Wood foundation walls and foundations formed with such walls

A permanent wood foundation wall which includes a frame having a first member, a second member spaced apart from the first member, and two side members. The first member, second member, and two side members each have a front surface and a rear surface that form the front frame surface and the rear frame surface. A cavity is formed between the front frame surface and the rear frame surface of the frame and the first member, second member, and two side members are formed from a wood material including a preservative. Further, the permanent wood foundation wall includes a sheathing board having a first side attached to the rear frame surface of the frame and a second side opposite the first side, a waterproofing membrane applied to the second side of the sheathing board, and a foam layer formed within the cavity of the frame.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to wood based foundation walls and related areas such as crawlspaces formed with the wood based foundation walls.

Description of Related Art

Current methods for constructing residential foundation walls, such as for northern climate basements or southeastern crawlspaces, require pouring concrete and/or using block masonry. For instance, current methods for constructing residential foundation walls typically require pouring concrete to form the footers and the interior floor of the basement and/or using concrete blocks. While concrete and block masonry provide a stable foundation wall, the process is time consuming, costly, and labor intensive. As such, it is desirable to provide improved foundation walls that overcome the deficiencies of current foundation walls that require pouring concrete and/or using block masonry.

SUMMARY OF THE INVENTION

In certain non-limiting embodiments, the present invention includes a permanent wood foundation wall. The foundation wall comprises a frame that includes a first member, a second member spaced apart from the first member, and two side members extending between the first and second members. The first member, second member, and two side members each have a front surface and a rear surface that form the front frame surface and the rear frame surface of the frame. A cavity is formed between the front frame surface and the rear frame surface of the frame and the first member, second member, and two side members are formed from a wood material comprising a preservative. Further, the permanent wood foundation wall includes a sheathing board comprising a first side attached to the rear frame surface of the frame and a second side opposite the first side, a waterproofing membrane applied to the second side of the sheathing board, and a foam layer formed within the cavity of the frame and which is bounded by the first member, the second member, two side members, and the sheathing board.

In some non-limiting embodiments, the permanent wood foundation wall further comprises an additional board attached to the front frame surface of the frame. The additional board can include drywall, for example. A gap can also be formed within the frame between the foam layer and the front frame surface.

In some non-limiting embodiments, the frame further includes at least one primary support member positioned between the two side members and extending between the first and second member in which the primary support member defines a front primary support surface and an opposite rear primary support surface corresponding to the front frame surface and rear frame surface. The frame can also include one or more secondary support members extending between the two side members.

In certain non-limiting embodiments, the foam layer is formed in situ during the manufacturing process. Moreover, in some non-limiting embodiments, the preservative is a copper based preservative such as a chromated copper arsenate preservative. The copper based preservative can have a minimum retention level of 0.30 lbs per cubic foot of wood.

Further, the waterproofing membrane can comprise a rubberized membrane, a UV resistant polyethylene sheet with all seams and overlaps embedded into a sealant material, or a combination thereof. The sheathing board can comprise polyisocyanurate, wood, high density insulation, composites of plastic materials, metal (e.g., metal sheet and/or metal netting), or any combination thereof. In addition, at least a portion of the second side of the sheathing board can comprise a cementitious parge coating.

The present invention also includes a foundation or crawlspace of a building comprising: (i) a gravel base layer; and (ii) the previously described permanent wood foundation wall positioned over the gravel base layer. A concrete footer can also be positioned between at least a portion of the second member of the frame and the gravel base. Further, a rod can be placed through the second member of the permanent wood foundation wall and the gravel base layer.

The present invention is also directed to the following clauses.

