CA2140421A1 - Extruded building and method and apparatus related to same - Google Patents
Extruded building and method and apparatus related to sameInfo
- Publication number
- CA2140421A1 CA2140421A1 CA 2140421 CA2140421A CA2140421A1 CA 2140421 A1 CA2140421 A1 CA 2140421A1 CA 2140421 CA2140421 CA 2140421 CA 2140421 A CA2140421 A CA 2140421A CA 2140421 A1 CA2140421 A1 CA 2140421A1
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- building structure
- extrusion
- wall sections
- outer layers
- defining
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- Extrusion Moulding Of Plastics Or The Like (AREA)
Abstract
A building structure includes a one piece extruded and cut to length structure including integral sidewalls, a roof, and a floor. The sidewalls roof and floor are configured to simulate conventional wood frame construction (both in color and surface texture), and include various flanges and integral members to facilitate transport of the building structure, attachment of the building structure to a foundation, and assembly of secondary parts to the building structure. Extruded end walls and intermediate walls are configured to mate with the main extrusion for tight and quick assembly thereto. The wall construction includes a beam like laminate of outer and inner layers of structure polymer bonded together with rigid foam. An extruded garage and extruded breezeway can be attached to the building structure to form a building having the appearance of a conventional ranch style wood frame residential building.
Description
21~04~1 EXTRUDED BUILDING AND METHOD AND APPARATUS RELATED TO SAME
BACKGROUND OF THE INVENTION
The present invention generally concerns building structures, and more specifically concerns a building structure made from a large extrusion of polymeric material which facili-5 tates m~nllf~ctllre of the building structure while advantageously m~int~ining the appearanceof conventional wood frame residential housing. The present invention further concerns a method and a~alalus for m~nllf~ctllring the building structure.
A number of building structures have been proposed for making low cost affordable housing. However, t-h-e known low cost building structures usually look "low cost" and lack 10 ~çsth~tir appeal, making them lm~ttr~tive to tenants. The known building structures can be made more attractive by customizing the building structure on-site; however, on-site cu~lollli~lion is not "low cost" since it requires use of skilled labor on-site. Also, additional features facilit~tin~ on-site construction and/or cu~Lollli~dlion of the building structure are desired. At the same time, improvements yielding greater mass production efficiencies are 15 desired.
Some low cost structures use cement as the load bearing structural material. Forexample, in U.S. Patent 2,691,291 (to Henderson) there are disclosed multiple precast con-crete segments that can be assembled to form a building structure. However, prefabricated cement segments are cast, which is a batch type process requiring multiple forms and 20 Co~ "~ g con~ hle time while the cement cures. Further, the segments are solid concrete, making them heavy even if they are only a few feet long. For example, Henderson discloses that the segments must be made relatively short in length to avoid segments that are "too large or unwieldy". (See Henderson, column 1, lines 13-14). It is noted that the short length makes the on-site assembly tedious since not only must multiple pieces be carefully 25 ~lign~l, but also equipment for manipulating the heavy segments must be present on-site.
Still further, concrete is not always the material of choice. For example, concrete is thermally conductive, and thus has a poor energy efficiency making it less desirable in cold c~imates. Still further, precast and uncovered concrete tends to have a cold, "uninviting"
~_ `` 21404~i appearance that is very di~clcllL from conventional wood frame residential housing. This often makes the bl1ilding~ unacceptable to tenants, unless substantial work is pelr~,lllled on-site to customiæ the building. However, the on-site customization is costly, as noted above.
Additionally, it is noted that it is very difficult to make on-site modifications and/or 5 customizations in the cement structure, such as the addition of windows or doors, since the walls and roof are solid concrete.
In U.S. Patent 3,923,436 (to Lewis) there is disclosed an elongated building structure m~nllf~rtllred on-site from foamed-in-place material. The load bearing material of the building structure is the foamed-in-place material, which must be made strong enough to 10 with~t~n-l the stresses and abuse encountered by a typical building. Lewis notes that it may be desirable to increase the durability and tol~ghnPss of the exterior skin of the foamed-in-place material, and for this purpose Lewis discloses that surfacing material may optionally be added to the inside and/or outside of the foamed-in-place material (see column 3, lines 18 et seq). However, even with the addition of the surfacing material, the foamed-in-place 15 material forms substantially the entire load bearing portion of the building structure. Lewis does not suggest constructing a load bearing wall section having structurally stiff layers at the inner and outer surfaces which, from an engineering standpoint, is where the load bearing structure is most nPede~l Further, in Lewis there are no flanges on the surfacing material that facilitate fini~hing the building structure, nor are there any features on the surfacing 20 material or on the foam material of the wall that facilitate installation onto a foundation.
Also, it is noted that the foamed structure in Lewis is substantially limited to on-site fabrication since the foam has a poor tensile ~LlcngLll and may crush or break if impacted or bent, such as often happens during shipping. However, on-site fabrication is expensive, difflcult to control, and does not take m~ximum advantage of mass production. Still further, 25 even with the addition of surfacing material to the foamed-in-place material in Lewis, the long term durability of the building walls is potentially not as good as desired.
In regard to the appaldLus and method disclosed in Lewis, Lewis teaches use of am~ in~ including a foaming device and adjustable forms which can be used on-site.
2140~1 ~, However, such equipment tends to be cumbersome to use, is expensive to ship, and requires skilled labor to safely operate. Further, the a~aldlus requires use of hazardous materials on-site, such as isocyanate material in the case of polyurethane foam. Still further, it is noted that the appaldLus is not productive during transport or setup, and further is subject to v~n~ m while on-site, thus making the overall cost higher than may initially be appal~
As a practical matter, it is noted that the sidewalls of a foam structure made by the Lewis m~rhin~ may tend to bulge or wander as the structure is being formed or as the foam is curing, thus leading to later complaints from tenants about the building quality. This is a difficult problem since the building is constructed on-site where there is less than optimal quality control. Lewis also suggests that the machine can be used to m~nllf~r.ture a building structure including a floor (column 6, lines 62 et seq). However, any such floor structure would require continuous support until the floor cured to a self-supporting state, which would be a slow and tedious process for foamed-in-place material or cement, and thus which is not conducive to mass production.
It is noted that the Lewis patent also discloses that cement can be used instead of foamed-in-place materials, however this produces a building structure having limitations not unlike those disclosed in Henderson, which were discussed above.
Thus, a building structure and method and appal~lus for m~nllf~cturing same solving the aforementioned problems are desired.
SUMMARY OF THE INVENTION
In one aspect, the present invention includes a building structure comprising anelongated tubular extrusion including integral wall sections r.~ hlg a floor, sidewalls, and a roof. The wall sections define an interior space large enough for a person to comfortably stand in, with the wall sections defining the floor and the sidewalls being generally planar and orthogonally related to each other, and further the wall section defining the roof having an inclined surface so that the extrusion has the shape and appe~ranre of a conventional wood frame residential building. The wall sections include at least one layer of non-foamed polymeric material forming a load bearing structural part of the wall section.
~ .
21~04~1 In another aspect, the present invention includes a building structure comprising an elongated extrusion including integral wall sections forming sidewalls and a roof, the wall section defining an interior space large enough for a person to stand in. The wall sections of a first layer and a second layer, the first layer being structural non-foamed polymeric 5 material and the second layer being one of lcil~l-;ement webs integrally extending from the first layer and a slab of rigid foam bonded to the first layer. In one aspect, the wall sections comprise inner and outer layers of non-foamed structural polymeric material bonded to and spaced apart by an interm~ te layer of foam material.
The plcrcllcd embodiments disclosed herein include several advantages over known10 prior art. The extruded building construction having a tubular shape has the rigidity, structure and leak proof shape of a tube. Further, the extruded wall sections have a high strength and durability due to the inner and outer layers of structural polymeric materials which are supported by an intermediate layer of rigid foam and/or reinforcement webs. Still further, the inner and outer layers can include multiple features "as-molded", such as 15 molded-in color (including different colors between the sidewalls and the roof, and di~clcllL
colors between the inner and outer surfaces), dilIelcnl surface textures and pattcrns on all surfaces, molded-in mounting flanges and other flanges facilitating installation of secondary components, and properties of light weight and high ~lcngLIl-to-weight ratio facilit~ting shipment and on-site in~t~ tion. Unlike other known products and processes, the present 20 invention aims to provide a "user friendly" product which sim~ tes conventional wood frame residential construction while siml-lt~n~-ously providing advantages of permanent color, moisture resistance, low air infiltration, high energy efficiency, and dramatically lower total cost after assembly and in~t~ tion. Notably the extruded structure of the present invention can be extruded in any length desired, and the ends of the extruded structure can be cut to 25 mate with other building structures. Further, the wall sections of the extruded home can be modified on-site with conventional hand tools such as with a skill saw or the like, yet are durable enough to with~t~n(l typical wear and tear on the exterior of a building. Still further, the low weight and high ~ sLh-to-weight ratio permit the extruded building structure to be 21~0421 , , , m~nllf~rt~lred at a central location for m~ximum mass production advantage, but permit the building structure to be readily shipped over roads and highways. Still further, the extruded home is compatible with a "co~ uLer integrated m~,k~ and m~mlf~hlring process" in which a mass produced but customer tailored high quality building can be provided. For 5 example, the colll~uL~l int~gr~ted m~krti~g and m~nllf~rtllring process allows the customer's applvv~d order to be lliln.~ iLI~d by modem directly to the com~uL~l driven m~mlf~ctllring processes and machinery. Notably, the extruded building unit itself is structurally whole, elimin~ting the need for a structural frame (such as is required in mobile homes).
