Patent Grant
11286658
The present invention is in the field of modular building construction methods and systems used within the construction industry.
Building construction systems including modular features are sometimes used in the construction field. For example, particularly in third world countries where skilled labor is not readily available, and building materials must be relatively inexpensive, cinder block or brick materials are used in constructing homes, schools, agricultural buildings, and other buildings. It can be difficult to learn to lay block or brick while keeping the walls square and plumb. In addition, such systems require mortar to hold the individual blocks or bricks together. A roof formed from a different material (other than block or brick) is needed. In addition, insulating and/or providing an air-tight seal (e.g., to employ negative pressurization) within such structures is difficult.
Stick frame construction methods are of course also well known, although such systems also require a considerable amount of skilled labor to construct a building therefrom. In addition to requiring skilled labor, such existing methods also require considerable strength for those involved in the construction. Because of such requirements, in practice, such construction systems are not readily usable by groups of both men and women, where women often make up the vast majority of the labor pool available in third world humanitarian construction projects.
Various other building materials and systems are also used in the art. Structural insulated panels (SIPs) are used in some circumstances within the construction industry as an alternative to stick frame construction with insulation blown or laid within the cavities between stick framing members. A typical structural insulated panel may include an insulating layer sandwiched between two layers of structural plywood or oriented strand board (“OSB”). The use of such panels within residential, commercial or other construction projects can often significantly decrease the time required for construction, and also typically provides superior insulating ability as compared to a traditional structure constructed of block or brick, or even stick frame construction with insulation blown or laid between frame members. That said, drawbacks with such systems is that stick frame construction and SIP construction typically require some level of skilled labor, and thus are not particularly well suited for use in environments where such skills are not readily available, and shipping such panels can represent a significant expense. In addition, heavy equipment (e.g., cranes) are often required to install such panels.
In one aspect, the present invention is directed to various building construction systems and methods. Such systems and methods may employ a plurality of modular panels, which may be based on a common modularity within each panel. The system could also be a fractal system, e.g., where larger panels could be provided, based on multiples of such a base panel. In any case, the modularity and particular panel design of the system also allows the modular panels to be easily and quickly cut, where the building blueprints dictate the need for only a portion of the overall modular panel length. Such modular characteristics will be apparent, in the following disclosure.
Furthermore, many existing systems provide excellent flexibility, but with that flexibility, there is significant room for error, such that skilled labor is required. Other systems that may employ a system of panels may reduce the room for error, but greatly reduce the available flexibility, necessitating use of many custom components and solutions to accommodate needs that the system does not anticipate. The present system provides a happy medium between providing flexibility, and requiring only little if any skilled labor.
A modular panel for use in construction may include a lightweight (e.g., foam) body, and one or more channels extending horizontally through a length of the panel. Each channel may be configured in size and shape to receive a flexible elongate spline therein, wherein each spline once received in the channel is at least partially disposed within the lightweight body, without the spline being exposed on the large outside planar face of the body.
One advantage of the present system is that the splines may simply be ripped strips of oriented strand board (OSB) or the like, which is readily available throughout nearly the entire world, and which is also more flexible in a direction that is normal to the width of the OSB spline (i.e., in the direction of its thickness), than would be typical for dimensional lumber, even of the same dimensions. Metal splines (e.g., aluminum) may also be used. For example, while Applicant has also developed earlier systems which use dimensional lumber as splines, it was found that because such lumber is notorious for being warped, it can be difficult to easily insert each spline into its corresponding channel, when a significant fraction of 2×4s or other dimensional lumber is warped, particularly where the channel is closed on all sides of a transverse cross section through the panel and channel. Flexible strips of OSB or similar material, or metal splines are far more easily inserted into the channels, as described herein, particularly where the channels are open along top or bottom edges of the panel (but are closed once the next panel is stacked thereon). In addition to wood splines, it will be apparent that metal or other splines (e.g., steel or aluminum, plastic, etc.) are of course also usable, e.g., where it may be desirable to avoid the use of wood.
The channels may include pairs of top and bottom channels, offset from the center of the thickness of the foam body, for use in providing horizontally extending I-beams at the top and bottom of each panel. For example, stacked panels may include an I-beam that is formed in-situ (or provided pre-formed), during construction of the wall, between such stacked panels. For example, as the panel is placed, the elongate splines are positioned in the top and/or bottom channels, another spline is positioned between such splines to form the central web portion of the I-beam (where the splines in the channels form the end flanges of the I-beam), and the next panel is stacked on top of the first panel. Of course, a pre-fabricated I-beam (e.g., formed of OSB, aluminum, or other suitable material) could also be similarly placed. The bottom channels of the second panel receive initially exposed portions of the splines forming the flanges of the I-beam inserted in the first panel, hiding these splines (and the I-beam) between and within the pair of stacked panels. It is advantageous that the splines run only one direction (e.g., horizontally) through the panel, without any transverse splines (e.g., vertical splines) required. It is also advantageous that the panel be of a consistent cross-section along its length (i.e., the cross-sectional shape does not change, as taken anywhere from one end to the other), which allows the panel to be easily formed by extrusion, or by hot wire CNC cutting, for example. While other panels exist, e.g., as disclosed in U.S. Pat. No. 2,202,783 to Morrell, such panels require placement of splines both horizontally and vertically, and necessarily include both horizontal and vertical channels within the panel to accommodate such splines. Where both horizontal and vertical channels are included in such a panel, it is impossible for the panel to include a transverse cross-section that remains consistent across its entire length, from one end to the other. As such, such panels cannot be formed by extrusion, or a simple single step hot-wire CNC cutting method, making them more expensive and complex.
The panels may optionally include one or more interior channels (e.g., for receipt of stiffening members, e.g., such as a furring strip), as well as a pre-cut slot in a first face of the modular panel, centered on the interior channel, where the pre-cut slot extends through the thickness of the foam at the first face of the panel, into the interior channel. In other words, such a narrow pre-cut slot may provide access into the channel from one exterior face of the panel. The width of such a pre-cut slot may be relatively thin, to ensure that a stiffening member (e.g., spline or furring strip) that may also be inserted into such interior channel remains restrained in the channel. For example, such a pre-cut slot may be no more than 0.25 inch, or no more than 0.125 inch wide, e.g., less than 20%, less than 15%, less than 10%, or less than 5% of the transverse cross-sectional length (e.g., a length of 2-6 inches may be typical) of the channel.