Clause 1: A permanent wood foundation wall comprising: (a) a frame comprising: a first member; a second member spaced apart from the first member; and two side members extending between the first and second members, wherein the first member, second member, and two side members each have a front surface and a rear surface that form the front frame surface and the rear frame surface of the frame, and wherein a cavity is formed between the front frame surface and the rear frame surface of the frame, wherein the first member, second member, and two side members are formed from a wood material comprising a preservative; (b) a sheathing board comprising a first side attached to the rear frame surface of the frame and a second side opposite the first side; (c) a waterproofing membrane applied to the second side of the sheathing board; and (d) a foam layer formed within the cavity of the frame and which is bounded by the first member, the second member, two side members, and the sheathing board.

Clause 2: The permanent wood foundation wall according to clause 1, further comprising an additional board attached to the front frame surface of the frame.

Clause 3: The permanent wood foundation wall according to clause 2, wherein the additional board is drywall.

Clause 4: The permanent wood foundation wall according to any of clauses 1-3, wherein a gap is formed within the frame between the foam layer and the front frame surface.

Clause 5: The permanent wood foundation wall according to any of clauses 1-4, wherein the foam layer is formed in situ during the manufacturing process.

Clause 6: The permanent wood foundation wall according to any of clauses 1-5, wherein the preservative is a copper based preservative.

Clause 7: The permanent wood foundation wall according to clause 6, wherein the copper based preservative has a minimum retention level of 0.30 lbs per cubic foot of wood.

Clause 8: The permanent wood foundation wall according to any of clauses 1-7, wherein the frame further comprises at least one primary support member positioned between the two side members and extending between the first and second member, wherein the primary support member defines a front primary support surface and an opposite rear primary support surface corresponding to the front frame surface and rear frame surface.

Clause 9: The permanent wood foundation wall according to any of clauses 1-8, wherein the frame further comprises one or more secondary support members extending between the two side members.

Clause 10: The permanent wood foundation wall according to any of clauses 1-9, wherein the waterproofing membrane comprises a rubberized membrane, a UV resistant polyethylene sheet with all seams and overlaps embedded into a sealant material, or a combination thereof.

Clause 11: The permanent wood foundation wall according to any one of clauses 1-10, wherein the sheathing board comprises polyisocyanurate, wood, high density insulation, composites of plastic materials, metal, or any combination thereof.

Clause 12: The permanent wood foundation wall according to any one of clauses 1-11, wherein the sheathing board comprises polyisocyanurate.

Clause 13: The permanent wood foundation wall according to any of clauses 1-12, wherein at least a portion of the second side of the sheathing board comprises a cementitious parge coating.

Clause 14: A foundation or crawlspace of a building comprising: (i) a gravel base layer; and (ii) a permanent wood foundation wall positioned over the gravel base layer, the permanent wood foundation wall comprising: (a) a frame comprising: a first member; a second member spaced apart from the first member; and two side members extending between the first and second members, wherein the first member, second member, and two side members each have a front surface and a rear surface that form the front frame surface and the rear frame surface of the frame, and wherein a cavity is formed between the front frame surface and the rear frame surface of the frame, wherein the first member, second member, and two side members are formed from a wood material comprising a preservative; (b) a sheathing board comprising a first side attached to the rear frame surface of the frame and a second side opposite the first side; (c) a waterproofing membrane applied to the second side of the sheathing board; and (d) a foam layer formed within the cavity of the frame and which is bounded by the first member, the second member, two side members, and the sheathing board.

Clause 15: The foundation or crawlspace according to clause 14, wherein a concrete footer is positioned between at least a portion of the second member of the frame and the gravel base.

Clause 16: The foundation or crawlspace according to clauses 14 or 15, further comprising an additional board attached to the front frame surface of the frame.

Clause 17: The foundation or crawlspace according to clause 16, wherein the additional board is drywall.

Clause 18: The foundation or crawlspace according to any of clauses 14-17, wherein a gap is formed within the frame between the foam layer and the front frame surface.

Clause 19: The foundation or crawlspace according to any of clauses 14-18, wherein the foam layer is formed in situ during the manufacturing process.

Clause 20: The foundation or crawlspace according to any of clauses 14-19, wherein the preservative is a copper based preservative.