These and other features, advantages, and objects of the present invention will be 10 further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a perspective view of a building structure embodying the present invention, the building structure including a tubular extrusion with wall sections defining sidewalls, a 15 roof, and a floor, and further including end walls (only one of which is shown)for closing the ends of the tubular extrusion, and an intermediate wall for subdividing interior space of the tubular extrusion;
Fig. 2 is an end view of the building structure shown in Fig. l;
Fig. 3 is a side view of the building structure shown in Fig. 1 but including both end 20 walls;
Fig. 4 is an exploded, perspective view of the building structure shown in Fig. 1, including an end wall, an intermediate wall, a main building extrusion, and a forced air heat duct assembly;
Fig. 5 is an enlarged, fragmentary side cross-sectional view of the circled area V-V
25 in Fig. 4;
Figs. 5A and 5B are fragmentary side views of two alternative wall sections having di~l~nl exterior surfaces;
` 2140~1 Fig. 6 is an enlarged, fragmentary cross-sectional view of the building structure rested on and joined to a foundation;
Figs. 7-9 are enlarged, fragmentary cross-sectional views of alternative modified extruded building structures rested on and joined to a foundation;
Fig. 10 is an enlarged, fragmentary cross-sectional view of the circled area X in Fig. 1 showing a baseboard at the corner defined by the floor and sidewall;
Fig. 11 is a side elevational view of the interm~ te wall shown in Figs. 1 and 4;
Fig. 12 is a cross-sectional view taken along the plane XII-XII in Fig. 11 showing the baseboard at the corner defined by the intermediate wall and the floor;
Fig. 13 is a cross-sectional view taken along the plane XIII-XIII in Fig. 11 showing the door casing and doorway opening;
Fig. 13A is a cross-sectional view comparable to Fig. 13 but showing an alternative door casing construction;
Fig. 14 is a fragmentary cross-sectional view of an end corner of the building lS structure taken along the plane XIV-XIV in Fig. 3;
Fig. 14A is a fragmentary cross-sectional view comparable to Fig. 14 but of an end corner of an alternative construction;
Fig. 15 is an end view of a modified extruded building structure embodying the present invention, the modified building structure including enlarged beam-like structures for en~ging a transport trailer;
Fig. 16 is an end view of another modified building structure embodying the present invention, the modified building structure being configured to form a double wide building structure and including a field applied roof cap/cover plate;
Fig. 17 is a side view of the building structure shown in Fig. 1 on a transport trailer;
Fig. 18 is a cross-sectional view taken along the planes XVIII-XVIII in Fig. 17;Fig. 19 is a perspective view of a building structure embodying the present invention, the building structure including a main extruded building structure configured to be used as 21404~1 ~f living quarters and an extruded garage structure attached to the main building structure by an extruded blee;~w~y structure defining a three-season room;
Fig. 20 is a front view of the building structure shown in Fig. 19;
Fig. 21 is a plan view of the building structure shown in Fig. 19;
Fig. 22 is a plan view of a modified building structure embodying the present invention, the building structure including a main extruded building structure configured to be used as living quarters and an attached garage structure attached to the main building structure by an extruded roof structure;
Fig. 23 is a cross-sectional view taken along the plane XXIII-XXIII in Fig. 22 showing the garage structure;
Fig. 24 is a cross-sectional view of a modified building structure generally similar to that shown in Fig. 23 but including integral but discrete truss members;
Fig. 25 is a cross-sectional view of another modified building structure generally similar to that shown in Fig. 23 but including non-unirollllly positioned discrete truss members;
Fig. 26 is a side elevational view of the extruded breeæway roof structure shown in Fig. 22;
Fig. 27 is an end view of the breeæway roof structure in Fig. 26; and Figs. 28 and 29 are flow diagrams for a method of m~nllf~turing the extruded building structures noted above.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An extruded building structure 30 (Figs. 1-4) embodying the present invention includes a one piece extruded and cut-to-length extrusion 32, including integral sidewalls 33 and 34, a roof 35, and a floor 36 defining an interior space 38. The sidewalls 33 and 34, roof 35, and floor 36 include various flanges and other features to facilitate mass production and shipping of the building structure while mi~ lli7.i~-g or simplifying secondary operations such as attaching the building structure to a foundation and assembling fixtures and secondary parts such as baseboards to the building structure. The extrusion 32 is configured to simulate - I 21401~i a quality conventional wood frame construction and allows a customer to select the siæ, shape, and color of various parts of the structure while m~int~ining advantages including pellllallell~ color, moisture resistance, low air infiltration, high energy efficiency, and lr~m~ti~lly lower total costs. Building structure 30 further includes a pair of end walls 40 5 and at least one interm~di~te wall 42 for eng~ging extrusion 32 to subdivide the interior space 38 within extrusion 32.
The wall sections defining members 33-36 include an inner layer 44 and an outer layer 46 spaced from inner layer 44 and interconn~ct~d to layer 44 by a supporting intermediate layer of r~il~l~;ement webs 48 and rigid foam 50, such as is illustrated in Fig.
5. Inner layer 44 and outer layer 46 are comprised of non-foamed structural materials such as thermoplastic polymeric materials chosen to provide load bearing structure to the wall sections. Reinforcement webs 48 are integr~lly extruded with inner and outer layers 44 and 46. Reinforcement webs 48 stabiliæ layers 44 and 46 at locations of relatively high stress along the wall sections, and at strategically located points, can include thicker sections to provide additional support for attached items such as cabinets or doors. Further, inner and outer layers 44 and 46 provide a very durable and long lasting surface that can withstand the abrasion and wear required of a building structure. Notably, layers 44 and 46 can be increased in thickness or otherwise shaped for added ~lell~Lh and/or aesth~qtirs as desired.
For example, outer layer 46 can be shaped to replicate clapboard or beveled siding (Fig. 5), dutchlap siding 46' (Fig. 5A), or log-type wall construction 46" (Fig. 5B). It is also contemplated that flanges can be extended inwardly from inner layer surface 45 into interior space 38 or that layer 44 can be made thicker in certain areas to facilitate locating and supporting baseboards, kitchen cabinets, and other building fixtures. Also, longit~ in~lly extending bosses or apertured webs 49 can be positioned on webs 48, such as for receiving a screw or fastener 58 for holding a door casing to a doorway opening (see Fig. 13A), as li~c~lssed below.
Still further, the surfaces 45 and 47 of inner and outer layers 44 and 46 respectively can be textured and colored as desired. For example, outer layer surface 47 can be colored 21404~
and textured to sim~ tP siding (e.g. al~ lll siding or wood siding) or a log home, while inner layer surface 45 can be colored a di~el~llL color and textured to simulate drywall, paneling or another surface. Still further, the inner and outer surfaces of any of sidewalls 33 and 34, roof 35 and floor 36 can be colored with di~l~llL colors selected by a customer.
5 The colors would be continuous throughout layers 44 and 46, and thus would be long lasting.
It is contemplated that the coloring could be efficiently and economically done as part of the extruding process such as by adding colorant to the polymer feedstock being fed into the extruding process. Also, additives resisting degradation from ultraviolet radiation could be added to outer layer 46 as desired.
The extruded thermoplastic layers 44 and 46 and lch~l~;ement webs 50 quickly solidify and become rigid after exiting the extruder and extruder die during the extrusion process. Thus, immP(li~tP.ly after extruding layers 44 and 46 or at some time soon thereafter, foam material 50 can be added to the wall section in the space between layers 44 and 46.
The inner and outer layers 44 and 46 contain the foam material 50 as it PYp~n~l~ As the foam material solidifies/cures, the foam 50 securely bonds and interconnects layers 44 and 46 to form a rigid "stressed skin" structure having structural elements or "skins" spaced apart by a rigid interconnPcting element in a beam-like manner. This stressed skin structure positions structural "skin" portions of the wall section at the outer edges of the wall section at an optimal position based on engineering principles for supporting loads.
It is contemplated that layers 44 and 46 and webs 48 will be about 1/8" thick, and will be a structural plastic such as thermoplastic, although alternative materials and thickness can be used. By use of these materials, the wall sections provide a rigid construction which can be cut, drilled, and sawed much like wood, and thus the wall sections readily permit modifications to the extrusion 32. For example, such modifications would be desired for such items as the addition of windows 56 (Fig. 4). Regarding windows, conventional window structures can be positioned in an openillg cut into wall section sidewall 33.
iv~ly, an inner and outer window frame 57 and 57' could be secured together in asandwich-like ~ n~lllent on sidewall 33 (Fig. 18).
` 21404~1 The wall sections also advantageously provide many final features sim~ ting features of a conventionally built wood frame building. For example, the wall section rullnillg the corner 59 (Fig. 4) defined by the roof 35 and sidewall 33 defines a drip edge 60. Notably, an eaves trough (not shown) could also be integrally formed in the extrusion, or, 5 alternatively, a flange could be added for secllrin~ an eaves trough to the building structure.
Shingles are also simlll~te~l by the exterior surface 62 of roof 35.
A pair of foundation eng~ging sections 64 extend duwllwdldly from floor 36 undersidewalls 33 and 34. Integral foundation en~ging side sections (64) allow space for a hydraulically lowered transport trailer (Fig. 17) to be removed at the construction site, allow 10 a crawlspace for on-site hook-up of utilities such as electricity, water, sewer lines, and elimin~te a need for skirting such as is required on conventional modular units. In this regard, a number of variations are possible. For example, foundation eng;~gin~ section 64 provides a flat surface 66 for resting on the upper surface 68 of a foundation 70 (Fig. 6).
A strap 72 attaches to the side of section 64 and foundation 70 to secure the extrusion 32 to the foundation 70. Strap 72 is interconn~cte~l by bolts or fasteners 76 to section 64 and to foundation 70. Al~lllaliv~ly, a foundation eng~ging section 64' (Fig. 7) can be provided which includes a laterally extending web 74' that extends laterally from the side of flat surface 66'. Foundation eng~gin~ section 64' is secured by a fastener 76' that extends through laterally extending web 74 into foundation upper surface 68'. A diagonallc;inrul~;elllent web 77' is used to stabilize laterally extending web 74 on foundation eng~ging section 64'. For example, the foundation eng~ging section 64' could be used when the building structure is to be secured to a concrete slab.
In another modification (Fig. 8), a web 74" is extended duwllwdldly so that it forms a pocket with flat surface 66" for eng;lging the side and upper surface 68" of foundation 70".