The opposite face of the modular panel may similarly include a pre-cut slot also aligned with an interior channel corresponding to the second (opposite) face of the panel, having similar characteristics as described above relative to the pre-cut slot in the first face of the panel.
When it becomes necessary to cut a modular panel (e.g., where a wall being built requires only a portion of the length of such a “full” panel), this is easily accomplished, as the panel may be formed from expanded polystyrene (“EPS”) or another similar insulative foam material.
The panels themselves are cut on a CNC controlled hot wire cutting device, which is capable of making very precise cuts, so that the panels themselves are very accurate in their geometry (e.g., to within 0.001 inch). Thus, the panels may be of any desired thickness, e.g., as dictated by the particular desired wall thickness. For example, a foam panel thickness of 5.5 inches may be equal in width to a 2×6 (which is actually 5.5 inches wide, rather than 6 inches wide). By way of further example, a panel corresponding to 2×8 dimensions may be 7.25 inches thick. A typical 7.25 inch thick foam panel may include channels cut with the CNC device that are sized to accept ½ inch or ⅝ inch thick OSB ripped splines, having a width of typically 2-6 inches (e.g., 3-4 inches), although it will be apparent that such dimensions could be varied, as needed. Where aluminum or other material splines are used instead of OSB, they may be thinner, while still providing similar strength characteristics.
The various channels may be off-center relative to the thickness of the foam body, and parallel to one another. For example, the various first channels (at least one top, and one bottom) may be positioned closer to the first face of the foam body, and the various second channels (also at least one top and one bottom) may be positioned closer to the second face of the foam body. Any of such channels may be generally rectangular in cross-section, with a length (i.e., the channel's height) of the transverse cross-section rectangle oriented vertically, for desired orientation of the flexible splines therein. As described above, an exemplary panel may include a pair of spaced apart top channels, exposed at the top end of the panel, a pair of spaced apart bottom channels, exposed at the bottom end of the panel, and optionally, a pair of interior channels, between the top and bottom channels. All such channels may receive splines during wall construction, and are configured so that such splines received therein are not exposed at the large planar exterior faces of the panel. The splines in the top (or bottom) channels may initially be exposed, until covered by the next panel, which is stacked over the initially placed panel. For example, the uncovered portion of splines positioned in the top channels becomes received in the bottom channels of the next panel, stacked over the first panel. Walls, floors, and roofs can be constructed from such a series of repeating placement of panels, connected by the I-beam (or other shaped) splines between adjacent panels. Specially configured transition panels are also described herein, for making the transition from wall to floor, or from wall to roof, which transition panels include similar channels, for joining with the standard panels in the same manner (i.e., using the same I-beam or similar splines) as the standard panels are joined to one another.
For example, first and second top channels extend horizontally through the length of the body, with the first and second top channels being aligned above the first and second interior channels, respectively (if interior channels are even present). There may also be provided first and second bottom channels extending horizontally through a length of the body, where the first bottom channel is aligned with and below the first top channel, and the second bottom channel is aligned with and below the second top channel. The top and bottom channels may be exposed and open at their top and bottom edges respectively, of the body. Each of the top and bottom channels may be generally rectangular in cross section, with the length of the transverse cross-section rectangle oriented vertically, so that each top and bottom channel is configured to also receive a flexible elongate spline therein. For example, where I-beam splines are used, the channels receive a portion of (e.g., one end of) flanges of such an I-beam. The central web of such an I-beam lays on the top (or bottom) edge of the panel, while the other portion of the flanges (the opposite end) is received in the adjacent panel, as the panels are stacked (in a wall) or laid adjacent to one another (in a roof or floor).
The panel may be configured to provide a horizontal I-beam at the top and bottom of the panel, so that the splines (or portions thereof in the case of a pre-assembled I-beam) in the top channels become flanges of such a top positioned I-beam, and the splines (or portions thereof in the case of a pre-assembled I-beam) in the bottom channels become flanges of a bottom positioned I-beam. A web center portion of each I-beam member can be positioned on a top (or bottom) edge of the foam body, so as to be positioned between the splines inserted in the top (or bottom) channels, so as to form I-beams at the top and bottom edges of the foam body. Such a construction results in horizontal I-beams running horizontally through the wall (or floor, or roof) being constructed with such a building system. The panels can be positioned between adjacent vertical post members, such that there is actually no need at all for vertical stud members within the panels of the wall construction, although the building system is still fully compatible with existing building codes.
The present disclosure also relates to wall systems, as well as methods of construction that use modular panels such as those described herein. For example, such a wall system may include a plurality of modular panels such as those described herein, in combination with a plurality of flexible splines that may serve as interior splines, as well as forming the horizontally extending I-beam members at the top and/or bottom of each panel. The modular panels are typically of a size such that they will not provide the entire height of a typical wall or room being constructed (e.g., they may only be 2 or 4 feet high), but it will typically be required to stack such panels one on top of another to achieve a desired wall height. The top and bottom exposed channels of each panel may be of a depth such that they only receive a portion (e.g., about half) of the width of the spline being received therein, which forms the flange of the I-beam member. The adjacent channels of the next adjacent channel may receive the other portion of the spline (I-beam flange). In other words, the top exposed channels may receive the bottom portion (e.g., bottom half) of the splines that form the flanges of the I-beam member positioned at the top of that panel, while another panel is positioned directly over the web of the I-beam member at the top of the first panel, into which the top portion (e.g., top half) of the splines that form the flanges of the I-beam member are also received. This arrangement may be repeated as necessary, depending on the desired wall height.