Clause 21: The foundation or crawlspace according to any of clauses 14-20, wherein the waterproofing membrane comprises a rubberized membrane, a UV resistant polyethylene sheet with all seams and overlaps embedded into a sealant material, or a combination thereof.

Clause 22: The foundation or crawlspace according to any of clauses 14-21, wherein the sheathing board comprises polyisocyanurate, wood, high density insulation, composites of plastic materials, metal, or any combination thereof.

Clause 23: The foundation or crawlspace according to any of clauses 14-22, wherein at least a portion of the second side of the sheathing board comprises a cementitious parge coating

Clause 24: The foundation or crawlspace according to any of clauses 14-23, further comprising a rod that extends through the second member of the permanent wood foundation wall and the gravel base layer.

DESCRIPTION OF THE INVENTION

Further, the terms “upper,” “lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,” “lateral,” “longitudinal,” and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the specification, are simply exemplary embodiments and aspects of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments and aspects disclosed herein are not to be considered as limiting.

In this application, the use of the singular includes the plural and plural encompasses singular, unless specifically stated otherwise. In addition, in this application, the use of “or” means “and/or” unless specifically stated otherwise, even though “and/or” may be explicitly used in certain instances.

Referring toFIGS. 1-3, in certain non-limiting embodiments, the present invention includes a wood foundation wall10having a frame12and a foam layer8. As shown inFIGS. 2 and 3, the frame12is defined by a first member14, a second member16spaced apart from the first member14, and two side members18extending between the first member14and the second member16. In certain non-limiting embodiments, the first member14, second member16, and two side members18each have a front surface14a,16a,18aand a rear surface14b,16b,18bthat define a front frame surface12aand a rear frame surface12b, respectively.

The frame12can be constructed into different shapes. In certain embodiments, as shown inFIGS. 1-3, the frame12can be constructed as a conventional industry standard rectangular or square frame12. For example, as shown inFIGS. 2 and 3, the first member14and second member16may be spaced apart and extend parallel to each other, and the two side members18may extend perpendicular to the first member14and second member16so as to form a rectangular or square frame12. The shape and design of the frame12is not so limited and can be constructed into any desired shape.

The frame12can also include additional members such as primary support members20that are positioned between the two side members18and which extend from the first member14to the second member16. The primary support members20may define a front primary support surface20aand a rear primary support surface20b.

In certain embodiments, the first member14, second member16, two side members18, and optionally, primary support members20are spaced apart to form cavities19. The cavities19may be defined by the area between the primary support members20, two side members18, first member14, and/or second member16. The size of each cavity19will vary based on the size of the frame12.

Further, the primary support members20, side members18, first member14, and/or second member16may comprise one or more plates, boards, beams, or the like. In certain embodiments, the two side members18and/or primary support members20are fixedly engaged to the first member14and second member16. For instance, in certain embodiments, the two side members18and/or primary support members20are fixedly engaged to the first member14and second member16with fasteners. Suitable fasteners that can be used with the present invention include, but are not limited to, nails, staples, bolts, screws, plates, and rivets.

The dimensions of the first member14, second member16, two side members18, and primary support members20can vary. In certain embodiments, the first member14, second member16, two side members18, and primary support members20have the same dimensions. For example, the first member14, second member16, two side members18, and primary support members20may have the same width and height dimensions. In one non-limiting embodiment, the first member14, second member16, two side members18, and primary support members20all have a width and height dimension of nominally 2×4 inches, 2×6 inches, or 2×8 inches.

In certain non-limiting embodiments, the first member14, second member16, and two side members18have the same dimensions that are different from the dimensions of the primary support members20. For example, the first member14, second member16, and two side members18may have the same width and height dimensions, and the primary support members20may have width and height dimensions that are different from the first member14, second member16, and two side members18.

