Abstract:
The instant invention features reinforced foam building components, and methods to form affordable, energy efficient structures assembled from a plurality of panel assemblies with common features. The structures are anchored to the foundation by straps passing through the panel assemblies and attached to the foundation. The structure, the panel assemblies, the anchoring system and the assembly methods, comprise a building system for dwellings and other structures.

Description:
BACKGROUND OF THE INVENTION:  
         [0001]    1. Field of Invention  
           [0002]    This invention relates to static structures, specifically to improved components and methods to build advantageous dwellings or other enclosures.  
           [0003]    2. Discussion of Prior Art  
           [0004]    Building structures with foam panels have been developed by others as an alternative to wood methods to reduce costs and improve energy efficiency. For example, the wall panels in patents 5,279,089 to Gulur, 1994 Jan. 18, in 5,787,665 to Carlin et al., 1998 Aug. 4, and in 4,641,468 to Slater, 1987 Feb. 10, use metal framing elements to strengthen and for assembly into structures. The metal framing adds complexity to the design and creates thermal paths that circumvent the benefits of the insulating foam. Other panels in 4,628,650 to Parker, 1986 Dec. 16, introduce wood framing elements to the foam. These walls are complex, heavy and expensive to construct. The thermal performance, while better than metal framing, is degraded.  
           [0005]    Other wall panel joints in 6,065,259 to Clear, 2000 May 23, and in 2,056,290 to Alexander et al., 1991 Oct. 15, provide means to fabricate structures from a plurality of panels. These joints require complex means to fabricate the unique shapes and increase costs. These metal joints create thermal shunt paths that deteriorate the energy efficiency of the structure. The panel joints in 6,035,584 to Barreto, 2000 Mar. 14, include sealing components, improving the thermal properties but add further to the complexity and costs of the structure.  
           [0006]    Wall panel passageways in 4,628,650 to Parker, 1986 Dec. 16, are provided for easy wire routing. The passageways are interior to the panels which requires time consuming cutting to create. The application is limited to wall panels.  
           [0007]    In summary, the prior art demonstrates numerous attempts to use foam to build energy efficient structures that are inherently complex in design, complex in assembly methods and costly.  
           [0008]    Objects and Advantages  
           [0009]    The present invention provides an inexpensive, easily constructed, energy efficient dwelling unit. Accordingly, several objects and advantages of my invention are:  
           [0010]    (a) to provide a reinforced foam panel as a fundamental construction unit that is simple to fabricate, contains a strengthening element and a multipurpose passageway for advantageous purposes;  
           [0011]    (b) to provide low cost by using common materials, features and methods for floor, wall and roof panels;  
           [0012]    (b) to provide methods of assembly and joining that avoids complex joints, sealing strips and fasteners but is, nevertheless, strong, thermally advantageous and easy to do at the construction site;  
           [0013]    (c) to provide doors and windows in a manner consistent with other wall panels;  
           [0014]    (d) to provide an anchoring system that resists high winds, low pressures, and earthquake forces;  
           [0015]    (e) to provide methods to rapidly and easily assemble a plurality of construction components into affordable and energy efficient structures;  
           [0016]    (f) to provide the structure with the benefits of strength, energy efficiency, fire-resistance and water resistance of the foam material;  
           [0017]    (g) to limit the skilled labor, especially carpenters, required building the structure.  
           [0018]    The present disclosure will, for convenience and clarity, relate to and disclose a preferred form of dwelling structure. It will be appreciated that the structure, with modifications, can be used and adapted as a commercial structure or as a structure of some unspecified use. Consequently, the present invention should not be limited.  
           [0019]    The above summary and further objects, features, variations and advantages of the present invention will become apparent from the accompanying drawings and the following detailed description of the invention.  
