Systems and methods for providing rounded vault forming buildings

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to systems and methods for providing a monolithic dome building. In particular, the present invention relates to systems and methods for providing a level, rectangular foundation and building a monolithic dome building thereon, the monolithic dome building having a plurality of integrated hip structures.

2. Background and Related Art

A monolithic dome is a dome-like structure which is cast in a one-piece form. As compared to a traditional home style, monolithic buildings are relatively straight-forward in their construction and comparatively inexpensive to construct. As such, monolithic dome homes are desirable in financially poor areas of the world.

The process for providing a monolithic dome typically begins with the formation of a round foundation which approximates the general outer circumferential shape of the dome's base. A dome form, such as an air form (i.e.: an air bladder) is generally secured to the cured foundation and inflated to provide a three-dimensional form on which the various materials of the building are placed. Once inflated, building materials are added to either the inner or outer surface of the dome form to provide the final building structure. For example, some dome buildings are formed by providing a lattice of rebar, or similar structural member to the dome form, and then covering the dome form and rebar with a cementitious material, such as cement, concrete, plaster, stucco, Air Krete® or fiber-reinforced cement. Once the cementitious material is cured, the form is deflated or otherwise removed from the structure thereby revealing the inner or other wall surface of the structure. The resultant dome structure provides a large interior dome-shaped living space that is generally energy efficient.

In some parts of the world, the exterior dome shape of the building is considered aesthetically undesirable, most especially when located in a neighborhood consisting of traditional rectangular-shaped homes. For this reason, most home builders will forgo the financial, environmental and energy savings of building a monolithic dome home, in favor of a home build with a more traditional shape and structure.

Thus, while techniques currently exist for providing monolithic dome structures, challenges still exist. Accordingly, it would be an improvement in the art to augment or even replace current techniques with other techniques.

SUMMARY OF THE INVENTION

In some implementations of the present invention, a method for providing a monolithic dome building includes steps for attaching a dome form to a surface of a foundation, attaching a dome hip form to a surface of a foundation, and applying a building material to an outer surface of the dome form and an outer surface of the dome hip form. The method further includes a step for providing a foundation on which the dome building is constructed. In some implementations, a laser mounting device is used to level and square the foundations forms.

In some implementations of the present invention, the dome hip forms comprise a plurality of modular sections that are interconnected to form a desired form shape. The hip forms include an inner surface, an outer surface, a base surface and an interface surface, wherein the base surface abuts the foundation, and the interface surface of the dome hip form abuts the outer surface of the dome form to provide a monolithic dome building form. In some implementations, a modular form securing system is provided having a channel for receiving a portion of a base surface of a dome form, the modular form securing system further having a fastener whereby to secure the modular form securing system to the foundation, wherein the base surface of the dome form is secured to the foundation via the modular form securing system.

In some implementations of the present invention, a set of color coded construction plans and color coded measuring tape or other device is provided which uses colors, symbols, and codes to provide instructions for constructing the monolithic dome building of the present invention.

Further, in some implementations of the present invention, a monolithic dome structure device is provided which includes a dome shell having an inner surface, an outer surface and an interior volume, the device further having an integrated dome hip structure having an interior volume in fluid communication with the interior volume of the dome shell. In some implementations, the integrated dome hip structure is a structural feature of the device which is at least one of a dormer, a garage, a nook, an entryway, and a room.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to set forth the manner in which the above recited and other features and advantages of the present invention are obtained, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. Understanding that the drawings depict only typical embodiments of the present invention and are not, therefore, to be considered as limiting the scope of the invention, the present invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 as shown in parts A-D is a perspective view of a monolithic dome building having a plurality of integrated hip structures in accordance with a representative embodiment of the present invention;

FIG. 2 as shown in parts A-C are perspective and plan views of a laser mounting device in accordance with a representative embodiment of the present invention;

FIG. 3 is a plan side view of a laser mounting device and foundation form in accordance with a representative embodiment of the present invention;

FIG. 4 as shown in parts A and B is a modular form securing system for securing a dome form to the foundation in accordance with a representative embodiment of the present invention;