In addition to the above, and as shown inFIGS. 1-3, one or more secondary support members22may be used. The secondary support members22may comprise one or more boards, beams, or the like. The secondary support members22are incorporated into the frame12to provide structural support. Further, the secondary support members22can have dimensions that are the same or different from the primary support members20, side members18, first member14, and/or second member16. As shown inFIGS. 1-3, the secondary support members22may have a front secondary support surface22aand a rear secondary support surface22b. It is appreciated that the secondary support members22can help form the cavities19.

In certain non-limiting embodiments, additional support members and structural elements may also be used. For example, a header24may be used to provide additional support. Other additional support members may be used for structural purposes, design purposes, and the like.

In accordance with the present invention, the frame12is formed from a wood material comprising a preservative. As such, the first member14, second member16, and two side members18are made of a wood material comprising a preservative. When additional members are used such as a primary support member20and/or a secondary support member22, the additional members can be made of a wood material comprising a preservative. As used herein, a “preservative” refers to a material that inhibits and protects wood against decay and rot. By using a preservative, the frame12is suitable as a frame12for a foundation wall10that can be used in conditions that would otherwise decay or rot a wood material.

Non-limiting examples of a wood preservative include a copper based preservative such as a chromated copper arsenate preservative. The copper based preservative can have a minimum retention level of 0.30 lbs per cubic foot of wood, or a minimum retention level of 0.60 lbs per cubic foot of wood. As used herein, a “retention level” refers to the amount of preservative left in the wood being with a preservative. The retention is measured by pounds of preservative per cubic foot of the wood.

In certain embodiments, a foam material is deposited into the frame12. As used herein, the term “foam material” refers to a substance that is formed by trapping pockets of gas in a liquid or solid. In some non-limiting embodiments, the foam material is a closed-cell foam. As used herein, “closed-cell foam” refers to foam that contains discrete, non-interconnecting cells. Non-limiting examples of foam material that can be used with the present invention include materials made with polyurethane, polyisocyanurate (also referred to as polyiso), and mixtures thereof.

In some embodiments, the foam material may be substantially free, may be essentially free, and may be completely free of halogen containing flame retardant additives. The term “halogen” refers to the halogen elements, which include fluorine, chlorine, bromine, and iodine, and the term “halogen containing flame retardant additives” refers to a substance that may be used to inhibit or resist the spread of fire and which contains halogen groups such as a fluoro, chloro, bromo, and/or iodo group. Further, the term “substantially free” as used in this context means the foam material contains less than 1000 parts per million (ppm), “essentially free” means less than 100 ppm, and “completely free” means less than 20 parts per billion (ppb) of halogen containing flame retardant additives.

The foam material can be deposited into the frame12such that the foam material forms a foam layer8within at least a portion of the frame12between the front frame surface12aand the rear frame surface12b. The foam layer8may extend beyond the front primary support surfaces20asuch that the foam layer8overlies the front support surfaces to form a continuous or uninterrupted exposed foam surface. As used herein, “continuous or uninterrupted foam layer” refers to a foamed material that is connected or bonded along at least one path without a break or interruption.

In certain embodiments, the foam layer8extends beyond the front primary support surfaces20aand the front frame surface12a. As such, the foam layer8forms a continuous or uninterrupted exposed foam surface over the front primary support surfaces20aand the front frame surface12a.

Alternatively, the foam layer8does not extend beyond the front frame surface12a. For example, the foam layer8can only extend beyond the front primary support surfaces20a. In some non-limiting embodiments, the foam layer8forms a continuous or uninterrupted exposed foam surface over the front primary support surfaces12aand is flush or contained between the front and rear frame surfaces12a,12b.

The foam layer8can be dimensioned to expand from the uninterrupted exposed surface to a position intermediate the front frame surface12aand rear frame surface12b, thereby forming a gap or opening40within the foam wall structure10between the foam layer8and the front frame surface12a. This gap40can be used as an area to incorporate home utility components42such as electrical wires, cords, heating and cooling pipes, and plumbing fixtures. These home utility components42may be inserted into the gap40located between the foam layer8and the rear frame surface12bsuch that utility components42are not surrounded or contacting the foam layer8. In certain embodiments, the gap40comprises at least two inches as measured between the foam layer8and the front frame surface12a.