A fastener 76" is extended through web 74" to secure extrusion 32" to foundation 70". Still another modification (Fig. 9) includes an L-shaped web 78"' having a lateral web portion 80"' and a dowllwdl-lly extending portion 82"', lateral web portion 80"' eng~ging the top of a foundation 70''' and dowllwdldly extending portion 82''' eng~ging the side of the foundation 70"'. Notably, an opposing web 84"' can be positioned opposite d~wllw~ldly t;AL~lldillg portion 82"'. Opposing web 84"' forms a channel or guide with portion 82"' which engages both sides of foundation 70"' and thus guides extrusion 32"' onto foundation 70"' such as when a trailer is pulling extrusion 32 onto foundation 70"'. Notably, a removable fixture could also be temporarily attached to the side of foundation eng~ging section 64"' to accomplish a similar function as web 84"'.
In another modification (Fig. 15), beam-like sections 63A extend the length of extrusion 32 to help rigidify floor 36. Also, jack-like supports on footers (not shown) can be used to support beam-like sections 63A interm~di~t~ their length over a crawlspace or basement. Still further, beam-like sections 63 and 63A provide structure that can be engaged by a trailer, as ~ cllcsed hereinafter. (See Figs. 17 and 18.) Rega,dillg duct 90 (Fig. 4), duct 90 includes a preassembled main heat duct 92 ~tt~h~cl to the underside of floor 36. One or more flexible tubular branches 94 are cormectable to main duct 92 and lead to an outlet 96. An opening 98 is cut into floor 36 to define an opening configured to receive outlet 96. One or more openings 98 can be located in the floor of each room. It is contemplated that flexible branch ducts 94 will be connected to the outlets after transporting building structure 30 to the construction site and transport trailer is removed.
A first baseboard en~gin~ flange 102 (Fig. 10) extends upwardly into interior space 38 from floor 36 and a second baseboard en~ging flange 104 extends laterally from sidewall 33 (or 34) proximate a corner 100 defined by floor 36 and sidewall 33. Baseboard 106 includes a cover section 108 for covering wires 101, and flange eng~gin~ edges 110 and 112 for en~ging flanges 102 and 104. Baseboard 106 is snap-locked onto flanges 102 and 104 to cover wires extending along the corner 100. Electrical outlets 114 are located along baseboard 106 as often as desired. It is contemplated that the wiring 101 will be prefabricated units that snap together much like a wiring harness in an automobile, although conventional wiring could also be used. The wiring 101 can be extended through ` 2140~21 I_ intermediate wall 42 through a hole 107 in interm~ te wall 42 (Fig. 11) at the corners of wall 42 or through doorway openings cut into wall 42 (see Fig. 13).
Fig. 12 shows an alternative all~n~,~lllent wherein both of baseboard eng~gin~ flanges 102' and 104' extend from, in this case, interm~ te wall 42. A modified baseboard 106' is configured to engage and be frictionally retained on flanges 102' and 104'. Wires 101' are routed through the space defined by baseboard 106' and corner 100' defined by floor 36 and intermediate wall 42. Notably, flanges 102' and 104' are located on both sides of intermediate wall 42, and baseboards 106' are also locatable on both sides of interm~ te wall 42.
It is contemplated that interm~ t~ wall 42 and end wall 40 will be constructed of an extrusion including inner and outer layers supported by an intermediate layer of foamed material and/or l~il~l~;ement webs not unlike the wall sections previously described. (See Figs. 12 and 13.) End wall 40 and interrn~ t~ wall 42, after extrusion, are precisely cut to the n~cess~ry shape to match up with main extrusion 32. Advantageously, excess material cut away from walls 40 and 42 can be separated and recycled back into the extrusion process. However, it is also contemplated that al~ iv~ intermediate wall constructions are possible, such as conventional 2 x 4 wood and drywall constructions. Advantageously, the extruded interrn~ t~ wall 42 can be cut with conventional hand-held or hand-operated equipment such as a skill saw or the like. Thus, doorway openings 120 (Fig. 11) and other Opellillg~ or holes can be readily formed in interrnP~ t~ walls 42.
Casings such as extruded C-shaped casings 122 (Fig. 13) can be positioned in doorway openings 120, with the legs 124 of C-shaped casings 122 eng~ging and ret~ining casings 122 in doorway opening 120. Casing 122 is shaped to mateably receive conventional wood casing 122A and is configured to be sufficiently rigid to support a door 123 including door hinges and a door catch or striker plate (not specifically shown). In one version, casing legs 124 are hollow and the web 124' conn~cting legs 124 has at least a hole through it so that wires 101 can be routed in casing 122 around and through doorway opening 120.
21404~ 1 . . , , i An al~lllaLiv~ door casing 122' (Fig. 13A) includes a pair of hollow casing legs 124' that are not unlike baseboard covers 106. In this ~ ge~ent, conventional wood casing 122A is secured to wall 42 by a fastener 58 that extends into a boss 49 in web 48 of intermediate wall 42.
End wall 40 (Fig. 14) is connected to the end of extrusion 32 by an extruded connector 125. Extruded connector 125 includes flanges 126, 127 and 128 for defining a first pocket 130 for receiving an edge of end wall 40. Connector 125 further includes flanges 132 and 133 that form with flange 128 a second pocket 134 for receiving an end of extrusion 32. Pockets 130 and 134 are oriented perpendicularly to each other. It is contemplated that multiple connectors 125 will be positioned around the five linear sides of end wall 40. The connectors 125 will be secured to end wall 40 and extrusion 32 by a&esive 136 which will seal the joint so that the joint is leak-free. Optionally, fasteners (not shown) such as nails, screws or bolts can be used to secure the joint together if desired. It is noted that a variety of di~el~lllly shaped connectors 125 are possible. For example, connector 125 could be made thinner, or flanges 126, 132 or 133 could be elimin~te~l.
In another al~ liv~, an L-shaped extruded connector 125' (Fig. 14A) including side pieces 126' and 127' is used. Outer layer 46' is extended past the end of extruded wall sections 33-36 to create a rabbit joint. End wall 42' is extended into the rabbit joint and the joint is secured together by adhesive, sealant, and fasteners as desired. Notably, separate connectors could be used inside and outside the joint, or the connectors could be elimin~t~cl by use of an a&esive that adequately seals and bonds the joint together.
It is contemplated that extrusions 32 can be modified for particular applications. For example, modified extrusion 32B (Fig. 16) includes a trapezoidal shape configured to mate with a second extrusion 32B (shown in phantom) to form a double-wide building structure.
Notably, it is not n~cess~ry that both extrusions (32B) have identical shapes. A roof cap or cover plate 147B is applied to the peak of the double wide building structure on-site to prevent moisture intrusion at the peak. The ends of the double wide building structure are covered or sealed as desired.
21404~;1 . . , , j Building structure 30 (Figs. 17 and 18) is transportable on a trailer 150. Trailer 150 includes a bed 151 supported by axles 152 and tires 153. Extrusion eng~ging jacks 154 are positioned on bed 151. Jacks 154 include an upper end 155 configured to engage beam-like sections 63 under floor 36 to hold building structure 30 on trailer 150 during transport.
Also, jacks 154 allow building structure 30 to be carried at a desired height on trailer 150 to meet local highway regulations, and in particular allow the building structure to be carried high enough so that the foundation eng~gin~ sections 64 do not drag on a road surface during transport. Jacks 154 allow building structure 30 to be lifted or lowered for positioning the building structure over a foundation 70. Building structure 30 can then be lowered onto the foundation 70 and secured thereto (see Figs. 6-9). A front cover or skirt applied after trailer is removed and utility connections are made.
A building structure 170 (Figs. 19 and 20) incorporates a building structure 30 with an extruded building structure 172 positioned parallel building structure 30 andinterconn~ctçcl to building structure 30 by an extruded breeæway 174. Building structure 30 is about 40 feet long to accommodate the floor plan illustrated in Fig. 21, but can be made subst~nti~lly any length desired. Breezeway structure 174 (Fig. 20) includes a tubular shape comparable to building structure 32. Specifically, breeæway structure 174 includes orthogonally related sidewalls and a floor having a length of about 10 to 12 feet in order to form a good siæd room. The sidewalls and floor are cut vertically so that the end of breezeway structure 174 closely engages the sides of building structure 30 and building structure 172. However, the roof of breeæway structure 174 is cut at an angle longihl(lin~lly so that the ends 176 and 177 of the roof mateably engage the sloping sides of the roofs on building structure 30 and building structure 172. Notably, the "garage" building structure 172 can be constructed as a double-wide structure in order to receive two cars (see Figs. 16 and 21), or as two short extrusions cut transversely to a siæ that will allow the building structure to be shipped on a highway. Optionally, the "garage" building structure can be made long enough to receive two cars (see Fig. 22). Notably, for tooling economy, the die 214049~1 for m~nllf~ctllring the building structure 172 could utilize the same extruding die as main building structure 32, except with the floor portion 36 closed off or "blocked out".
As illustrated in Fig. 22, modified building structure 170A includes an extrudedbuilding structure 30A, an extruded building structure 172A, and an extrusion 174A
interconnPcting same. Building structure 30A is extruded and cut to a shorter length than building structure 30 to accommodate a reduced floor plan. Notably, building structure 172A
is a one car structure and is smaller in width than the building structure 172 shown in Fig.
21. Breezeway structure 174A defines a roof with ends 186A and 188A (Figs. 26 and 27) that rest on and engage the sloping sides of the roofs of building structure 30A and 172A.
(See Fig. 20 for comparison.) Notably, breezeway structure 174A does not includesidewalls. It is noted that dilTerelll breezeway structures could be developed that incorporate one or more sidewalls, and that the blee~w~ structures can be of any length or shape as desired.
Breeæway structure 174A (Fig. 27) includes inner and outer layers l90A and 192A
interconnPcte~l by truss sim~ ting webs 194A. The spaces within breezeway structure 174A
can be filled with foam 196A for additional rigidity or load bearing capability if needed. The thicknPss of breezeway structure 174A increases to a thickness Tl near the peak 198A and the thicknP-ss lessens near the edges l95A to a thickness T2.
