The present invention relates to a glass pultrusion build system to accept a combination of mineral based boards for constructing buildings, rooms or parts thereof

Although the following description refers to a composite system for constructing residential buildings and storage units, the skilled person will appreciate that the present invention can be used to construct virtually any building type for any use and is not limited to residential buildings, rooms or storage units etc.

Modular panel build systems are known. Typically in conventional modular systems the building components or sections are constructed remote from the building site, and delivered to the intended site for construction or assembly. Installation of the prefabricated sections is usually completed on site.

Often, these conventional construction or build systems use components that are not sustainable and/or are not from environmentally friendly sources.

Those building systems that do use more environmentally friendly components often suffer from substandard building performance regarding heat conduction and sound and vibration insulation.

It is therefore an aim of the present invention to provide a modular or composite building system that addresses the abovementioned problems.

It is a further aim of the present invention to provide a construction or building method that addresses the abovementioned problems.

It is a yet further aim of the present invention to provide building components that can be used in modular construction systems that are environmentally friendly and address the abovementioned problems. In a first aspect of the invention there is provided a construction system suitable for constructing at least part of a building or room said system including one or more frame means and at least one panel means, said frame means comprising elongate frame members adapted to receive and/or attach to at least part of said panel means characterised in that the frame means includes fibre-reinforced polymer.

Typically, the frame means receive and/ or attach to substantially the edge of one or more panel means. Further typically the frame means are structural components in that the frame means is load bearing.

As such the system provides a complete modular panel build system, with the essential structural components comprising the frame means and said panel means.

In a preferred embodiment the fibre reinforced polymer is glass fibre reinforced. Typically, the fibre reinforced polymer is pultruded. Further typically the frame means comprises glass fibre reinforced pultrusions.

In one embodiment the frame means comprise substantially linear lengths or sections of glass fibre reinforced pultrusion.

In one embodiment the frame means comprises glass fibre reinforced polymer wherein the polymer is any one or any combination of polyester, epoxide, polyamide, polycarbonate, polyoxymethylene, polypropylene, polybutylene terephthalate and/ or polyvinyl ester polymer.

In one embodiment the glass fibres are any one or any combination of SiCT, AI2O3, B2O3, CaO, and/ or MgO.

In one embodiment the frame means includes at least one channel or recess to receive at least part of the panel means. Typically, the channel or recess runs along the length of and/or is formed in the linear frame means. Further typically the channels or recesses are at least partially defined by one or more wall members.

In one embodiment the frame means includes at least two channels or recesses. Typically the frame means includes at least two elongate or linear channels or recesses formed substantially orthogonally and/or at right angles relative to one another. Further typically said orthogonal channels or recesses extend coaxially along the length of the frame means with the wall members at least partially defining the same located perpendicularly, orthogonally or substantially at right angles relative to each other.

In one embodiment the frame means includes at least one channel or recess defined by one or more wall members substantially at 45 degrees with respect to other wall members defining other channels or recesses.

In one embodiment the frame means includes at least one channel or recess defined by one or more wall members substantially at or between 20-45 degrees with respect to other wall members defining other channels or recesses.

In one embodiment the frame means includes at least one channel or recess defined by one or more wall members substantially 30 degrees with respect to other wall members defining other channels or recesses.

Typically the channels extend along the length of the frame means in a parallel or coaxial direction.

In one embodiment two or more frame means can be aligned and/or attached. Typically the frame means are connected and/or orientated in a substantially parallel manner to form a single unit or frame means.

In one embodiment at least two frame means are aligned and/ or attached such that a linear channel or grove is formed in the same to accept and/or receive at least the edge part of a panel means.

In one embodiment the frame means includes at least one formation configured to abut, receive or lie against and adjacent or parallel frame means. Typically one or more wall members include at least one formation, recess, channel and/or protrusion that interlinks, receives and/or abuts an adjacent wall member on a second substantially structurally identical frame means that is positioned adjacent or next to the first frame means. In one embodiment the frame means includes one or more surface coverings or wraps. Typically at least one of the surface coverings or wraps reinforcement or structural support, at least in the transverse direction. Further typically at least one of the coverings or wraps provide light protection, particularly UV-light protection.

