Patent Application
20210040733
The present invention is in the field of modular building construction methods and systems used within the construction industry, particularly those that can provide at least an interior environment that is sealed so as to be air-tight and/or water-tight.
Building construction systems including modular features are sometimes used in the construction field. 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 or water-tight seal within such structures is difficult. Such a sealed structure is particularly difficult to attain in existing agricultural barns or other warehouse constructions.
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. 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 various 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. Drawbacks associated with such systems is that SIP construction still requires skilled labor, shipping such panels can represent a significant expense, and the results are still not air-tight or water-tight. In addition, heavy equipment (e.g., cranes) are often required for installation. Furthermore, because the exterior skins of SIPs are formed of wood, they are subject to water damage, fire damage, and they present a food source for insects.
The present invention is directed to building constructions, e.g., such as an agricultural barn, warehouse, or small shed (e.g., greenhouse, dog kennel, or storage shed) that can be easily and quickly constructed. Such structure may include a floor (e.g., concrete slab), and walls extending upward from the floor, comprising foam wall panels covered over with a wainscot of impact panels to provide the wainscot portion of the wall with impact resistance. The structure may also include a roof assembly, e.g., over the walls. The roof assembly may include roof trusses with foam roof panels attached between adjacent horizontal members of the roof trusses providing an interior ceiling. The foam roof panels of the interior ceiling may provide sufficient strength for a worker to walk on an opposite face of the foam roof panels, above the interior ceiling, in an attic space between the upward angled members of the roof trusses (defining the angled roof) and the interior ceiling below. The impact panels of the wainscot portion of the wall, a remaining portion of the wall above the wainscot portion of the roof assembly, and an interior face of the foam panels of the roof assembly are coated with a polymeric abrasion resistant and impact resistant coating that seals the interior space defined between the floor, the walls and the ceiling in a seamless, air-tight configuration such that the walls, floor and ceiling of the interior space can be washed down as needed, without leaking or otherwise causing damage (e.g., water damage) to the structure. For example, drywall and many wood-based materials in existing constructions, particularly where exteriorly exposed during such washing, would routinely be damaged.
Another embodiment is directed to a structure (e.g., an agricultural barn for housing cattle or other animals) comprising a sloped floor, walls extending upward from the sloped floor, comprising foam panels covered over with a wainscot of impact panels to provide the wainscot portion of the wall with impact resistance against goring or running into by cattle other animals. The structure further includes a roof assembly over the walls, the roof assembly including roof trusses with foam roof panels attached between adjacent horizontal members of the roof trusses providing an interior ceiling, the foam roof panels of the interior ceiling providing sufficient strength for a worker to walk on an opposite surface of the foam roof panels, above the interior ceiling, in an attic space. The impact panels of the wainscot portion, the remaining portion of the wall above the wainscot portion to the roof assembly, an interior face of the foam panels of the roof assembly, and an interface between the sloped floor and the walls may be coated with a polymeric, abrasion resistant and impact resistant coating that seals the interior space defined between the sloped floor, the walls and the ceiling in a seamless, air-tight, water-tight configuration such that the walls, floor and ceiling of the interior space can be washed down as needed, without leaking or otherwise causing damage.
Another embodiment is directed to a structure (e.g., an agricultural barn or warehouse), where the interior space of the structure is under negative pressure to allow pull-through filtration of the interior space, the structure including a floor, and walls extending upward from the floor comprising foam wall panels covered over with a wainscot of impact panels to provide the wainscot portion of the wall with impact resistance. A roof assembly over the walls, including roof trusses with foam roof panels attached between adjacent lower horizontal members of the roof trusses (e.g., generally triangular) provide an interior ceiling to the interior space where the foam roof panels of the interior ceiling provide sufficient strength for a worker to walk on an opposite surface of the foam panels above the interior ceiling, in an attic space. The impact panels of the wainscot portion of the wall, a remaining portion of the wall above the wainscot portion to the roof assembly, and the interior ceiling can be coated with a polymeric abrasion resistant and impact resistant coating that seals the interior space defined between the floor, walls, and ceiling in a seamless air-tight, water-tight configuration so that the interior space can be negatively pressurized to allow pull-through filtration of the interior space, without any significant leaks. In addition, the walls, floor, and ceiling of the interior space can be washed down as needed, without leaking or otherwise causing damage.
