehouse, a salon, a restaurant, etc.), and/or still other possible buildings or structures.

As shown in FIG. 65, cementitious composite building 1100 is constructed using cementitious composite panels 200, similar to cementitious composite shelter 100. For example, cementitious composite building 1100 may constructed using cementitious composite panels 200 having doors 210, windows 220, etc. However, unlike cementitious composite shelter 100, cementitious composite building 1100 may include cementitious composite panels 200 that include additional features that provide for a more suitable long-tern living or commercial space (e.g., water connections, gas connections, electrical connections, HVAC connections, drywall interior surfaces, etc.).

By way of example, liner 500 of cementitious composite panel 200 may be drywall. Liner 500 may also be provided with a protective sheet or covering to prevent damage thereto during installation (e.g., a peel away protective plastic on drywall to shield drywall during construction of cementitious composite building 1100 and prevent dust formation thereon to provide a dust-free painting surface, drywall could also be painted with a desired color prior to shipping, etc.). In some embodiments, some of cementitious composite panels 200 for cementitious composite building 1100 (e.g., for interior walls of cementitious composite building 1100, etc.) do not include cementitious composite mats 10. In such embodiments, cementitious composite mat 10 may be replaced with a second liner 500 (e.g., a second drywall panel, etc.). In some embodiments, insulation sheet 400 and/or liner 500 includes a soundproofing material.

As shown in FIGS. 66 and 67, cementitious composite panel 200 for cementitious composite building 1100 includes a conduit assembly, shown as conduit assembly 1200. According to the exemplary embodiment shown in FIGS. 66 and 67, conduit assembly 1200 extends within and/or through insulation sheet 400. In some embodiments, conduit assembly 1200 additionally or alternatively extends within and/or through cementitious composite mat 10 (e.g., for exterior walls of cementitious composite building 1100 that have lights attached thereto; to facilitate connecting to gas lines, water lines, electrical lines, etc. outside or under cementitious composite building 1100; etc.), as described in more detail herein. In some embodiments, conduit assembly 1200 is positioned between insulation sheet 400 and liner 500 (i.e., sandwiched therebetween). In some embodiments, insulation sheet 400 only extends through a portion of the thickness of cementitious composite panel 200. For example, insulation layer 400 may (i) extend to only cover half the thickness of conduit assembly 1200, (ii) extend to cover all of conduit assembly 1200, (iii) extend from liner 500 only partially to cementitious composite mat 10, (iv) extend from cementitious composite mat 10 only partially to liner 500, or (v) extend entirely between liner 500 and cementitious composite mat 10.

As shown in FIGS. 66 and 67, conduit assembly 1200 of cementitious composite panel 200 includes (i) a first conduit, shown as electrical conduit 1210, configured to facilitate running wiring through cementitious composite panel 200 to facilitate powering an electrical component of cementitious composite building 1100 (e.g., lights, speakers, TVs, fans, electrically-operated appliances, a HVAC system, etc.), (ii) a second conduit, shown as water conduit 1220, configured to facilitate running water through cementitious composite panel 200 to facilitate providing water to a water appliance of cementitious composite building 1100 (e.g., a dishwasher, a washing machine, an ice maker, a sink, a shower, a bathtub, a toilet, a water heater, etc.), and (iii) a third conduit, shown as gas conduit 1230, configured to facilitate running gas through cementitious composite panel 200 to facilitate providing gas to a gas appliance of cementitious composite building 1100 (e.g., a gas stove, a gas oven, a gas water heater, an HVAC system, etc.). As shown in FIG. 67, conduit assembly 1200 additionally includes a fourth conduit, shown as air conduit 1240, through which electrical conduit 1210, water conduit 1220, and/or gas conduit 1230 are positioned and extend. Air conduit 1240 may provide protection for electrical conduit 1210, water conduit 1220, and/or gas conduit 1230. In some embodiments, air conduit 1240 does not receive electrical conduit 1210, water conduit 1220, and/or gas conduit 1230. Air conduit 1240 may be configured to facilitate running conditioned air through cementitious composite panel 200 to facilitate providing conditioned air received from a HVAC system throughout cementitious composite building 1100 to thermally regulate spaces/rooms of cementitious composite building 1100. In some embodiments, conduit assembly 1200 additionally or alternatively includes a fifth conduit or waste conduit configured to facilitate running waste through cementitious composite panel 200 to facilitate providing waste from restrooms within cementitious composite building to a waste collection system (e.g., a septic tank, a sewer, etc.) associated with cementitious composite building 1100.