FIG. 5 is a cross-section view of a dome form secured to the foundation via a modular form securing system in accordance with a representative embodiment of the present invention;

FIG. 6 is a plan view of a dome form and various dome hip forms in accordance with a representative embodiment of the present invention;

FIG. 7 as shown in parts A-C is a perspective view of an assembled dome hip form in accordance with a representative embodiment of the present invention;

FIG. 8 is a perspective, exploded view of a disassembled dome hip form in accordance with a representative embodiment of the present invention;

FIG. 9 as shown in parts A and B is a cross-section view of a completed dome structure wall prior to removal of the dome form in accordance with a representative embodiment of the present invention;

FIG. 10 as shown in parts A and B is a dome form and form extension piece installed in a basement foundation in accordance with a representative embodiment of the present invention;

FIG. 11 is a cross-section view of a monolithic dome building set on a basement foundation prior to removal of the various forms of the shoring system in accordance with a representative embodiment of the present invention; and

FIG. 12 as shown in parts A and B is a prolate dome form in accordance with a representative embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIGS. 1A-1D, a monolithic dome building 10 is shown. In some embodiments, monolithic dome building 10 comprises a unitary structure having a centrally located dome 12 and a plurality of integrated hip structures 20. As used herein, the term “monolithic” is understood to mean a single, integrated structure that is formed of a single unitary material and structure. Thus, the various monolithic dome buildings and structures of the present invention do not include dome structures which are subsequently modified to include non-dome structures, additions, and so forth. Rather, the monolithic dome buildings 10 and structures of the present invention are single, unitary dome structures having various appendages or hip structures 20 that formed concomitantly during the construction process. Thus in some embodiments, dome 12 comprises a partial dome structure, wherein portions of dome 12 are integrated hip structures 20.

In some embodiments, hip structures 20 comprise a dormer, such as a window dormer. In other embodiments, hip structures 20 comprise at least one of a garage, a nook, an entryway or a room. Monolithic dome building 10 further comprises doors and windows to provide access to the interior of the building. In some embodiments, openings for doors and windows are formed during the process of forming building 10. In other embodiments, access holes are cut into building 10 following construction of the building 10 to allow installation of doors and windows. In some embodiments, the exterior of building 10 is decorated with brick, stucco, siding or other ornamental exterior covering materials to provide a desired aesthetic look. In other embodiments, a cementitious outer construction material of building 10 is stamped, painted and/or stained to resemble a desired ornamental exterior covering material. Thus, the exterior of building 10 may be modified and decorated to match or closely resemble a desired traditional home style.

The process for constructing or forming monolithic dome building 10 generally begins with a foundation. Traditional monolithic dome buildings use a circular foundation, wherein the dimensions of the circular foundation approximate the circumference of the dome's base. However, some embodiments of monolithic dome building 10 require a rectangular foundation whereby to support the non-circular base of building 10.

In some embodiments, a laser mounting device 30, as shown in FIGS. 2A-3 is used to ensure that a foundation is provided that is square and level. Some embodiments of laser mounting device 30 comprise an angled box having a first channel 32 and a second channel 34 for positioning mounting device 30 on the outside corner of any forming system. In some embodiments, first and second channels 32 and 34 are configured to snuggly receive nominal 2× material 50, such as a 2×4, 2×6, 2×8, or 2×10 piece of lumber. In other embodiments, channels 32 and 34 further comprises an adjustable clamp 36 whereby the width of channels 32 and 34 may be adjusted to snuggly receive and secure larger or smaller dimensioned forming materials 52.

Laser mounting device 30 further comprises a top compartment 40 for receiving a laser device 42. One having skill in the art will appreciate that any type of laser device may be used with laser mounting device 30, such as a dot/plumb laser, a grade laser, a manual leveling laser, a self-leveling laser, a line laser level, a pipe laser, a 180° line laser, and a 360° line laser. Laser device 42 is secured in top compartment 40 via laser vise or clamp 38.

