Abstract:
One embodiment of a Perimeter foundation panel with a leveler (FIG.  7 B) for the use in constructing a foundation wall assembled in plurality to affix a building structure to land. The panels erect on manufactured levelers, which create a freestanding foundation (FIG.  1 ) wall that adjust vertically before encasement. Formed from a single sheet of material (FIG.  3 ); cut in a pattern that comprise a top rail ( 1 ), bottom rail ( 2 ), top rim ( 5 ), bottom rim ( 6 ), a right tab ( 3 ) a left tab ( 4 ) and a flat smooth face ( 7 ). After fabrication vertical Z braces ( 14 ) are rigidly affixed in plurality with-in the cavity of the panel. C brace ( 16 ) installing at the inside of tab ( 3 , or  4 ) of adjoining panel. Constructed within a footer void ( 24 ) and cast in-situ.

Description:
CROSS-REFERENCE RELATED APPLICATION 
       [0001]    This application claims the benefit of provisional patent application Ser, No. 60/802,537, filed 2006 May 22 by the present inventor. 
     
     FEDERALLY SPONSORED RESEARCH 
       [0002]    Not Applicable 
       SEQUENCE LISTING OR PROGRAM 
       [0003]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0004]    1. Field of Invention 
         [0005]    This invention relates to the building industry, specifically to the perimeter foundation 
         [0006]    2. Prior Art 
         [0007]    Building foundations are required for all structures. The classic method is to construct a self standing foundation, then construct or install a building onto it. This method is preferred, correcting the natural undulation within the building. Although the technique is preferred; the materials are flawed 
         [0008]    U.S. Pat. No. 6,205,725 to Butler (2001) and incorporated herein by reference discloses an interlocking corrugated fluted panel that assembled in plurality, hung by an existing structure, and cast in-situ. In other words the panels are pre-hung from the existing building relying on the sill to hold the weight of the panel prior to casting. Thus, it is not self-standing 
         [0009]    Further, it evades the natural load transfer of gravity that occurs when a structure is set upon, or built upon a self-standing foundation. Also the foundation mirrors the structures flaws with in the building such as undulation. Undulation occurs when a structure moves across various terrains. Distortion of the structure occurs thus, creating tension and stress on the windows, doors, cabinets, floors, joints and seams. Consequently, the use of this foundation locks-in the undulation with no way to correct it. Some manufactures of the housing industry have denounced the use of this and voids warrantees. 
         [0010]    Further, the detail of the interlocking flute is flawed. The panel more accurately rests one edge of the flute into and onto the next. There is no rigid attachment to the adjacent panel prior to cast and thus waves, along the lateral plane, exist. 
         [0011]    U.S. Pat. No. 6,205,720 to Wolfrum incorporated herein by reference discloses a prefabricated foundation panel attaches to a pre cast concrete footer. This requires various degrees of skill and is expensive along with numerous building inspections. Further, the panel has a decorative coated facing that has no shear force or load bearing properties. In addition, numerous components comprise the panel leaving it vulnerable to failure. Failures can occur due to manufacturing, inferior quality and exposure to critical areas. 
         [0012]    The large majorities of all building foundations are either poured concrete or cinder block. Poured concrete and cinder block wall foundations are not with out problems, they frequently fail. The failures are consistent with the soil conditions and environment. Dramatic temperature change along with soil saturation, soil erosion, excessive water-bearing soil, and ground vibrations are some of the contributors. Ground vibration can be caused by mechanical means such as road traffic, construction, un-natural phenomenon (such as an explosion), and earth quakes, Another cause of failure can be attributed to a rapid undermining of surrounding soils due to floods, poor construction, or design. 
         [0013]    Several types of peering foundations for the mobile homes and manufactured homes exist. U.S. Pat. No. 6,550,199 to Phillips (2003) incorporated herein by reference, U.S. Pat. No. 6,256,940 to MacKarvich (2001) incorporated herein by reference, U.S. Pat. No. 6,536,170 to Stuever (2003) incorporated herein by reference, are all systems that support the structures “I” beam only. The I beam is the load carrying frame of the building. The frame is typically made of steel. With respect to all of these foundations the peripheral of the structure has not been addressed which requires further expense. 
       SUMMARY 
       [0014]    In accordance with one embodiment, a prefabricated foundation panel created from singular uniform sheet of metal, formed into a completed panel comprising of a top rail and rim, bottom rail and rim, a right and left side tab, and a front. The general shape of the panel is rectangular with a possible height of 14 feet and a possible width of 14 feet. However; due to the properties of the metallic material, the panel may be radius or angled. As well a metal “Z” braces of the same or lighter gauge spaced in vertical plurality at the required dimension needed for the load specification; Ridgley affixed at the top rim, bottom rim, and front of the panel. A metal C brace of the same gauge or lighter installed at each seam vertically. The panel is erected on adjustable leveler stands rigidly affixed to the bottom rail in plurality and rigidly affixed to adjacent panel with-in the void of the footer trench and cast in-situ, thus; creating a single uniform load bearing foundation structure. 
     