In some embodiments, one or more cementitious composite panels 200 of cementitious composite building 1100 do not include conduit assembly 1200. In some embodiments, one or more cementitious composite panels 200 of cementitious composite building 1100 only include one of electrical conduit 1210, water conduit 1220, gas conduit 1230, air conduit 1240, or waste conduit. In some embodiments, one or more cementitious composite panels 200 of cementitious composite building 1100 only include two of electrical conduit 1210, water conduit 1220, gas conduit 1230, air conduit 1240, or waste conduit. In some embodiments, one or more cementitious composite panels 200 of cementitious composite building 1100 only include three of electrical conduit 1210, water conduit 1220, gas conduit 1230, air conduit 1240, or waste conduit. In some embodiments, one or more cementitious composite panels 200 of cementitious composite building 1100 only include four of electrical conduit 1210, water conduit 1220, gas conduit 1230, air conduit 1240, or waste conduit. In some embodiments, a cementitious composite panel 200 of cementitious composite building 1100 includes two or more electrical conduits 1210, two or more of water conduit 1220, two or more gas conduits 1230, two or more air conduits 1240, and/or two or more waste conduits. The various conduits of conduit assembly 1200 may extend in different directions, extend all the way across cementitious composite panel 200, exit from lateral edges and/or longitudinal edges of cementitious composite panel 200, and/or extend out of liner 500 and/or cementitious composite mat 10 to facilitate connections to various components (e.g., outlets, switches, vents, electrical interfaces, lights, etc.) and conduits of adjacent cementitious composite panels 200.

As shown in FIG. 68, a first conduit (e.g., electrical conduits 1210, water conduits 1220, gas conduits 1230, air conduits 1240, waste conduit, etc.), shown as conduit 1202, of conduit assembly 1200 of a first cementitious composite panel 200 is configured to engage with a second conduit, shown as conduit 1204, of conduit assembly 1200 of a second, adjacent cementitious composite panel 200. Conduit 1202 includes a first interface, shown as interface 1206, and conduit 1204 includes a second interface, shown as interface 1208. According to the exemplary embodiment shown in FIG. 68, interface 1208 has a first diameter and interface 1206 has a protrusion with a second diameter that is less than the first diameter such that interface 1206 is received by interface 1208 to facilitate coupling conduit 1202 to conduit 1204.

In some embodiments, interface 1206 and interface 1208 are coupled with an interference fit. In some embodiments, interface 1206 and/or interface 1206 are manually coated with an adhesive (e.g., light, heat, etc. activated cement; epoxy; etc.) prior to coupling the panels together to provide an adhesive seal (e.g., air tight seal, water tight seal, etc.) between conduit 1202 and conduit 1204. According to the exemplary embodiment shown in FIG. 68, interface 1206 and/or interface 1208 includes a sealing element, shown as seal 1209, positioned/disposed therebetween. In some embodiments, seal 1209 is or includes a resilient element (e.g., a rubber ring, an O-ring, etc.). In some embodiments, seal 1209 additionally includes or alternatively is a rupturable adhesive element configured to rupture when conduit 1202 engages with conduit 1204 to adhesively seal interface 1206 and interface 1208. In some embodiments, interface 1206 and interface 1208 additionally or alternatively include a mechanical retaining element (e.g., clips, a snap fit interface, exterior latches, etc.) that mechanically secure conduit 1202 and conduit 1204 together. In some embodiments, interface 1206 and interface 1208 are bonded together via a heat treatment and/or ultrasonic welding processes. In some embodiments, liner 500 is selectively removable to attach the conduits disposed therein to the conduits of adjacent panels or to perform maintenance on the conduits. In some embodiments, the conduits are loose within cementitious composite panel 200 and, therefore, can be manually pushed from a free end thereof such that the opposing ends can be forced (e.g., pushed, etc.) into engagement with the conduits of an adjacent panel.

