Reinforced foam building components and structures made therefrom

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] FIG. 1 is an elevation view of a typical structure;

[0026] FIG. 2 is a section view along line 2-2 in FIG. 1;

[0027] FIGS. 3A to 3E are top views of various foam slabs;

[0028] FIGS. 4A to 4D are enlarged top views of portions of the foam slabs exhibiting various recess areas, reinforcing elements and fixing means;

[0029] FIG. 5 is the front portion of the section view along line 5-5 in FIG. 1;

[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 29A, molded or extruded from expanded polystyrene. In the preferred embodiment, the foam slab 29A is strengthened by including recess area 26A (best seen in FIG. 3.), and reinforcing element 28A fixed into the recess area 26A 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 26A, reinforcing element 28A fixed into the recess area 26A 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 26A, reinforcing element 28A fixed into the recess area 26A 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] FIGS. 3A to 3E show various foam slabs 29A to 29E. FIGS. 3B to 3E show variations in recess area 26A of foam slab 29A to new recess areas 26B to 26D. 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] FIGS. 4A to 4D show portions of foam slab 29A and 29D, 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 26A (best seen in FIG. 3A) with steel stud 28A. The portion of recess area 26A not filled by the steel stud 28A is passageway 31A. In FIG. 4B the steel stud 28A is placed in the recess 26D (best seen in FIG. 3C) which has a dovetail shape. The dovetail shaped recess 26D design increases the ease of installation and increases the retention force of the stud 28A. In FIG. 4C the stud 28A is bonded with polyurethane or similar adhesive 27 into recess 26A (best seen in FIG. 3A) In FIG. 4D the stud 28A is bonded with polyurethane or similar adhesive 27 into recess 26D (best seen in FIG. 3D).

[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 31B. 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 31B of wall panel assembly 21 into passageway 31B 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] FIG. 6 is an exploded view of the window panel assembly 22. The three parts are: (1) Foam slab 33 with recess 26A 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 28A (best shown in FIG. 4) may be fixed into recess 26A 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.

Claims

1. A reinforced building component comprising: a foam slab, generally a rectangular parallelepiped with width and length greater than the thickness, a recess area disposed along the complete length of a side that includes the shortest edge, a reinforcing member, a fixing means for securing said reinforcing member to said foam slab at the surface defined by said recess area, and a passageway comprising the area of said recess area not filled by said reinforcing member and said fixing means.

2. The reinforced building component of claim 1 wherein said foam slab is expanded polystyrene.

3. The reinforced building component of claim 1 wherein said recess area is a channel with uniform rectangular cross section.

4. The reinforced building component of claim 1 wherein said recess area is a channel with uniform dovetail cross section.

5. The reinforced building component of claim 1 wherein said reinforcing member is a steel stud.

6. The reinforced building component of claim 1 wherein said fixing means is adhesive.

7. The reinforced building component of claim 6 wherein said foam slab is polystyrene, said recess area is a dovetail, said recess area is offset from the centerline of said side, said reinforcing member is a steel stud, and said adhesive is polyurethane.

8. The reinforced building component of claim 1 wherein said fixing means is thermal welding.

9. The reinforced building component of claim 1 wherein said recess area is offset from the centerline of the side.

10. The reinforced building component of claim 1 further comprising a second recess disposed on the opposite side of said foam slab.

11. The reinforced building component of claim 10 further comprising:

a reinforcing member, and fixing means for securing said reinforcing member in said second recess area.

12. A window panel assembly comprising said reinforced building component of claim I further comprising: a window mounting surface area disposed in said foam slab, a window assembly, a fixing means to attach said window assembly to said window mounting surface area, a window trim foam component, a fixing means to attach said window trim foam component to said window assembly and said foam slab.