Building structure 172A (Fig. 23) includes a roof 196A not unlike breezeway structure 174A, however building structure 172A further includes sidewalls 200A and 201A. Notably, building structure 172A does not include a floor but rather is rested on a concrete slab 202A
with footers 204A, slab 202A providing a rough non-slip surface 205A for supporting an automobile.
Additional various garage-like building structures are disclosed in Figs. 24 and 25.
Rllil(lin~ structure 172B (Fig. 24) is similar to building structure 172A except it includes discrete truss sim~ ting beams 206B that extend longihl~lin~lly. Access to the attic area 208B can be achieved by cutting an access opening through one or more locations in the lowermost of beams 206B. Building structure 174C (Fig. 25) is similar to building structure 2l~0~a~
174B, except it includes non-ullirollllly positioned truss sim~ ting beams 210C for supporting non-ulliro~ loads on the roof of building structure 172C. For example, non-unirollll loads may be experienced by placing a breezeway structure such as extrusion 174A
thereon. (See Figs. 26 and 27.) The beams 210C support this increased load from 5 breezeway structure 174A.
The method of m~nllf~tllre of an extruded building structure such as structures 30, 40, 42, 124, 172, 172A, 172B, 172C, 174 and 174A is illustrated in Figs. 28 and 29. The process of extruding thermoplastic material is generally known, and thus detailed equipment disclosure is not n.ocess~ry for a wulhhlg underst~ntling of the present invention. Initially 10 in a step 214, thermoplastic material is extruded by an extruder through an extruding die to form integral wall sections, such as wall sections 33-36 for building structure 30 (Fig. 28).
Notably, where a multicolored extrusion is desired, multiple extruders (such as extruders 220A, 220B and 220C) (Fig. 29) can be used to process different materials (such as materials and colorants 222A, 222B and 222C) through a die 224. Thus, extrusion 32 would have 15 multicolored wall sections customized to a customer's specifications. For example, the sidewall and roof interior surfaces could be off-white in color, while the sidewall interior surface could be tan in color and the roof exterior surface could be black in color. In step 216 the extrusion is extruded to the desired length and cut off by cutoff device 226 (Fig. 29).
It is contemplated that cutoff device 226 will move with the extrusion during the step of 20 cutting so that the extrusion process is continuous, although the extrusion process could also be stopped temporarily to permit cutting if desired. Simlllt~n~ously, while extruding extrusion 32 (i.e. step 218) or some time soon thereafter, foam material 50 is injected into the space between thermoplastic inner and outer layers 44 and 46. Optimally it is contemplated that the foaming device will attach to and be an integral part of the extruding 25 die.
Once the wall sections of the extrusion are sufficiently rigid, window openings and doorways are cut into the extrusion (i.e. step 230) by a device such as a colnL Ul~l controlled traveling saw. Window assemblies, doorway c~in~s, fixtures and other items are then 21404~1 attached to the wall sections in a step 232. Also, intermediate walls and end walls are added as required. Building structure 30 is otherwise substantially completely assembled at the factory such as by the in~t~ tion of kitchen appliances and cabinets, bathroom fixtures, and etc.
Once subst~nti~lly completed, the building structure is loaded onto a trailer for transport (i.e. step 234). After in~t~ tion on a foundation (step 236), the building utilities of building structure 30 are connPcted to utility hook-ups on-site in a step 238. Also, in the case of multiple extrusions, the extrusions are interconnPcted in a predetermined alldngelllent according to a layout (i.e. step 240).
Thus, a plurality of building structures are provided including a one piece tubular extrusion which is a "user friendly" product that sim~ tes conventional wood frame housing, but which provides advantages of permanent color, moisture resistance, low air infiltration, high energy efficiency, and dram~tir~lly lower cost. The extruded home is capable of high volume mass production, but allows custom m~mlf~-~tllre with high quality product. The wall construction includes inner and outer layers of structural polymeric materials bonded with rigid foam, which allows fabrication of an extrusion having flanges and other structural members specifically adapted to allow transportation of the building structure, attachment of the building structure to a foundation, and assembly of secondary parts to the building structure. In another aspect, a tubular extrusion providing living quarters is connPcted to an inverted U-shaped extrusion r~lllfillg a garage for an automobile, which components are interconnPcted by an extruded breezeway structure.
In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without depal~illg from the concepts dis-closed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.
BACKGROUND OF THE INVENTION
The present invention generally concerns building structures, and more specifically concerns a building structure made from a large extrusion of polymeric material which facili-5 tates m~nllf~ctllre of the building structure while advantageously m~int~ining the appearanceof conventional wood frame residential housing. The present invention further concerns a method and a~alalus for m~nllf~ctllring the building structure.
A number of building structures have been proposed for making low cost affordable housing. However, t-h-e known low cost building structures usually look "low cost" and lack 10 ~çsth~tir appeal, making them lm~ttr~tive to tenants. The known building structures can be made more attractive by customizing the building structure on-site; however, on-site cu~lollli~lion is not "low cost" since it requires use of skilled labor on-site. Also, additional features facilit~tin~ on-site construction and/or cu~Lollli~dlion of the building structure are desired. At the same time, improvements yielding greater mass production efficiencies are 15 desired.
Some low cost structures use cement as the load bearing structural material. Forexample, in U.S. Patent 2,691,291 (to Henderson) there are disclosed multiple precast con-crete segments that can be assembled to form a building structure. However, prefabricated cement segments are cast, which is a batch type process requiring multiple forms and 20 Co~ "~ g con~ hle time while the cement cures. Further, the segments are solid concrete, making them heavy even if they are only a few feet long. For example, Henderson discloses that the segments must be made relatively short in length to avoid segments that are "too large or unwieldy". (See Henderson, column 1, lines 13-14). It is noted that the short length makes the on-site assembly tedious since not only must multiple pieces be carefully 25 ~lign~l, but also equipment for manipulating the heavy segments must be present on-site.
Still further, concrete is not always the material of choice. For example, concrete is thermally conductive, and thus has a poor energy efficiency making it less desirable in cold c~imates. Still further, precast and uncovered concrete tends to have a cold, "uninviting"
~_ `` 21404~i appearance that is very di~clcllL from conventional wood frame residential housing. This often makes the bl1ilding~ unacceptable to tenants, unless substantial work is pelr~,lllled on-site to customiæ the building. However, the on-site customization is costly, as noted above.
Additionally, it is noted that it is very difficult to make on-site modifications and/or 5 customizations in the cement structure, such as the addition of windows or doors, since the walls and roof are solid concrete.
In U.S. Patent 3,923,436 (to Lewis) there is disclosed an elongated building structure m~nllf~rtllred on-site from foamed-in-place material. The load bearing material of the building structure is the foamed-in-place material, which must be made strong enough to 10 with~t~n-l the stresses and abuse encountered by a typical building. Lewis notes that it may be desirable to increase the durability and tol~ghnPss of the exterior skin of the foamed-in-place material, and for this purpose Lewis discloses that surfacing material may optionally be added to the inside and/or outside of the foamed-in-place material (see column 3, lines 18 et seq). However, even with the addition of the surfacing material, the foamed-in-place 15 material forms substantially the entire load bearing portion of the building structure. Lewis does not suggest constructing a load bearing wall section having structurally stiff layers at the inner and outer surfaces which, from an engineering standpoint, is where the load bearing structure is most nPede~l Further, in Lewis there are no flanges on the surfacing material that facilitate fini~hing the building structure, nor are there any features on the surfacing 20 material or on the foam material of the wall that facilitate installation onto a foundation.
Also, it is noted that the foamed structure in Lewis is substantially limited to on-site fabrication since the foam has a poor tensile ~LlcngLll and may crush or break if impacted or bent, such as often happens during shipping. However, on-site fabrication is expensive, difflcult to control, and does not take m~ximum advantage of mass production. Still further, 25 even with the addition of surfacing material to the foamed-in-place material in Lewis, the long term durability of the building walls is potentially not as good as desired.
In regard to the appaldLus and method disclosed in Lewis, Lewis teaches use of am~ in~ including a foaming device and adjustable forms which can be used on-site.
2140~1 ~, However, such equipment tends to be cumbersome to use, is expensive to ship, and requires skilled labor to safely operate. Further, the a~aldlus requires use of hazardous materials on-site, such as isocyanate material in the case of polyurethane foam. Still further, it is noted that the appaldLus is not productive during transport or setup, and further is subject to v~n~ m while on-site, thus making the overall cost higher than may initially be appal~
As a practical matter, it is noted that the sidewalls of a foam structure made by the Lewis m~rhin~ may tend to bulge or wander as the structure is being formed or as the foam is curing, thus leading to later complaints from tenants about the building quality. This is a difficult problem since the building is constructed on-site where there is less than optimal quality control. Lewis also suggests that the machine can be used to m~nllf~r.ture a building structure including a floor (column 6, lines 62 et seq). However, any such floor structure would require continuous support until the floor cured to a self-supporting state, which would be a slow and tedious process for foamed-in-place material or cement, and thus which is not conducive to mass production.
It is noted that the Lewis patent also discloses that cement can be used instead of foamed-in-place materials, however this produces a building structure having limitations not unlike those disclosed in Henderson, which were discussed above.
Thus, a building structure and method and appal~lus for m~nllf~cturing same solving the aforementioned problems are desired.
SUMMARY OF THE INVENTION
In one aspect, the present invention includes a building structure comprising anelongated tubular extrusion including integral wall sections r.~ hlg a floor, sidewalls, and a roof. The wall sections define an interior space large enough for a person to comfortably stand in, with the wall sections defining the floor and the sidewalls being generally planar and orthogonally related to each other, and further the wall section defining the roof having an inclined surface so that the extrusion has the shape and appe~ranre of a conventional wood frame residential building. The wall sections include at least one layer of non-foamed polymeric material forming a load bearing structural part of the wall section.
~ .