As shown in FIGS. 69-71, cementitious composite panels 200 can include various electrical components, shown as electrical components 1300, embedded within and/or disposed along liner 500. In some embodiments, electrical components 1300 are additionally or alternatively embedded within and/or disposed along cementitious composite mat 10. In alternative embodiments, electrical components 1300 are provided separate from cementitious composite panels 200 and installable on site. According to an exemplary embodiment, electrical components 1300 are connected to the wiring within electrical conduit 1210 of cementitious composite panel 200. As shown in FIG. 69, electrical components 1300 include first electrical components, shown as recessed can lights 1310. As shown in FIG. 70, electrical components 1300 include a second electrical component, shown as electrical outlet 1320, a third electrical component, shown as light switch 1330, and a fourth electrical component, shown as speaker 1340. As shown in FIG. 71, electrical components 1300 include a fifth electrical component, shown as electrical interface 1350, configured to facilitate coupling an electrical component of the installers choosing to cementitious composite panel 200 on-site (e.g., a ceiling fan, a security camera, a light, a chandelier, a thermostat, etc.). It should be understood that the arrangement, combination, and selection of electrical components 1300 shown in FIGS. 69-71 is for illustration purposes and should not be considered limiting. Cementitious composite panels 200 may include any combination of suitable electrical components embedded therein or disposed therealong.

As shown in FIG. 71, cementitious composite panel 200 includes a vent, show as air vent 1250, disposed along liner 500. According to an exemplary embodiment, air vent 1250 is positioned to cover an air outlet in liner 500 that is connected to air conduit 1240. Therefore, conditioned air (e.g., heated, cooled, etc.) may be provided by a HVAC system connected to an air inlet of a respective cementitious composite panel 200 and through air conduits 1240 of connected cementitious composite panels 200 to facilitate providing the conditioned air through the connected cementitious composite panels 200 to an air outlet of a respective cementitious composite panel 200 having air vent 1250 to thermally regulate a space or room that air vent 1250 is situated within cementitious composite building 1100. Similarly, water may be provided from a water source outside of cementitious composite building 1100 to a water inlet of a respective cementitious composite panel 200 and through water conduits 1220 of connected cementitious composite panels 200 to facilitate providing the water through the connected cementitious composite panels 200 to a water outlet of a respective cementitious composite panel 200 connected to a water appliance within cementitious composite building 1100. Similarly, gas (e.g., natural gas, propane, etc.) may be provided from a gas source outside of cementitious composite building 1100 to a gas inlet of a respective cementitious composite panel 200 and through gas conduits 1230 of connected cementitious composite panels 200 to facilitate providing the gas through the connected cementitious composite panels 200 to a gas outlet of a respective cementitious composite panel 200 connected to a gas appliance within cementitious composite building 1100.

Following assembly of the various cementitious composite panels 200, cementitious composite building 1100 can be hydrated. Seams between cementitious composite mats 10 outside of cementitious composite building 1100 and/or seams between liners 500 inside of cementitious composite building 1100 can be grouted and sanded smooth to hide the seams. The cured cementitious composite mats 10 may then be painted, covered in plaster, covered in brick, covered in stone, covered with siding, etc. to provide a desirable exterior aesthetic. Alternatively, cementitious mixture 30 may include a color additive that changes the exterior color of cementitious composite panels 200 upon curing to a desired color for cementitious composite building 1100. Liners 500 may also be painted, covered in wall paper, etc. Flooring may be added to a concrete slab poured prior to construction of cementitious composite building 1100 or the flooring may be added to floor panels of cementitious composite panels 200 used to create the concrete slab. As shown in FIG. 65, the roof panels are covered in tiles, shown as roofing tiles 1400. Roofing tiles 1400 may be fitted to exposed hooks protruding from the roof panels or have snap fit connectors that engage with interfaces of the roof panels. The roof panels may include brackets or flanges that interface with the wall panels to secure the rood panels to the wall panels. Alternatively, frames of the roof panels and the wall panels join together like described herein regarding cementitious composite shelter 100.