Another advantage of the present systems is that because the horizontal splines (or entire I-beam) are generally restricted to movement within a single degree of freedom (only along the longitudinal direction of the channel—horizontally, either left to right), once the wall is assembled, it is not necessary that the splines inserted into a given channel be of a single, unitary piece of spline material. For example, scraps of OSB or other spline materials may be advanced or inserted into the channels, to make up the needed spline length. Such ability reduces on-site construction waste, as such small spline lengths may be simply pushed sequentially into the channel, forming the needed spline. There may even be no need to attach such small spline segments together in at least some cases, although they could be attached to one another (e.g., glued, nailed, screwed, or the like) if desired. For example, they may simply become trapped in the interior channels of the panel, between adjacent posts of the wall. Post members positioned between panels may be formed of dimensional lumber, or other standard dimensional material, steel, etc. For example, in an embodiment, a frame is formed, providing the overall shape of the building (e.g., from steel, aluminum, or other standard dimensional material), and then the panels are then used to fill in the space between such frame members, forming the walls, floor, and roof. I-beam or other splines extend between (e.g., horizontally) adjacent panels. Ear brackets or the like can be used to connect the spline within the panel channels to the adjacent frame member (i.e., so that the spline (including the ear bracket) extends beyond the panel, for integration/attachment to the post positioned between adjacent side-by-side panels). Specially configured transition panels provide transitions between wall-to-floor, and wall-to-roof, where the transition panels include the same channel structures, to connect to the adjacent standard panel (of the wall, floor or roof) in the same manner (panel connected to I-beam spline, connected to adjacent panel).
As mentioned, the present building systems may include a specially configured transition panel for making a transition from a wall (e.g., constructed using the standard panels described herein) to a roof structure, or from a wall to a floor (which can also be constructed using the standard panels). In an embodiment, the roof and/or floor may similarly be constructed of the same standardized panels as the wall. Such transition panels are similarly lightweight (e.g., formed from EPS foam). The wall-to-roof transition panel may be formed as a single piece of lightweight foam material, forming a transition between the wall structure and the roof structure. The wall-to-roof transition panel may similarly include channels for receiving splines as the standard wall panels described herein, for providing a horizontally extending I-beam between the wall-to-roof transition panel and the top standard panel of the wall structure below. The wall-to-roof transition panel may include another pair of exposed channels for receiving splines, for forming an I-beam between the wall-to-roof transition panel and the adjacent roof panel (which may be a standard panel, identical or similar to the standard wall panel).
Such a wall-to-roof transition panel may dictate the pitch of the roof structure, by having the desired pitch built into the panel, as the angle between the channels that engage with the adjacent wall panel (in a wall leg of the transition panel), and the channels that engage with the adjacent roof panel (in a roof leg of the transition panel).
The wall-to-roof transition panel may also include any desired overhanging eave structure that overhangs the underlying wall structure. Such transition panel includes the eave, with a desired eave length. It is advantageous to be able to provide such an eave as part of the single piece transition panel (e.g., rather than assembling an eave from numerous components that are typically nailed/screwed together). In an embodiment, the wall-to-roof transition panel may include additional slots or channels into which stiffeners (e.g., OSB, aluminum, or other material) could be inserted. For example, such slots or channels (used interchangeably) could be positioned in the overhanging eave portion of the panel so that when such stiffeners are inserted, they strengthen the foam in the eave portion of the panel, or provide an underlying attachment point, reducing any risk of damage to the eave. Such eave slots may run parallel to the other channels of the panel (e.g., horizontally). Such furring slot may be of any desired cross-sectional geometry (e.g., an I-beam shape, H-shape, C-shaped, L-shaped, or the like).
A wall-to-floor transition panel may similarly be provided, for providing a transition from standard panels used in constructing a wall, to standard panels used in constructing a floor. Such a wall-to-floor transition panel may include a top portion that is identically configured to the standard panels, with channels at a top edge of the panel, for receipt of flanges of an I-beam spline therein. Rather than positioning the bottom channels in the bottom edge of the wall-to-floor transition panel, the bottom channels may be in the major face of the panel, at a lower portion thereof, for engagement with a corresponding I-beam spline. It is important that even though the bottom channels are in the major planar face of the wall-to-floor transition panel, they are at a position where they will not be exposed on the planar face, once the wall-to-floor transition panel is connected to an adjacent standard panel of the floor (which receives the other portion or half of the flanges of the I-beam spline, as the wall-to-floor transition panel is connected to the first standard panel of the floor.
Differences necessary to accommodate any desired wall height (which may not be a multiple of the standard panel height (e.g., 2 feet) can be accommodated by adjusting the height of the wall-to-floor transition panel, and/or by adjusting the height of the wall leg of the wall-to-roof transition panel. It will be apparent that a wall is formed by a wall-to-floor transition panel (at the bottom of the wall), any desired number of standard panels stacked one on top of another, capped by a wall-to-roof transition panel (at the top of the wall). Between each panel is the I-beam or other spline, connecting the adjacent panels, for example, with the bottom portion of the flanges (below the web) of the I-beam in the channels of the lower panel, and the top portion of the flanges (above the web) of the I-beam in the channels of the upper panel (i.e., that panel stacked on top of the lower panel). This same structure is used, whether the adjacent panels are two standard panels adjacent to one another (e.g., in the roof, walls, or floor), or the two adjacent panels are a wall-to-floor transition panel adjacent to a standard panel (at the bottom of the wall), or the two adjacent panels are a wall-to-roof transition panel adjacent to a standard panel (at the top of the wall).
The above described wall-to-floor transition panel may be L-shaped. A T-shaped wall-to-floor transition panel is also possible, e.g., for use in constructions where a transition from a lower floor to an upper floor is desired. Such a T-shaped wall-to-floor transition panel may include two wall legs (e.g., each 180° apart), with a floor leg therebetween (e.g., at 90° relative to the wall legs). Each of the wall legs and the floor leg may similarly include the described channels, to allow such legs to be mated to adjacent standard panels (forming the lower story wall, the upper story wall, and the upper floor).