     
       DRAWING—FIGURES 
         [0015]      FIG. 1  is a view of the foundation interior 
           [0016]      FIG. 2  is a view of the cross section of the panel while in the footer. 
           [0017]      FIG. 3  is a view of the panel prior to formation 
           [0018]      FIG. 4  is a magnified view of the vent 
           [0019]      FIG. 5  is a view of the panel after formation 
           [0020]      FIG. 6A  is a view of the inside of the foundation with Z brace prior to C brace and leveler. 
           [0021]      FIG. 6B  is a view of the panel with the Z brace, C Brace, and leveler assembled 
           [0022]      FIG. 7A  is a view of the leveler before being assembled 
           [0023]      FIG. 7B  is a view of the leveler after being assembled 
       
    
    
     DRAWING—REFERENCE NUMERALS 
       [0024]      
         [0000]    
       
         
               
               
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                  1 
                 top rail 
                  2 
                 bottom rail 
               
               
                   
                  3R 
                 right side tab 
                  3L 
                 left side tab 
               
               
                   
                  5T 
                 top rim 
                  5B 
                 bottom rim 
               
               
                   
                  7 
                 face of panel 
                  8 
                 hole 
               
               
                   
                 12 
                 vent 
                 14 
                 Z brace 
               
               
                   
                 16 
                 C brace 
                 18 
                 nut 
               
               
                   
                 20 
                 bolt 
                 22 
                 washer 
               
               
                   
                 24 
                 footer floor 
                 26 
                 threaded rod 
               
               
                   
                 28 
                 resting top plate 
                 30 
                 bottom plate 
               
               
                   
                 28A 
                 resting top plate flange 
                 30A 
                 bottom plate tab 
               
               
                   
                 34 
                 building 
                 36 
                 concrete 
               
               
                   
                 38 
                 lag bolt 
                 40 
                 earth 
               
               
                   
                 42 
                 locking plate 
                 44 
                 rivet 
               
               
                   
                 46 
                 45 degree cut 
                 48 
                 seam 
               
               
                   
                   
               
             
          
         
       
