| US3170828A | 1965-02-23 | |||
| US4365455A | 1982-12-28 | |||
| US4307554A | 1981-12-29 | |||
| US4324074A | 1982-04-13 | |||
| US3277219A | 1966-10-04 |
| 1. | A method for forming a structure comprising t steps of: (a) Forming a foundation, ζb) Attaching panels to said foundation, ζc) Installing windows and doors in said panels, (d) Fabricating a flexible membrane, (e) Draping and attaching said flexible membrane to sa assembled wall panels, (f) Inflating said membrane with air pressure, (g) Applying foam to a surface of said panels, (h) Applying foam to a surface of said membrane, (i) Applying a fire barrier to the . interior or exteri exposed side of said foam, and (j) Applying an exterior sealant to any exterior expos foam surfaces, Whereby structures of various sizes and configurations c be constructe and modified without the necessity of extensive structural framework. |
| 2. | Claim. |
| 3. | The method of Claim 1 wherein step (a), forming foundation, further includes, pouring a concrete slab within the confines of a t piece form such that a narrow, contiguous transverse step formed along the periphery of said slab, and retaining an upper contiguous portion of said two pie form which comprises a vertically disposed peripheral bas board surrounding an upper edge portion of said slab abo said step. |
| 4. | Claim. |
| 5. | The method of Claim 1 wherein step (b), attachi panels to the foundation, further includes, fastening a first, inner panel to said baseboard abo said step such that said panel conforms generally to t configuration of said baseboard and said slab, fastening a first outer panel to an outer surface said first inner panel so that said second panel halfla said first panel, SUBSTITUTE SHEET fastening a second said inner panel to an inner surfac of said first outer panel with vertical edges of said firs and second inner panel is abutting engagement, and serially continuing the fastening of further said inne and outer panels to said baseboard and to one another aroun the periphery of said slab forming vertical wall forms. |
| 6. | Claim. |
| 7. | The method of Claim 1 wherein step (c), installin windows and doors, further includes, cutting out portions of said vertical walls to receiv windows and doors, framing said cutout portions, and installing the windows and doors therein. |
| 8. | Claim. |
| 9. | The method of Claim 1 wherein step (d), fabri cating a flexible membrane, further includes, fabricating a contiguous, large, flexible, relativel light membrane large enough to overlie said walls on sai slab with substantial excess in all directions, and spraying said membrane with a sealant if necessary t make said membrane relatively impervious to air flow there through. |
| 10. | Claim. |
| 11. | The method of Claim 1 wherein step (e), drapin and attaching, further includes, draping said fabricated membrane over a top edge of al said panels such that central portions of said membrane han lower than said top edges of said walls, adjusting the distance said central portions an peripheral portions of said membrane hang to appropriat levels so that when inverted upwardly said membrane• form the upper limit of a desired configuration of a roof fo said building, and contiguous by attaching and sealing said membrane to inner upper portions of said walls proximate to said uppe edges of said walls. SUBSTITUTE SHEET _O Claim. |
| 12. | The method of Claim 1 wherein step (f) , inflatin said membrane, further includes, closing and sealing all orifices in said structur except one, and placing inflation means in the one remaining ope orifice to force outside air into the interior of sai structure creating a high pressure area therein whic inflates said membrane upwardly creating a foamed surface o a desired configuration upon which to spray foam. |
| 13. | Claim. |
| 14. | The method of Claim 1 wherein step (g), applyin foam to a surface of said panels, further comprises, applying foam by means of spraying to a desired thick ness upon the interior surfaces of said panels attached t said slab, whereby said foam forms the interior walls of th said structure. |
| 15. | Claim. |
| 16. | The method of Claim wherein step (h) , applyin foam to a surface of said membrane, further includes, applying foam by means of spraying to a desired thick ness upon an interior surface of said membrane, whereby sai foam forms a roof for said structure. |
| 17. | Claim. |
| 18. | The method of Claim 1 wherein step (i), applyin a fire barrier, further includes, applying a coat of a fire barrier medium in contiguous fashion on the interior or exterior surfaces o said structure, whereby said foam is isolated from direc exposure to the interior space of said structure. |
| 19. | Claim. |
| 20. | The method of Claim 1 wherein step (j), applyin exterior sealant, farther includes, applying an exterior sealant medium to any exterio foam surfaces whereby said surfaces are thereby protecte from elemental deterioration. SUBSTITUTE SHEET Claim. |
| 21. | The method of Claim 1 wherein step (g) and (h) applying foam to surfaces of said panels and said membrane further include, applying foam by means of spraying to a desired dept upon exterior surfaces of said panels and said membrane whereby said structure is formed from applying foam t exterior surfaces rather than interior surfaces. |
| 22. | Claim. |
| 23. | The method of Claim 1 wherein steps (g) and (h) applying foam to said panels and said membrane, further include applying foam by means of spraying to a desired dept upon both interior and exterior surfaces of said membran and said panels thereby forming said structure by means of foamsandwich construction. /// SUBSTITUTE SHEET. |
BACKGROUND OF THE INVENTION
The instant application relates generally to a method fo forming structures and more specifically to a method fo constructing a building which may be used as a dwelling.