21~04~1 In another aspect, the present invention includes a building structure comprising an elongated extrusion including integral wall sections forming sidewalls and a roof, the wall section defining an interior space large enough for a person to stand in. The wall sections of a first layer and a second layer, the first layer being structural non-foamed polymeric 5 material and the second layer being one of lcil~l-;ement webs integrally extending from the first layer and a slab of rigid foam bonded to the first layer. In one aspect, the wall sections comprise inner and outer layers of non-foamed structural polymeric material bonded to and spaced apart by an interm~ te layer of foam material.
The plcrcllcd embodiments disclosed herein include several advantages over known10 prior art. The extruded building construction having a tubular shape has the rigidity, structure and leak proof shape of a tube. Further, the extruded wall sections have a high strength and durability due to the inner and outer layers of structural polymeric materials which are supported by an intermediate layer of rigid foam and/or reinforcement webs. Still further, the inner and outer layers can include multiple features "as-molded", such as 15 molded-in color (including different colors between the sidewalls and the roof, and di~clcllL
colors between the inner and outer surfaces), dilIelcnl surface textures and pattcrns on all surfaces, molded-in mounting flanges and other flanges facilitating installation of secondary components, and properties of light weight and high ~lcngLIl-to-weight ratio facilit~ting shipment and on-site in~t~ tion. Unlike other known products and processes, the present 20 invention aims to provide a "user friendly" product which sim~ tes conventional wood frame residential construction while siml-lt~n~-ously providing advantages of permanent color, moisture resistance, low air infiltration, high energy efficiency, and dramatically lower total cost after assembly and in~t~ tion. Notably the extruded structure of the present invention can be extruded in any length desired, and the ends of the extruded structure can be cut to 25 mate with other building structures. Further, the wall sections of the extruded home can be modified on-site with conventional hand tools such as with a skill saw or the like, yet are durable enough to with~t~n(l typical wear and tear on the exterior of a building. Still further, the low weight and high ~ sLh-to-weight ratio permit the extruded building structure to be 21~0421 , , , m~nllf~rt~lred at a central location for m~ximum mass production advantage, but permit the building structure to be readily shipped over roads and highways. Still further, the extruded home is compatible with a "co~ uLer integrated m~,k~ and m~mlf~hlring process" in which a mass produced but customer tailored high quality building can be provided. For 5 example, the colll~uL~l int~gr~ted m~krti~g and m~nllf~rtllring process allows the customer's applvv~d order to be lliln.~ iLI~d by modem directly to the com~uL~l driven m~mlf~ctllring processes and machinery. Notably, the extruded building unit itself is structurally whole, elimin~ting the need for a structural frame (such as is required in mobile homes).
These and other features, advantages, and objects of the present invention will be 10 further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a perspective view of a building structure embodying the present invention, the building structure including a tubular extrusion with wall sections defining sidewalls, a 15 roof, and a floor, and further including end walls (only one of which is shown)for closing the ends of the tubular extrusion, and an intermediate wall for subdividing interior space of the tubular extrusion;
Fig. 2 is an end view of the building structure shown in Fig. l;
Fig. 3 is a side view of the building structure shown in Fig. 1 but including both end 20 walls;
Fig. 4 is an exploded, perspective view of the building structure shown in Fig. 1, including an end wall, an intermediate wall, a main building extrusion, and a forced air heat duct assembly;
Fig. 5 is an enlarged, fragmentary side cross-sectional view of the circled area V-V
25 in Fig. 4;
Figs. 5A and 5B are fragmentary side views of two alternative wall sections having di~l~nl exterior surfaces;
` 2140~1 Fig. 6 is an enlarged, fragmentary cross-sectional view of the building structure rested on and joined to a foundation;
Figs. 7-9 are enlarged, fragmentary cross-sectional views of alternative modified extruded building structures rested on and joined to a foundation;
Fig. 10 is an enlarged, fragmentary cross-sectional view of the circled area X in Fig. 1 showing a baseboard at the corner defined by the floor and sidewall;
Fig. 11 is a side elevational view of the interm~ te wall shown in Figs. 1 and 4;
Fig. 12 is a cross-sectional view taken along the plane XII-XII in Fig. 11 showing the baseboard at the corner defined by the intermediate wall and the floor;
Fig. 13 is a cross-sectional view taken along the plane XIII-XIII in Fig. 11 showing the door casing and doorway opening;
Fig. 13A is a cross-sectional view comparable to Fig. 13 but showing an alternative door casing construction;
Fig. 14 is a fragmentary cross-sectional view of an end corner of the building lS structure taken along the plane XIV-XIV in Fig. 3;
Fig. 14A is a fragmentary cross-sectional view comparable to Fig. 14 but of an end corner of an alternative construction;
Fig. 15 is an end view of a modified extruded building structure embodying the present invention, the modified building structure including enlarged beam-like structures for en~ging a transport trailer;
Fig. 16 is an end view of another modified building structure embodying the present invention, the modified building structure being configured to form a double wide building structure and including a field applied roof cap/cover plate;
Fig. 17 is a side view of the building structure shown in Fig. 1 on a transport trailer;
Fig. 18 is a cross-sectional view taken along the planes XVIII-XVIII in Fig. 17;Fig. 19 is a perspective view of a building structure embodying the present invention, the building structure including a main extruded building structure configured to be used as 21404~1 ~f living quarters and an extruded garage structure attached to the main building structure by an extruded blee;~w~y structure defining a three-season room;
Fig. 20 is a front view of the building structure shown in Fig. 19;
Fig. 21 is a plan view of the building structure shown in Fig. 19;
Fig. 22 is a plan view of a modified building structure embodying the present invention, the building structure including a main extruded building structure configured to be used as living quarters and an attached garage structure attached to the main building structure by an extruded roof structure;
Fig. 23 is a cross-sectional view taken along the plane XXIII-XXIII in Fig. 22 showing the garage structure;
Fig. 24 is a cross-sectional view of a modified building structure generally similar to that shown in Fig. 23 but including integral but discrete truss members;
Fig. 25 is a cross-sectional view of another modified building structure generally similar to that shown in Fig. 23 but including non-unirollllly positioned discrete truss members;
Fig. 26 is a side elevational view of the extruded breeæway roof structure shown in Fig. 22;
Fig. 27 is an end view of the breeæway roof structure in Fig. 26; and Figs. 28 and 29 are flow diagrams for a method of m~nllf~turing the extruded building structures noted above.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An extruded building structure 30 (Figs. 1-4) embodying the present invention includes a one piece extruded and cut-to-length extrusion 32, including integral sidewalls 33 and 34, a roof 35, and a floor 36 defining an interior space 38. The sidewalls 33 and 34, roof 35, and floor 36 include various flanges and other features to facilitate mass production and shipping of the building structure while mi~ lli7.i~-g or simplifying secondary operations such as attaching the building structure to a foundation and assembling fixtures and secondary parts such as baseboards to the building structure. The extrusion 32 is configured to simulate - I 21401~i a quality conventional wood frame construction and allows a customer to select the siæ, shape, and color of various parts of the structure while m~int~ining advantages including pellllallell~ color, moisture resistance, low air infiltration, high energy efficiency, and lr~m~ti~lly lower total costs. Building structure 30 further includes a pair of end walls 40 5 and at least one interm~di~te wall 42 for eng~ging extrusion 32 to subdivide the interior space 38 within extrusion 32.
The wall sections defining members 33-36 include an inner layer 44 and an outer layer 46 spaced from inner layer 44 and interconn~ct~d to layer 44 by a supporting intermediate layer of r~il~l~;ement webs 48 and rigid foam 50, such as is illustrated in Fig.
5. Inner layer 44 and outer layer 46 are comprised of non-foamed structural materials such as thermoplastic polymeric materials chosen to provide load bearing structure to the wall sections. Reinforcement webs 48 are integr~lly extruded with inner and outer layers 44 and 46. Reinforcement webs 48 stabiliæ layers 44 and 46 at locations of relatively high stress along the wall sections, and at strategically located points, can include thicker sections to provide additional support for attached items such as cabinets or doors. Further, inner and outer layers 44 and 46 provide a very durable and long lasting surface that can withstand the abrasion and wear required of a building structure. Notably, layers 44 and 46 can be increased in thickness or otherwise shaped for added ~lell~Lh and/or aesth~qtirs as desired.
For example, outer layer 46 can be shaped to replicate clapboard or beveled siding (Fig. 5), dutchlap siding 46' (Fig. 5A), or log-type wall construction 46" (Fig. 5B). It is also contemplated that flanges can be extended inwardly from inner layer surface 45 into interior space 38 or that layer 44 can be made thicker in certain areas to facilitate locating and supporting baseboards, kitchen cabinets, and other building fixtures. Also, longit~ in~lly extending bosses or apertured webs 49 can be positioned on webs 48, such as for receiving a screw or fastener 58 for holding a door casing to a doorway opening (see Fig. 13A), as li~c~lssed below.
Still further, the surfaces 45 and 47 of inner and outer layers 44 and 46 respectively can be textured and colored as desired. For example, outer layer surface 47 can be colored 21404~
and textured to sim~ tP siding (e.g. al~ lll siding or wood siding) or a log home, while inner layer surface 45 can be colored a di~el~llL color and textured to simulate drywall, paneling or another surface. Still further, the inner and outer surfaces of any of sidewalls 33 and 34, roof 35 and floor 36 can be colored with di~l~llL colors selected by a customer.
5 The colors would be continuous throughout layers 44 and 46, and thus would be long lasting.
It is contemplated that the coloring could be efficiently and economically done as part of the extruding process such as by adding colorant to the polymer feedstock being fed into the extruding process. Also, additives resisting degradation from ultraviolet radiation could be added to outer layer 46 as desired.
The extruded thermoplastic layers 44 and 46 and lch~l~;ement webs 50 quickly solidify and become rigid after exiting the extruder and extruder die during the extrusion process. Thus, immP(li~tP.ly after extruding layers 44 and 46 or at some time soon thereafter, foam material 50 can be added to the wall section in the space between layers 44 and 46.
