US20240117628A1

US20240117628A1 - Modular complete thermal break foundation, wall and roof assemblies for buildings

Info

Publication number: US20240117628A1
Application number: US18/045,385
Authority: US
Inventors: Brian IVERSON
Original assignee: Individual
Current assignee: Envirobon Inc
Priority date: 2022-10-10
Filing date: 2022-10-10
Publication date: 2024-04-11

Abstract

Prefabricated, modular, completely like-constructed foundation, wall and roof assemblies are used to build inexpensively energy efficient houses and commercial buildings therefrom with a panel of preform weather resistant exterior skin. Being pre-built horizontally, above and away from the skin are suspended an array of parallel studs. Partially around the studs, between the studs and between the studs and skin is an expanding poured foam layer that is introduced forming a complete rigid thermal break. Apertures or openings in the unexposed stud portions provide for the mounting of conduiting, wiring and internal fixtures. Internal wall treatments, such as sheet rock, are then secured to the studs.

Description

The present invention relates to modular complete thermal break foundation, wall and roof assemblies for houses and commercial buildings. More specifically, the present invention relates to prefabricated like-constructed foundation, wall and roof assemblies to completely build inexpensively energy efficient houses and commercial buildings therefrom.
Standard construction today uses either 2×4″ or 2×6″ solid lumber generally spaced 16″ on center. Where energy conservation is a concern, most builders frame an exterior wall with 2×6″s. Up to 30 percent of the exterior wall (studs, top and bottom plates, cripple studs, window/door jambs and headers and the rim area of the floor) is solid wood framing. Thermal bridges are points in the wall that allow heat and cold conduction to occur. Heat and cold follow the path of least resistance-through thermals bridges of solid wood across a temperature differential wherein the heat or cold is not interrupted by thermal insulation. The more volume of solid wood in a wall also reduces available insulation space, and further, the thermal efficiency of the wall suffers and the R value (resistance to conductive heat flow) decreases.
The most common way to minimize thermal bridging is to wrap the entire exterior of the building in rigid insulation to minimize heat loss and cold from entering the building. This effort significantly increases materials, carbon footprint and labor costs and can be undesirable in increasing the thickness of the building walls with non-structural materials.
Attempts have been made to construct framing systems with built in thermal breaks with the use of dimensional lumber (2×4″, 2×6″, 2×8″, 2×10″ and 2×12″). Such efforts require extensive labor and materials costs and have not resulted in effective thermal breaks throughout the whole wall, corners and building envelope structure.
Applicant has previously patented framing systems with near-complete thermal breaks throughout the walls, corners and building structure made of non-dimensional lumber with rigid insulation that has increased strength, more surface area for building materials to be fastened to, uses less lumber, has more space for insulation to greatly increase thermal efficiencies. Some of these U.S. utility patents are U.S. Pat. Nos. 9,783,985 and 10,731,332.
A significant patentable feature of these patents include a wall core structure that includes a wall stud comprised of two spaced apart parallel boards with mechanical fasteners therebetween of a structure of diagonally spaced, alternating angled wood dowels connecting the boards and surrounded with injected rigid insulation, such as expanded polyurethane, polystyrene or polyisocyanurate. The foam 76 may suitably made by mixing an isocyanate, such as methylene diphenyl diisocyanate (MDI) with a polyol blend, or other suitable rigid foam sheet or there equivalent. In fact, it is to be anticipated that rigid foams of yet even high R values are on the market now with more being created that are and will be suitable for use with the present invention. Polyurethane insulation has the highest thermal resistance (R-values) at a given thickness and lowest thermal conductivity. This stud design is currently being marked under the registered trademark TSTUD® by applicant's company Roosevelt Energy, Inc. of Ham Lake, Minnesota under Federal Registration U.S. Pat. No. 5,481,842.
More recently, applicant has been granted design patents alternating or rotating the two boards with respect to each other visually imitating a T-shape in cross section under U.S. Design Pat. D912,496; D938,618; D942,049; D941,498 and D936,242.
There is a need to design a prefabricated modular framing system with absolute complete thermal breaks throughout the foundations, walls, roofs of building structures with poured-in expanding rigid insulation that has increased strength, more surface area for building materials to be fastened to, uses less lumber, has more space for wiring and fixtures and greatly increases thermal efficiencies while reducing building costs, labor, energy usage and time to build such structures.

