Integrated, high strength, lightweight, energy efficient building structures
An integrated, high strength, lightweight building structure that withstands seismic, flooding, and 250 mph wind loads and is resistant to wood destroying organisms, mildew, mold, rot, and water damage. The structural system incorporates watertight seals between the walls and flooring system, the joints in the walls, and around the doors and windows. The eaves and roof incorporate a novel design that distributes to the structural members the uplift forces caused by extreme wind loading events.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/898,916, filed on Feb. 1, 2007.
BACKGROUND OF THE INVENTIONThe present invention relates generally to structural systems and components for residential and light commercial buildings, and more specifically to high-strength structural components for eaves, wall panels, ceiling panels, roof panels and floor joints, overhead joist and columns of these buildings. Also included are methods of attaching the components together, thereby forming a high strength integrated structure or enclosure.
In recent years, hurricanes have caused billions of dollars in damage by decimating many homes in the coastal regions of the Carolinas and Gulf states. The destruction is caused by high wind forces and flooding due to excessive rain and high storm surges. As a result of this destruction, many families have lost their homes, and some of the largest insurance companies no longer offer new homeowner policies in coastal states. The invention described herein seeks to address these problems.
The invention comprises an integrated, high strength, lightweight building structure to withstand 250 mph wind loads and resist wood destroying organisms, mildew, mold, rot, and water damage. The design incorporates special integration of high strength composite structural panel designs, which enable the structure to resist more than twice the allowable wind loads without increasing the framing requirements. The rigid reinforced foam panels with the lightweight steel structure become highly energy efficient. Heat flow through the walls and roof become less than half of conventional structures due to the foam in the panels and the increased wall thickness. In addition, the panels in these structures are particularly resistant to seismic loading because of their greatly increased shear strength. The wall panels in the structural system are installed in or on sealed floor tracks, thereby creating a watertight seal between the wall and the flooring system. Finally, the eaves of the structure incorporate a design that enhances the strength of the structural connection between the roof panel and the top of the exterior wall. This added strength resists the magnified uplift forces experienced by the structure during extreme wind loading events.
The composite design of the structure provides for factory production of finished wall, ceiling, and roof panels. All plumbing and wiring can be installed in a factory setting, greatly streamlining the building fabrication and permitting process, allowing for quick and quality construction at a lowered cost to the consumer. These structures will dramatically decrease the risk to owners, lenders, insurance providers and municipalities.
SUMMARY OF THE INVENTIONThe structure is built on a generally solid foundation, such as a concrete slab. Floor tracks are attached to the foundation, and columns and wall panels are attached to the floor tracks or directly to the floor of foundation. Seals are placed around the floor tracks of the exterior walls to create a bond to the foundation and a watertight seal. Seals are incorporated into the joints in the exterior walls, further enhancing the strength and the watertight properties of the structure. The exterior doors open outward, and a seal is attached to the doorframe between the frame and the outward-opening door. Thus, the seal tightens as wind and hydrostatic pressure forces increase.
The wall panels connect with a cross-in-cube arrangement incorporating high-strength connection brackets and high strength wall panels. Ceiling panels are attached across the top of the wall panels to complete the cross-in-cube arrangement. The panels are typically made of structural sheeting, fibers and bonding agents attached to each other on opposite sides of composite stud members. In addition to these composite panels, composite beams and columns may be used to add strength to the structural frame. The fibers may be manufactured from current materials such as glass, carbon, arimid or nano technology structures.
The eave structure distributes roof loads across the top of the exterior wall, thus preventing overloading of local members. The eave members, connected by high strength brackets, form a rigid truss. A roof truss is not needed because of the high strength eave connection and the high strength exterior wall, ceiling, and roof panels.
With reference to the drawings, the invention will now be described with regard for the best mode and the preferred embodiment. In general, the invention comprises an integrated, high strength, lightweight building structure to withstand flooding, seismic, and up to 250 mph wind loads. In addition, the building structure is constructed from materials that resist wood destroying organisms, mildew, mold, rot, and water damage. The structural system is made from composite beams, columns, and structural panels.
In
The first alternate design of these members, as shown in
The second alternate beam design, shown in
The third alternate beam design, shown in
The fourth alternate beam design, shown in
The fifth alternate beam design, shown in
The sixth alternate beam design, shown in
The seventh alternate beam design, shown in
Preferably, the structural panels 20 described here are prefabricated. One alternate design of the panels 20, as shown in
Generally, the structural panels 23 are connected to the panel studs 21 by sheeting fasteners 32 (shown in
In one alternative design, the rigid reinforced foam 22 is bonded to the panel studs 21, which are made from any metal, polymer, carbon composite, or other sufficiently rigid material. The structural panels 23 are constructed from any metal, carbon composite, plywood, chip board, polymer panel, fiber-reinforced material or other material with sufficient strength. When fiber-reinforced material is used, such material can comprise a bonding agent, such as latex or polyester resin or epoxy material, adhered to a tight weave cloth, scrim, or roving member. The roving member can be glass, carbon, metal, aramid, and other materials depending on cost and weight limits to the design. Optionally, the bonding agents are also used to bond the panels to the structure. The sheeting fasteners 32, which are mechanical fasteners used either with or without adhesive bonds, are used to attach the panels to the structure in a manner to transmit the forces directly through the mechanical/bonded joints 32 and into the structural panels 23, which become the primary resistance to shear and bending. In this alternative design, the pressure force on one side of the panel sheeting is transmitted to the opposite sheeting via rigid reinforced foam 22, thus allowing thinner sheeting.