In one embodiment the frame means includes at least one channel and/ or recess configured to receive a buffer strip. Typically, the buffer strip is a section of material insulation. Further typically the buffer strip insulates the system against sound and/ or vibration.

In one embodiment the panel means includes at least one board or layer. Typically, the board or layer is a layer of composite board or cement board.

In one embodiment the panel means includes at least one layer of insulation. Typically, the insulation is a closed cell foam and/or expanded insulation material.

In one embodiment the panel means includes two layers or surfaces of composite board with a layer of insulation material located between the same.

In one embodiment the insulation includes water based acrylic foam.

In one embodiment the frame means and/ or frame members comprise glass reinforced polyester resin.

In one embodiment the frame means include one or more wrapping elements or sheets. Typically the wrapping sheets include a UV resistant material or veil. Further typically the wrapping elements include carbon fibre mats and/or graphene enhanced mats. The mats typically provide additional strength to the frame means in the transverse direction.

In one embodiment the frame means includes rovings or grooves formed in the same. Typically the rovings or grooves are longitudinally formed in the frame means. Further typically the rovings provide reinforcement in the longitudinal direction. Preferably at least the ends of the frame means or frame mambers can be aligned linearly, orthogonally and/or at an angle to hold, encase or substantially surround the edges of one or more panel means such that the panels can be arranged to form building units. Typically the building units are walls, floors, roofs and the like. Further typically adjacent panels can be aligned on substantially the same plane or at an angle to one another.

In one embodiment one or more frame means are frame members may be joined at an angle. Typically such joints form corner units and the like.

In one embodiment the system includes one or more inset members that are configured to be received in one or more channels of the frame means. Typically the insert members strengthen the joints between frame means or frame members.

Preferably the frame means includes one or more fire retardants.

In one embodiment the board layers comprise cement. Typically, the cement includes or contains glass reinforcing fibres.

In one embodiment the system includes at least one foil layer or lining. Typically, the foil layer or lining is a polyurethane insulation layer. Further typically the insulation includes air bubbles or pockets.

In one embodiment the system includes an aerogel insulation layer.

In a preferred embodiment the frame means is situated around the edge of a panel means thereby encasing or enclosing the same as a surrounding loadbearing structure with the panel means located therein.

In one embodiment the system includes one or more facing boards or facing panels. Typically, the facing boards or facing panels act as exterior or outer layers to the system. Further typically the frame means includes one or more surfaces to which the outer boards or layers can be attached.

In one embodiment the panel means comprises recycled glass insulation. Typically the panel can be made to any thickness, size and thermal/ sound/ strength specification. Further typically the panel means can be used to replace current SIP panels but includes a fire graded, quality finished surface for the interior and easily rendered/painted/interchangeable finished exterior surface.

In a second aspect of the system there is provided a method of constructing a building or room within a building, said method including combining or attaching one or more frame means and at least one panel means together to form a building module or unit, said frame means comprising elongate frame members adapted to receive and/or attach to at least part of said panel means characterised in that the frame means includes fibre-reinforced polymer.

In one embodiment the system components of frame means and/ or panel means are pre-cut to predetermined sizes, either as part assembled panels or as packed components for attachment together or assembly on site.

In one aspect of the invention the frame means or members interconnect with a plurality of panels without the necessity of additional fixings or adhesives.

Specific embodiments of the invention are now described with reference to the following Figures wherein:

Figure 1 shows a cutaway view of the building system in situ.

The present inventive building system uses building panels and frame members that are created using primarily waste derived, or recycled, materials that are both abundant and can be locally sourced. This ensures our build system is both extremely sustainable and has the lowest environmental impact possible. Being waste derived, the system has significantly less embodied energy than systems that use common and pristine building materials, primarily as a large part of the processing needed in our manufacturing has already taken place during its first life/lives.

Termed the new “FLY Build System” system, this system is a complete modular panel build system. Its adaptable integral multi-layered approach takes into consideration every performance aspect required for both the building regulations of today and the every growing eco/performance requirements of the future.

The system comes pre-cut to final sizes, either as part assembled panels or flat packed components. This form of prefabrication massively reduces onsite construction waste, one of the largest contributors to landfill and wasted carbon emissions. Any material trimmings created in manufacturing and/ or assembly can be recycled again forming parts of panels or frames.