The process for setting the foundation forms starts with a first forming material 54 being attached to a second forming material 56 at their ends to roughly provide a 90° corner θ. First and second forming materials are generally secured via fasteners, such as nails or screws 58. Laser mounting device 30 is then placed over the corner and clamps 36 are tightened thereby ensuring that the corner is maintained at 90°. Laser device 42 is then secured in top compartment 40 such that the laser beam 44 is directed along either of the first or second forming materials 54 and 56.

A target card 60 having a plurality of target lines 62 is then placed on the forming material 54 adjacent to laser mounting device 30. The position of the beam 44 relative to the target lines 62 is then recorded as a target mark. Target card 60 is then moved to the opposite end of forming material 54, whereafter forming material 54 is adjusted 64 until beam 44 registers at the target mark on the target card 60. The second end of forming material 54 is then secured at the desired position. At this point, the first and second ends of forming material 54 are level and aligned. This process is then repeated for each corner of the foundation forming system to provide a level and square foundation form.

In some embodiments, laser mounting device 30 further comprises a connection piece for compatible use with the Plastiform® system. As such, the process for building the foundation slab is simplified. This connection piece allows the form system to be suspended away from form stakes, which in turn allows for the use of a spin-screed to be used for screeding the foundation material within the slab or foundation form.

Once formed, the foundation form is then filled with a foundation material by any method known in the art, thereby providing a rectangular foundation 70, as shown in FIG. 4. In some embodiments, the finished concrete slab foundation receives a burnished finish which allows for floor staining and polish, thereby eliminating the need for other floor finishes in the building 10.

In some embodiments, the length, width and height of foundation 70 is determined by use of a ruler or standard measuring tape. In other embodiments, foundation 70 and monolithic dome building 10 are constructed with the aid of coded architectural plans which utilize colors and symbols instead of numbers and words. In some embodiments, the coded architectural plans are accompanied by a set of tape measures that include matching symbols and colors. In other embodiments, the coded architectural plans are further accompanied with a video having various sections that allow those with limited or no reading skills to perform the necessary tasks to complete the monolithic dome building 10. Further, in some embodiments physical or computer generated models are further provided to assist the user in constructing the building 10. In this way, foundation 70 and building 10 may be constructed without considerations for user education, nationality, language or sophistication.

Building 10 is formed with the aid of a plurality of various forms. A first step in providing these forms is to secure a dome form to the concrete slab 70 via a modular form securing system 80, as shown in FIGS. 4 and 5. In some embodiments, form securing system 80 comprises a plurality of interlocking c-channel sections 82, such as an aluminum c-channel, which are combined in a modular fashion to provide ring approximately equal to the circumference of a desired dome form 90. In some embodiments, adjacent sections 82a and 82b are interconnected wherein a tongue 88 of section 82b is inserted into an opening 96 of section 82a. Sections 82a and 82b are then secured together via a plurality of fasteners 104.

In some embodiments, sections 82b are secured to foundation 70 via fasteners 84, such as a nail or a screw. Fasteners 84 are generally placed in sections 82b which are positioned closest to the perimeter edge 72 of foundation 70. As such, fasteners 84 are located adjacent to the outer wall of the final structure 10, as opposed to being positioned away from the wall opposite a corner 74 of the foundation 70. Prior to securing the sections 82 to foundation 70, a portion 92 of dome form 90 is secured within the channel 86 of sections 82, such that a part of dome form 90 is secured between shoring system 80 and foundation 70. For example, in some embodiments a rope or wire 92 is sewn into a bottom seam 98 of dome form 90, thereby providing a surface which is capable of being retained in channel 86. Dome form 90 is then connected to a fan, such as a squirrel cage fan or other blower to inflate form 90, as shown.

When an air dome form is used for shoring and support for the structure, the dome form is placed as the main support structure for building 10 and therefore is placed approximately in the center of foundation 70. The fan for the air dome form is set to maintain at least a three inch water column of continuous pressure within the interior of the dome form. In some embodiments, an entrance is provided that is separate from the direct flow of air by the fan system. In some embodiments, the entrance is provided at the eventual location of a door or window of building 10, such that interior work on the building may be accomplished simultaneously with the exterior work of the building 10.