As shown inFIGS. 4 and 5, the secondary support members22can extend through the foam layer8.FIG. 4further illustrates horizontal blocking members100(e.g. wood, plastic, metal, or any combination thereof) that can be placed between the secondary support members22to provide more strength to the foundation wall10. The spacing and size of the secondary support members22is determined by the foundation wall10design, location, soil type, and back fill height.

Further, the foam layer8can be formed in-situ during the manufacturing process. The term “formed in situ during the manufacturing process” refers to the formation of a foam layer8as described herein during manufacturing of the wood foundation wall structure10off-site at a facility remote or away from a building construction site. As such, the foam layer8may not be formed at a construction site as is required by conventional methods.

The foam layer8is able to fill tight spaces and seal gaps40that are not visible to the naked eye. The foam layer8, such with an uninterrupted exposed foam surface, also acts as a vapor and thermal insulating barrier, which reduces energy consumption in buildings and residential homes when the present invention is used as a wall panel. In addition, the foam layer8provides structural stability to the foam wall structure10such as improved wall racking strength. As used herein, “wall racking strength” refers to the ability of a wall structure to maintain its shape under duress.

In certain embodiments, the foam layer8may include a coating adhered to at least a portion of the exposed foam surface. As used herein, the term “coating” includes a partial or continuous film or layer that can be applied to a surface. Non-limiting examples of coatings that can be adhered or attached to the exposed foam surface includes coatings that provide protection from ultraviolet (UV) radiation, weathering, or a combination thereof. The coating36can also provide stability to the exposed foam surface. For example, the coating36may include fibrous materials such as, but not limited to, glass fibers.

An example of a frame structure having a foam layer is described in U.S. Pat. No. 8,925,270, which is incorporated by reference herein in its entirety.

In accordance with the present invention, a sheathing board50is attached to the rear frame surface12b. In particular, and as shown inFIG. 1, the sheathing board50comprises a first side52attached to the rear frame surface12b, such as directly to the rear frame surface12b, and a second side54opposite the first side52. Non-limiting examples of a sheathing board include a board formed with polyisocyanurate, wood, high density insulation, composites of plastic materials, metal, and any combination thereof.

In certain non-limiting embodiments, the sheathing board50is applied to the frame12off-site at a facility remote or away from a building construction site. Further, the sheathing board50can be applied to the frame12such that the sheathing board50is applied over the entire rear frame surface12b. The sheathing board50can also have a coated glass facer on the front and/or back of the board50. It was found that the sheathing board50provides good water resistance and additional strength.

In certain non-limiting embodiments, at least a portion of the second side54of the sheathing board50comprises a cementitious parge coating55. The cementitious parge coating55can also be applied over the coated glass facer when used. A “cementitious parge coating” refers to a partial or continuous film or layer of cementitious or polymeric mortar. The cementitious parge coating55helps provide water-resistant properties. In some non-limiting embodiments, the cementitious parge coating55is only applied over a portion of the sheathing board50that is not applied over the foundation walls. Alternatively, the cementitious parge coating55is applied over an entire portion of the second side54of the sheathing board50. The cementitious parge coating55can also be applied off-site at a facility remote or away from a building construction site.

In some non-limiting embodiments, a waterproofing membrane60is applied to the second side54of the sheathing board50. The waterproofing membrane60can be applied directly to the sheathing board50, or the waterproofing membrane60can be applied to the sheathing board50after application of a cementitious parge coating55. The waterproofing membrane60can be applied over a portion of the sheathing board50such as, in certain embodiments, over a portion of the sheathing board50that does not have a cementitious parge coating55for example. In some non-limiting embodiments, the waterproofing membrane60can be applied over the entire portion of the sheathing board50, directly or over a cementitious parge coating55or both. The waterproofing membrane60can be applied off-site at a facility remote or away from a building construction site.