Generally, the arrangement of elements in the panels 20, as described above, applies to the ceiling, floor, and roof panels, as shown in
In an alternative design, the panel studs 21 are steel shapes, preferably having a closed cross section (see
One alternative orientation of panels 20, shown in
The fascia cover 45, which can be continuous and decorative, connects the soffit 46, which is preferably a high strength vinyl covered element, thereby preventing uplift of the roof sheeting 47 and securing the cover of the soffit 46 as wind forces shift. The fascia cover 45 and soffit 46 can be ornamented as desired. All attachments in the “Hurricane Eave” may be accomplished with mechanical fasteners, welds, or chemical bonds. The fascia cover 45 and all other brackets may be made of any metal, polymer, carbon composite, or other material with sufficient strength, which allows standard architectural designs or achievements.
The ceiling panel 26 is attached to the exterior wall 29 by a sill plate 27 and a lower bracket 28, which preferably form continuous attachments. Rather than resting on top of the exterior wall 29, the ceiling panel 26 is oriented so that it abuts the exterior wall 29 on the wall's interior side. The vent 49 is an opening in the foam of the roof panel 33 that allows for thermostatically and volumetrically controlled forced draft ventilation of the attic, thereby preventing rapid pressure changes in the attic spaces caused by high wind pressure. The vents 49 also promote ventilation of the structure, which can be an important feature when the lower level structural joints and seams are vapor tight. The roof cover 50 is bonded or mechanically fastened to the roof sheeting 47. Alternatively, the roof cover 50 can be bonded or mechanically fastened directly to the roof panel 33, without any roof sheeting 47.
Referring to
In another embodiment, depicted in
In another embodiment, shown in
The vertical joints of the exterior wall, depicted in
As shown in
A “Living Module” as shown in
The embodiments disclosed above are merely representative of the invention and are not meant for limitation thereof. For example, an ordinary practitioner would understand that there are several commercially available substitutions for some of the features and components described above. Several embodiments described above incorporate elements that are interchangeable with the features of other embodiments. It is understood that equivalents and substitutions for certain elements and components set forth above may be obvious to those having ordinary skill in the art, and therefore the true scope and definition of the invention is to be as set forth in the following claims.
Claims
1. A high-strength structure comprising:
- a structural frame having one or more composite columns and one or more composite beams attaching to the one or more composite columns;
- vertical composite panels attached to the structural frame, said composite panels forming the walls of the structure, the outermost vertical composite panels being the exterior walls and the remaining vertical composite panels being the interior walls, wherein said composite panels further comprise studs, a structural panel attached to each of the opposite sides of the studs, a sheeting layer attached to the structural panel on the side of the structural panel opposite that of the studs, sheeting fasteners connecting the interior sheeting and structural panel to the studs, and rigid reinforced foam placed between the studs and bonded to the structural panels;
- at least one horizontal composite panel attached to the top of the vertical composite panels, said at least one horizontal panel being a ceiling panel;
- two or more composite roof panels, one side of each composite roof panel attaching to an exterior wall by a roof bracket, the opposite side of each roof panel attaching to the opposing roof panel in a manner forming a peak above the ceiling panel; and
- at least one high strength eave having at least one substantially horizontal eave member attached to the exterior wall by a bracket at a location below the top of the exterior wall, at least one roof joist attached at one end to the roof panel and attached at the other end to the eave member, thereby forming a triangular truss.
2. The structure of claim 1, wherein at least one vertical composite panel attaches to at least one other vertical composite panel forming a vertical joint between the two panels.
3. The structure of claim 2, additionally comprising:
- a concrete slab that forms a foundation for the structure;
- a watertight floor seal between the base of the exterior walls and the foundation;
- watertight vertical joints between adjoining exterior wall panels; and
- an exterior door to the structure opening outward and away from the structure, said door being installed inside a frame having watertight seals such that when a force external to the structure pushes against the door, a watertight seal forms between the door and the seals.
4. The structure of claim 1, wherein said composite beams and composite columns further comprise a foam inner core, a foam outer core comprising a fiber-reinforced material consisting of a resin material adhered to a scrim, a primary skin bonded to the foam outer core, and a secondary skin attached to the top and bottom of the beam by mechanical fasteners.
5. The structure of claim 2, wherein said composite beams and composite columns further comprise a foam inner core, a foam outer core comprising a fiber-reinforced material consisting of a resin material adhered to a scrim, a primary skin bonded to the foam outer core, and a secondary skin attached to the top and bottom of the beam by mechanical fasteners.
