Patent Application
20090044461
The present invention relates to a modular dwelling structure made from recycled tire materials, a kit for a modular dwelling structure made from recycled tire materials, and a method for constructing a modular dwelling structure made from recycled tire materials. In particular, the present invention relates to a dwelling structure whose foundation, supporting framework, walls, floors/ceilings and roof are made from very strong, and in some cases internally reinforced, compressed rubber materials obtained from recycled tires.
Many dwelling structures, particularly houses, are commonly built on concrete foundations using a wood-based support frame, walls, ceilings and roof structures. In many climates, additional insulation material is provided to insulate exterior walls, attic and basement regions against extreme temperature conditions to maintain interior climate control. The outer portions of the insulated or un-insulated walls are typically sided with a facing material, such as vinyl or aluminum siding, for example, and the roof decking is typically faced with standard roofing materials. Interior walls and ceilings are generally finished with a material such as plaster, drywall or the like that is applied to fortify and cosmetically disguise the wood structure. Even century-old brick homes, or modern homes that at least appear from the outside to be made of brick, often have wood and drywall or plaster interior structures and wood-based structural framework. In addition, while some modern structures may have steel-based support structural framework, these structures are mainly commercial buildings rather than residential dwelling structures. But, in the case of residences or dwelling structures, even steel-based skeletal framework may still have wood-based walls, floors/ceilings and roofs that are similarly insulated and cosmetically faced on both the interior and exterior surfaces thereof.
However common they may be, the above-described dwelling structures are fraught with a number of drawbacks For example, the dwelling structures described above require additional layers of insulation that is applied during or after construction to enable more efficient interior climate control within the interior portions of the dwelling. For example, in colder, northern climates, additional insulation is needed to ensure that the home heating systems are able to effectively and efficiently heat the home in a cost-effective manner, and to retain the warmth within the dwelling. Similarly, in warmer, southern climates, insulation is needed to ensure that home cooling systems are able to effectively and efficiently cool the home in a cost-effective manner, and retain the cool air within the dwelling. Additional insulation is also just as important in moderate climates, since efficiently heating and cooling homes is an issue with respect to conserving energy costs in every environment.
Another drawback is that these commonly known dwelling structures are also susceptible to significant damage from forces such as wind and water that accompany natural disasters, such as hurricanes, tornados and tsunamis, for example. These harsh conditions, and other damaging conditions such as domestic fires caused by human error or accident, or even those caused by natural disasters such as earthquakes, are also known to destroy not only the interior of the dwelling and the possessions therein, but also to consume or damage the home's skeletal framework itself. In cases of such severe damage, the home must be rebuilt from the foundation up in order to eliminate any weak or potentially damaged portions of the support structure of the home.
Yet another significant drawback associated with known residential dwelling structures is the cost associated with building traditional wood-based structures. The cost of wood, such as sheet and dimensional products, for example, often spikes during times of need, particularly when one portion of a nation is struck by a natural disaster that leaves so much damage in its wake that entire cities or regions require rebuilding, such as New Orleans and many portions of the Gulf Coast following Hurricane Katrina in 2005. In these cases, the cost of rebuilding homes and the cost of building new or repairing existing homes, even in physically unaffected regions of the nation, increases as the cost of raw materials is driven up by severe demand.
Another factor that contributes to the high cost of building materials is the use and depletion of natural resources (such as wood) in certain areas. That is, the depletion of local sources of natural resources for building supplies brings about the need to ship or otherwise relocate the raw building materials (such as wood in particular) for their ultimate use. Shipping and transport costs are then added to the lumber costs and are, of course, transmitted directly to the builders and buyers.