According to an exemplary embodiment, cementitious composite panels 200 facilitate providing a modular and fully customizable building. By way of example, a customer may be able to design a floor plan and where appliances, lights, speakers, windows, doors, water inlets, gas inlets, HVAC locations, etc. should be located. Cementitious composite panels 200 may then be designed and manufactured to meet the customer's specifications. A kit will then be shipped to the customer that includes cementitious composite panels 200 that simply need to be assembled to construct a cementitious composite building 1100 with all electrical, water, gas, and air conduits and connections included in the panels. The kit may also be provided with various appliances (e.g., fans, light fixtures, washer, dryer, dishwasher, oven, microwave, HVAC system, furnace, stove, grill, water heater, sinks, toilets, showers, tubs, a barbeque, Jacuzzi, garage door systems, etc.), furniture (e.g., couches, tables, chairs, lamps, beds, desks, gas meters, electrical meters, etc.), electronics (e.g., TVs, sound systems, alarm, thermostat, cameras, internet router/modems, solar panels, battery storage, etc.), finishing materials (e.g., roofing tiles 1400, carpeting, tile, hardwood, paint, brick, stone, wall paper, siding, etc.), accessories (e.g., blinds, towels, pillows, cookware, etc.), and/or other home or business goods of the customers choosing. Accordingly, the kit may be an all-inclusive kit that includes all goods and items a customer may want or need for constructing and providing a suitable living or work space.

The kit may also include various cementitious composite mats 10 to facilitate constructing various external amenities such as driveways, sidewalks, walkways, patios, pools, Jacuzzis, fire places/pits, etc. on the property where cementitious composite building 1100 is situated. The external amenities may similarly be designed and manufactured according to the customer's specifications and delivered within the kit. Alternatively, brick pavers, stone, etc. may be provided with the kit to facilitate constructing the driveways, sidewalks, walkways, patios, pools, Jacuzzis, fire places/pits, etc. The kit may also include various gardening and yard materials (e.g., sod, plants, seeds, sprinkler system, etc.) based on yard and garden designs in accordance with the customer's specifications.

In some embodiments, cementitious composite building 1100 may be configured as a smart home having various sensors, connected devices, and/or home automation systems that facilitate seamless control of various features of cementitious composite building 1100 while present or while away. By way of example, the kit for cementitious composite building 1100 may come with a central control system connected to various electrically operated components of cementitious composite building 1100. For example the electrically operated components may include a security system (e.g., cameras, alarms, sensors, etc.), lights, coffee makers, toaster ovens, ovens, pool heater, Jacuzzi jets, TVs, TV recording systems, sound systems, water heaters, fans, solar panels and/or energy storage, garage doors, refrigerators, home intercoms, trash compactor, sprinkler systems, mailbox sensor/cameras, pantry and/or refrigerator cameras/sensors, electrical and/or gas shutoffs, window blinds, electronic door locks, air filtration systems, humidifier/dehumidifier systems, water filtration systems, showers, bathtubs, floor heating systems, etc.

The various electrically operated components are configured to be controllable through the central control system via an interface installed within cementitious composite building 1100 and/or via a user's portable device (e.g., smartphone, portable controller, smartwatch, tablet, laptop, computer, etc.) locally (e.g., over Wi-Fi, Bluetooth, radio, NFC, etc.) or remotely (e.g., via the Internet, cellular, etc.). Various commands to the electrically operated components may be provided through an application and/or using voice commands (e.g., through the interface, portable device, directly to the central control system microphone, etc.). The user may also be able to view live and/or recorded footage from the cameras (e.g., pantry camera, refrigerator camera, mailbox camera, security cameras, etc.). The user may be able to view data regarding operation of the various components of cementitious composite building 1100 (e.g., water filtration data, water temperature data, water usage data, oven temperature data, light status data, solar panel output data, energy storage data, etc.). The central control system may provide a user with the ability to notify the fire department if a smoke detector detects smoke and/or notify the police is an alarm is triggered. Timed actions may be set by a user and initiated. For example, the central control system may initiate a morning routine that starts a shower, opens blinds, adjusts temperature, turns on various lights, brews coffee, etc. automatically based on time or in response to a user command. As another example, the central control system may utilize geolocation tracking to determine the estimated arrival of the user and initiate an arrival routine (e.g., turn on air conditioning, open garage door, unlock doors, turn on lights, turn on music, etc.) based on the location of the user relative to cementitious composite building 1100.

As utilized herein, the terms “approximately,” “about,” “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.

It should be noted that the term “exemplary” and variations thereof, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

The term “coupled” and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic.

References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

Although the figures and description may illustrate a specific order of method steps, the order of such steps may differ from what is depicted and described, unless specified differently above. Also, two or more steps may be performed concurrently or with partial concurrence, unless specified differently above. Such variation may depend, for example, on the software and hardware systems chosen and on designer choice. All such variations are within the scope of the disclosure. Likewise, software implementations of the described methods could be accomplished with standard programming techniques with rule-based logic and other logic to accomplish the various connection steps, processing steps, comparison steps, and decision steps.