Due to the rising cost in producing adequate housing, ther has been a dramatic increase in the methods and materials use .for constructing good looking and economical dwellin structures. The costs of materials and labor of a custom buil home have put the price of such a home beyond the reach of thos of normal means. Therefore, a plethora of pre-fabricate building structures and structures constructed from kits hav been proferred to the consumer claiming to fill the need for lo cost, economical, yet attractive dwelling structures. However, prior art devices along these lines are replete with problem and inadequacies. For example, many prior art devices will not meet building or fire codes and exhibit other problem associated with appearance, energy efficiency, and structural integrity. Furthermore, many of the pre-fabricated or kit-type structures are not amenable to erection on a difficult or remote site which may be chosen as the location for a second or vacation home in the mountains, at the beach or anywhere else that presents unique site requirements.
Prior art devices require extensive structural members to be erected and fastened together to create a structural framework to which walls and roofs are attached. This increases the time, labor and materials involved in erecting the structure. These problems are greatly alleviated or eliminated by the structure according to applicant's disclosure which provides a unique way of forming walls and roofs wherein the forming process provides the structural integrity needed to support the entire structure. Therefore, there is a strong felt yet unfulfilled need for the building method according to applicant's disclosure which provides a low cost, energy efficient, and attractive method for forming economical building structures.
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The following citations represent the prior art of which applicant is aware that would appear to be germane to the patent process:
3,324,611 Gamber 3,643,393 Pierce, et al. 3,815,301 Beard, et al. 3,973,367 Johnsen, et al. 4,241,555 Dickens, et al. 4,265,961 Bena
The patent to Dickens et al. is of interest since he teaches the use of a composite panel structure and an associated method of manufacturing in which the building panel has an expanded plastic core which is first molded and then removed from the mold so as to allow reinforcing strips to be placed on the front and back surfaces thereof. The instant application is easily distinguished in that the structure according to the disclosure is itself molded over a form created from wall panels and an inflated or supported membrane so that the forming and molding process also provides the structural shell which supports the structure. The panels formed according to Dickens are prefabricated and then assembled, which is not the case in the instant disclosure.
The remaining references show the state of the art further. For example, Beard et al. teaches the use of applying polyurethane on a roof to form the roof and seal it into a single unit. Thus a supporting surface is provided upon whic the polyurethane is to be sprayed. ///
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OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present inventi to provide a novel method and apparatus for forming structur which are economical, energy efficient, easily constructed any site, and utilize modern techniques and materials.
It is a more particular object of the present invention t provide a novel method for forming structures which greatl reduce the numbers and size of structural members employed thereby reducing the cost of labor and materials utilized i construction.
It is another object of the present invention to provide novel method and apparatus for forming structures which can b erected in a minimal amount of time due to the efficiency of th techniques performed.
It is a still further object of the present invention t provide a novel method and apparatus for forming structure which utilizes a membrane supported in any desired configuratio upon which a foam material is sprayed to form the roof of structure.
It is still another object of the present invention t provide a novel method and apparatus for forming structure which utilizes air pressure to inflate a membrane of any desire shape upon which a foam material is sprayed to form the roof o a structure, thereby eliminating the need to erect structura members upon which a roof is built.
It is a further object of the present invention to provide novel method and apparatus for forming structures in which th configuration of the roof portion is predetermined by adjustin the draping of the membrane upon which the foam is sprayed thereafter using air pressure tp. inflate the membrane to th convex proturberance which represents the form upon which th roof is fashioned.
It is yet another object of the present invention to provid a novel method and apparatus for forming a structure which ca be used to form structures of various size, shape and configu ration according to the desires of the builder. Thus structure
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of conventional configurations can be erected using the meth of the instant disclosure.