Another drawback is the time required to complete a traditionally built residence project from start to finish. That is, there is a significant period during which time a homeowner must find temporary accommodations while their home is rebuilt after flood loss or fire damage, for example. In cases where homes are completely destroyed and need to be rebuilt from the foundation up, the rebuild time is even greater. This can be particularly troublesome in certain parts of the United States, and in certain regions globally, that commonly experience natural disasters and where residents who choose to remain in these areas, or who must remain without a choice, are required to rebuild frequently, sometimes even on an annual basis. For example, it is commonly known that certain areas of the United States that are prone to repeated natural disaster damage include Florida (hurricane season), California (earthquakes, mudslides and wildfires), and Tornado Alley. Nevertheless, these regions are still heavily populated. Likewise, certain parts of Asia are frequently plagued with heavy rain, wind and flood conditions that damage or destroy dwellings and leave hundreds of thousands of people homeless. And, in many cases, despite the repeated need to rebuild, it is typically seen that the same structures which have the same problems are simply erected in the same manner as the previously destroyed structure and in the same location that is likely to again experience such catastrophic damage in the future.
In addition to the above, many regions of the United States and the world commonly experience pestilence problems that cannot only be a nuisance to those living in the residence, but which can also destroy the structural integrity of the dwelling structure itself. For example, termites are just one type of insect that are known to infest and damage homes. Other pests such as cockroaches, ants and mice can also easily infest traditionally built homes at weak points in the foundation or at other locations in the structure which may provide a sufficient opening for example, due to the home's settling and shifting. In many areas of the world, insect and pest infestation of crudely built dwellings can cause the rapid spread of disease and significantly deteriorate the quality of life for the residents.
In view of the above-mentioned drawbacks, it would be desirable to provide easy-to-assemble dwelling structures that can be quickly and effectively assembled from low-cost raw materials that are locally and readily available in many regions of the nation and the globe; that eliminate the need for and the additional cost of insulation materials while improving the overall energy efficiency of home heating and cooling systems; that have sufficient strength to be used in most residential building applications in the same manner as traditional building materials and ultimately provide structures which have a higher capacity to withstand the natural disasters that strike all areas of the world; that can be cosmetically treated with traditional siding and roofing products to closely resemble traditional wood-based or brick homes; and that effectively block the unwanted infestation of insects or pestilence and the structural damage caused thereby, even in areas that are heavily prone to such nuisances.
The present invention has been conceived in light of the following drawbacks associated with common building materials, and it is an object of the present invention to provide easy-to-assemble dwelling structures that can be quickly and effectively assembled from low-cost raw materials that are locally and readily available and which eliminate the need for and the additional cost of insulation materials, while improving the overall energy efficiency of home heating and cooling systems. Its is also an object of the present invention to provide materials and kits for residential dwelling structures which have sufficient strength to be used in most residential building applications in the same manner as traditional building materials and which provide structures that have a higher capacity to withstand or recover from the affects of the natural disasters that strike all areas of the world. It is also an object of the present invention to provide a residential dwelling structure that can be cosmetically treated with traditional siding and roofing products to closely resemble traditional wood-based or brick homes, and that can effectively resist and prevent the nuisance of insect and pest infestation and damage.
According to one embodiment of the present invention, a modular dwelling structure is provided, comprising a plurality of first panel members (also referred to as panels herein) having predetermined dimensions and configured to define a floor having a main plane and a plurality of second panel members having predetermined dimensions and configured to define an outer peripheral wall structure surrounding the floor and extending in a direction that is substantially perpendicular to the main plane of the floor. The dwelling structure also includes a plurality of third panel members having predetermined dimensions and configured to define a roof structure substantially enclosing an interior space defined by the main plane of the floor, an interior planar surface of the outer peripheral wall structure and an interior surface of the roof structure. Each of the first, second and the third panel member comprises a recycled rubber tire material, such as compressed crumb rubber. A plurality of engagement means are also provided for securing the first, the second and the third panel members to one another in a secured relation to define the dwelling structure.
According to one aspect of the present invention, the panels further comprise one or more reinforcement members embedded therein. Preferably, the reinforcement members comprise a material selected from the group consisting of plastic materials, fiberglass materials, metal-based materials and composite materials.
Providing reinforcement members within the panels during the manufacture thereof imparts additional strength characteristics to the panels and enables the panels to withstand greater pressures and stresses without the risk of experiencing failure. For example, reinforced panels would be able to support greater loads, achieve larger length and width dimensions without sacrificing structural integrity, and maintain their integrity under greater externally applied pressure loads, which, for example, would give reinforced panels the ability to withstand stronger wind forces than non-reinforced panels. This feature is particularly important when the dwelling structures are assembled in an area that is either more susceptible to natural disasters, where high degree of external forces are applied to the home structures on a regular or cyclic basis, or when the dwelling structure is assembled in an area that simply has stricter building code requirements.