     
       DETAILED DESCRIPTION 
     First Embodiment 
       [0025]      FIG. 1  is a view of the foundation panel  FIG. 6B  from the backside of the foundation during assembly. 
         [0026]    Panel  FIG. 6B  fabricated from a single sheet of galvanized steel.  FIG. 3  is the pre-formed galvanized steel sheet with an average thickness of 0.079 inches (14 gauge). Cut into a pattern that comprises of a top rail  1 , bottom rail  2 , a right side tab  3 R and left side tab  3 L, and a top rim  5 T and a bottom rim  5 B thus; leaving the balance of the sheet as the face of the panel  7 . However, panel  FIG. 6B  can be of any suitable material that meets load and lift requirements and the thickness of the steel can be heavier or lighter depending on the load specification. 
         [0027]    Panel  FIG. 5  is the formed panel after top rail  1 , and bottom rail  2  are bent perpendicular to the face of the panel in the same direction. Additionally; tab  3 R and tab  3 L are bent all in the same direction as the top and bottom rails, and are perpendicular to the face  7 . Finally, the top rim  5 T and bottom rim  5 B are bent perpendicular to the top  1  and bottom  2  rails towards each other.  FIG. 5  is of a rectangular shape. 
         [0028]    Panel  FIG. 5  is rigidly fastened in to shape by joining the 45° degree cuts  46  on the side,  3 R top and bottom, and tabs  3 L top and bottom. This is done by placing the locking plate  42  on the inside of tab  3 L and  3 R, straddling the seam line  48  and rigidly affixing the locking plate  42  to the inside of the tab  3 R and  3 L by the use of locking rivets  44 . In other words, the rivet inserts through the outside of the steel into the locking plate. 
         [0029]      FIG. 4  is a magnified view of the vent  12  detail. The vent  12  is directly machined into the panel leaving the surface smooth. The diameter of the vent holes  12 A is determined by the required airflow specification. The vent  12  is machined into the panel in a lateral plane commencing at a minimal one inch below the top rail  1  running parallel maintaining the minimal one-inch distance for a length determined by the required specification. The vent  12  descends longitudinally down the face of the panel. The distance of the longitudinal plane is determined by the required square feet of vent. Both the length distance and the height distance of vent  12  will be in relation to the square footage of the building  34  and the required airflow. 
         [0030]    The Panel  FIG. 5  has the benefit of using the leveler  FIG. 7B . The leveler allows for correcting the horizontal plane of the panel  6 B in the completed foundation prior to casting in concrete. In other words, the foundation panel levels by adjusting the nuts  18  on the threaded rod  26 . 
         [0031]    The leveler  FIG. 7B  benefits from a simple design.  FIG. 7A  shows the top resting plate  28  and the bottom plate  30  have flanges  28 A and  30 A for attachment with matching guide holes not numbered. The top plate flange  28 A slides down the inside vertical face of the bottom plate flange  30 A until the guide holes line up and can receive the stabilizer bolt  20 A. Further, a threaded rod  26  along with nuts  18  and washer  22  attaches the bottom plate  30  to the top plate  28  through mirrored hole not numbered thus, creating an adjustable stand  FIG. 7B  for the panel  FIG. 5   
         [0032]    The panel  FIG. 5  has the advantage allowing for the addition of vertical Z brace  14  with in the panel cavity in plurality rigidly affixed to the top rim  5 , bottom rim  6  and face  7  by the means of a locking rivet  44  for added gravity and lateral load requirements. 
         [0033]      FIG. 6A  shows the addition of the C brace  16  into the panel cavity. This is achieved by placing the face of the C channel against the inside face of the side tabs  3 R and  3 L. While securing to the adjoining panel  FIG. 6B . 
         [0034]      FIG. 1  shows the complete formed panel  FIG. 6B  in process of assembly within the footer void  24  resting upon the leveler  FIG. 7B , assembled in plurality whereas encompassing the periphery prior to cast and attachment of the structure  34 . The panels align side by side in plurality resting upon the leveler  FIG. 7   b  in succession. The panels rest on the adjacent panels leveler  FIG. 7B  while bolting together  FIG. 6A . This process continues until the foundation is complete and a uniform foundation exists. 
         [0035]    It can be appreciated and is shown in drawings although hard to see  FIG. 1  that the leveler  FIG. 7B  is offset on the panel thus, leaving a resting area for the adjoining panel while it is affixed to the preceding panel.  FIG. 6A  shows the use of a nut  18  and bolt  20  as the preferred method of ridged attachment of the panels in  FIG. 1 . 
         [0036]    Further, not shown in the drawings is the ability to manipulate the face of the panel  FIG. 5 . With plurality of reliefs notched into the top rail  1  and bottom rail  2  the panel face  7  can be angled or radius. Corner panels not shown in the drawings are made of the panel  FIG. 5  by notching a relief in the top rail  1  and the bottom rail  2  then bent inward 90° degrees and rigidly fixed into shape. 
         [0037]    Panel  6 B galvanization on the steel should be a minimum “G90” protective coating. Further, not indicated in the drawing commencing the completion, the use of polyurethane based caulk or mastic on the joint creates a watertight seal. Also not shown upon completion of the foundation the use of an emulsified tar, epoxy based paint or a cement coating of no less than 33% Portland cement applied directly to the panel face  7  for increasing the longevity of panel from many soil types. 
         [0038]    The concrete depth  36  is in relation to the load and forces requirement. 
         [0039]      FIG. 2  is of the cross section of a completed foundation after concrete cast. The building  34  attaches by the use of a lag screw  38 . In other words, the drawing depicts a typical construction detail provided for this style of foundation. 
       Operation—FIG. 1 