It will be apparent that methods of construction may involve (i) providing a frame that defines an overall shape for the building; (ii) installing a spline so as to span between two frame members of the framed (e.g., using ear brackets to extend the length of the spline); (iii) installing a wall-to-floor transition panel between the two frame members, with the spline of (ii) at least partially engaged in a channel of the wall-to-floor transition panel; (iv) installing a standard modular panel adjacent the wall-to-floor transition panel of (iii), with at least a portion of the spline of (ii) engaged in a channel of the standard modular panel, so that the spline of (ii) joins the wall-to-floor transition panel with the adjacent standard modular panel, with the spline of (ii) engaged in opposed facing channels of the wall-to-floor transition panel and the standard modular panel; (v) installing another of the plurality of splines in another channel on an opposite end of the standard modular panel of (iv), followed by installation of any number of a series of additional standard modular panels and splines, until reaching another transition, from wall-to-floor, where another wall-to-floor transition panel is installed; (vi) installing a spline into a top channel of the wall-to-floor transition panel of (v); (vii) installing any number of a series of additional standard modular panels and splines to form a wall, until reaching another transition, from wall-to-roof, where a wall-to-roof transition panel is installed, the wall-to-roof transition panel dictating a roof pitch and shape and length of an eave associated with the roof of the building; and (viii) installing a spline in a roof leg of the wall-to-roof transition panel, and installing any number of a series of additional standard modular panels and splines to form a roof.
Where the roof is a pitched roof (e.g., not a flat roof, at 90° to the wall), a roof cap transition panel may also be employed, at the apex of such a pitched roof, with the roof cap transition panel at the apex, with standard panels on either side thereof, sloping downward, with the same spline-panel-spline arrangement as any of the other panels. While the steps are identified above with roman numerals, it will be appreciated that the steps may be performed in numerical order, or in another order, if desired.
Features from any of the disclosed embodiments may be used in combination with one another, without limitation. In addition, other features and advantages of the present disclosure will become apparent to those of ordinary skill in the art through consideration of the following detailed description and the accompanying drawings.
To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrated embodiments of the invention and are therefore not to be considered limiting of its scope. The drawings illustrate several embodiments of the invention, wherein identical reference numerals refer to identical or similar elements or features in different views or embodiments shown in the drawings.
Some ranges may be disclosed herein. Additional ranges may be defined between any values disclosed herein as being exemplary of a particular parameter. All such ranges are contemplated and within the scope of the present disclosure.
Numbers, percentages, ratios, or other values stated herein may include that value, and also other values that are about or approximately the stated value, as would be appreciated by one of ordinary skill in the art. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result, and/or values that round to the stated value. The stated values for example thus include values that are within 10%, within 5%, within 1%, etc. of a stated value.
All numbers used in the specification and claims are to be understood as being modified in all instances by the term “about”, unless otherwise indicated. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the subject matter presented herein are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the content clearly dictates otherwise.
Any directions or reference frames in the description are merely relative directions (or movements). For example, any references to “top”, “bottom”, “up” “down”, “above”, “below” or the like are merely descriptive of the relative position or movement of the related elements as shown, and it will be understood that these may change as the structure is rotated, moved, the perspective changes, etc.
All publications, patents and patent applications cited herein, whether supra or infra, are hereby incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference.
In one embodiment, the present invention is directed to modular building methods and systems where the building is constructed using lightweight foam modular panels in which the panels include one or more horizontal channels formed through the length of the lightweight foam body of the panel, and in which the panel is of a geometry where the cross-section is consistent, across its entire length (i.e., a geometry that could be extruded). The channels are configured to receive elongate splines, which may simply be flexible strips of OSB, plywood, aluminum, or the like. It will be appreciated that such splines do not necessary need to be formed of wood, such that metal splines, or even other materials (e.g., plastic, or otherwise) could be used. The splines and associated channels into which they are received are configured so that the splines are not exposed on an outside face of the lightweight body (at least once the construction is finished, if not before), but so that the spline is restrained in the wall (e.g., it can only slide in and out of the channel once placed—with 1 degree of freedom).
The channels may be configured to provide an interior horizontally positioned I-beam or other geometry beam in a wall (or floor or roof) constructed with such panels, where each horizontal I-beam is positioned between adjacent panels (e.g., vertically stacked panels in the case of a wall). The flanges and web of each I-beam may be formed from individual flexible elongate splines, such that the I-beam is not prefabricated, but is actually assembled in-situ, at the construction site, as the panels are positioned to build the wall structure. Of course, in another embodiment, the I-beam spline may be prefabricated, e.g., as shown in
The panels may include channels for additional horizontal splines, beyond those that accommodate the I-beams. For example, the panels may include top and bottom channels which receive splines, which may become or be the flanges of the I-beam. The panels may also include one or more interior channels (i.e., furring slots), e.g., positioned off-center relative to a thickness of the foam panel, towards the first and opposite second faces of the panel (which faces correspond to the inside and outside of a constructed wall structure). Such interior splines may serve as furring strips, for attachment points for nails, screws or the like, e.g., for sheathing or other material positioned over the wall, floor, or ceiling, away from the panel's top and bottom edges. In an embodiment, the standard panels used in constructing the walls, floor, and roof may not include any such furring slots, but such furring slots may be provided in one or more of the various types of transition panels (e.g., wall-to-floor transition panel, wall-to-roof transition panel or roof cap transition panel).
The modular panels may have a thickness (e.g., foam thickness) that is typically greater than 4 inches, e.g., 5.5 inches, (the same width as a 2×6) or 7.25 inches (the same width as a 2×8). Because the panels include a cross-sectional geometry that is consistent across the length of the panel, they provide excellent flexibility in constructing any desired wall structure or building. For example, the foam panels may easily be cut off at whatever appropriate length, where the wall ends, or where a door, window or other opening is needed, in the horizontal direction of the wall. The vertical direction of the wall is easily formed by simply stacking a desired number of the panels on top of one another, forming the in-situ formed I-beams between each pair of stacked panels. Where desired, the top of a top-most panel could also be cut off, to accommodate an overall desired wall height, or the top-most standard wall panel may be topped with a transition panel (e.g., an upper story wall-to-floor transition panel or a wall-to-roof transition panel) as described herein that is configured to connect the wall panels to roof panels (in the case of a wall-to-roof transition panel) or to connect the wall panel to floor panels and wall panels of an upper story (in the case of a upper story wall-to-floor transition panel). Such a transition panel may include one or more wall portions (e.g., wall leg(s)) that engages with the top-most wall panel, making up any desired additional wall height, allowing a user to accommodate any desired wall height. The wall-to-roof transition panel also includes a roof portion (e.g., roof leg) that similarly engages with the adjacent standard roof panel. The roof leg can be configured to have a desired length, to accommodate any desired roof length (e.g., where the length of the roof is not divisible into a whole number of standard panels (e.g., each 2 feet). An upper story wall-to-floor transition panel can be T-shaped, including two wall legs (one for the lower story wall, one for the upper story wall, and a floor leg), therebetween.