Preferably, the panels each include one or more mating surfaces designed to engage at least one of a corresponding mating surface of other panels and an engagement surface of one or more of the engagement members. It is even more preferable that the panels engage one another in a secured relationship at least via the mating surfaces to form a water-tight junction. Accordingly, a suitable adhesive, such as a joining compound, for example, is provided to adhere the panel members at the junctions therebetween and to facilitate such a water-tight junction. Preferably, the adhesive or joining compound is a material selected from the group consisting of rubbers, glues, epoxies, composite resins, and the like.
According to another embodiment of the present invention, a kit for a modular dwelling structure is provided, comprising a plurality of panels having predetermined dimensions, each panel comprising a recycled tire material, and a plurality of engagement members for maintaining the panels in a predetermined configuration to form a shape of the structure.
According to a third embodiment of the present invention, a method of assembling a dwelling structure made from recycled tire materials is provided, comprising the steps of providing a plurality of panel members made from recycled tire materials and having predetermined dimensions, arranging a first plurality of the panel members into a substantially planar floor configuration in secured relation to one another, and arranging a second plurality of the panel members into a peripheral wall configuration in a secured relation to one another and to the panels of the floor configuration such that a main plane of the panels of the peripheral wall configuration extends in a substantially perpendicular direction with respect to a main plane of the planar floor configuration. The method also includes the steps of arranging a third plurality of the panel members to define a roof structure in secured relation to one another and to the panel members of the wall and/or floor configurations to define a substantially enclosed interior space. Preferably, the method also includes the steps of arranging a fourth plurality of the panel members to define one or more internal wall structures having a main plane that extends in a direction that is substantially parallel to the main plane of the outer peripheral wall structure.
The method also preferably includes the steps of providing at least one of an interior cosmetic and/or structural treatment, such as sheet rock, plaster, paneling or wall paper, for example, on an interior planar surface of the main plane of the panels defining the peripheral wall configuration and to surfaces of panels defining the main plane of the interior wall configuration, providing a floor covering material on the planar surface of the main plane of the panels defining the floor configuration, providing an exterior siding material on exterior or external planar surfaces of the main plane of the panels defining the peripheral wall configuration, and providing a roofing material on exterior planar surfaces of the panels defining the roof configuration.
Moreover, the method also preferably includes the steps of forming one or more openings in the panels of the peripheral wall configuration to define at least one of an entryway opening and a window opening. It is also preferred that a transparent, insulative material, such as glass, plexi-glass or the like, is supplied to the window openings. The method also preferably includes a step of supplying an entryway enclosing structure to the entryway openings that is capable of permitting or preventing objects from passing into the interior portion of the dwelling structure from an exterior environment via the entryway opening.
There are many benefits that are attributed to providing building panels made from recycled rubber tire materials, particularly compressed crumb rubber products, according to the modular dwelling structure, kit and method of the present invention. For example, recycled rubber tire material is a very inexpensive raw material and is easily obtainable in nearly all areas of the nation, and even globally. Since rubber tires are recycled in many locations, both nationally and globally, recycled rubber tire materials are typically readily available in nearly all parts of the world. Given the extremely low cost of obtaining and recycling rubber tire materials, to produce, for example, crumb rubber, and in view of the widespread availability of the raw crumb rubber product, processing centers could be established in many parts of the nation of the world to handle the local supply of rubber tire disposal and turn those unwanted tired into houses. Providing many locations would reduce the need to ship the building materials made from the recycled tire materials long distances, since the products themselves could be easily manufactured in situ all around the nation or the world. Thus, the costs of the modular dwelling structures according to the present invention would be significantly lower than those associated with common building media.