The inner and outer layers 44 and 46 contain the foam material 50 as it PYp~n~l~ As the foam material solidifies/cures, the foam 50 securely bonds and interconnects layers 44 and 46 to form a rigid "stressed skin" structure having structural elements or "skins" spaced apart by a rigid interconnPcting element in a beam-like manner. This stressed skin structure positions structural "skin" portions of the wall section at the outer edges of the wall section at an optimal position based on engineering principles for supporting loads.
It is contemplated that layers 44 and 46 and webs 48 will be about 1/8" thick, and will be a structural plastic such as thermoplastic, although alternative materials and thickness can be used. By use of these materials, the wall sections provide a rigid construction which can be cut, drilled, and sawed much like wood, and thus the wall sections readily permit modifications to the extrusion 32. For example, such modifications would be desired for such items as the addition of windows 56 (Fig. 4). Regarding windows, conventional window structures can be positioned in an openillg cut into wall section sidewall 33.
iv~ly, an inner and outer window frame 57 and 57' could be secured together in asandwich-like ~ n~lllent on sidewall 33 (Fig. 18).
` 21404~1 The wall sections also advantageously provide many final features sim~ ting features of a conventionally built wood frame building. For example, the wall section rullnillg the corner 59 (Fig. 4) defined by the roof 35 and sidewall 33 defines a drip edge 60. Notably, an eaves trough (not shown) could also be integrally formed in the extrusion, or, 5 alternatively, a flange could be added for secllrin~ an eaves trough to the building structure.
Shingles are also simlll~te~l by the exterior surface 62 of roof 35.
A pair of foundation eng~ging sections 64 extend duwllwdldly from floor 36 undersidewalls 33 and 34. Integral foundation en~ging side sections (64) allow space for a hydraulically lowered transport trailer (Fig. 17) to be removed at the construction site, allow 10 a crawlspace for on-site hook-up of utilities such as electricity, water, sewer lines, and elimin~te a need for skirting such as is required on conventional modular units. In this regard, a number of variations are possible. For example, foundation eng;~gin~ section 64 provides a flat surface 66 for resting on the upper surface 68 of a foundation 70 (Fig. 6).
A strap 72 attaches to the side of section 64 and foundation 70 to secure the extrusion 32 to the foundation 70. Strap 72 is interconn~cte~l by bolts or fasteners 76 to section 64 and to foundation 70. Al~lllaliv~ly, a foundation eng~ging section 64' (Fig. 7) can be provided which includes a laterally extending web 74' that extends laterally from the side of flat surface 66'. Foundation eng~gin~ section 64' is secured by a fastener 76' that extends through laterally extending web 74 into foundation upper surface 68'. A diagonallc;inrul~;elllent web 77' is used to stabilize laterally extending web 74 on foundation eng~ging section 64'. For example, the foundation eng~ging section 64' could be used when the building structure is to be secured to a concrete slab.
In another modification (Fig. 8), a web 74" is extended duwllwdldly so that it forms a pocket with flat surface 66" for eng;lging the side and upper surface 68" of foundation 70".
A fastener 76" is extended through web 74" to secure extrusion 32" to foundation 70". Still another modification (Fig. 9) includes an L-shaped web 78"' having a lateral web portion 80"' and a dowllwdl-lly extending portion 82"', lateral web portion 80"' eng~ging the top of a foundation 70''' and dowllwdldly extending portion 82''' eng~ging the side of the foundation 70"'. Notably, an opposing web 84"' can be positioned opposite d~wllw~ldly t;AL~lldillg portion 82"'. Opposing web 84"' forms a channel or guide with portion 82"' which engages both sides of foundation 70"' and thus guides extrusion 32"' onto foundation 70"' such as when a trailer is pulling extrusion 32 onto foundation 70"'. Notably, a removable fixture could also be temporarily attached to the side of foundation eng~ging section 64"' to accomplish a similar function as web 84"'.
In another modification (Fig. 15), beam-like sections 63A extend the length of extrusion 32 to help rigidify floor 36. Also, jack-like supports on footers (not shown) can be used to support beam-like sections 63A interm~di~t~ their length over a crawlspace or basement. Still further, beam-like sections 63 and 63A provide structure that can be engaged by a trailer, as ~ cllcsed hereinafter. (See Figs. 17 and 18.) Rega,dillg duct 90 (Fig. 4), duct 90 includes a preassembled main heat duct 92 ~tt~h~cl to the underside of floor 36. One or more flexible tubular branches 94 are cormectable to main duct 92 and lead to an outlet 96. An opening 98 is cut into floor 36 to define an opening configured to receive outlet 96. One or more openings 98 can be located in the floor of each room. It is contemplated that flexible branch ducts 94 will be connected to the outlets after transporting building structure 30 to the construction site and transport trailer is removed.
A first baseboard en~gin~ flange 102 (Fig. 10) extends upwardly into interior space 38 from floor 36 and a second baseboard en~ging flange 104 extends laterally from sidewall 33 (or 34) proximate a corner 100 defined by floor 36 and sidewall 33. Baseboard 106 includes a cover section 108 for covering wires 101, and flange eng~gin~ edges 110 and 112 for en~ging flanges 102 and 104. Baseboard 106 is snap-locked onto flanges 102 and 104 to cover wires extending along the corner 100. Electrical outlets 114 are located along baseboard 106 as often as desired. It is contemplated that the wiring 101 will be prefabricated units that snap together much like a wiring harness in an automobile, although conventional wiring could also be used. The wiring 101 can be extended through ` 2140~21 I_ intermediate wall 42 through a hole 107 in interm~ te wall 42 (Fig. 11) at the corners of wall 42 or through doorway openings cut into wall 42 (see Fig. 13).
Fig. 12 shows an alternative all~n~,~lllent wherein both of baseboard eng~gin~ flanges 102' and 104' extend from, in this case, interm~ te wall 42. A modified baseboard 106' is configured to engage and be frictionally retained on flanges 102' and 104'. Wires 101' are routed through the space defined by baseboard 106' and corner 100' defined by floor 36 and intermediate wall 42. Notably, flanges 102' and 104' are located on both sides of intermediate wall 42, and baseboards 106' are also locatable on both sides of interm~ te wall 42.
It is contemplated that interm~ t~ wall 42 and end wall 40 will be constructed of an extrusion including inner and outer layers supported by an intermediate layer of foamed material and/or l~il~l~;ement webs not unlike the wall sections previously described. (See Figs. 12 and 13.) End wall 40 and interrn~ t~ wall 42, after extrusion, are precisely cut to the n~cess~ry shape to match up with main extrusion 32. Advantageously, excess material cut away from walls 40 and 42 can be separated and recycled back into the extrusion process. However, it is also contemplated that al~ iv~ intermediate wall constructions are possible, such as conventional 2 x 4 wood and drywall constructions. Advantageously, the extruded interrn~ t~ wall 42 can be cut with conventional hand-held or hand-operated equipment such as a skill saw or the like. Thus, doorway openings 120 (Fig. 11) and other Opellillg~ or holes can be readily formed in interrnP~ t~ walls 42.
Casings such as extruded C-shaped casings 122 (Fig. 13) can be positioned in doorway openings 120, with the legs 124 of C-shaped casings 122 eng~ging and ret~ining casings 122 in doorway opening 120. Casing 122 is shaped to mateably receive conventional wood casing 122A and is configured to be sufficiently rigid to support a door 123 including door hinges and a door catch or striker plate (not specifically shown). In one version, casing legs 124 are hollow and the web 124' conn~cting legs 124 has at least a hole through it so that wires 101 can be routed in casing 122 around and through doorway opening 120.
21404~ 1 . . , , i An al~lllaLiv~ door casing 122' (Fig. 13A) includes a pair of hollow casing legs 124' that are not unlike baseboard covers 106. In this ~ ge~ent, conventional wood casing 122A is secured to wall 42 by a fastener 58 that extends into a boss 49 in web 48 of intermediate wall 42.
End wall 40 (Fig. 14) is connected to the end of extrusion 32 by an extruded connector 125. Extruded connector 125 includes flanges 126, 127 and 128 for defining a first pocket 130 for receiving an edge of end wall 40. Connector 125 further includes flanges 132 and 133 that form with flange 128 a second pocket 134 for receiving an end of extrusion 32. Pockets 130 and 134 are oriented perpendicularly to each other. It is contemplated that multiple connectors 125 will be positioned around the five linear sides of end wall 40. The connectors 125 will be secured to end wall 40 and extrusion 32 by a&esive 136 which will seal the joint so that the joint is leak-free. Optionally, fasteners (not shown) such as nails, screws or bolts can be used to secure the joint together if desired. It is noted that a variety of di~el~lllly shaped connectors 125 are possible. For example, connector 125 could be made thinner, or flanges 126, 132 or 133 could be elimin~te~l.
In another al~ liv~, an L-shaped extruded connector 125' (Fig. 14A) including side pieces 126' and 127' is used. Outer layer 46' is extended past the end of extruded wall sections 33-36 to create a rabbit joint. End wall 42' is extended into the rabbit joint and the joint is secured together by adhesive, sealant, and fasteners as desired. Notably, separate connectors could be used inside and outside the joint, or the connectors could be elimin~t~cl by use of an a&esive that adequately seals and bonds the joint together.
It is contemplated that extrusions 32 can be modified for particular applications. For example, modified extrusion 32B (Fig. 16) includes a trapezoidal shape configured to mate with a second extrusion 32B (shown in phantom) to form a double-wide building structure.
Notably, it is not n~cess~ry that both extrusions (32B) have identical shapes. A roof cap or cover plate 147B is applied to the peak of the double wide building structure on-site to prevent moisture intrusion at the peak. The ends of the double wide building structure are covered or sealed as desired.
21404~;1 . . , , j Building structure 30 (Figs. 17 and 18) is transportable on a trailer 150. Trailer 150 includes a bed 151 supported by axles 152 and tires 153. Extrusion eng~ging jacks 154 are positioned on bed 151. Jacks 154 include an upper end 155 configured to engage beam-like sections 63 under floor 36 to hold building structure 30 on trailer 150 during transport.