The modular panels can be formed on a CNC hot wire cutting device, where all necessary deep cuts are formed (as it can be difficult to accurately cut foam material thicker than about 2 inches without such a device). Because the panels are formed under such conditions, during manufacture, high precision and accuracy are possible (which may not be practical to achieve on a job site). Furthermore, by cutting the panels on such a CNC device, the rectangular panels themselves can be formed to very high precision and accuracy dimensions. For example, a 2 foot by 4 foot, or 2 foot by 8 foot panel, 5.5 or 7.25 inches thick will be perfectly “square” and plumb, allowing the panel itself to be used as a square, level, or jig. This characteristic greatly reduces the need for skilled labor, as the panel itself serves as a template (i.e., no tape measure or square is needed). This helps to ensure a robust composite structure having the proper geometry (e.g., right angled walls where such is desired, level floors, level ceilings, and the like).
The present methods and systems of assembly allow for relatively open source construction, with a relatively high degree of customizability to the building being constructed, all achievable at lower cost and/or time as compared to existing methods of construction. Furthermore, even with such relative flexibility, little if any skilled labor is required. For example, a model or blueprint image of the building to be constructed could simply be provided, with the crew only being required to connect the modules as shown in the model or blueprint (e.g., akin to LEGO instructions).
It is also advantageous that the foam material (e.g., expanded polystyrene, or other foamed insulative materials) from which the modular panels are constructed may be readily available nearly anywhere, such that the foam panels may be manufactured at a foam production facility near the construction site (minimizing shipping distance and expense). This provides savings and convenience in that the foam panels can be manufactured locally, avoiding the significant expense of shipping foam (which occupies a large volume, even though it weights little).
For example, such foam may typically have a density from about 1 lb/ft3 to 2 lb/ft3, and provide an insulative value of about R4 per inch of foam thickness. A wall constructed using a 5.5 inch or 7.25 inch thick foam panel as described herein may provide an R value of about R25 or R30, respectively.
Modular panel 100 includes a lightweight body 102. Body 102 may comprise or otherwise be formed from a foam material, such as expanded polystyrene (EPS) foam. Such material may be rigid. Such panels may be precision cut from blocks of rigid, already cured EPS foam. For example, EPS foam is often available as 3×4×8 foot blocks. Such a block may be sufficient to produce several modular panels as shown in
Each panel 100 includes one or more (e.g., a plurality of) channels 104 extending horizontally through the length of panel 100. In the illustrated configuration, panel 100 includes first and second interior channels 104a, 104b, each of which is positioned off-center relative to the thickness of foam body 102, with channel 104a positioned towards (i.e., closer to) panel face 106a and channel 104b positioned towards panel face 106b (i.e., closer to panel face 106b than the center of the thickness of foam body 102). Panel 100 also includes top and bottom channels, which will be discussed in further detail hereafter. In an embodiment, such a panel may actually not include the interior channels 104a, 104b, but only the top and bottom channels (i.e., the interior channels are optional). Each of channels 104a, 104b is sized and shaped to receive therein a flexible elongate spline, where the channels 104a, 104b are not open at faces 106a and 106b of panel 100, but are only open at left and right ends 108a, 108b of panel 100. In an embodiment, splines 116 are advantageously not dimensional lumber, which although readily available, is notorious for being warped, making it difficult to slide such a spline through any of such channels. Rather, splines may be formed from oriented strand board (“OSB”), plywood, aluminum or another material that is easily inserted into such a channel. The spline may exhibit significant flexibility in the direction of the thickness of such sheet material. Such flexibility is readily apparent when holding such a strip of such sheet material at one end, as the other end will flex significantly downward under the weight of the sheet or strip alone. Such does not occur to the same degree with dimensional lumber, even in the same dimensions, as such dimensional lumber is significantly more rigid. Such OSB or similar spline materials are easily obtained, e.g., by ripping sheets of OSB or the like, which are as readily available as dimensional lumber, but with better flexibility in such direction, while exhibiting minimal if any warping. Although such OSB strips are a particularly suitable material, it will be apparent that a variety of other wood, plastic, or even metal materials (e.g., aluminum) could alternatively be used for splines.
Channels 104a, 104b within panel 100 have dimensions just slightly larger than those of the elongate spline so as to not bind within the channel, but so as to be freely slidable therein (e.g., a clearance of 1/16 inch or so, as will be apparent to those of skill in the art, may be provided).
The channels (particularly top and bottom channels 104a′, 104b′, 104a″ and 104b″) which are associated with the internal horizontally extending I-beams that are formed in-situ, as the wall is assembled (or provided installed prefabricated) may be spaced apart from one another to accommodate any particular desired spacing of such I-beams, as dictated by the height of each modular panel. For example, in the illustrated configuration where the panel 100 is 2 feet high, such I-beams will be provided horizontally, 2 feet apart, between adjacent panels. Taller or shorter panels could be provided where it is desired to adjust such spacing. Similarly, the panel length (e.g., 4 or 8 feet) may dictate the spacing of adjacent vertical posts of the frame in the wall, which may be provided between adjacent panels placed side by side (while I-beams are provided between adjacent panels stacked one on top of another). Spacings other than 4 feet (e.g., 8 feet, 12 feet, etc.) for such posts or other frame members, and for the panel length may be possible. Such spacing characteristics are well accepted within the building industry, and compatible with existing building codes, which allows the present panels and systems to be readily accepted and implemented, once made known by Applicant. Importantly, when a spline is received into any of the channels (104a, 104b, 104a′, 104b′, 104a″ or 104b″), the spline is not exposed on either exterior face 106a or 106b of panel 100. Applicant has found that other systems that provide for structural members or other features that are exposed on the exterior of a panel exhibit a “ghosting” problem, in that even once such structures are finished over, because of the different material characteristics underlying drywall or other sheathing associated with such surface exposure at the face during framing, there is a noticeable “ghost” that shows up through paint or other interior or exterior wall finishes that plague such systems. It is thus important that no such spline surface exposure is provided with the present panels. For example, particularly in the standard panels, the full interior and exterior faces 106a, 106b are provided entirely by the material from which the lightweight foam body is formed (e.g., EPS). Even in the wall-to-floor transition panel described in further detail below, even though the I-beam spline is provided exposed on the major planar face of the panel, this portion of the major planar face is covered, adjoining the adjacent standard floor panel in the finished construction, preventing any ghosting problem that might otherwise be associated therewith.