Referring now to FIG. 6, the various forms used to construct building 10 further comprise a plurality of dome hip forms 100. In some embodiments, dome hip forms 100 comprise a desired three-dimensional shape which is attached to dome form 90. Thus, the outer surface 94 of dome form 90 and the outer surfaces 102 of dome hip forms 100 provide a combined outer surface that defines the final inner and outer shape, profile and/or design of monolithic dome building 10. Dome hip forms 100 may include any desired shape or structure. For example, in some embodiments dome hip form 100 comprises a dormer shape. In other embodiments, dome hip form 100 comprises a shape reflective of a garage, a nook, an entryway, and/or a room.

In some embodiments, hip forms 100 comprise a system of vertical and horizontal modular pieces 110 that are interconnected via spring clips 114 and rods 116 which are manufactured to best fit the forms, as shown in FIGS. 7 and 8. In some embodiments, vertical and horizontal pieces 110 are sized so as to facilitate removal of hip forms through a window, door, or sliding glass door following completion of building 10. For example, in some embodiments pieces 110 are sized such that building 10 must include an opening having a diagonal dimension of at least six feet to enable removal of the individual pieces 110 from the interior of the finished monolithic dome building 10.

In some embodiments, the vertical and horizontal pieces 110 are configured of grids of tubular steel made to match a one foot center rebar layout, as shown in FIGS. 7B and 7C. This system allows for rebar to be installed around the perimeter of building 10 without the use of tape measures or measuring sticks. In some embodiments, hip forms 100 are manufactured to include cutouts 122 configured to fit windows and doors of varying sizes and layouts. This allows the builder to perfectly place door and window layouts without the use of tape measures or other devices which require literacy capabilities. In some embodiments, the hip form system is used for interior applications. In other embodiments, the hip form system is used for exterior applications. Further, in some embodiments hip forms 100 include turnbuckle braces placed periodically around the perimeter of the dome form 90 so that the assembled pieces of the shoring system 80 can stand independently. Further still, in some embodiments adjacent sections are interconnected at 90° via a jig 118, as shown in FIG. 7C.

In some embodiments, a top section 112 is provided to form various roof shapes. The top section pieces 112 are made in a similar manner as the vertical and horizontal hip form pieces, only rods 116 are placed in the end of hollow form pieces that can extend to match various roof pitches, or to circular dome air forms 90. In some embodiments, top sections 112 further comprise a clamping mechanism whereby to allow each extension rod 116 to be set at a desired extension length. Once the dome form 90 is lowered, rods 116 are covered with a tubular shield, such as one-inch polyvinylchloride pipe. The tubular shield then acts as a cutting guide for foam or insulation pieces which are positioned over the shields between top sections 112 and the outer surface of dome form 90.

Once the forms are completed, the next step in the construction process of monolithic dome building 10 is to cover the various forms 90 and 100 with an insulating material, such as dense or medium-dense polystyrene sheet foam. In some embodiments, a liquid thermoset foam is sprayed onto the exterior surfaces of forms 90 and 100. In some embodiments, a releasing agent is applied to outer surfaces of forms 90 and 100 prior to applying or spraying a liquid insulating material to the forms.

The process for applying the insulating material to the outer surfaces of forms 90 and 100 entails cutting the insulating material into shapes and sizes that correspond to the cumulative outer surface of forms 90 and 100. Thus, a continuous layer of insulating foam in applied to the entire outer surface of forms 90 and 100. In some embodiments, an adhesive is used to join adjacent pieces of insulating material. In other embodiments, adjacent pieces of insulating material are interconnected via rods, clips, adhesive tape, rope or some other tethering device or material. Once completed, a lattice of rebar is applied to the outer surface of the insulating material.