13. A door panel assembly comprising said reinforced building component of claim 1 further comprising:

a door mounting tang disposed in said foam slab a door and frame assembly a fixing means to attach said door and frame assembly to said door mounting tang

14. A method for constructing said window panel assembly of claim 12 comprising (a) proving a reinforced building component of claim 1 (b) providing removal means for said foam slab (c) providing a window assembly with a mounting flange (d) providing a window trim foam component (e) use said removal means to provide a window mounting surface in said reinforced foam building component sized for said window assembly mounting flange (f) further use removal means to provide a window opening perpendicular to said window mounting surface of said reinforced building component (g) provide fixing means to secure said window assembly to said mounting surface areas (h) providing fixing means to secure said window foam trim component to said window assembly (i) providing fixing means to secure said window foam trim component to said reinforced foam building component (j) fix said window assembly to said window mounting surface, (i) fix said window trim foam component to said window assembly and said foam slab

15. A method for window panel assembly of claim 14 wherein said fixing means is adhesive.

16 A method for window panel assembly of claim 14 wherein said removal means is hot wire cutting.

17. A method for constructing a door panel assembly comprising (a) providing a reinforced building component of claim 1 (b) providing removal means for said foam slab (c) providing a door and frame assembly with mounting channel (d) providing fixing means to secure said door frame assembly to said reinforced foam building component (e) use said removal means to provide a door opening through said reinforced building component (f) further use said removal means to provide a door mounting tang in said reinforced building component (g) attach a door and frame assembly to said door mounting tang by apply fixing means to said door and frame assembly mounting channel to door mounting tang.

18 A static structure comprising at least one said reinforced construction component of claim 1.

19 A static structure of claim 16 further comprising said window panel assembly of claim 7.

20 A static structure of claim 16 further comprising said door panel assembly of claim 8.

21. A method for an extended passageway in said static structure of claim 18 comprising: (a) providing a first reinforced building component of claim 1 (b) providing a second a second reinforced building component of claim 1 (c) locate said first reinforced building component such that said passageway is in proximity to said passageway of said second reinforced building component.

22. A method for constructing static structures from a plurality of said reinforced building components of claim 1 comprising: (a) providing a first reinforced building component of claim 1 (b) providing a foundation for the structure (c) apply fixing means to attach said first building component on said foundation (d) providing a second reinforced building component of claim 1 (e) apply fixing means to attach said second reinforcing building component to said foundation and said first second reinforced building component, (f) repeat steps (d) and (e) with additional reinforced building components until the floor is complete (g) providing a third reinforced building component of claim 1 (h) applying fixing means to attach said third reinforced building component vertically perpendicular to the edge of said floor, orientated with said side of said foam slab containing said recess horizontally perpendicular to said edge of said floor. (i) repeat steps (g) and (h) with additional reinforced building components until the walls are complete (j) providing a forth reinforced building component of claim 1 (k) applying fixing means to attach said forth reinforced building component horizontally perpendicular to said walls, orientated with said side of said foam slab containing said recess horizontally perpendicular to said wall. (l) repeat steps (g) and (h) with additional reinforced building components until the roof is complete

23. A method for structure anchoring for static structures of claim 18 comprising (a) providing a foundation with structure anchoring means disposed in pairs on opposite areas of said foundation (b) providing a static structure of claim 18 with said extended passageways of claim 19 on said foundation (c) providing an anchoring strapping means (e) providing fixing means to attach said anchoring strapping means to said foundation anchoring means (f) routing said anchoring strapping means through said extended passageway in walls and roof panels to opposite said anchoring means (g) attach said anchoring strapping means to said anchoring means with said fixing means (h) repeat steps (c) through (g) if more than one said anchor strap is disposed

24. An edge passageway comprising:

a first reinforced building components of claim 1, a second reinforced building component of claim 1 orientated perpendicular and fixed to said first reinforced building component, a trim foam component generally rectangular in cross section with a portion of one corner removed, and fixing means to simultaneously attach said trim component to said first reinforced building component and to said second reinforced building component orientated to form said edge passageway along the interior edge,

25. A static structure of claim 18 further comprising at least one said edge passageway of claim 22.

26. The structure anchoring method of claim 22 wherein said anchoring strapping means is a metal band.