The recycled rubber tire material, such as crumb rubber, can be easily molded into panels having the desired, predetermined dimensions by using known compression molding or extrusion techniques, for example. In view of the above, the panels defining the modular dwelling structures according to the present invention can be easily mass produced at a low cost in any region without the risk of depleting local natural resources or incurring any significant costs associated with acquiring raw materials from distant locations.
Since the panels defining the modular dwelling structures can be molded as single pieces having predetermined shapes and sizes, entire structures can be provided in kit form by including all of the necessary, predesigned panels for each different portion of the structure. The panels can also be molded to provide openings, chases or channels to accommodate the installation of utilities in the dwelling structure, or certain utility components can be inserted into molded panels and encased. In that manner, not only can the panels be quickly mass-produced at low cost, but entire dwelling structures can be mass-produced based on the design specifications of a few panel pieces, where the positions of the utility accommodations are predetermined and known during assembly.
In addition, panels made from recycled tire materials such as compressed crumb rubber products according to the present invention are highly insulative, thus eliminating the need to buy, install and maintain separate insulation products for homes constructed from these panels. While the superior insulating properties of rubber materials are generally known by those skilled in the art, prior to the present invention, the Applicant submits that compressed crumb rubber materials have not been used to form panels that are used to define insulating foundation, floor, wall and roof structures for residential dwellings. Moreover, the highly insulative properties imparted to dwelling structures made from such panels according to the present invention significantly improve the home heating and cooling systems that are installed in such dwelling structures, which reduces energy usage, and thereby, the costs associated with temperature regulation and interior climate control can be significantly reduced.
Moreover, the panels according to the present invention are impervious to insect or pest infestation, unlike wood, and are not susceptible to the damage that wood experiences when termites infest a wood-based structure, for example. Furthermore, other insects and pests can effectively be prevented from entering the modular dwelling structures according to the present invention since the cracks, holes and other openings that are typically associated with concrete-poured foundations and wood-based structures are simply not present by virtue of the panel composition and assembly methods of the present invention.
Panels made from recycled rubber tire materials such as compressed crumb rubber according to the present invention are physically stronger than wood equivalents, and structures made from these panels can withstand greater forces than typical homes. This is particularly important in areas where high winds or tornadoes, for example, are prevalent forces of nature, or in areas having stricter building codes.
Additionally, the panels defining the modular dwelling structure according to the present invention are not susceptible to water damage that conventional building materials are known to experience when a home is flooded or when high pressure water is used to douse a house fire, for example. That is, while the internal and external cosmetic features of the dwelling structures may suffer some damage, the overall integrity of the dwelling structure framework, walls, ceilings and floors is not significantly degraded, even in cases of floods. What's more, compressed rubber products require higher temperatures before they will ignite, which decreases the overall damage that fires can cause. The structures can be treated with a high-pressure water spray to remove mold or the like that may result from water damage situations, and the blank structure would again be ready for cosmetic treatment and, if necessary, immediate occupation. That is, any damaged portions of the dry wall, wall paper, carpeting, etcetera that remain can simply be removed and then reapplied to the remaining structure after the structure is checked and cleaned. This two-fold benefit not only reduces the overall damage to homes in cases of floods or fires, but also effectively decreases the time required to recover and rebuild, since the entire structure itself does not need to be rebuilt.
When a home is lost to fires, floods or other devastating circumstances, a new modular dwelling structure according to the present invention can be quickly and easily assembled, for example, using the kit and method of the present invention, on the same site in a matter of days to replace the prior structure. The panels and engagement members are designed to fit together to provide a secure joining arrangement that is fixed with fasteners such as screws, bolts and the like, along with a water-tight sealing compound that is applied at the panel-to-panel and panel-to-fastener interfaces and joints. The modular pieces or panels made from the compressed crumb rubber obtained from recycled rubber tire materials can be easily and quickly assembled to one another by providing engaging surfaces and connector members that connect, fasten and hold the panels together to define the skeletal support features, and wall, floors, ceilings and roofs of the modular swelling structures according to the present invention.
The kits according to the present invention include all of the materials required to completely assemble a modular dwelling structure made from reinforced, or non-reinforced, compressed crumb rubber panels. Professional builders are not required in order to assemble these modular dwellings using the kits according to the present invention. But even without the aid of professional contractors, assembly can be completely performed in a short amount of time.
