Abstract:
A composite panel for use in constructing a foundation wall for a building, the panel having: a main wall having an exterior side and an interior side; a plurality of horizontal stiffeners extending from the interior side of the main wall; a plurality of vertical stiffeners extending from the interior side of the main wall; and complementary first and second lips positioned on opposite ends.

Description:
BACKGROUND 
       [0001]    The present invention is directed to foundation walls for modular structures. 
         [0002]    Modular structures, such as mobile homes, are typically supported both on interior piers and on a perimeter foundation wall. Once a site is selected for placement of a mobile structure, the site is prepared such as by grading and filling. Once the site is prepared, then the location and dimensions of the perimeter foundation walls and the interior piers are determined and laid out. The perimeter foundation walls and interior piers are then constructed. 
         [0003]    Once the perimeter foundation walls and interior piers are in place, the modular structure is positioned onto the perimeter foundation walls and interior piers. The modular structure can be moved into position using a crane. However, cranes of suitable capacity are often unavailable. Without a crane, movement of the modular structure involves a difficult process of sliding, adjusting, lowering, fitting and blocking. Quite often the perimeter foundation walls and the perimeter of the modular structure have enough deviation in measurements such that the modular structure does not fit well on the perimeter foundation wall. 
         [0004]    U.S. Pat Nos. 6,076,320 and 6,205,725 teach a perimeter-wall foundation that is created by attaching galvanized-steel corrugated panels to an in-place structure. The bottom edges of the panels are cast in-situ with footing concrete, so becoming a cast-in-place perimeter wall foundation, capable of residential-scale bearing and shear loadings. However, the galvanized-steel corrugated panels are heavy for handling, difficult to cut and fit to size, and have limited surface finishes. Additionally, galvanized-steel corrugated panels are vulnerable to rust and rot if scratched or damaged during installation and need to be coated for protection, such as by tar, stucco, or paint. 
         [0005]    Thus, there is a need for an improved perimeter foundation wall for modular structures. 
       SUMMARY 
       [0006]    Accordingly, the present invention is directed to a panel for use in constructing a foundation wall for a building that remedies the shortcomings of the prior art. A panel for constructing a foundation wall, according to an embodiment of the present invention comprises: a main wall having an exterior side and an interior side; a plurality of horizontal stiffeners extending from the interior side of the main wall; a plurality of vertical stiffeners extending from the interior side of the main wall; and complementary first and second lips positioned on opposite ends. The panel is made from composite. 
         [0007]    The panel can also have a plurality of diagonal stiffeners extending from the interior side of the main wall. Optionally, the lips can have a plurality of holes configured to facilitate attachment of the panel to other panels. Additionally, at least one of the horizontal stiffeners, the vertical stiffeners and the diagonal stiffeners can have a plurality of holes configured to facilitate the placement of rebar through the panel. In an embodiment, the exterior side of the main wall can be textured to look like stucco or loose dirt. 
         [0008]    The present invention is also directed to a method of constructing a foundation wall for a structure. The method, according to an embodiment comprises the steps of: placing the structure at a predetermined height above ground; digging a trench around the perimeter of the structure, the trench being configured to have a depth necessary to accommodate the foundation wall; attaching a plurality of composite panels to the structure such that the panels hang approximately vertically in the trench. The method further comprises attaching the plurality of panels together; and thereafter placing an anchoring material in the trench around the panels to create a perimeter footing holding the panels in place and forming the foundation wall. 
         [0009]    The step of attaching the plurality of panels together can further comprise attaching the first lip of one of the plurality of panels to a second lip of a first adjacent panel and attaching the second lip of the one of the plurality of panels to a first lip of a second adjacent panel. The step of attaching the plurality of panels together may also further comprise attaching a corner piece to each two panels adjacent to each corner of the structure. Additionally, the method can further comprise the step of backfilling dirt against the foundation wall. 
         [0010]    The present invention is also directed to a kit for constructing a foundation wall for a building. The kit, comprising a plurality of panels according to the present invention; and a plurality of fasteners for attaching the panels to each other. Optionally, the kit can further comprise a plurality of corner pieces, each corner piece being configured to attach two of the panels adjacent to each corner of the building. The corner pieces can be textured to match the plurality panels. 