It is important to note that the construction and arrangement of the cementitious composite mats 10, cementitious composite shelter 100, and the components thereof as shown in the various exemplary embodiments is illustrative only. Additionally, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. Although only one example of an element from one embodiment that can be incorporated or utilized in another embodiment has been described above, it should be appreciated that other elements of the various embodiments may be incorporated or utilized with any of the other embodiments disclosed herein.

Claims

1. A kit for a structure, the kit comprising:

a plurality of frame elements that facilitate constructing a frame structure of the structure; and
a plurality of cementitious composite mats;
wherein the plurality of frame elements and the plurality of cementitious composite mats are assemblable to provide the structure; and
wherein, in response to the plurality of cementitious composite mats being hydrated in-situ, the plurality of cementitious composite mats cure to provide cement panels for the structure.

2. The kit of claim 1, wherein the plurality of frame elements and the plurality of cementitious composite mats are provided in a disassembled kit, wherein the plurality of frame elements are selectively connectable to provide the frame structure, and wherein each of the plurality of cementitious composite mats is selectively couplable to one or more frame elements of the plurality of frame elements.

3. The kit of claim 2, further comprising at least one of a door or a window, wherein the at least one of the door or the window is pre-installed within or installable into a respective one of the plurality of cementitious composite mats.

4. The kit of claim 1, wherein the plurality of frame elements are pre-arranged into a plurality of sub-frame assemblies, wherein each of the plurality of cementitious composite mats is pre-coupled to a respective one of the plurality of sub-frame assemblies such that the kit includes a plurality of prefabricated cementitious composite panels, and wherein the plurality of sub-frame assemblies are selectively connectable to provide the frame structure.

5. The kit of claim 4, wherein the plurality of prefabricated cementitious composite panels are shippable in a flat configuration.

6. The kit of claim 4, wherein the plurality of prefabricated cementitious composite panels are shippable in a rolled configuration.

7. The kit of claim 4, wherein the plurality of prefabricated cementitious composite panels include a first type of panel and a second type of panel different than the first type of panel.

8. The kit of claim 7, wherein the first type of panel is provided in a flat configuration and the sub-frame thereof is non-bendable, and wherein the second type of panel is provided in a pre-bent configuration.

9. The kit of claim 7, wherein the first type of panel is provided in a flat configuration and the sub-frame thereof is non-bendable, wherein the second type of panel is provided in the flat configuration and the sub-frame thereof is selectively bendable by hand, and wherein a frame element of the second type of panel defines a plurality of adjacent notches that facilitate selectively bending the frame element from a flat, shipping configuration to a bent, installation configuration prior to hydration of the cementitious composite mat of the second type of panel.

10. The kit of claim 4, wherein the plurality of cementitious composite mats extend beyond at least one of a lateral end or a longitudinal end of the plurality of sub-frame assemblies such that adjacent cementitious composite mats of adjacent cementitious composite panels at least partially overlap when the structure is assembled.

11. The kit of claim 4, wherein at least one of the plurality of prefabricated cementitious composite panels includes a door embedded within the cementitious composite mat thereof, and wherein at least one of the plurality of prefabricated cementitious composite panels includes a window embedded within the cementitious composite mat thereof.

12. The kit of claim 1, wherein at least one frame element of the plurality of frame elements defines a plurality of adjacent notches that facilitate selectively bending the at least one frame element from a flat, shipping configuration to a bent, installation configuration by hand.

13. The kit of claim 1, wherein each of the plurality of cementitious composite mats includes a coupling system disposed along an outer surface thereof, and wherein the coupling system is configured to facilitate detachably coupling the plurality of cementitious composite mats to the plurality of frame elements.

14. The kit of claim 1, further comprising an insulation layer, wherein the insulation layer is couplable to an interior of the frame structure, and wherein the plurality of cementitious composite mats are couplable to an exterior of the frame structure.

15. The kit of claim 14, further comprising one or more conduits embedded within the insulation layer, wherein the one or more conduits include at least one of (i) an electrical conduit configured to facilitate running wiring through the insulation layer to facilitate powering an electrical component of the structure, (ii) a water conduit configured to facilitate running water through the insulation layer to facilitate providing water to a water appliance of the structure, (iii) a gas conduit configured to facilitate running gas through the insulation layer to facilitate providing gas to a gas appliance of the structure, (iv) an air conduit configured to facilitate running conditioned air through the insulation layer to facilitate providing conditioned air received from a HVAC system throughout the structure, or (v) a waste conduit configured to facilitate running waste through insulation layer to facilitate providing the waste to a waste collection system external to the structure.