Another embodiment is directed to a method for constructing structures such as those described herein. For example, such a method may include providing a floor, constructing walls extending upward from the floor, the walls comprising foam wall panels, covering over a lower portion of the foam wall panels with impact panels so as to form a wainscot that provides impact resistance to the lower portion of the walls, constructing a roof assembly over the walls, the roof assembly including roof trusses with foam roof panels attached between adjacent lower horizontal members of the roof trusses providing an interior ceiling to an interior space of the structure, the foam roof panels of the interior ceiling providing sufficient strength for a worker to walk on an opposite surface of the foam roof panels, above the interior ceiling, in an attic space. The impact panels of the wainscot, a remaining portion of the wall above the wainscot portion to the ceiling, and the interior ceiling may be coated with a polymeric, abrasion resistant and impact resistant coating so as to seal the interior space defined between the floor, the walls, and the ceiling in a seamless air-tight, water-tight configuration such that the interior space can (a) be negatively pressurized to allow pull through filtration of the interior space without leaks, and (b) the walls, floor, and ceiling of the interior space can be washed down as needed, without leaking or otherwise causing structural damage.
Another embodiment is directed to a small shed (e.g., for use as a greenhouse, dog kennel, storage shed, or the like) that is at least 10 ft2, but less than about 100 ft2. Such a shed comprises a floor, walls extending upward from the floor comprising foam wall panels, a roof assembly over the walls, the roof assembly including foam roof panels providing an interior ceiling. The interior surface of the walls, an interior face of the foam panels of the roof assembly, and the floor may be coated with a polymeric abrasion resistant and impact resistant coating that seals the interior space defined between the floor, the walls, and the ceiling in a seamless configuration such that the walls, floor and ceiling of the interior space can be washed down as needed, without leaking or otherwise causing damage. The exterior surfaces of the walls and any interior eaves may also be coated with the polymeric coating, such that the entire shed is of a monocot structure. Such a shed, because of the use of lightweight foam panels in the construction, may weigh less than about 300 lbs total.
Features from any of the disclosed embodiments may be used in combination with one another, without limitation. In addition, these and other benefits and features of the present invention will become more fully apparent from the following description and appended claims or may be learned by the practice of the invention as set forth hereinafter.
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.
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.
Before describing the present invention in detail, it is to be understood that this invention is not limited to particularly exemplified systems or process parameters that may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments of the invention only, and is not intended to limit the scope of the invention in any manner.
The term “comprising” which is synonymous with “including,” “containing,” or “characterized by,” is inclusive or open-ended and does not exclude additional, unrecited elements or method steps.
The term “consisting essentially of” limits the scope of a claim to the specified materials or steps “and those that do not materially affect the basic and novel characteristic(s)” of the claimed invention.
The term “consisting of” as used herein, excludes any element, step, or ingredient not specified in the claim.
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.
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. As such, all values herein are understood to be modified by the term “about”. 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 include at least the variation to be expected in a typical manufacturing process, and may include values that are within 10%, within 5%, within 1%, etc. of a stated value. Furthermore, where used, the terms “substantially”, “similarly”, “about” or “approximately” represent an amount or state close to the stated amount or state that still performs a desired function or achieves a desired result. For example, the term “substantially” “about” or “approximately” may refer to an amount that is within 10% of, within 5% of, or within 1% of, a stated amount or value.
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.
In some embodiments, the compositions or articles described herein may be free or substantially free from any specific components not mentioned within this specification.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although a number of methods and materials similar or equivalent to those described herein can be used in the practice of the present invention, the preferred materials and methods are described herein.