         SUMMARY  
         [0020]    A building construction component, structured in accordance with one aspect of the invention, includes an elongated slab of rigid foam insulating material, such as expanded polystyrene, with density and thickness appropriate for the intended use, exhibiting a recess disposed along one of the longitudinal sides of the slab, wherein a reinforcing member is fixed, a portion of the recess remaining open as a passageway for wiring or other elements. In one form of the invention, the elongated slab has recesses disposed along both of the longitudinal sides with reinforcing members and passageways provided therefore on both sides. The overall dimensions of the slabs are selected, in accordance with the density and thickness of the foam, to construct a dwelling with a plurality of the building construction units used in the floor, walls and roof. Variations on the size and shape of the recess would accommodate a variety of reinforcing members and create a variety of passageways. In the preferred embodiment the recess is off-center to provide advantages in bending strength, ease of electrical connections and a large contiguous area for bonding. The reinforcing member is fixed into the recess by interference fit, adhesive bonding or other suitable means.  
           [0021]    The reinforced foam slabs of the building construction units, with windows and doors fixed to the interior thereof, are interspersed as required by the design of the structure. Reinforcing members and passageways, on one or both longitudinal sides, provide strength and space for wiring or other elements. In one form of the invention, a process is described that includes (1) cutting an appropriate opening in the foam slab, (2) bonding the window in the resulting opening, and (3) bonding a portion of the removed foam to create a flat surface. Door panels are completed in a similar manner. A structure in one of the embodiments, comprising a plurality of the building construction components of the floor, roof, and wall panels interspersed with door panels and window panels, is fabricated by applying a polyurethane or similar adhesive to the mounting area of the foundation for the first floor panel. The first floor panel is placed on the adhesive and allowed to bond. Next, adhesive is applied to the foundation area for the second panel and the surface that will abut the first panel. The second panel is placed and allowed to bond. The process is repeated for each additional panel that makes up the floor. Note that the adhesive on the side surfaces is applied in a manner to create a continuous joint that is sealed against ingress of air and moisture. Wall panels are added to edge of the floor by adhesive bonding to the floor and adjacent panels in a manner similar to the floor panels. Window and door panels are interspersed, each panel bonded as the foregoing panels, to meet the design requirements of the structure. The foam is of sufficient thickness that the wall sections are free standing and can be easily positioned into a planar surface. In one embodiment of the invention, the walls are supported by an aligning means during the bonding process to improve the flatness of the resulting wall. Roof panels are bonded in place in a like manner. Long roof spans use interior walls to provide support. Joints on the interior of the structure are bonded to control noise and air passage between spaces. The bonding material fills and seals the joint area; thereby creating a building envelope that is sealed for moisture and air leakage. The foregoing process produces a complete structure meeting the objects of the invention.  
           [0022]    One use of the passageways is to accommodate a storm strap system. This is accomplished by sizing and deploying the roof and wall panels in such a manner that the passageway of the wall and roof panels are in close proximity. A strap, such as a metal band of sufficient strength, traverses the passageway of the one wall panel, one or more roof panels, and the opposite wall panel. The strap has terminating means to attach to the foundation anchoring means. A plurality of storm straps is deployed to provide sufficient strength for the anticipated wind, pressure and earthquake loads. The straps can be inserted during or after the envelope construction since the passageways are accessible until cap pieces are added to complete the structure.  
           [0023]    The building systems of the present invention, with minor variations, can be used with a variety of foundation systems; for example, pier supports, below grade foundations, or concrete slab-on-grade. 
       
    
    
     DRAWINGS  
       [0024]    Typical embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings. In the drawings, closely related figures and items have the same number with alphabetic suffixes.  