It is still a further object of the present invention provide a novel method and apparatus for ormin ' structures which a finished structure formed thusly may be easily expand by simply cutting through a foam wall and casting a furth foundation upon which wall forms are erected with a membra draped across the entire top thereof, the membrane bei inflated before the entire structure is sprayed with a- o substance.
These and other objects and features of the insta invention will become apparent when viewed in light of t following description taken in conjunction with the append drawing figures.
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BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a flowchart depicting the various steps involv in the method associated with the instant invention.
Figure 2 is a side view of a simple structure fashion according to the method of the invention.
Figure 3 is a sectional view of that which is shown Figure 2 taken along lines 3-3.
Figure 4 is a sectional view of that which is shown Figure 2 taken along lines 4-4.
Figure 5 is a sectional view ' of that which is shown Figure 2 taken along lines 5-5.
Figure 6 is a side sectional view of a top portion of t wall panels showing the membrane attached to the top there prior to inflation and foaming. ///
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DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail wherein lik reference numerals represent like parts through the severa figures, reference numeral 10 refers generally to a structur formed according to the method of the instant invention.
The first step in the method, step (a) in the flowchart involves pouring a foundation slab of concrete or the like upo which to erect a structure. As shown in Figure 3, th foundation slab has an outer peripheral edge a stepped portio 12 with a vertical baseboard 13 which was part of the form int which the concrete was poured. The baseboard 13 is left intac after the remainder of the concrete form is removed. The inne wall panels 14 and the outer wall panels IS. are attached to th baseboard 13 and the slab 11 by means of fasteners 16. The wal panels 14 and 15 may consist of sheets of plywood or any simila substance which can be "readily flexed for conformation engagement with the peripheral edges of the slab 11 if the sla is nonrectalinear in configuration. By way of example only, slab may be poured in a circular configuration such that t circles intersect, or are tangential, thereby requiring the wal panels 14 and 15 to conform to curved peripheral surfaces alon the slab 11. Therefore, a material must be chosen for wal panels which is flexible enough to conform to vario configurations yet provide the structural integrity to stand alone.
As indicated by step (b), the wall panels 14 and 15 ar attached to the slab somewhat above the stepped portion 12. On inner panel 14 is applied to the slab first, then an outer pane 15 is applied half-lapping the inner panel such that adjacen edges 1 of inner panel 14 directly underlie an outer panel 15 as best shown in Figure 5. This overlapping configuration o inner and outer panels is continued around the entire peripher of the slab 11 until a contiguous wall form is constructed. Th outer panels 15 may be adhesively bonded to the inner panels 1 to ensure structural integrity and conformational engagement.
As indicated by step (c), after a contiguous wall panel fo has been constructed, prefabricated doors and windows may b
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installed by cutting appropriately sized holes in the wa panels then installing windows 22, doors, or the like as sho in Figure 4. After the desired windows and doors have be framed into the wall panels 14 and 15, then the electrical a plumbing conduits are applied accordingly to the interi surface of the inner wall panel. Similarly, any interior wal designed to carry electrical conduit may be framed out at th point or subsequent to inflating the roof membrane.
As indicated by step (d), a fabric membrane is construct from any flexible but strong membrane material or fabric such cloth, polyethelene or the like. The membrane 18 must relatively impervious to air flow, or if it is not, it mu receive a coating of a sealant to close any pores in t membrane. The membrane 18 need not be formed in any particul shape, as long as it is large enough to encompass the perimet defined by the wall panels 14 and 15. If necessary, bolts fabric may be sewn together to form a large sheet capable encompassing the entire structure.
After a membrane of sufficient size is constructed, indicated by step (d), then the membrane is draped over t entire structure such that middle portions of the membrane ha lower than peripheral portions of the membrane which will attached to top of the wall panels 14 and 15. The shape a configuration of the membrane 18 is then adjusted, keeping mind that when attached and inflated it will become the conver of the configuration observed in the draped mode. Thus th height and configuration of the ceiling to be formed is pre determined by adjusting the drape of the membrane 18 to contour complemental to the shape desired to be made prior .t inflation of same. As shown in Figure 5, the membrane 18 may b attached to the upper ' edge of the outer wall panel 15 by mean of a strip 19 which is attached to the upper peripheral edge o the outer wall panel 15 with the membrane 19 captured there between. Alternatively, the strip 19 may be placed on th interior panel 14 by placing the strip on the interior surface as shown in phantom in Figure 5.