Single level and multilevel modular dwelling structures can be made according to the kit and method of the present invention, and these dwelling structures can be built in any climate. Dwellings that even include rubber panel-based basement sub-structures, as well as those without basements, can be quickly and easily built, all at a significantly lower cost than that of a traditional home.
The present invention is described in detail below, in accordance with a preferred mode of practicing the invention, with reference to the following drawings, in which:
a) is an end-view of a modular dwelling structure made from compressed crumb rubber panels according to one embodiment of the present invention, and
a) is a perspective view of two panel members according to the present invention showing one example of a mating relationship between the panels, and
a)-3(e) are end views of panel members according to the present invention having different mating portions provided on the end portions thereof;
a)-4(d) are end views showing various mating and joining relationships between panel members according to the present invention that are used to define a modular dwelling structure according to the present invention;
a)-5(f) are end views of various engagement members according to the present invention that are used in connection with fastening means to further secure the panel members together at joining portions thereof to define a modular dwelling structure according to the present invention;
a) is a top view of a conventionally used reinforced corner unit, and
a) is an end-view of a modular dwelling structure made from compressed crumb rubber panels according to one embodiment of the present invention, and
As shown in
As shown, the modular dwelling structure 1 according to the present invention can be a multi-level structure including a basement sub-structure. For example, additional panel members 15 can be provided and arranged in secure relation with one another and with the floor panel members 11 to define a foundation and/or basement sub-structure (basement structure is shown) including a main plane 151. One of ordinary skill in the art would readily understand how to arrange and connect the foundation/base panel members 15 to one another to instead define a foundation pad for building sites which do not call for basement sub-structures.
It should be noted that the dimensions and thickness of the panel members according to the present invention are not limited, and can be any dimension that is suitably moldable and sufficiently strong enough to provide the required structural strength characteristics. For example, the panel members can be made to have standard planar dimensions of 4′×8′ and a thickness of 4-10″ depending upon the application. For example, foundation or base panel members could desirably have a thickness of 8″, while the floor panel members could suitably be made to have a thickness of 4″ and the peripheral wall panel members to have a thickness of 6″. Similarly, the roof panel members could have a thickness of 4″ for example. The dimensions of the panel members are not limited to the above example, and can be of any size that is suitable for the particular building application. For example, the panel members may range in planar size from 2′×4′ to 8′×10′, and even greater dimensions can be provided without sacrificing strength and stability characteristics when internal reinforcement members are provided therein, as discussed in more detail below in connection with
It will be readily understood by those of ordinary skill in the art that the thickness of the panel members should be determined based on the intended structural application and in view of the requirements imposed by the relevant building codes. In any case, the panel members according to the present invention can be molded or molded and tooled to have the exact dimensions and mating surfaces required to assemble the various panels into modular dwelling structures, and all of the panels having predetermined sizes and mating configurations required to completely assemble a modular dwelling can be included in a kit, together with the required engagement members, fastening means and adhesives and/or joining compounds to secure the panels defining the structure.
As shown in
It should be noted that, due to the particular characteristics of the compressed rubber panel members according to the present invention, these openings can easily be made using a reciprocating saw, a chain saw or the like in the desired locations. The positions of any reinforcement members included would be known to the assemblers based on plans or instructions included with the kit, and could thus be avoided. In cases where one or more reinforcement member runs along substantially the entire length of the panel member, it may be necessary to cut through the reinforcement member as well. This is not problematic, however, particularly when the reinforcement members are made from a material that imparts added strength but which can also be cut with a reciprocating saw or a chain saw, such as a hard plastic, for example.