In some embodiments, the insulating material 120 is equipped with a rebar anchoring system 130, as shown in FIGS. 9A and 9B. For example, in some embodiments a staple 130, such as a landscape staple is melted into the insulating material 120 prior to installing the insulating material onto the outer surface of forms 90 and 100. Staple 130 may be preheated via an open flame and subsequently pushed into insulating material 120 thereby leaving free ends 132 on the outer surface of material 120. When applying rebar 140 to the outer surface of material 120, rebar 140 is secured to material 120 by twisting or wrapping free ends 132 around rebar 140. Free ends 132 are further secured by being covered and set in cementitious exterior coating material 150. In some embodiments, staple 130 is further tied around a portion of form 100 thereby securing insulating material 120 to forms 100. Following application of coating material 150, staples 130 are cut thereby releasing forms 100 from insulating material 120. The cut ends of staples 130 are then bent flat against insulating material 120 and covered by an interior finishing material, such as plaster, insulation, or another finishing material.

A finishing step in the construction process for monolithic dome building 10 is the application of an exterior coating material 150. As previously discussed, exterior coating material 150 generally includes a cementitious material which is rigid and weather resistant. In some embodiments, material 150 is fire resistant. In some embodiments, material 150 is applied using an air assist spray and pump. In other embodiments, material 150 is applied by hand. In some embodiments, material 150 is applied to a desired thickness via a plurality of thin coats. Once a desired thickness is achieved, forms 90 and 100 are left in place for the required cure time according to the requirements of the selected exterior coating material 150. Once cured, forms 90 and 100 may be removed from the building structure 10.

In some embodiments, a further finishing step is performed wherein a polyicocyanurate foam or urethane foam is applied to the inside and/or outside surfaces of the completed dome building 10. This additional material is applied at one to three inches and is then covered with various elastomeric coatings or other appropriate surfaces to achieve a desired aesthetic appearance and other practical needs for the structure.

In most plumbing applications for home construction the plumbing system is built on site, or in a warehouse for manufactured homes, yet the systems are still built into the home at the time of construction. In some embodiments, a main plumbing tree for building 10 is built off-site. In some embodiments, the plumbing tree is incorporated into an interior wall of the dome building 10, and is configured to accommodate all of the building's underground waste in a single run. This allows for the main “trunk” of the plumbing waste system to be built offsite.

Above-ground plumbing for building 10 may also be built into a 6″, 2 lbs density foam wall. Block-outs are left in the base of the foam wall to “accept” a rubber connector that attaches the wall and plumbing section to the underground tree that would be buried and covered with concrete prior to the wall assembly being attached at the jobsite. In some embodiments, hard plumbing, such as PEX pipe would also be attached at this time and block-outs for these particular attachments would be made at the appropriate locations.

As previously discussed, for some embodiments foundation 70 is screeded using the Plastiform® system or other similar systems. For these embodiments, some will include a system of pre-marked, color coded attachments which will indicate specific locations where to place the underground electrical system in the pre-placed concrete. This conduit system, whether flex or solid, may be built in an offsite facility and coded with coloration that matches the selected slab form system. For some embodiments, the electrical conduit and wires are pre-run and designed to be interchangeable in length and layout. This features allows for ease in installation. A loom will be attached on the end of each wire length (a quick connect loom) that attaches to outlet receptacles around the exterior of the building. For some embodiments, a wireless toggle switch is used in building 10 in an effort to eliminate the difficulty of running conduit for switching lights.

The interior space of monolithic dome building 10 may be divided by any method known in the art. In some embodiments, a mobile wall system is provided wherein the interior space of building 10 by be easily adjusted into a one, two, three, four, or more bedroom home, an office space, or even a duplex unit. Since building 10 has a completely structural, integral exterior shell, interior partition walls may be easily and freely moved around the interior of the structure, with exception of the plumbing wall which is a stationary wall.