         [0011]    The present invention is also directed to a building having a foundation wall comprising a plurality of panels according to the present invention; and an anchoring material anchoring the plurality of panels. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    A better understanding of the present invention will be had with reference to the accompanying drawings in which: 
           [0013]      FIG. 1  is a side elevation view of a structure having foundation walls according to an embodiment of the present invention; 
           [0014]      FIG. 2  is a cross sectional view of the foundation walls of  FIG. 1 , taken along line  2 - 2 ; 
           [0015]      FIG. 3  is a side elevation view showing an interior side of a panel according to an embodiment of the present invention; 
           [0016]      FIG. 4  is a top view of the panel of  FIG. 3 ; 
           [0017]      FIG. 5  is a cross sectional view of the panel of  FIG. 3  taken along line  5 - 5 ; 
           [0018]      FIG. 6  is a side elevation view showing an interior side of two interlocked panels according to an embodiment of the present invention; 
           [0019]      FIG. 7  is a side elevation view showing an exterior side of two interlocked panels according to an embodiment of the present invention; and 
           [0020]      FIG. 8  is perspective view of a corner piece according to an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    As shown in  FIGS. 1 and 2 , the present invention is directed to a foundation wall  10  for a modular structure  12 . The structure  12  has a plurality of support beams  14 . The structure  12  is situated and the support beams  14  are placed on a plurality of piers  16  resting on pads  18 . The foundation wall  10  is formed of a plurality of panels  20  coupled to the structure  12 , anchored in an anchoring material  22 , such as concrete, and backfilled with dirt  24 . 
         [0022]    The panels  20  are formed of a composite. As used herein the term “composite” means thermoplastic containing materials. Preferably, the composite also contains reinforcing materials. The composite can also have pigments. Suitable thermoplastics will be known to those of skill in the art with reference to this disclosure, but may include, for example, acrylonitrile butadiene styrene (ABS), polypropylene, polyethylene and polyvinyl chloride (PVC). 
         [0023]    Suitable reinforcing materials will also be known to those of skill in the art with reference to this disclosure, but may include, for example, aromatic polyamide (Aramid) fiber, polyester fiber, and/or fibrous glass. Fibrous glass can include continuous and/or chopped filament glass fiber formed from oxides of, for example, silicon, aluminum, calcium, boron, and magnesium. 
         [0024]    The selection of composite materials may depend on the environment and building regulations of the location where the panels  20  are to be used. In a preferred embodiment of the present invention, the composite has by weight from about 45% to about 80% polypropylene, about 15% to about 50% fibrous glass and less than about 5% by weight carbon black. 
         [0025]    The characteristics of the panels  20  will now be considered in more detail. With reference to  FIGS. 6 and 7 , the panels  20  have an interior side  26  and an exterior side  28 . As used herein the term “interior side” refers to the side of the panel that is intended to face toward the interior of the structure. Likewise, the term “exterior side” refers to the side of the panel that is intended to face out from the structure. As will be understood by those skilled in the art, the panels can be oriented in both directions without harm to the integrity of the foundation wall. 
         [0026]    Preferably, the exterior side is textured so that if backfilled earth is not covering the panel, then the panel is attractive to look at. In an embodiment, the texture is intended to mimic the look of stucco. In an alternative embodiment, the texture is intended to mimic the look of loose dirt. 
         [0027]    With reference to  FIGS. 3 to 7 , the panels  20  are typically rectangular, but may be square. The panels  20  preferably have a length of from about 30 inches to about 60 inches, and more preferably from about 40 to about 50 inches. The panels preferably have a height of from about 30 inches to about 60 inches, and more preferably from about 36 to about 42 inches. The panels preferably have a depth of at least about 1½ inches and more preferably at least about 2 inches. The depth of the panel may vary depending on the thickness of the composite, and the environment and building regulations of the location in which the panels are to be used. 
         [0028]    The panels  20  have a first longitudinal side  30  and second longitudinal side  32 . Additionally, the panel  20  has a first lip  34  and a second lip  36  on opposite ends. The first and second lips  34 ,  36  are sized and shaped to be complementary such that two panels can be placed adjacent to each other and the first lip of one panel coupled to the second lip of the other panel to form a continuous wall. Preferably, each lip has a length of about 1½ inches to about 3 inches. Preferably, one lip maintains the appearance of the exterior side  28  of the panel, while the other lip maintains the appearance of the interior side  26  of the panel. This is so that when joined to each other, the panels appear as a solid piece. 
         [0029]    The panel  20  has a main wall  38 . The main wall  38  has an exterior side that forms the exterior side  28  of the panel and an interior side  39 . Preferably the main wall  38  has a thickness of from about 0.15 inches to about 0.25 inches. 
         [0030]    The panel  20  is formed as a webbed structure for strength. In particular, a plurality of horizontal stiffeners  40  extend from the interior side of the main wall  38  across the length of the panel  20 . Preferably, the horizontal stiffeners are spaced at intervals of about 6 inches or less. 
         [0031]    A plurality of vertical stiffeners  42  extend from the interior side of the main wall  38  across the height of the panel  20 . The vertical stiffeners  42  are spaced at intervals of about 8 inches or less. Preferably, two diagonal stiffeners  44  extend diagonally from the interior side of the main wall  38  across the panel. 
         [0032]    Preferably, the horizontal, vertical and diagonal stiffeners have a thickness of from about 0.20 inches to about 0.30 inches and extend rearward at least about 1½ inches from the main wall  38 . As will be understood by those of skill in the art, the thickness of the panel is variable as necessary to satisfy foundation structural requirements. 