Also, jacks 154 allow building structure 30 to be carried at a desired height on trailer 150 to meet local highway regulations, and in particular allow the building structure to be carried high enough so that the foundation eng~gin~ sections 64 do not drag on a road surface during transport. Jacks 154 allow building structure 30 to be lifted or lowered for positioning the building structure over a foundation 70. Building structure 30 can then be lowered onto the foundation 70 and secured thereto (see Figs. 6-9). A front cover or skirt applied after trailer is removed and utility connections are made.
A building structure 170 (Figs. 19 and 20) incorporates a building structure 30 with an extruded building structure 172 positioned parallel building structure 30 andinterconn~ctçcl to building structure 30 by an extruded breeæway 174. Building structure 30 is about 40 feet long to accommodate the floor plan illustrated in Fig. 21, but can be made subst~nti~lly any length desired. Breezeway structure 174 (Fig. 20) includes a tubular shape comparable to building structure 32. Specifically, breeæway structure 174 includes orthogonally related sidewalls and a floor having a length of about 10 to 12 feet in order to form a good siæd room. The sidewalls and floor are cut vertically so that the end of breezeway structure 174 closely engages the sides of building structure 30 and building structure 172. However, the roof of breeæway structure 174 is cut at an angle longihl(lin~lly so that the ends 176 and 177 of the roof mateably engage the sloping sides of the roofs on building structure 30 and building structure 172. Notably, the "garage" building structure 172 can be constructed as a double-wide structure in order to receive two cars (see Figs. 16 and 21), or as two short extrusions cut transversely to a siæ that will allow the building structure to be shipped on a highway. Optionally, the "garage" building structure can be made long enough to receive two cars (see Fig. 22). Notably, for tooling economy, the die 214049~1 for m~nllf~ctllring the building structure 172 could utilize the same extruding die as main building structure 32, except with the floor portion 36 closed off or "blocked out".
As illustrated in Fig. 22, modified building structure 170A includes an extrudedbuilding structure 30A, an extruded building structure 172A, and an extrusion 174A
interconnPcting same. Building structure 30A is extruded and cut to a shorter length than building structure 30 to accommodate a reduced floor plan. Notably, building structure 172A
is a one car structure and is smaller in width than the building structure 172 shown in Fig.
21. Breezeway structure 174A defines a roof with ends 186A and 188A (Figs. 26 and 27) that rest on and engage the sloping sides of the roofs of building structure 30A and 172A.
(See Fig. 20 for comparison.) Notably, breezeway structure 174A does not includesidewalls. It is noted that dilTerelll breezeway structures could be developed that incorporate one or more sidewalls, and that the blee~w~ structures can be of any length or shape as desired.
Breeæway structure 174A (Fig. 27) includes inner and outer layers l90A and 192A
interconnPcte~l by truss sim~ ting webs 194A. The spaces within breezeway structure 174A
can be filled with foam 196A for additional rigidity or load bearing capability if needed. The thicknPss of breezeway structure 174A increases to a thickness Tl near the peak 198A and the thicknP-ss lessens near the edges l95A to a thickness T2.
Building structure 172A (Fig. 23) includes a roof 196A not unlike breezeway structure 174A, however building structure 172A further includes sidewalls 200A and 201A. Notably, building structure 172A does not include a floor but rather is rested on a concrete slab 202A
with footers 204A, slab 202A providing a rough non-slip surface 205A for supporting an automobile.
Additional various garage-like building structures are disclosed in Figs. 24 and 25.
Rllil(lin~ structure 172B (Fig. 24) is similar to building structure 172A except it includes discrete truss sim~ ting beams 206B that extend longihl~lin~lly. Access to the attic area 208B can be achieved by cutting an access opening through one or more locations in the lowermost of beams 206B. Building structure 174C (Fig. 25) is similar to building structure 2l~0~a~
174B, except it includes non-ullirollllly positioned truss sim~ ting beams 210C for supporting non-ulliro~ loads on the roof of building structure 172C. For example, non-unirollll loads may be experienced by placing a breezeway structure such as extrusion 174A
thereon. (See Figs. 26 and 27.) The beams 210C support this increased load from 5 breezeway structure 174A.
The method of m~nllf~tllre of an extruded building structure such as structures 30, 40, 42, 124, 172, 172A, 172B, 172C, 174 and 174A is illustrated in Figs. 28 and 29. The process of extruding thermoplastic material is generally known, and thus detailed equipment disclosure is not n.ocess~ry for a wulhhlg underst~ntling of the present invention. Initially 10 in a step 214, thermoplastic material is extruded by an extruder through an extruding die to form integral wall sections, such as wall sections 33-36 for building structure 30 (Fig. 28).
Notably, where a multicolored extrusion is desired, multiple extruders (such as extruders 220A, 220B and 220C) (Fig. 29) can be used to process different materials (such as materials and colorants 222A, 222B and 222C) through a die 224. Thus, extrusion 32 would have 15 multicolored wall sections customized to a customer's specifications. For example, the sidewall and roof interior surfaces could be off-white in color, while the sidewall interior surface could be tan in color and the roof exterior surface could be black in color. In step 216 the extrusion is extruded to the desired length and cut off by cutoff device 226 (Fig. 29).
It is contemplated that cutoff device 226 will move with the extrusion during the step of 20 cutting so that the extrusion process is continuous, although the extrusion process could also be stopped temporarily to permit cutting if desired. Simlllt~n~ously, while extruding extrusion 32 (i.e. step 218) or some time soon thereafter, foam material 50 is injected into the space between thermoplastic inner and outer layers 44 and 46. Optimally it is contemplated that the foaming device will attach to and be an integral part of the extruding 25 die.
Once the wall sections of the extrusion are sufficiently rigid, window openings and doorways are cut into the extrusion (i.e. step 230) by a device such as a colnL Ul~l controlled traveling saw. Window assemblies, doorway c~in~s, fixtures and other items are then 21404~1 attached to the wall sections in a step 232. Also, intermediate walls and end walls are added as required. Building structure 30 is otherwise substantially completely assembled at the factory such as by the in~t~ tion of kitchen appliances and cabinets, bathroom fixtures, and etc.
Once subst~nti~lly completed, the building structure is loaded onto a trailer for transport (i.e. step 234). After in~t~ tion on a foundation (step 236), the building utilities of building structure 30 are connPcted to utility hook-ups on-site in a step 238. Also, in the case of multiple extrusions, the extrusions are interconnPcted in a predetermined alldngelllent according to a layout (i.e. step 240).
Thus, a plurality of building structures are provided including a one piece tubular extrusion which is a "user friendly" product that sim~ tes conventional wood frame housing, but which provides advantages of permanent color, moisture resistance, low air infiltration, high energy efficiency, and dram~tir~lly lower cost. The extruded home is capable of high volume mass production, but allows custom m~mlf~-~tllre with high quality product. The wall construction includes inner and outer layers of structural polymeric materials bonded with rigid foam, which allows fabrication of an extrusion having flanges and other structural members specifically adapted to allow transportation of the building structure, attachment of the building structure to a foundation, and assembly of secondary parts to the building structure. In another aspect, a tubular extrusion providing living quarters is connPcted to an inverted U-shaped extrusion r~lllfillg a garage for an automobile, which components are interconnPcted by an extruded breezeway structure.
In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without depal~illg from the concepts dis-closed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.
Claims (59)
1. A building structure comprising:
an elongated tubular extrusion including integral wall sections forming a floor,sidewalls, and a roof, said wall sections defining an interior space large enough for a person to comfortably stand in, said wall sections defining said floor and said sidewalls being generally planar and orthogonally related to each other, and further said wall section defining said roof having an inclined surface so that said extrusion has the shape and appearance of a conventional residential building, said wall sections including non-foamed polymeric material forming a load bearing structural member of said wall section.
an elongated tubular extrusion including integral wall sections forming a floor,sidewalls, and a roof, said wall sections defining an interior space large enough for a person to comfortably stand in, said wall sections defining said floor and said sidewalls being generally planar and orthogonally related to each other, and further said wall section defining said roof having an inclined surface so that said extrusion has the shape and appearance of a conventional residential building, said wall sections including non-foamed polymeric material forming a load bearing structural member of said wall section.
2. A building structure as defined in claim 1 wherein said wall sections include inner and outer layers, and one of said inner and outer layers includes said non-foamed polymeric material.
3. A building structure as defined in claim 2 wherein both of said inner and outer layers include said non-foamed polymeric material.
4. A building structure as defined in claim 1 wherein said sidewalls include an outer surface textured to replicate siding on a conventional wood frame residential building.
5. A building structure as defined in claim 1 wherein said elongated tubular extrusion is at least about 10 feet long.
6. A building structure as defined in claim 5 wherein said elongated tubular extrusion is at least about 40 feet long.
7. A building structure as defined in claim 1 wherein said wall sections are comprised of inner and outer layers of said non-foamed polymeric material bonded to and supported by an intermediate layer of rigid foam, said inner and outer layers forming with said intermediate layer a beam-like structure wherein bending stresses are primarily focused at said inner and outer layers.
8. A building structure as defined in claim 7 wherein one of said inner and outer layers includes first areas having a particular thickness and second areas having an increased thickness for added strengh, said second areas being located in high stress areas on said wall sections such as where fixtures are attached to said wall sections.
9. A building structure as defined in claim 1 wherein said wall sections include inner and outer layers of said non-foamed polymeric material that are spaced apart and further include reinforcement webs that extend between and interconnect said inner and outer layers.
10. A building structure as defined in claim 9 wherein said inner and outer layers are comprised of structural thermoplastic material.
11. A building structure as defined in claim 1 wherein said load bearing structural member includes flanges extending into said interior space, said flanges being configured to facilitate attaching auxiliary components to said wall sections.
12. A building structure as defined in claim 11 including a baseboard, and wherein said flanges are located proximate the juncture of said floor and one of said sidewalls and are configured to securely engage said baseboard.
13. A building structure as defined in claim 1 wherein said roof includes an exterior sufface shaped to simulate shingles on a conventionally built residential house.