Non-limiting examples of waterproofing membranes60include a rubberized membrane, a UV resistant polyethylene sheet with all seams and overlaps embedded into a sealant material, or a combination thereof. Further, non-limiting examples of sealant materials include heat sealable polymeric materials.

The wood foundation wall10can also include additional components. For example, the wood foundation wall10can have additional board(s)70attached to the front frame surface12aof the frame12. The additional board(s)70can include, but are not limited to, gypsum boards. The wood foundation wall10can further include additional end plates at the corners.

The wood foundation wall10can be prepared using various techniques. In certain non-limiting embodiments, the wood foundation wall10is prepared off-site such as, for example, by first forming the frame12horizontally on a framing table. The wood materials used to form the frame12are treated with a preservative as previously described. A sheathing board50can then be applied to the rear frame surface12bof the frame12. After turning the frame12to the opposite side, foam can be sprayed into the cavities19to form the foam layer8. The wood foundation wall10can be turned again to apply a cementitious parge coating55over at least a portion of the sheathing board50followed by a waterproofing membrane60. After placing the wood foundation wall10in a building, additional boards70such as a gypsum board can be placed over the front frame surface12aof the wall10.

As indicated, the claimed invention is also directed to a foundation or crawlspace of a building that can include any of the previously described wood foundation walls10. The foundation or crawlspace can comprise a gravel base layer80and a permanent wood foundation wall10positioned over the gravel base layer80. As shown inFIG. 1, a concrete footer82can further be positioned between at least a portion of the frame12, such as the second member16of the frame12, and the gravel base layer80. Alternatively, and as shown inFIGS. 6 and 7, there is no concrete footer82, and the frame12is positioned only over a gravel base layer80. It is appreciated that utilities42such as plumbing and electrical components can be placed in the gap40of the wall10.

Referring toFIG. 1, a cable90can also extend through the gap40of the wood foundation wall10to provide further support to the foundation. It is appreciated that the cable90can extend through the entire building to provide support to the entire structure.

As shown inFIG. 8, a rod92can be placed through at least a portion of the second member16(and optional end plate if used) and the gravel base80and into the soil prior to pouring concrete. For example, the rod92can extend through the soil at a length of at least 20 inches or at least 24 inches. The use of the rod92can help resist lateral loads from the back fill of gravel and soil against the wall10and prevent the wall10from sliding into the basement or crawlspace of the home prior to pouring a finished floor in the basement or crawlspace. The rod92will therefore help speed up the build cycle for the home and not be dependent on the timing of pouring the slab in the basement or crawlspace.

It was also found that the wood foundation wall10provides a fully integrated and insulated/waterproofed structure that is prepared offsite and which exhibits good energy efficiency properties, easy routing of utilities, and no condensation and moisture risks. In addition, the wood foundation wall10also provides significant cost savings because it can be prepared off-site with less materials and labor requirements.

It is appreciated that the wood foundation wall10can be used with other wall structures. For example, multiple wood foundation walls10can be used together in a basement and/or crawlspace. In such embodiments, the first member12of the wood foundation wall10can be placed below a second member16of a second wood foundation wall10, directly or indirectly. As shown inFIG. 9, when two wood foundation walls10are used, the waterproofing membrane60of one of the wood foundation walls10can be extended over the waterproofing membrane60of the second wood foundation wall10in order to provide a continuous waterproofing barrier.

The wood foundation wall10can also be used with different wall structures such as wall structures used on different floors in which the wall foundation wall(s)10and the other wall structures extend together through the entire house or building.

While several embodiments of the invention were described in the foregoing detailed description, those skilled in the art may make modifications and alterations to these embodiments without departing from the scope and spirit of the invention. Accordingly, the foregoing description is intended to be illustrative rather than restrictive.