In one embodiment, the present invention is directed to structures, such as agricultural barns, warehouses, or sheds or small structures (e.g., less than about 100 ft2) that may be constructed in a manner where the interior surfaces provide a sealed interior envelope, accomplished using simple construction techniques. An exemplary structure 100 may be such as that seen in
By way of example,
In any case, returning to
Such wainscot impact panels 108 are not necessarily required, e.g., in the small shed configuration, or where the abrasion resistant, impact resistant coating 116 is simply applied somewhat thicker along the lower portion of the wall 104, as compared to the upper wall portion. For example, where cattle or other large animals are being housed, or in a warehouse, the impact panels 108 may very well be desired, but in a small shed, e.g., used as a dog kennel or greenhouse, there may not be the same need for impact resistance. In such a configuration, the spray applied coating 116 may provide sufficient impact resistance to the foam panels 106, 106′ at the core of the wall structure. By way of example, the coating thickness may be greater than 5 mils, and up to 500 mils, although typically no more than 150 mils would be needed (e.g., 6 mils to 150 mils, or 6 mils to 30 mils).
It will be apparent that a relatively thick foam panel (e.g., 6 inches or more, such as 8 to 12 inches) will then provide a strong surface above the interior space, in the illustrated attic space within the trusses. This surface will be strong enough to allow workers or others to walk on the top surface of the foam roof panels 106, 106′, without fear of breaking through. This will also allow easy installation of air conditioning, electrical, plumbing, or other components in the attic space 122. Such equipment can easily be accessed and fully supported by the foam roof panels, without fear of breaking through the ceiling. Small structure construction roof foam panels may similarly provide sufficient strength for walking on.
The foam roof panels (e.g., expanded polystyrene, like the other foam panels of the walls and/or floor) may have a density 1 lb/ft3 or greater (e.g., but less than 10 lb/ft3, or less than 5 lb/ft3). The other foam panels may similarly have a density of about 1 lb/ft3, or somewhat greater (e.g., such as those values noted above). The foam panels may be nailed and/or glued at the notched edges and/or elsewhere to the trusses.
As shown in
Because of the applied once-piece coating 116, there are no seams or joints that are exposed in the coated boundary of the walls, and ceiling (all of which may be coated with a single piece coating). The interface between the walls 104 and the floor 102 may also be coated, or otherwise sealed. This coating seal allows the interior space of the structure to easily be pressurized, or more particularly, subjected to a negative pressure, without risk of leaks from the exterior, through the sealed floor, walls, and ceiling. Such a sealed construction is quite different from existing agricultural and warehouse constructions, where any attempt to negatively pressurize the building (i.e., dropping the internal pressure below atmospheric pressure) results in air seeping in through various tiny cracks and joints throughout the construction, as traditional constructions do not provide a sealed coating or even a sealed interior, as described herein. Because of these difficulties in sealing the structure, buildings are typically provided with positive pressure.
Such negative pressure would allow the building to operate a more efficient filtration system, which could rely on pull-through filtration, rather than a push-through configuration, as is traditionally required. In other words, normally a building is pressurized, which requires significant energy consumption. It actually requires significantly less energy to subject the same interior building space to negative pressure, if the building could be well sealed. The present system provides the necessary sealing of the building interior. Such a difference could save a typical farm of agricultural barns tens of thousands of dollars each year, in energy and filtration costs, alone. Using a negative pressure filtration system allows filtration to be achieved with far lower air flow, and energy use to filter the same given building volume. This greatly decreases energy costs and filtration costs.
The coated interior also facilitates easy pressure washing of all the interior surfaces, and because of the non-stick characteristics of the coating, such washing is far easier than attempting to wash conventional construction wall surfaces such as concrete, stucco, and the like. The foam panels being used are typically provided precut, as rigid foam sheet panels, exhibiting near perfect planar characteristics, rather than a spray-in type foam, as described in application Ser. No. 15/987,366 (18944.10.2). The rigid, pre-cut, planar characteristics of the foam panels of the walls, ceiling, and optionally even the floor (i.e., a foam panel floor) ensure that the foam panels are flat, which aids in creating an easy to clean surface. This is not the case with spray-in expandable foam, which does not result in a planar wall face. For example, spray-in foam walls result in crevices and a macro texture which tends to collect soils and the like, making such a surface far more difficult to clean.