         [0025]    [0025]FIG. 1 is an elevation view of a typical structure;  
         [0026]    [0026]FIG. 2 is a section view along line  2 - 2  in FIG. 1;  
         [0027]    [0027]FIGS. 3A to  3 E are top views of various foam slabs;  
         [0028]    [0028]FIGS. 4A to  4 D are enlarged top views of portions of the foam slabs exhibiting various recess areas, reinforcing elements and fixing means;  
         [0029]    [0029]FIG. 5 is the front portion of the section view along line  5 - 5  in FIG. 1;  
         [0030]    [0030]FIG. 6 is an exploded view of the window panel assembly 
     
    
     DETAILED DESCRIPTION  
       [0031]    Preferred Embodiment  
         [0032]    With reference now to the drawings, FIG. 1  shows a simplified elevation view of a building structure  20  incorporating a plurality and combination of wall panels  21 , window panel assemblies  22 , door panel assemblies  23 , roof panels  24 , and floor panels (Not Shown), all incorporating the elements of the present invention. Also shown are roof-to-wall caps  46 , wall-to-wall caps  48  and floor-to-wall caps  50 .  
         [0033]    As shown in FIG. 1 and the section shown in FIG.2., the structure  20  incorporates a plurality of wall panels  21  comprised of structural foam slabs  29 A, molded or extruded from expanded polystyrene. In the preferred embodiment, the foam slab  29 A is strengthened by including recess area  26 A (best seen in FIG. 3.), and reinforcing element  28 A fixed into the recess area  26 A with adhesive  27 . The structure  20  may include one or more window panel assemblies  22 , comprised of structural foam units  33  and  34 , and a window  36  fixed to the interior of the foam slab  33 , which slab  33  has been shaped to provide a mounting surface  37 . Foam slab  33  is strengthened by including recess area  26 A, reinforcing element  28 A fixed into the recess area  26 A with adhesive  27 . These later three elements are off center to provide advantages in bending strength, ease of electrical connections and a large contiguous area for bonding. The structure  20  also includes one or more exterior door panel assemblies  23  comprised of structural foam slabs  32  shaped to provide a mounting tang  35  sized appropriately for the door assembly  30 . The foam slab  32  is strengthened by including recess area  26 A, reinforcing element  28 A fixed into the recess area  26 A with adhesive  27 . A wall-to-wall cap  48  encloses the wall ends and adds passageway space in the area of the junction whereby electrical wiring  52 , telephone wire  54  and video cable  56  are routed from floor to roof. The use of the passageway shown in FIG. 2 is a typical one; other advantageous uses are anticipated.  
         [0034]    [0034]FIGS. 3A to  3 E show various foam slabs  29 A to  29 E. FIGS. 3B to  3 E show variations in recess area  26 A of foam slab  29 A to new recess areas  26 B to  26 D. The variations shown are representative of useful designs but should not be viewed as a limitation of the invention. Additional recess area designs could arise from selections of reinforcing elements or passageway requirements.  
         [0035]    [0035]FIGS. 4A to  4 D show portions of foam slab  29 A and  29 D, as representative of foam slabs that are used for any of the construction units  21  through  24 , exhibiting various means to fix the reinforcing element to any of the foam slabs described herein. FIG. 4A shows a close fit of the interior wall of recess  26 A (best seen in FIG. 3A) with steel stud  28 A. The portion of recess area  26 A not filled by the steel stud  28 A is passageway  31 A. In FIG. 4B the steel stud  28 A is placed in the recess  26 D (best seen in FIG. 3C) which has a dovetail shape. The dovetail shaped recess  26 D design increases the ease of installation and increases the retention force of the stud  28 A. In FIG. 4C the stud  28 A is bonded with polyurethane or similar adhesive  27  into recess  26 A (best seen in FIG. 3A) In FIG. 4D the stud  28 A is bonded with polyurethane or similar adhesive  27  into recess  26 D (best seen in FIG. 3D).  
