Wall construction method using injected urethane foam between the wall and autoclaved concrete (AAC) blocks

9,745,739

14/544818

February 20, 2015

The present invention provides novel wall construction systems and materials for residential and commercial construction that incorporate grooved lightweight building material units (e.g., blocks, panels, and the like), a plurality of connection devices, a track system, and (injected) polyurethane structural foam. The wall construction system comprises building material units married to a building frame with a plurality of connection devices (e.g., clip fasteners) slidingly retained in a track system that is attached to the building's structural (e.g., load-bearing) framing. The building material units are joined to each other with a suitable binding agent. The cavity between the frame and the building material units is injected with an insulating structural polyurethane foam. The exterior of the wall is finished with a waterproof applied finish such as cementitious stucco. The interior of the wall is amenable to standard finish options.

Riepe, Frank Warner (Sudbury, MA, US)

BRETON SYSTEMS LLC (Sudbury, MA, US)

1. A composite construction system comprising: a load-bearing frame and a lightweight concrete construction unit, and a cavity between the load-bearing frame and the lightweight concrete construction unit, wherein one side of the lightweight concrete construction unit faces towards the load-bearing frame, further wherein the load-bearing frame is adhered to the lightweight concrete construction unit using at least a single layer of polyurethane foam interposed between the load-bearing frame and the lightweight concrete construction unit to fill the cavity, and at least one clip fastener, wherein the clip fastener comprises a main body section having a first terminus and second terminus, further wherein the first terminus comprises two compressible leg sections emanating from the main body section and the second terminus comprises an upward interlock stub and a downward interlock stub, the clip fastener being positioned between the load-bearing frame and the lightweight concrete construction unit such that the clip fastener is slidingly retained in the track system section.

2. The composite construction system of claim 1 , wherein the load-bearing frame is made out of at least one of a group of materials consisting of solid wood, timber materials, engineered wood products, wood composite materials, steel and aluminum.

3. The composite construction system of claim 1 , wherein the compressible leg sections are separated by a gap.

4. The composite construction system of claim 1 , wherein each compressible leg section ends in a semicircular hook.

5. The composite construction system of claim 1 , wherein the upward interlock stub and the downward interlock stub of the clip fastener, each protrude at a right angle from the main body section of the clip fastener.

6. The composite construction system of claim 1 , wherein the clip fastener is made out of at least one of a group of materials comprising metals and plastics.

7. The composite construction system of claim 6 , wherein the plastics comprise ABS plastics.

8. The composite construction system of claim 1 , wherein the clip fastener is thermally non-conductive.

9. The composite construction system of claim 1 , wherein the track system section comprises a main body having opposed top and bottom edges comprising two short protrusions at a right angles from the axis of the main body, further wherein the protrusions terminate in two opposing inwardly semicircular sections.

10. The composite construction system of claim 9 , wherein the track system section is made out of at least one of a group of materials comprising metals and plastics.

11. The composite construction system of claim 10 , wherein the plastics comprise ABS plastics.

12. The composite construction system of claim 1 , wherein the track system section is thermally non-conductive.

13. The composite construction system of claim 1 , wherein the lightweight concrete construction unit comprises an autoclaved aerated concrete (AAC) block.

14. The composite construction system of claim 13 , wherein the AAC block comprises at least one groove for attaching to the clip fastener.

15. The composite construction system of claim 1 , wherein the distance between the load-bearing frame and the lightweight concrete construction unit comprises about 1″ to about 4″.

16. The composite construction system of claim 1 , wherein the single layer of polyurethane foam comprises a width of about 2″ to about 8″.

17. A method for constructing a wall of a building, comprising the steps of: a) erecting a load-bearing frame having an interior facing surface and an exterior facing surface on a support such as a conventional foundation or slab; b) placing at least one shelf angle on top of the foundation on the exterior surface of the load-bearing frame, wherein the shelf angle comprises an upwardly projecting interlock stub, further wherein the shelf angle is placed such that the interlock stub extends in an upward direction from the foundation distal from the load-bearing frame; c) placing a first lightweight concrete construction unit having a top groove and a bottom groove on top of the shelf angle by inserting the interlock stub of the shelf angle into the bottom groove of the lightweight concrete construction unit, such that a cavity is created between the load-bearing frame and the lightweight concrete construction unit, further wherein the lightweight concrete construction unit has an interior facing surface facing the load-bearing frame and an opposite exterior facing surface and a top facing surface and an opposite bottom facing surface; d) attaching at least one track support section to the exterior surface of the load-bearing frame; e) attaching at least one track system section to the track support section; f) providing at least one clip fastener, wherein the clip fastener comprises a main body section having a first terminus and second terminus, and further wherein the first terminus comprises two compressible leg sections emanating from the main body section and the second terminus comprises a downward interlock stub and an upward interlock stub; g) compressing the leg sections of the clip fastener to compressively insert the first terminus of the clip fastener into the track system section such that the clip fastener is slidingly retained in the track system section, wherein the clip fastener is placed such that the downward interlock stub is inserted into the top groove of the first lightweight concrete construction unit; h) applying a layer of adhesive to the top surface of the lightweight concrete construction unit; i) placing a second lightweight concrete construction unit on top of the first lightweight concrete construction unit such that the top interlock stub of the clip fastener is inserted into the bottom groove of the second lightweight concrete construction unit; j) repeating steps (d) through (i) until a desired exterior wall height and cavity separating the lightweight concrete construction units and the load-bearing frame are achieved; and k) injecting a polyurethane foam into the cavity.

18. The method for constructing a wall of a building of claim 17 , wherein the compressible leg sections of the clip fastener are separated by a gap.

19. The method for constructing a wall of a building of claim 17 , wherein each compressible leg section ends in a semicircular hook.

20. The method for constructing a wall of a building of claim 17 , wherein the upward interlock stub and the downward interlock stub of the clip fastener, each protrude at a right angle from the main body section of the clip fastener.

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