6. The structure of claim 4 additionally comprising at least one composite panel forming a foundation for the structure.
7. The structure of claim 4 additionally comprising a concrete slab that forms a foundation for the structure.
8. The structure of claim 3, wherein said high strength eave further comprises a tension bar assembly having an anchor embedded in the foundation, a bar connected to the anchor and running to a plate bearing on the top of the wall panel, and one or more couplings incorporated into the bar, said couplings capable of tightening the tension bar assembly.
9. The structure of claim 7, wherein said high strength eave further comprises a tension bar assembly having an anchor embedded in the foundation, a bar connected to the anchor and running to a plate bearing on the top of the wall panel, and one or more couplings incorporated into the bar, said couplings capable of tightening the tension bar assembly.
10. A flood-resistant structure comprising:
- a foundation;
- a structural frame having one or more composite columns attached to the foundation by at least one mechanical anchor, and one or more composite beams attaching to the one or more composite columns;
- vertical composite panels attached to each other and to the structural frame, said composite panels forming the walls of the structure, the outermost vertical composite panels being the exterior walls and the remaining vertical composite panels being the interior walls;
- a watertight floor seal between the base of the exterior walls and the foundation;
- watertight vertical joints between the exterior wall panels; and
- an exterior door to the structure opening outward and away from the structure, said door being installed inside a frame having watertight seals such that when a force external to the structure pushes against the door, a watertight seal forms between the door and the seals.
11. The watertight structure of claim 10 wherein said watertight floor seal further comprises at least one floor track attached to the foundation by fasteners, said floor track being sealed to the foundation by a sealant selected from the group consisting of caulking, epoxy, rubber, neoprene, elastomeric pads, plastic, and foam, and said columns and exterior wall panels resting inside and attached to the floor tracks by mechanical fasteners.
12. The watertight structure of claim 10 wherein said watertight floor seal further comprises a continuous strip on the exterior side of the exterior wall attaching the exterior wall directly to the foundation, and a bonding sealer sealing the base of the exterior wall to the foundation, wherein the bonding sealer is selected from the group consisting of caulking, epoxy, rubber, neoprene, elastomeric pads, plastic, and foam.
13. The structure of claim 11 wherein said watertight vertical joints further comprise a void defined by the ends of the exterior wall panels and a support member, said support member providing structural support to the void, a vertical bracket attaching the adjacent exterior wall panels together, and a bonding sealer sealing the support member to the exterior wall panel and sealing the vertical bracket to the adjacent exterior wall panels.
14. The structure of claim 12 wherein said watertight vertical joints further comprise a void defined by the ends of the exterior wall panels and a support member, said support member providing structural support to the void, a vertical bracket attaching the adjacent exterior wall panels together, and a bonding sealer sealing the support member to the exterior wall panel and sealing the vertical bracket to the adjacent exterior wall panels.
15. The structure of claim 11 wherein said watertight vertical joints further comprise the exterior walls abutting to form a corner, at least one tube passing through one of the exterior wall panels, a threaded fastener passing through the tube and into the adjacent exterior wall panel, the threaded fastener having a nut that is tightened to secure the adjacent exterior wall panels together, and a bonding sealer sealing the interface between the exterior wall panels.
16. The structure of claim 12 wherein said watertight vertical joints further comprise the exterior walls abutting to form a corner, at least one tube passing through one of the exterior wall panels, a threaded fastener passing through the tube and into the adjacent exterior wall panel, the threaded fastener having a nut that is tightened to secure the adjacent exterior wall panels together, and a bonding sealer sealing the interface between the exterior wall panels.
17. A high strength eave assembly for a structure comprising:
- a foundation;
- at least one exterior wall resting on the foundation;
- at least one substantially horizontal ceiling panel bearing on the top of the exterior wall;
- at least one inclined roof member bearing on the ceiling panel at a location above the exterior wall;
- at least one substantially horizontal eave member attached to the exterior wall by a bracket at a location below the top of the exterior wall; and
- at least one roof joist having a roof bracket attaching one end of the roof joist to one of the roof panels and to the top of the exterior wall, said roof joist being attached at the other end to an eave member, thereby forming a triangular truss.
18. The high strength eave of claim 17 further comprising a tension bar assembly having an anchor embedded in the foundation, a bar connected to the anchor and running to a plate bearing on the top of the ceiling panel, and one or more couplings incorporated into the bar, said couplings capable of tightening the tension bar assembly.
19. The high strength eave of claim 17 further comprising a space formed between the inclined roof panel and the ceiling panel, said space filled with a structural element bonded to the roof panel and ceiling panel.
20. The high strength eave of claim 18 further comprising a watertight floor seal having a continuous strip on the exterior side of the exterior wall attaching the exterior wall directly to the foundation, and a bonding sealer sealing the base of the exterior wall to the foundation, wherein the bonding sealer is selected from the group consisting of caulking, epoxy, rubber, neoprene, elastomeric pads, plastic, and foam.
Type: Application
Filed: Feb 1, 2008
Publication Date: Jan 1, 2009
Inventor: Newman Stanley (Jacksonville, FL)
Application Number: 12/012,400
International Classification: E04D 13/00 (20060101); E04B 1/19 (20060101); E04B 1/66 (20060101); E04D 1/30 (20060101);