16. A cementitious composite panel for a structure, the cementitious composite panel comprising:

a frame; and
a cementitious composite mat coupled to the frame, the cementitious composite mat including: an inner layer disposed along the frame; an outer layer that is permeable to water; and a cementitious mixture disposed between the inner layer and the outer layer;
wherein the frame is configured to connect to adjacent frames of adjacent panels of the structure; and
wherein, in response to the cementitious composite mat being hydrated in-situ, the cementitious mixture cures to provide a cement panel for the structure.

17. The cementitious composite panel of claim 16, wherein the cementitious composite mat has a longer longitudinal length than the frame such that the cementitious composite mat extends beyond at least one end of the frame.

18. The cementitious composite panel of claim 16, wherein at least one frame member of the frame defines a plurality of adjacent notches that facilitate bending the at least one frame member of the frame from a flat, shipping configuration to a bent, installation configuration prior to hydration of the cementitious composite mat.

19. The cementitious composite panel of claim 16, further comprising an insulating layer, wherein the cementitious composite mat is disposed along a first side of the frame, and wherein the insulating layer is disposed at least one of (i) along an opposing second side of the frame such that the frame is sandwiched between the insulating layer and the cementitious composite mat or (ii) within gaps between frame members of the frame.

20. The cementitious composite panel of claim 19, further comprising one or more conduits extending within cementitious composite panel, wherein the one or more conduits include at least one of (i) an electrical conduit configured to facilitate running wiring through the cementitious composite panel to facilitate powering an electrical component of the structure, (ii) a water conduit configured to facilitate running water through the cementitious composite panel to facilitate providing water to a water appliance of the structure, (iii) a gas conduit configured to facilitate running gas through the cementitious composite panel to facilitate providing gas to a gas appliance of the structure, (iv) an air conduit configured to facilitate running conditioned air through the cementitious composite panel to facilitate providing conditioned air received from a HVAC system throughout the structure, or (v) a waste conduit configured to facilitate running waste through cementitious composite panel to facilitate providing waste through the cementitious composite panel to a waste collection system external to the structure.

21. The cementitious composite panel of claim 20, wherein the one or more conduits are one or more first conduits, and wherein the one or more first conduits are configured to engage with one or more second conduits of the adjacent panels.

22. The cementitious composite panel of claim 21, wherein an interface between the one or more first conduits and the one or more second conduits includes a seal or a mechanical retainer to secure the interface.

23. The cementitious composite panel of claim 22, wherein the seal includes an adhesive element configured to rupture when the one or more first conduits engage with the one or more second conduits to adhesively seal the interface.

24. The cementitious composite panel of claim 20, further comprising a liner disposed along a side of the insulating layer opposite the frame.

25. The cementitious composite panel of claim 24, wherein the liner is drywall.

26. The cementitious composite panel of claim 24, wherein the one or more conduits includes the electrical conduit, further comprising an electrical component embedded within or disposed along the liner or the cementitious composite mat, wherein the electrical component is connected to the wiring within the electrical conduit.

27. A structure comprising:

a plurality of cementitious composite panels coupled together, each of the plurality of cementitious composite panels including: a sub-frame assembly interconnected with sub-frame assemblies of adjacent cementitious composite panels to provide a frame structure of the structure; an inner, non-permeable layer disposed along the sub-frame assembly; an outer, water-permeable layer; and a cementitious mixture disposed between the inner, non-permeable layer and the outer, water-permeable layer;
wherein, in response to the plurality of cementitious composite panels being hydrated in-situ, the cementitious mixture cures to provide cement panels of the structure.
Patent History
Publication number: 20210270030
Type: Application
Filed: Sep 3, 2019
Publication Date: Sep 2, 2021
Applicant: Cortex Composites, Inc. (Pacific Palisades, CA)
Inventors: Curren E. Krasnoff (Pacific Palisades, CA), Antonin Yuji Maeno (Paris)
Application Number: 17/272,762
Classifications
International Classification: E04B 1/343 (20060101); E04B 1/16 (20060101); E04C 2/288 (20060101); E04C 2/34 (20060101); E04C 2/52 (20060101);