Referring back to
a) and 2(b) are perspective views showing various ways in which the panel members are joined to one another via corresponding mating surfaces and additionally, in connection with engagement means and fastening means (see
b) is a perspective view showing four panel members 12 arranged in secure relation with respect to one another. Various portions of the panel members 12, such as end and edge surfaces, are provided with corresponding mating structures so that when the panels are assembled together, the mating structures mate to join the panel members.
a)-3(e) are end views of panel members 31-35 according to the present invention, each having a different type of mating structure provided on at least one of the end surface thereof. Though the mating surfaces are only shown on the top and/or top and bottom surfaces of the panel members in these figures, it should be noted that any of the edge surfaces of the panel members could be molded or tooled to include similar structures, particularly panel members that are designed to be corner panels of the dwelling structure, and central portions of the panel members could be provided with similar corresponding structures.
In
Although
a) to 5(f) show different embodiments of engagement means and fastening members that can be included in a kit and used to maintain the position s of the panel members in a secured relation with respect to one another according to the methods disclosed herein to define the dwelling structures according to the present invention. The engagement means 24 shown in
The reinforcement members can be inserted or embedded during the molding process, such that the panels are ready for assembly after removal from the mold. Even if the panel members are subsequently tooled to form the corresponding mating surface configurations, the arrangement and positions of the reinforcement members can be designed and controlled according to the desired properties of the panels.
In some cases, special considerations are taken in building the corners of residential and commercial structures, with respect to providing improved strength and insulation features.
As it can readily be seen from
For example, in
On the other hand, as shown in
The rubber panel member corner forms 701 can be fabricated according to the methods described above, and can be made to have any height and width desired. Typically, a height of 2-10′ and a length of 2-12′ are useful for most buildings, though this could vary depending upon the number of stories to be built and is not limited herein. These types of novel corner units are useful in residential dwellings, where enhanced corner strength is particularly desired for multi-story structures. The corner units 700 according to the present invention can be ordered and provided on an a la carte basis for industrial and commercial applications, for example, or as part of the modular dwelling structure kit according to the present invention.
As it can be seen from the foregoing, the modular dwelling structure, kit for assembling a modular dwelling a structure and method for assembling a modular dwelling structure provided by the present invention offer significant advantages over conventional building materials and methods. Stronger homes that can better withstand the forces of many natural disasters as well as mother nature's other damaging weather conditions conditions, can now be built faster and at a lower cost, and can also be refurbished and repaired in less time. Dwelling structures according to the present invention are not susceptible to insect infestation, are substantially water-tight, and do not ignite as readily as wooden homes. The compressed crumb rubber materials comprising the panel members that define the dwelling structures provide superior insulative properties, which eliminates the need for additional insulation materials, allows home heating and cooling systems to be more efficiently operated, and provides significant heating and cooling cost savings.
It should be noted that the dwelling structures, kits and methods according to the present invention can be used in a variety of global applications, in times of great need as well as for ordinary commercial residential development applications. For example, the low-cost dwelling structures can be quickly erected in war-torn or damaged areas in a matter of days by military or other agents conducting humanitarian efforts to aid the citizens of countries that have recently experienced a devastating phenomena. Homes in areas that are continually stricken with harsh environmental conditions, such as floods in Southeast Asia, or hurricanes in Florida and the Keys, for example, can be rebuilt using the low-cost dwelling structures according to the present invention rather than the prior methods and means of construction to ensure that future conditions will not have such devastating effects, and such that the dwellings can merely be refurbished instead of completely rebuilt a damaging event. Given the fact that the modular dwelling structures according to the present invention can be built to suit substantially any architectural design and can be cosmetically enhanced to resemble typical homes, the dwelling structures can be quickly assembled in times of need not only in impoverished third world nations and poor economic regions, but even in areas where homes are large and more luxurious, such as resort areas. Plants for producing the compressed crumb rubber panels used in the construction of the dwelling structures according to the present invention can be easily established in any region given the overall availability of recycled tires as raw materials for the compressed crumb rubber panels in most areas of the nation and the world.
As mentioned above, while the present invention has been particularly shown and described with reference to the preferred mode as illustrated in the drawings, it will be understood by one skilled in the art that various changes in detail may be effected therein without departing from the spirit and scope of the invention as defined by the claims.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/US2007/060440 | 1/12/2007 | WO | 00 | 7/9/2008 |
| Number | Date | Country | |
|---|---|---|---|
| 60758676 | Jan 2006 | US |