Figure 1 shows a typical configuration for a frame member 2. The elongate member is constructed primarily from glass fibre pultrusion and includes a number of elongate channels 4, 4’ to receive panels of various configurations. In this example the longitudinal channels are defined by the channel walls such that they are at 45 degrees to each other. The skilled person will appreciate that other angles can be used such as 90 degrees as shown in figure 2. In this example the frame member 2 includes the optional features of a UV protective wrap 6 and a graphene reinforcement cover 8. In addition optional rovings are includes to provide longitudinal strength to the length of frame.

Figure 2 shows an embodiment where the frame members 2 can be aligned such that the channels 4, 4’ can hold structural panels 10 therebetween and orthogonally, or at right angles to each other.

Figure 3 shows how combinations of frame members 2, 2’ with channels 4, 4’ at different angles (90 degrees and 45 degrees in this example) can be combined to form a building structure. Figure 3 also shows how different panel types can be held in various configurations.

Figure 6 shows how outer channels 14 can incorporate cladding or outer panels. Furthermore, many types of panels, including insulation 12 can be received between the frame members 2 and/ or other panels 10.

The FLY Build System reduces environmental impact by focusing on a Cradle to Cradle (C2C) approach, focusing on recycled content, renewable resources and low/no Volatile Organic Compounds (VOCs). Then to cap that all, the systems component longevity being almost endless, recycling at the end of the building’s life cycle for second and third life applications will be a given. So much so, in some cases, we will be able to offer a take back at end-of-life service if required.

Passive Heating and Cooling Principles

The FLY Build System panel system is designed to optimise thermal performance and targets a substantial reduction in annual energy consumption. For example, approximately 20% of greenhouse gas emissions in the UK comes from the heating and cooling of buildings.

The extremely low environmental footprint of our products, and the buildings using our system, is achieved through low impact lightweight construction, zero or low concrete foundations and through applied advanced material technology.

By reducing use of Portland cement and negating the need for coastal sand (using recycled glass instead), heavily used in traditional construction and foundations, we greatly reduce the impact to the Natural environment.

With a strong organisational focus on sustainability, Fusion Build provides the components for the design and construction of highly insulated Eco Houses.

In the case of our own house designs, we focus on maximising energy efficiency through advanced passive heating and cooling principles, and we leverage the use of natural light by carefully considering location and orientation for optimum energy efficient solutions.

Using non-conductive glass composite framing over traditional steel, aluminium, etc, and our aerogel jointing sheets, minimises thermal bridging to a level never seen in normal, affordable building systems.

The building system in Figure 1 shows a building system 2 that includes a frame means 4 which receives a panel means 6. The frame means is made up of two frame members 8,10 which enclose the edge of the panel means.

In this example the panel means includes outer layers or boards that are fibre mineral boards comprising ordinary Portland cement with inorganic glass reinforcing fibres. Ideal for exterior sheathing of SFS frames due to high durability and non-combustibility.

They contains no hazardous volatiles, is asbestos free and its process dust is none aggressive. They are highly moisture tolerant. The entire panel means could be made from such a board however in this example the performance and environmentally friendly credentials are improved by incorporating Eco insulation in various forms.

In this example the foam insulation is water based closed cell foam that creates a fully sealed panel system that can be used as an air and vapor barrier.

The frame members in this example are structural profiles is made out of glass reinforcements and graphene enhanced ISO polyester resins. The profiles or frame means can be made to any length.

The thermal and/or acoustic performance can be enhanced with various linings. It offers superior water-vapour resistance, thermal resistance, durability and it helps boost UValue ratings.

Advantages of Pultruded Glass are; operating conditions from -100°C to + 180°C, self extinguishing and halogen free, linear behaviour, low weight, electrical insulating, thermal isolation, chemical resistant, corrosion and weather resistant, UV resistant, economic efficiency, high strength, easy assembly, short construction period.

As a standard, isophtalic polyester resins can be used for the matrix. To fulfil special requirements the following resin types can be applied; metal free - non-magnetic, electrical grounding is not required, no further maintenance is necessary, vinylester resin provides extreme corrosion resistance, phenolic resin provides high temperature and fire resistance, easy to work on, even on-site with the use of common hand tools, epoxy resin provides special electrical properties, acrylic resin provides low smoke emissions in case of fire, no ridges when drilling and sawing, bio resins can be used for eco applications.