In addition to “ghosting” issues, exposure of splines on the exterior surface also can result in thermal bridging problems, e.g., particularly where metal sheathing is present (e.g., on a roof or otherwise). By ensuring that the splines are positioned internally, rather than externally exposed, there is less of a problem of thermal bridging through the wall, which increases overall insulative efficiency of the wall, roof, floor, or other building structure constructed therefrom. Where thermal bridging occurs, undesired condensation can often occur in such spots due to a thermal gradient associated with such thermal bridging. The present systems ensure there is a thermal break between such structural spline members and any metal or other sheathing that may eventually be placed over roofs, walls, or the like.
Furthermore, because the splines are positioned within the panel thickness, with approximately 1 to 2 inches of foam thickness between the spline and the nearest face, building codes do not require that electrical wiring (e.g., 120V) be run within conduit, as there is at least 1.5 inches between the exterior of any sheathing (e.g., ½ inch or ⅝ inch drywall or the like) applied over the panel and such electrical wiring. In addition, as shown in
In
The channels are offset towards one of the two faces 106a, 106b of the foam body 102, with two channels at each given height (e.g., interior channels 104a, 104b are at a central portion (e.g., the middle) of the height, channels 104a″ and 104b″ are at the bottom of the panel, and channels 104a′ and 104b′ are at the top of the panel. Because 2 channels are present at any given height, equally spaced from their respective faces, the same length fasteners can be used to attach sheathing on one face of the panel versus the other face.
In any case, when attaching such drywall or other sheathing, the present system avoids point loading onto screws, nails, or other fasteners employed, because of the foam thickness (e.g., 1 to 2 inches) between the sheathing and the spline encased within the foam panel. Such avoidance of point loading can be beneficial in an earthquake or the like, which may otherwise cause such fasteners to shear off.
In addition to the various internal, top and bottom channels described, the illustrated panel 100 further includes a pre-cut slot 112 in face 106a of panel 100, centered relative to channel 104a. Pre-cut slot 112 extends from first face 106a into channel 104a. For example, such a pre-cut slot allows internal formation of channel 104a in body 102 with a CNC controlled hot wire cutter. The width of slot 112 is advantageously very narrow, e.g., rather than providing a wide opening from channel 104a to the area adjacent face 106a. For example, where the height of channel 104a may be just over 3 inches (e.g., to accommodate a 3 inch spline), the width of slot 112 (the width of which is parallel thereto) may be no more than 0.25 inch, or no more than 0.125 inch. Stated another way, the width of slot 112 may be no more than 20% of, 15% of, 10% of, or no more than 5% of the transverse cross-sectional height of channel 104a. On the face 106b, opposite face 106a, there is shown another pre-cut slot 112, identically configured, but with respect to channel 104b and face 106b. The alignment of slots 112 with interior channels 104 is further beneficial once a wall structure has been built, where the panels are stacked one over another, as the channels and splines may no longer be visible. The slots 112 are visible in such circumstances, allowing a user to quickly and easily see where the splines are located within a given wall structure. Such slots 112 make attachment of drywall or other sheathing over the foam panels very easy, as the slots 112 mark the location of the center of the splines, which are easily nailed or screwed into, through the thickness of the foam between channels 104 and each respective face 106a, 106b. As internal channels 104a, 104b are optional, if they are not included, the pre-cut slots may also be omitted. In such instances, the positioning of the I-beam flanges (which also serve as attachment points for drywall or other sheathing) at the edge, or interface between adjacent panels similarly allows a user to quickly and easily see where the splines are located, for easy attachment of drywall, etc.
While web spline 116′ may only have a length that is equal to that of the panel 100 (e.g., 4 or 8 feet), the splines that form the flanges of the I-beam 117 may have a length greater than the panel, so as to extend across the vertical post 138, as shown in
Any of the splines may be more securely retained within any of the channels with any suitable adhesive. Without use of such an adhesive, the building system may actually be reversible, allowing dis-assembly of the components in a way that allows them to easily and quickly be re-assembled, e.g., at a different time, or in a different location. Such characteristics may be particularly beneficial for temporary structures (e.g., emergency housing, sets for plays or other drama productions, and the like). Where an adhesive is used, such adhesive may be injected into the channel through pre-cut slot 112 (for channels 104), injected directly into the open top or bottom channels (for channels 104a′, 104b′ 104a″ or 104b″), or placed on the splines 116, prior to channel insertion. Once drywall or other sheathing is placed over the foam panel faces 106a or 106b, nails or screws may further be used to secure such sheathing to the splines 116 within any of such channels.
As described above, the splines 116 may have a length that is greater than the length of a given modular panel 100. In one such embodiment, a single spline 116 can run through aligned channels (similarly numbered) of more than one modular panel, positioned side by side.
Many of the following Figures described hereafter show various configurations and uses in which the panels, splines, and building systems may be employed, as well as methods of use therefore.
Any desired roof pitch may be accommodated by such construction. Exemplary pitches include any desired pitch ratio, such as from 12/1 to 12/18 (e.g., 12/1; 12/2, 12/3; 12/4; 12/5; 12/6; 12/7; 12/8; 12/9; 12/10; 12/11; 12/12; 12/13; 12/14; 12/15; 12/16; 12/17; or 12/18). Another roof configuration using a transition panel is shown and described hereafter, in
While shown with straight planar walls, it will be appreciated that curved walls are also possible, e.g., by providing closely spaced (e.g., 6 inches or less, 4 inches or less, 3 inches or less, or 2 inches or less, such as 1 inch spacing) pre-cut slits into at least one face of the panel that is to be used in forming a curved wall. Such slits would allow the panel to be flexed, creating a curved continuous face along the opposite major planar face. Such slits could of course be filled in on the cut face, for finishing, if desired.