         [0036]    [0036]FIG. 5 shows a vertical cross section of structure  20  along line  5 - 5  of FIG.1. A floor panel assembly  25  is shown bonded with adhesive  27  to foundation  40  containing anchor  42 . Wall panel assembly  21  is bonded to floor panel assembly  25  and roof panel assembly  24  with adhesive  27 . Each of the panel assemblies exhibits passageway  31 B. As shown in FIG. 5, the various panel assemblies, with recess areas located at the surface of the joint are bonded in relative positions such that the passageways are in close proximity thereby creating a continuous path. Anchoring strap  44  is shown attached to the anchor  42  and routed through passageway  31 B of wall panel assembly  21  into passageway  31 B of roof panel assembly  24 . The anchoring strap continues across the roof, through the opposite wall and connects to the anchor on the opposite side of the foundation (not shown). A plurality of straps, placed in additional passageways, of sufficient size and strength, anchors the structure to the foundation to provide sufficient strength for the anticipated wind, pressure and earthquake loads. FIG. 5 also shows a section view of the adhesive joint  27  between abutting panel assemblies. The passageway may also used for various utility services; the figure shows, for example, electrical wiring  52 , telephone wiring  54  and video cable  56  routing as shown in FIG. 2.  
         [0037]    [0037]FIG. 6 is an exploded view of the window panel assembly  22 . The three parts are: (1) Foam slab  33  with recess  26 A disposed on both sides and mounting area  37 , (2) window assembly  36  and (3) foam window trim component  34 . The window assembly  36  is bonded with adhesive  27  (not shown) to mounting area  37 . The foam window trim component  34  is then bonded to window assembly  36  and foam slab  33  to complete the window panel assembly  22 . A reinforcing stud  28 A (best shown in FIG. 4) may be fixed into recess  26 A before or after the window is bonded in place.  
         [0038]    The process of building a structure in accordance with this invention is described in the following. For example, consider the components shown in FIGS. 1 and 5, a structure  20  of one of the embodiments of the present invention, comprising a plurality of the building construction panel assemblies for the floor  25 , roof  24 , wall  21 , interspersed with window panels  22 , and door panels  23 , is fabricated by applying a layer of polyurethane or similar adhesive to the area of the foundation  40  for the first floor panel. The first floor panel assembly is placed on the adhesive and bonds to the foundation  40 . Next, adhesive is applied to the foundation area for the second panel and the surface of the first panel that will abut the second. The second panel is placed and allowed to bond to the foundation  40  and the first panel. The process is repeated for each additional panel that makes up the floor. Note that the adhesive on the side surfaces is applied in a manner to create a continuous joint that is sealed to air and moisture passage. Wall panel assemblies are added to edge of the floor by adhesive bonding to the floor and adjacent panels in a manner similar to the floor panels. Window and door panel assemblies are interspersed, each panel bonded as the foregoing panels, to meet the design requirements of the structure. Roof panels are bonded in place in a like manner. Long roof spans use interior walls to provide support the span. Bonding trim foam components  46 ,  50 , and  48  between roof, floor and wall ends respectively, completes the structure. The bonding provided by the instant process produces a strong, energy efficient structure that is sealed for moisture and air leakage. The process steps may be rearranged in many ways to produce the structure; the specific sequence provided herein is not a limitation of the invention. For example, the first wall assemblies can be bonded to the floor as soon as sufficient floor panel assemblies are bonded to the foundation.  
         [0039]    Building structures may also be fabricated from a combination of the components of the instant invention and other traditional materials. For example, the wall panel assemblies  21  may be used with a concrete wall foundation and a conventional trussed roof finished with shingles. Details of the wall panel assemblies may vary from the preferred embodiment but remain within the scope of the invention.  
         [0040]    Structure  20  has numerous advantages over buildings constructed using conventional techniques, and in particular to typical wood framed construction. Structure  20  is energy efficient, easy to construct, incorporates common construction items, such as windows, avoid complexity in both prefabrication and on-site stages, and has passageways throughout for anchoring, utility runs and other purposes. The net effect of these advantages is a structure that has lower cost per square foot of usable space than conventional construction.  
         [0041]    While the invention has been herein shown and described and what is presently conceived to be the most practical and preferred embodiment thereof, it will be apparent that many modifications may be made within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent methods and devices.