14. A building structure as defined in claim 1 wherein said roof includes inner and outer layers of said non-foamed polymeric material, and further includes webs interconnecting said inner and outer layers, said webs being configured to form a truss simulating arrangement with said inner and outer layers.
15. A building structure as defined in claim 14 wherein said wall section forming said roof has a nonuniform thickness from the edge of said roof adjacent said sidewalls to the center of said roof.
16. A building structure as defined in claim 1 wherein said wall sections include inner and outer layers of said non-foamed polymeric material which form seamless load bearing skins on said wall sections.
17. A building structure as defined in claim 1 including a separate second extrusion of non-polymeric material, and means for connecting said second extrusion to one of said sidewalls of said first tubular extrusion, said second extrusion defining an interior space large enough for a person to stand in.
18. A building structure as defined in claim 17 wherein said second extrusion includes second wall sections forming second sidewalls and also forming a second roof defining a garage simulating shape.
19. A building structure as defined in claim 17 wherein said means for connecting includes a third extrusion extending between said first extrusion and said second extrusion, said third extrusion forming one of a room and a breezeway between said first and second extrusions.
20. A building structure as defined in claim 1 including an end wall, and means for sealingly connecting said end wall with said elongated tubular extrusion.
21. A building structure as defined in claim 20 wherein said means for connecting includes an extruded bracket defining a first pocket configured to receive a portion of an end of said elongated tubular extrusion and further defining a second pocket configured to receive an edge of said end wall.
22. A building structure as defined in claim 1 including an extruded intermediate wall configured to engage said wall sections and to divide said interior space into adjacent rooms.
23. A building structure as defined in claim 22 wherein said intermediate wall includes an opening defining a doorway, and further including a casing extending around said doorway opening and a baseboard extending along the bottom of said intermediate wall, said casing and said baseboard defining a continuous shield configured to receive and protect wiring extending throughout said building structure.
24. A building structure as defined in claim 23 including at least one electrical switch located in said casing adjacent said doorway opening.
25. A building structure as defined in claim 1 including material in one of said sidewalls defining a window opening, and including a window structure secured in said window opening, said window structure including a frame engaging the inside and the outside of said one sidewall.
26. A building structure as defined in claim 1 wherein said wall section includes a foundation engaging section extending below said floor proximate the joinder of said floor and said sidewalls, said foundation engaging section including non-foamed material defining a surface for resting on said foundation.
27. A building structure as defined in claim 1 wherein said wall section includes a foundation engaging section defining a first surface for resting on a foundation and a second surface oriented orthogonally to said first surface for engaging a side of said foundation to locate said building structure securely on said foundation.
28. A building structure as defined in claim 1 including understructure extending below said floor, said understructure defining side surfaces configured to engage a trailer to facilitate shipping.
29. A building structure comprising:
an extrusion including integral wall sections forming sidewalls and a roof, said wall sections defining an interior space large enough for a person to stand in and park a motorized vehicle in, said wall sections being a composite of a first layer and a second layer, said first layer being structural non-foamed polymeric material, said second layer being one of a matrix of reinforcement webs integrally extending from said first layer and a slab of rigid foam bonded to said first layer.
an extrusion including integral wall sections forming sidewalls and a roof, said wall sections defining an interior space large enough for a person to stand in and park a motorized vehicle in, said wall sections being a composite of a first layer and a second layer, said first layer being structural non-foamed polymeric material, said second layer being one of a matrix of reinforcement webs integrally extending from said first layer and a slab of rigid foam bonded to said first layer.
30. A building structure as defined in claim 29 wherein said wall sections comprise inner and outer layers of said structural non-foamed polymeric material bonded to and spaced apart by an intermediate layer of material.
31. A building structure as defined in claim 30 wherein said intermediate layer of material includes rigid foam.
32. A building structure as defined in claim 31 wherein said intermediate layer includes reinforcement webs extending between said inner and outer layers.
33. A building structure as defined in claim 32 wherein said reinforcement webs and said inner and outer layers of said polymeric material define a truss-like matrix of reinforcement structures in said wall section defining said roof.
34. A building structure as defined in claim 30 wherein said intermediate layer includes reinforcement webs connecting said inner and outer layers for rigidifying and supporting said wall sections at locations of high stress.
35. A building structure as defined in claim 29 wherein said extrusion includes an integral wall section forming a floor between said sidewalls, and thus defines a tubular shape.
36. A building structure as defined in claim 29 wherein said extrusion includes a foundation engaging section extending below said sidewalls, said foundation engaging section including non-foamed polymeric material defining a surface for engaging a foundation.
37. A building structure comprising:
a tubular first extrusion including an integral roof, floor, and sidewalls defining a living space;
a second extrusion including an integral roof and sidewalls defining a garage for storing an automobile; and means for connecting said second extrusion to said first extrusion.
a tubular first extrusion including an integral roof, floor, and sidewalls defining a living space;
a second extrusion including an integral roof and sidewalls defining a garage for storing an automobile; and means for connecting said second extrusion to said first extrusion.
38. A building structure as defined in claim 37 wherein said connecting means includes one of a sun room and a breezeway structure.
39. A building structure as defined in claim 38 wherein said means for connecting includes a third extrusion including a roof extending between said first and second extrusions.
40. A method for constructing a building structure comprising:
extruding an extrusion including integral wall sections forming sidewalls and a roof, said wall sections defining an interior space large enough for a person to comfortably stand in; and cutting said extrusion to a predetermined length.
extruding an extrusion including integral wall sections forming sidewalls and a roof, said wall sections defining an interior space large enough for a person to comfortably stand in; and cutting said extrusion to a predetermined length.
41. A method as defined in claim 40 wherein said step of extruding includes extruding a tubular shape including a wall section forming a floor.
42. A method as defined in claim 41 including cutting one of a window opening and a doorway opening in one of said wall sections.
43. A method as defined in claim 40 including extruding a flange on one of said wall sections and mechanically fastening a fixture to said one wall section.
44. A method as defined in claim 40 including providing different colorants that can be selected for customizing the color of each of said wall sections, and wherein said step of extruding includes extruding said wall sections in selected of said different colorants.
45. A method as defined in claim 44 wherein said wall sections include an interior surface and an exterior surface, and said step of extruding includes selectively coloring said interior and exterior surfaces with different colors.
46. A method as defined in claim 40 wherein said step of extruding includes extruding inner and outer layers of non-foamed polymeric material, and further including filling a space between said inner and outer layers with a foam material, said inner and outer layers and said foam material defining said wall sections.
47. A method as defined in claim 40 wherein said step of extruding includes extruding inner and outer layers of non-foamed polymeric material along with a plurality of reinforcement webs interconnecting said inner and outer layers, said inner and outer layers and said reinforcement webs defining said wall sections.
48. A method as defined in claim 40 wherein said step of extruding includes extruding downwardly extending members on said extrusion configured to engage a foundation, and further including a step of positioning said extrusion on a foundation with said downwardly extending members engaging said foundation.
49. A method as defined in claim 40 wherein said step of cutting includes cutting said extrusion to form a non-planar end on said extrusion.
50. A method for forming a building structure comprising:
extruding an extrusion including wall sections forming sidewalls and a roof, said wall sections being made of inner and outer layers of non-foamed polymeric materials bonded to and supported by an intermediate layer.
extruding an extrusion including wall sections forming sidewalls and a roof, said wall sections being made of inner and outer layers of non-foamed polymeric materials bonded to and supported by an intermediate layer.
51. A method as defined in claim 50 including foaming material between said inner and outer layers to form said intermediate layer.
52. A method as defined in claim 50 including providing different colorants for the inside and outside surface of each of said sidewalls and said roof, and extruding said wall sections with said selected different colorants.
53. A method as defined in claim 50 wherein said extruding includes extruding said extrusion in a tubular shape large enough to stand in, said extrusion including a wall section defining a floor.
54. A method as defining in claim 53 including cutting said extrusion to a desired length.
55. A method comprising:
extruding an extrusion including wall sections defining a roof, said wall sections being made of inner and outer layers of non-foamed structural polymeric material connected by and spaced apart by angled reinforcement webs, said inner and outer layers forming a truss simulating arrangement with said reinforcement webs.
extruding an extrusion including wall sections defining a roof, said wall sections being made of inner and outer layers of non-foamed structural polymeric material connected by and spaced apart by angled reinforcement webs, said inner and outer layers forming a truss simulating arrangement with said reinforcement webs.
56. A method as defined in claim 55 including cutting said extrusion to a predetermined length.
57. A method as defined in claim 56 wherein said step of cutting includes cutting at an angle to the longitudinal direction of said extrusion, said angle being chosen so that said extrusion mateably engages a roof on another building structure.
58. An apparatus for extruding a building structure comprising:
an extruding die including an opening defining an extrusion profile including wall sections defining sidewalls and a roof and an interior space large enough to stand in, said opening including first portions for forming an inner layer and second portions for forming an outer layer spaced from said first layer;
an extruder for extruding structural polymeric material through said extruding die; and an injector for injecting foam material between said inner and outer layers to support said inner and outer layers in said spaced condition.
an extruding die including an opening defining an extrusion profile including wall sections defining sidewalls and a roof and an interior space large enough to stand in, said opening including first portions for forming an inner layer and second portions for forming an outer layer spaced from said first layer;
an extruder for extruding structural polymeric material through said extruding die; and an injector for injecting foam material between said inner and outer layers to support said inner and outer layers in said spaced condition.
59. An apparatus as defined in claim 58 including a cutting device for cutting said extruded building structure to a desired length and end configuration.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US18763594A | 1994-01-26 | 1994-01-26 | |
| US08/187,635 | 1994-01-26 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2140421A1 true CA2140421A1 (en) | 1995-07-27 |
Family
ID=22689811
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2140421 Abandoned CA2140421A1 (en) | 1994-01-26 | 1995-01-17 | Extruded building and method and apparatus related to same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2140421A1 (en) |
-
1995
- 1995-01-17 CA CA 2140421 patent/CA2140421A1/en not_active Abandoned
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