A strap or any other desired typical connector may be used to attach any of the vertical posts 138 to a foundation, as will be appreciated by those of skill in the art, in light of the present disclosure.
While electrical raceways 136 may provide a simple way to make electrical runs, other methods for wiring a structure using the present panel, post and beam constructions are also possible. For example, because the exterior of the wall prior to sheathing is formed from a material such as EPS foam that is easily worked, a portable hot wire cutting tool may be used to quickly cut traces or raceways through the foam face, in any configuration desired, for receipt of electrical wiring. Furthermore, current code allows such wiring to not need any conduit, where there is 1.5 inches or more between the exterior of any eventually applied sheathing, and the location of the wiring. The 1-2 inch foam thickness before reaching any of the channels (i.e., spline), coupled with a typical ½ inch or ⅝ inch drywall sheathing allows the wiring to simply be pressed into grooves cut into the foam face during wiring of the building, without the need for any conduit for housing such wiring. No posts or splines need be drilled or cut to accommodate such.
Where the wiring crosses over a spline or post, a spiked or other metal plate may simply be pressed over the wiring, over the spline or post, to prevent a fastener from penetrating the wiring, when attempting to fasten into the spline or post. Such forming of a raceway in the face of the panels can be quickly and easily accomplished after the panels have been raised into the desired wall structures, during wiring of the building. A portable hot wire groove cutting tool can be used for such raceway formation. Such a tool is very quick (e.g., an 8 foot groove length may be formed in a matter of seconds, and the grooves may be freely run over the face of the panels, without regard to spline location, and without passage through any splines or posts (as would be typical in traditional framing). For example, such a groove may simply be “drawn” from a switch or other location to where the power is to be delivered (e.g., a light, outlet, etc.) in a straight line, across the panel(s) face(s).
In an embodiment, either the interior, exterior, or both foam panel faces of walls of a building may be tiled over with cementitious panels, e.g., such as available from Applicant. Because of the presence of the splines within the channels of the wall system, screws or other fasteners may be used for such attachment. An adhesive may additionally or alternatively be used. Any suitable adhesive may be used to adhere such panels to the foam face. While epoxy or urethane adhesives may be suitable in theory, a polymer modified cement based adhesive may be preferred, as the urethane and epoxy adhesives have been found by the present inventor to be finicky, making it difficult if a user wishes to reposition a panel once it has initially been placed over the adhesive coated foam.
For example, the epoxy and urethane adhesives typically set very quickly, providing little time for the user to perform any needed repositioning or adjustment of a placed panel. Furthermore, because the bonding strength is so great, when attempting to reposition such a bonded panel, chunks of underlying foam may be pulled from the foam frame structure (floor, wall, ceiling, roof, or the like) when attempting debonding, which is of course problematic. A polymer modified cement based adhesive provides greater cure time, allowing some flexibility in positioning, and repositioning, before the bond between the panel and foam frame member becomes permanent and strong. That said, urethane and epoxy adhesives (e.g., foaming adhesives) may also be used, where desired. Methods and other characteristics for such tiling, information relative to adhesives, and the like is found within Applicant's Application Serial No. U.S. patent application Ser. No. 15/426,756 (18944.9), herein incorporated by reference in its entirety. Examples of Applicant's other building systems which may include various features that can be incorporated to some degree herein include U.S. patent application Ser. Nos. 13/866,569; 13/436,403; 62/722,591; 62/746,118; 16,549,901, and 16/653,579, each of which is incorporated herein by reference in its entirety. The last four patent applications describe exterior applied sealants that may be used, as such, in the present invention.
All components and steps of the method and system can be handled without heavy equipment (e.g., cranes), with the possible exception of any very large, heavy reinforcing structural frame members that may be embedded in any of the foam modular panel members, positioned between such panels, or the like. In fact, the modular panels and splines are so light as to be easily handled and positioned by a crew of women. For example, the panels (e.g., 2 feet×4 feet) may weigh less than 40 lbs, less than 30 lbs, less than 20 lbs, or less than 15 lbs. A 2 foot×8 foot panel (e.g., see
In the case of OSB or similar splines, because strips of such OSB material are very light (e.g., less than 10, 5 or even 3 lbs), and/or because there is typically no need to use splines that are of a single piece of continuous material, such crew members could push scrap material (e.g., scrap OSB strips) into the channels, which scrap material could serve as the splines. As a result, a construction site using such methods may generate very little, if any waste, e.g., far less such waste than is generated when using traditional framing techniques. In addition, it will be apparent that when constructing a given building, far fewer 2×4s will be needed, as there are no conventional single “studs” present in the construction, but rather use of OSB or similar elongate strips of material, as the splines are used, in conjunction with vertical post members and other members of the frame (which may be formed from pairs of 2×4s, steel, or the like), but which are only spaced typically every 4 feet, 8 feet or 12 feet (depending on structural requirements), requiring far fewer 2×4s than a typical frame construction in which 2×4 studs are spaced at 24 or 16 inches on center.
Wall-to-roof Transition panel 200 thus allows in-situ formation of an I-beam between the wall-to-roof transition panel 200 and the top most wall panel 100, and another I-beam between the wall-to-roof transition panel 200 and the adjacent roof panel 100. Wall-to-roof Transition panel 200 can include slots 203 for insertion of stiffening members (e.g., furring splines or strips), as shown, to provide additional attachment points for attachment of covering materials placed over the panel.
The floor panel optionally may not include channels adjacent the bottom face of the floor panels 204 (such panels may simply be positioned over a pea gravel base or the like). Alternatively, as shown in
The building system includes a frame that carries loads from the splines to the frame to the foundation. The frame can be designed to include any conceivable architectural shape, and can be engineered to handle appropriate external loads. The frame can act as a template to which splines and the insulating lightweight panels can be attached. This allows the splines and lightweight panels to remain standardized, with unique frames (formed from frame members) and unique transition panels defining the shape of the structure. This system makes it possible to construct walls, floors and roof of the system with precisely the same method.