For example, as described in Applicant's applications already incorporated by reference, the foam panels are typically cut to an accuracy of 0.001 inch (i.e., 1 mil). Thus, the planar surface may have low surface roughness (e.g., less than 0.1 inch, less than 0.01 inch, or no more than 0.001 inch variability in the “normal” direction relative to the plane). Such is not achievable with spray-in expandable construction foams.
Even though the final exterior coating is applied by spraying, e.g., this surface is relatively thin, and is able to maintain the substantially planar characteristics of the underlying foam, even as the coating is sprayed thereover, e.g., in a similar manner as a coating of paint.
Any doors provided into the structure could similarly be sealed around and coated with the same coating, providing excellent resistance against impact and abrasion, clawing, chewing, etc.
A pressure washing system could even be integrated into the building, e.g., where at the push of a button, the interior of the building could be pressure washed, much like a giant dishwasher.
The floor may be constructed of floor foam panels, similar to those of the walls and/or ceilings, if desired. In another embodiment, a concrete floor could be provided. In any case, the interface between the walls and the floor is sealed, e.g., by coating with the same polyurethane or other abrasion resistant impact resistant coating as applied to the ceiling and walls, tying all these structures together into a single piece structure. In the case where the exterior surfaces are also coated (e.g., in the case of a dog kennel or the like), the entire building itself becomes a monocot structure, acting as a monocot, integral single structure, rather than an assembly of separate walls, floor, and roof (which can be separated and break apart at their attachment points).
In addition to use in agricultural barns or warehouses, the construction could be used in other similar configurations where such benefits of abrasion resistance, easy power washing of the interior and the like may be beneficial. One such example would be in small shed construction (e.g., less than about 100 ft2, such as from 10 ft2 to 100 ft2, or 25 ft2 to 100 ft2, or 50 ft2 to 100 ft2). For example, a 8′×8′ shed may easily weight less than 300 lbs (e.g., about 250 lbs), when constructed as described herein. Such a small shed could easily be lifted and moved by two people. Conventional construction methods for a similar shed typically result in a weight more like 1000 lbs. Such cannot easily be moved by two people by hand. In addition, conventionally constructed sheds can be damaged when attempting to move them, as the walls, floor, or roof structures may begin to come apart at the attachment points, because these components are not tied together in a monocot structure, as the present small sheds would be, as a result of the applied coating. Such small sheds, particularly very small ones, such as a dog kennel, may not use roof trusses, but may employ any desired roof assembly, particularly one that is formed from foam roof panels.
Such structures may be particularly suitable for use as a greenhouse, dog kennels or the like. It would be easy to pressure wash (or self-wash) such a dog kennel, with a slopped floor. Where the inside and outside (e.g., walls, floors, ceilings, etc. are coated). In a very small shed structure, the entire floor (not just the floor/wall interface) may be coated. Such monocot structures can be moved as a single piece, without damage to the floor, walls, or roof components, because of the impact resistant, abrasion resistant, elastic interior coating tying everything together. Such small sheds could be placed on a skid or provided with a hook or the like for easily moving them from place to place, as needed.
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.
This application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application No. 62/722,591 (18944.13), filed Aug. 24, 2018, which is entitled SEALED ENVELOPE AGRICULTURAL BUILDING CONSTRUCTION; U.S. Patent Application No. 62/777,648 (18944.18), filed Dec. 10, 2018, which is entitled LIGHTWEIGHT POST AND BEAM CONSTRUCTION SYSTEM BASED ON HORIZONTALLY PRE-SLOTTED PANELS, U.S. Patent Application No. 62/890,818 (18944.18.1), filed Aug. 23, 2019, which is entitled LIGHTWEIGHT POST AND BEAM CONSTRUCTION SYSTEM BASED ON HORIZONTALLY PRE-SLOTTED PANELS; and U.S. Provisional Application No. 62/746,118 (18944.17), filed Oct. 16, 2018, which is entitled BELOW GRADE FLUID CONTAINMENT, each of which is herein incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62722591 | Aug 2018 | US | |
| 62777648 | Dec 2018 | US | |
| 62890818 | Aug 2019 | US | |
| 62746118 | Oct 2018 | US |