         [0033]    The webbed structure allows for increased thickness and strength while using less material than a solid thickened panel. Additionally, the web of stiffeners allows for the panels to remain light enough to be easily lifted by one person. In an embodiment, the web is visible on the interior side of the panel. In an additional embodiment, an additional wall is formed on the interior side of the panel to cover the stiffeners. 
         [0034]    To span corners of the structure, two adjacent panels are joined by a corner piece  45 , as shown in  FIG. 8 . The corner piece is preferably made of the same materials as the panels  20  and preferably has the same height as the panels  20 . Preferably, the corner pieces are textured on two sides so that the corner pieces can be mounted to the interior surface or the exterior surface of the two adjacent panels. 
         [0035]    Preferably, the corner piece  45  has two rectangular portions  46 ,  48  at an angle to each other. The angle can be about 90 degrees, or another angle to suit the shape of the modular structure. Each portion has a length of from about 2 inches to about 4 inches. In an embodiment, the corner piece  45  is sized so that each face  46 ,  48  sits on one lip of each adjacent panel. One skilled in the art will recognize that it is also possible to form a corner by cutting two adjacent panels to remove the adjacent lips and fastening adjacent panels to each other on an angle. 
         [0036]    A method of forming the foundation wall of the present invention will now be described with particular reference to  FIG. 2 . Either prior to placement of the structure  12  on the piers  16 , or once the structure  12  is situated on the piers  16 , a trench is dug around the perimeter of the structure  12  for a perimeter footing. Once the trench is dug, the panels  20  are attached to the structure  12 , such as to an outer end of a floor joist or a rim joist of the structure  12 . The panels  20  can be attached to the structure  12  using a plurality of fasteners  50 , such as screws. 
         [0037]    The panels  20  can be further attached to the structure by coupling a plate  52  to both the structure  12  and the panel  20  using fasteners  50 . As used herein, the term “plate” includes boards, brackets, and other supports as typically used in by those of skill in the art. Optionally, trim panels  54  are placed over the plate  52  and affixed to the structure  12  and the panels  20 , such as by an adhesive, nails, screws or other fasteners to hide the presence of the plate  52 . 
         [0038]    The panels are attached to each other along the length of each side of the structure using fasteners such as screws  50  by attaching the first and second lips  34 ,  36  lips of adjacent panels. At the corners of the foundation wall, two panels are joined to each corner piece  45  using fasteners such as screws  50 . If necessary the panels adjacent to the corner are cut to size prior to attachment of the corner piece  45 . As will be recognized by one skilled in the art, the panels can also be attached to each other and to the corner pieces using caulking or an adhesive. 
         [0039]    Once the panels  14  are attached to the structure, the panels extend from the structure approximately vertically down into the perimeter trench. The anchoring material  22 , such as concrete, is then poured into the trench to create a perimeter footing  56  holding the panels  20  firmly in place. Preferably, the panels  20  extend at least 6 inches into the poured concrete. The concrete fills the spaces between the horizontal, vertical and diagonal stiffeners  40 ,  42 ,  44  and helps anchor the panels  20  in the concrete. 
         [0040]    Optionally, the panels  20  have holes  58  for placement of rebar  60  through the panels to strengthen the perimeter footing  56  and further anchor the panels  20  in the perimeter footing  56 . Additionally, rebar can be tied to the panels  20  using ties through holes  58 . 
         [0041]    Once in place, the panels  20  provide additional vertical support for the structure  12 . As will be understood by those skilled in the art, the panels  20  can be arranged with an opening to provide access to underneath the structure  12  such as for repairs to structural systems. Additional openings can be provided in the panels for venting as required. Dirt is then backfilled against the panels  20 . Once dirt has been backfilled, the panels provide horizontal support for the structure and prevent horizontal movement of the structure. 
         [0042]    The panels of the present invention provide several advantages. The panels are lightweight and can typically carried by one person. The panels are fast and easy to install. The panels will not rust or rot and can be installed in damp, wet or high mineral content soils. The panels are easy to cut and fit to size. The panels are easy to vent for government required ventilation. The horizontal and vertical webbing construction of the panels provides for substantial horizontal and vertical weight loads. Additionally, the panels are less expensive than metal panels. 
         [0043]    Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions described herein. 
         [0044]    All features disclosed in the specification, including the claims, abstracts and drawings, and all the steps in any method or process disclosed, may be combined in any combination except combination where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in the specification, including the claims, abstract, and drawings, can be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. 
         [0045]    As used herein, the term “coupled” means connected, such as with a fastener, connector, adhesive, or weld, and also includes structures that are integrally formed. 
         [0046]    Any element in a claim that does not explicitly state “means” for performing a specified function or “step” for performing a specified function, should not be interpreted as a “means” or “step” clause as specified in 35 U.S.C. §112.