Transition panel 200 is also shown as including various shaped slots 203 for insertion of stiffening members, e.g., to provide attachment points for facia, etc. The illustrated configuration includes a C-shaped slot 203 running horizontally, parallel to the free eave end E of the transition panel 200. As shown, a pre-cut slot 112 may be provided in eave end E, e.g., centered on C-shaped slot 203. In the illustrated configuration, the open end of the C is oriented inward, away from eave end E, providing an attachment point into which facia or other covering structures can be screwed, nailed, or otherwise fastened into. Other shaped slots could be provided, for receiving other shaped spline members (e.g., I-beam shaped, H-beam shaped, L-beam shaped, etc.).
Wall-to-roof transition panel 200 may be described as including 3 portions—a wall leg (terminating in channels 104a″, 104b″) that mates with the adjacent top-most wall panel of the wall being constructed; a roof leg (terminating in channels 105a′, 105b′) that mates with the adjacent first roof panel of the pitched roof being constructed; and an eave portion, e.g., coplanar with the roof portion, but extending oppositely, away from channels 105a′, 105b′ and the roof portion, so as to form an eave of a desired configuration. It will be apparent that the length of the wall leg and the length of the roof leg can be independently specifically selected as needed, to accommodate a desired wall height (that is not an even multiple of the height of the standard panel 100), as well as to accommodate a desired roof plane length (that is not an even multiple of the width of the standard panel 100 used on the roof). Adjustments in roof plane length can also be made by adjusting the lengths of the two ends of the roof cap transition panel 202.
It will be appreciated that a differently configured wall-to-floor transition panel may be provided, e.g., for providing the floor of an upper floor (e.g., a 2nd floor) in a multistory building construction. An example of such is shown in
In such a building construction, the wall-to-roof transition panel 200 may thus only be used on the top-most story, adjacent the roof, while any lower stories would include the T-shaped “2nd story” wall-to-floor transition panel 208′, at the transition from a lower story, to the adjacent higher story.
As shown, the structure can be supported on a plurality of pier footings 218. Such a configuration as described does not require the use of any continuous footings, or the use of a typical concrete or similar slab. The present configurations may advantageously be void of such features, which otherwise increase costs, and result in decreased comfort (e.g., the present configuration provides for an insulated, “soft” floor, as compared to a concrete slab, as will be apparent from the present description).
Turning to
While I-beam configurations are shown in particular, it will be appreciated that other geometry beams (e.g., C-beams, H-beams, L-beams, or other shapes, providing other moment of inertia characteristics) could alternatively be used for positioning in between any of the various modular panels, as splines. The description and claims generally reference “I-beam” for simplicity, although it will be appreciated that other such geometries can be included within the scope of the claimed invention.
Because the panels 100 used on the floor are rotated (laid horizontally (e.g., “on the ground” instead of oriented vertically, as in a wall construction), what would be “top” and “bottom” channels are now simply adjacent to the top and bottom faces of the panel, on the right, and left sides. As shown, the floor may actually be a “floating floor”, positioned above the ground in which the pier footings are positioned. While a pea gravel other base could be provided, such is not necessary, and may not be present.
As shown in
The height of any desired wall can be accommodated (even where the height does not correspond to an even multiple of the standard panel height, such as 2 feet), by adjusting the length of the vertical wall leg W (
A similar adjustment to the length of the roof plane is similarly provided by the length that is selected for the roof leg (the leg that is adjacent to the wall leg W, which is angled therefrom, at an angle corresponding to the pitch of the roof being formed). In other words, accommodation of specific roof plane lengths are possible by adjusting the length of the roof leg of panel 200, (i.e., that leg including channels 105a′ and 105b′). The length of this roof leg portion of the wall-to-roof transition panel 200 allows selection of an appropriate length to accommodate a desired roof length for the roof which it forms a top portion of.
It is also apparent that the transition panel also dictates the shape and length of the eave associated with the roof. Such integration of the eave into the transition panel 200 is advantageous, as it eliminates the need for construction of separate eave members (which is time consuming, and tedious, as those in the construction trade will appreciate). For example, the eave portion of the panel 200 is shown as being coplanar with the roof leg, extending oppositely therefrom (i.e., on the other side from the roof leg, relative to the wall leg W that separates the eave portion from the roof leg of the transition panel 200).
As shown in
As shown in
By way of example, the standard (and other panels) may each be provided in a standard dimension, such as 2 feet in height, by 8 feet in length. Such exemplary panels are lightweight, for example, weighing about 6 lbs for the standard panels 100 shown. If pre-fabricated I-beams 117 are used, e.g., made of aluminum, such similarly only weigh about 7 lbs. The system is thus easily employed by those of limited strength, and without any skilled training.
While the Figures illustrate construction of simple exemplary walls and buildings to illustrate concepts of the present construction methods and systems, it will be appreciated that the methods and systems may be used to construct a nearly endless variety of buildings.
It will also be appreciated that the present claimed invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative, not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. Additionally, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise.
The present application is a continuation-in part under 35 U.S.C. 120 of U.S. patent application Ser. No. 16/824,209 filed Mar. 19, 2020, which claims priority to and the benefit of U.S. Provisional Patent Application No. 62/991,889, filed Mar. 19, 2020, which is herein incorporated by reference in its entirety. Application Ser. No. 16/824,209 is also a continuation-in part under 35 U.S.C. 120 of U.S. patent application Ser. No. 16/709,674 filed Dec. 10, 2019, which claims priority to and the benefit of U.S. Provisional Patent Application Nos. 62/777,648 and 62/890,818 filed Dec. 10, 2018 and Aug. 23, 2019, respectively. Each of the above applications is herein incorporated by reference in its entirety.
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| Number | Date | Country | |
|---|---|---|---|
| 20200354945 A1 | Nov 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62991889 | Mar 2020 | US | |
| 62890818 | Aug 2019 | US | |
| 62777648 | Dec 2018 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16824209 | Mar 2020 | US |
| Child | 16942166 | US | |
| Parent | 16709674 | Dec 2019 | US |
| Child | 16824209 | US |