       [0040]    The manner of using the perimeter panel foundation  FIG. 6B  for the attachment of a building structure to the earth is achieved by assembling the panel within in the footer void  24  and cast in-situ. 
         [0041]    A footer void is created by excavating a specific amount of earth material typically with the use of hand tools such a shovel to a perspective depth determined by the load factors. 
         [0042]    The panel  FIG. 6B  is set into the footer void with the leveler standing on the bottom of the footer. The panel  FIG. 6B  is then placed side by side to the previous keeping the faces flush. 
         [0043]    The panels are lifted off the footer floor  24  via the leveler  FIG. 7B , the c brace  16  is then placed into the panel cavity  FIG. 1  with the face of the C brace  16  towards the inside; side tab  3 L, and the parallel C tabs not numbered heading toward the Z brace  14 . A bolt  20  is then placed through the C brace  16  and through the existing panels side tab  3 L from the inside of the panel, through the adjoining panel side tab  3 R. A nut  18  completes the rigid attachment. 
         [0044]    This process repeats longitudinally down the tabs  3 L and  3 R and C brace  16  until the side tabs of each panel are complete and rigidly fastened down the vertical plane. 
         [0045]    A bubble lever or equivalent device checks along the horizontal plain making sure the top rails are level. Adjustments to the leveler stand  FIG. 7B  is done by releasing the tension on the top nut  18  or in other words, backing the nut up and then turning the opposing nut on the bottom side of the top plate in the direction required for the adjustment. Once the adjustment is satisfied, the top nut is firmly tightened against the inside of the bottom rail  FIG. 6B  not shown. 
         [0046]    The previous process repeats until the entire foundation wall is level. The use of temporary braces made of wood against the face of the panel or in the back, wedged at a 45° degree angle to maintain the vertical plumb plain of the face of the panel. 
         [0047]    With the panels level and plumb to each other; concrete  36  pumps into the footer void encasing the base of the panel and the leveler both front and back to become the footing and foundation  FIG. 2 . After ample time is allowed for the curing of the concrete the building is then to be placed on the foundation or built. By attaching the sill to the top rail via a lag screw  38   
         [0048]    Prior to back filling against the wall, a coating is applied comprising of either emulsified tar, rubber based sealant, or a concrete coating. To maintain a watertight joint seam between panels a polyurethane caulking is applied. 
       Advantages 
       [0049]    From the above description, a number of advantages of some of the embodiments of my perimeter foundation panel become obvious.
       (a) The simplicity of the panel allows all skill levels to assemble the foundation without extensive knowledge or training.   (b) The simplicity in the design uses basic hand tools thus not requiring expensive proprietary devices.   (c) The structural integrity is evident with the use of a singular uniform sheet of metallic material not requiring attachment of each separate component. The uniform panel has limited attachment points and a uniform face that integrates with-in the panel structure adding immense strength to the panel.   (d) The face of the panel acts a structural support for shear forces, gravity loads, lifting loads and side impact loads.   (e) The uniquely designed leveler allows for the vertical adjustment of the horizontal plain of the panels leading edge prior to encasement, allowing for an accurately level surface accepting the sill plate.   (f) The method of assembly within the footer void is advantageous in that the panel becomes an internal component of the footing and thus creates a uniform structure with unlimited beneficial strength.   (g) The unique method of assembly in the footer void is advantageous in that the footer void is established and the panel assembly is the only metallic material required to comprise the structural integrity of the footer after encasement, further, no special skill levels are required to construct the footing.   (h) The simplicity in the panel design and method of use reduces the time need to erect a foundation.   (i) The use of the perimeter foundation panel on manufactured buildings reduces the installation time.   (j) The use of the perimeter foundation panel is beneficial in existing buildings that need foundation wall replacement.   (k) The use of the perimeter foundation panel on new construction reduces the foundation expense whereas steel material is less expensive.   (l) The use of the perimeter foundation panel is easily handled requiring limited installers   (m) The encasement of the panel allows for future conversions of the building by easy detachment of the panel.       
 
       CONCLUSION, RAMIFICATION AND SCOPE 
       [0063]    Accordingly, the reader will see that the perimeter foundation panel of various embodiments provides a more reliable prefabricated panel with limited skill requirement, comprised of light weight alternative to block or concrete, yet less expensive, free standing, that is an accelerated assembly, and adaptable for any building requiring a foundation. 
         [0064]    While my above description contains many specificities, these should not be construed as limitation on the scope of the invention, but rather as an exemplification of several preferred embodiments thereof. Many other variations are possible. For example
       The leveler can be changed or removed   The thickness of the material can be changed   The material composition of the panel can be changed   The face of the panel can have various facade   The shape of the panel can change   The design of the leveler can be modified   The method of securing the shape can change   The method of attachment to sill can change   Addition of alternative structural beams and supports   Encasement methods can change   Encasement materials can change   C brace can be changed or removed or added   Z brace can be changed or removed or added