A movable wall system in accordance with the present invention may include a wall frame built using 2×4 metal studs framing and track at 24 inch centers, with 3 inch, 2×8 foam panels inserted between the metal studs. Every two feet, two metal studs are used back to back making an “H” shape channel for retaining the foam panels. In some embodiments, the panels are routed, or a dado is cut in the top, bottom, and side of the panel to run electrical wiring. This wiring then uses standard wiring procedures to fasten gang boxes to the studs and run the wiring. At the end of each wall a special outlet with a male plug is run that will plug into the interior side of the exterior wall receptacle. This allows for the electrical in the movable wall system to become active. In some embodiments, the sturdy foam wall panels are covered with a fire resistant fabric, or a fire retardant elastomeric paint. In some embodiments, the panels are adhered to the floor surface with silicone caulking. Further, metal tabs are provided on the top tracks which allow the wall to be fastened to a ceiling track system.

In some embodiments, a ceiling track system is provided having a similar construction to the modular interior wall system, discussed above. A ceiling track system may include a metal stud configuration having a plurality of channels in which to retain three inch thick, two pound density expanded polystyrene foam panels, having an outer dimension of 2-feet by 8-feet. In some embodiments, the ends of the panels are modified to include dadoes for running electrical circuitry. As such, various ceiling fixtures (such as lights, ceiling fans, fire detectors, etc.) may be changed easily, or moved around to fit various wall arrangements. The 2×4 metal studs are used where the ceiling spans of building 10 allow. Where the ceiling span exceeds the capabilities of a 2×4 metal stud, larger studs may be used.

In some embodiments, building 10 further comprises a basement 170, as shown in FIGS. 10A and 10B. Basement 170 is provided by any known method in the art. Subsequent to providing basement 170, dome form 90 is combined with an air form extension piece 190, as shown. Air form extension piece 190 generally comprises a cylindrical air form that extends or lengthens the base of dome form 90 such that dome form 90 and extension piece 190 are secured to basement 170 by form securing system 80, as discussed previously. Dome hip forms 100 are applied to dome form 90 as previously discussed, wherein the base of dome hip forms 100 are supported by a surface edge 172 of basement 170, as shown in FIG. 11. In some embodiments, an extruded foam coating 174 is further applied to an outer surface of basement 170, whereby to provide insulation or act as a water barrier.

Referring now to FIGS. 12A and 12B, in some embodiments an adjustable prolate form 200 is provided. Prolate form 200 generally comprises a dome form section 210 having a plurality of eyelets or grommets 212 evenly spaced around the form's base perimeter. Prolate form 200 further comprises an extension base form 220 which is generally cylindrical and comprises a plurality of eyelets or grommets 222 which are evenly spaced around the form's perimeter. In some embodiments, grommets 212 and 222 are equally spaced along their respective perimeters thereby permitting the grommets to be aligned. Once aligned, grommets 212 and 222 are fastened together via a fastener 232, such as a zip tie, a piece of rope, or a piece of wire.

In some embodiments, extension base form 220 further comprises a system of adjustable grommets 230 whereby the circumference of base form 220 may be selectively adjusted to match the circumference of dome form 210. A desired circumference of base form 220 is maintained by coupling adjustable grommets 230 via a fastener 232. Unused grommets 230 are covered and sealed with an adhesive strip, such as an adhesive tape, thereby providing an airtight base form 220. In some embodiments, the seam 240 is further sealed with an adhesive tape as may be necessary to provide an airtight form.

In some embodiments, dome form section 210 is joined to base form 220 by interwrapping base form edge 224 with dome form edge 214. In some embodiments, a rope is sewn into edges 224 and 214 to assist in interwrapping the two edges. The interwrapped configuration of the two edges 224 and 214 is maintained by securing a fastener 232 through grommets 212 and 222. An adhesive tape may be further applied to seam 242 and grommets 212 and 222 as necessary to provide an airtight form.

In some embodiments, base form 220 further comprises a rope 226 which is sewn into the base perimeter edge to facilitate securement of form 220 to basement foundation 170 via securing system 80. In other embodiments, base form 220 further comprises a mid-rope 228 which is sewn into a pocket 234. In some embodiments, mid-rope 228 is secured to basement foundation 170 via securing system 80 to compensate for a shallower basement depth. In some embodiments, base form 220 comprises a plurality of mid-ropes to facilitate various basement foundation depths.

The present 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 and 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.

Systems and methods for providing rounded vault forming buildings

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