After all the portals such as windows and doors are close and sealed, an air blower is used to draw air from the outsid
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of the structure to the inside of the structure, thereb creating a slight high pressure area within the -structure whic forces the membrane 18 to inflate and rise upwardly to th configuration desired. The strip 19 holds the membrane 18 i place and seals same along the entire upper periphery of th wall panels 14 and 15. After the membrane 18 has been raised b the blower, as indicated in step (f) , the structure is ready fo the application of a foam to either the interior or exterio wall and membrane surfaces.
It should .„be noted that the membrane 18 may also b supported by temporary structural members (not shown) in orde to form roof shapes complemental with a desired configuratio which is more readily achieved by suspending the membrane 1 rather than inflating it.
As indicated in step (g), a foam substance is then applie to the interior or exterior surfaces of the structure includin the wall panels 14 and 15, ,but " not the windows and doors, an the membrane 18 which forms a template upon which the foam i sprayed. The foam may be, but is not limited to, a polyurethan fire retardant foam which is sprayed onto desired surfaces. I one embodiment, the foam is sprayed onto the interior surfaces the foam 20 adhering to the interior wall panels 14 and th interior of the membrane 18, as shown in Figures 3, 4, and 5. A shown in Figure 4, the foam thus forms an interior wall 20 whic is sprayed in sufficient thickness to approach the raise portion of the framing 21 of the window 22 which has bee installed in the wall panels 14 and 15. Thus the foam forms window casement around the window framing 21 whil simultaneously forming the interior wall surface 20. Typically the foam components are sprayed together in a liquid for thereafter capturing gas in elemental bubbles and raising o increasing in thickness forming a hard shell several inche thick. The foam spray is applied in layers until a desire thickness is reached.
In an alternate embodiment, the foam layers 20 may b applied to the exterior surfaces of the structure leaving th interior surfaces without foam. Similarly, a third embodimen contemplates applying the foam layer 20 to both the interior an
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exterior surfaces in a sandwich-type fashion with an option structural reinforcement web 24 captured within the foam. the first embodiment, the foam is applied to the interi surfaces thereby covering and hiding any electrical and/ plumbing conduits that have been applied to the interi surfaces of the structure, thereby eliminating the proble associated with cosmetic cover-up at a later time. Thus indicated by steps (g) and (h) , the foam is applied to eith the outside or the inside surfaces of the membrane 18 and wa panels 14 and 15. If the foam is applied to the outside of t panels 14 and 15, then the plumbing and electrical conduits a also installed on the outside so that the foam will cover them
After the foam has had an opportunity to cure, a fi barrier 23 is applied to the exposed side of the foam layer 2 The fire barrier 23 may be a thin coat of conventional plast or the like which forms an attractive textured interior wa surface which may thereafter, be painted if desired. Similarl plaster applied to the inner surface of the foam comprising t roof portion of the structure provides an attractive textur surface which may be painted or left as is. If the foam applied to the outside of panels 14 and 15, then so is t plaster 23.
An indicated in step (j), a final coat of roof coating m be applied to the exterior foam surfaces in order to preser same from the elements including rain and sun which may caus foam deterioration. Similarly, the exterior of the panels 1 and 15 may be finished with paint, plaster, shingles, etc., t present an attractive outer facade.
In order to control and gauge thickness to which the foam i applied a wire gauge (not shown) of a desired length may b pierced through the surface upon which the foam is to be spraye thereby providing a visual gauge as to the progress of the foa spray. Thus a uniform thickness can be achieved by applying number of wire gauges at various positions across the surface to be sprayed with the foam.
As an option, a stressing ring 25 may be installed wit blocks 26 at an upper, outer edge of the outer panels 15 wher the roof starts. The ring 25 serves to structurally reinforc
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the structure and provides an attractive facia board to trim th roof line.
It should be noted, that the foam provides not only a insulation value, but its primary function is that of structural member integral to the structural integrity of th entire edifice. Once the foam has cured, it is the sustainin element that holds the entire structure together and becomes hard shell capable of supporting loads comparable to thos applied to structures utilizing typical rectalinear constructio techniques. Furthermore, if the structure needs to be enlarge or enhanced this is easily accomplished by cutting away the foa in a desired area, creating another form adjacent thereto an applying a new coat of foam to the form using the technique disclosed hereinabove.
It should be noted further that numerous structura modifications and changes are contemplated as available for us without departing from the spirit of the invention. Fo example, the rounded structure shown in Figure 1 is depicted fo the purpose of explanation and example only, and . it i contemplated by applicant to form structures of any desire configuration including those with the appearance of norma rectalinear construction techniques. ///
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