SUMMARY OF THE INVENTION

Prefabricated, modular, completely like-constructed foundation, wall and roof assemblies are used to build inexpensively energy efficient houses and commercial buildings therefrom with a panel of preform weather resistant exterior skin. Being pre-built horizontally, above and away from the skin are suspended an array of parallel studs. Partially around the studs, between the studs and between the studs and skin is an expanding poured foam layer that is introduced forming a complete rigid thermal break. Apertures or openings in the unexposed stud portions provide for the mounting of conduiting, wiring and internal fixtures. Internal wall treatments, such as sheet rock, are then secured to the studs.
A principal object and advantage of the present invention is that the increase in wall construction energy efficiency is approximately 30 R to 50+ R depending on the current energy code within each municipality.
Another principal object and advantage of the present invention is that, according to the US Home Builders Association or www.census.gov, the median home built in America (in 2016) is actually 2456 square feet in size and the present invention would save a minimum of 51 to 110 vertical studs over the standard construction. There are approximately 1,170,000 of these median homes built per year (2016 US Housing Starts).
Another principal object and advantage of the present invention is that using the International Log Rule on board feet per 16′ section of a tree that is 22″ in diameter and 3 sections per tree equates into a savings of 493,000 trees not being cut down in a single year to build the approximately 1,170,000 median homes in a single year.
Another principal object and advantage of the present invention is that the invention has a smaller carbon footprint than standard building construction simply by use of less materials and labor costs.
Another principal object and advantage of the present invention is that there is more insulation in the wall cavity with less solid wood to increase thermal efficiency.
Another principal object and advantage of the present invention is that there could be a reduction in the needed and required sizing for furnaces and air conditioning equipment.
Another principal object and advantage of the present invention is that the Tstud design and framing system is modular and prefabricated which requires less carpenter time to rough-in a building.
Another principal object and advantage of the present invention is that all these objects and advantages are accomplished without losing any integrity in building performance or structural qualities.
Another principal object and advantage of the present invention is that there will be a reduction on the future utility grid and a reduction on the future carbon footprint required to produce the electricity and gas to heat and cool a home or a building built to according to this invention.
Another principal object and advantage of the present invention is that the foundation, wall and roof assemblies are substantially the same modular prefabricated construction ready for delivery to the job sight for quick assembly of houses and commercial buildings.
Another principal object and advantage of the present invention is the imbedded wire mesh with the assemblies will deter debris during a hurricane or tornado from piecing the building walls and roof assemblies. The assemblies will stop a 2×4″ 12′ long traveling at 120 miles per hour from piecing the building. Also the wire mesh will hold the building together during an earthquake or seismic occurrences.
Another principal object and advantage of the present invention is that the window and door jamb can be installed from within the building and thereby negating the need for ladders and scaffolding on the outside of the buildings.
Another principal object and advantage of the present invention is that the window and doorjamb structure assists in mounting and securing siding and sheet rock or drywall to the buildings.
Another principal object and advantage of the present invention is that the R value of the houses and commercial building made in accordance to the present invention will have an insulation R value approaching 50 or better.
Another principal object and advantage of the present invention is that the buyers of houses made in accordance to the present invention will be affordable and not exceed 30% of income and thereby not be an excessive burden according to the U.S. Department of Housing and Urban development (HUD).
Another principal object and advantage of the present invention is that the houses and commercial building made in accordance to the present invention will last one hundred years with the least amount of maintenance.
Another principal object and advantage of the present invention is that the axial load of the foundation wall is 14,000 pounds per foot.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a broken away perspective view of a 1200 square foot house built according to the present invention having a basement, an above ground living space and a roof;

FIG. 2 is a perspective view of the T-shaped stud with mechanical fasteners therebetween the parallel boards as suggested for use with the present invention;

FIG. 3A is a cross section through the house along lines 3A-3A of FIG. 1 ;

FIG. 3B is a cross sectional view through an alternative roof structure for the present invention;

FIG. 4 is an extracted perspective cross sectional broken away view of the foundation taken from dash lines 4 of FIG. 1 ;

FIG. 5 is a cross sectional broken away view taken along lines 5-5 of FIG. 4 ;

FIG. 6 is an extracted cross sectional broken away perspective view of the roof taken from dash lines 6 of FIG. 1 ;

FIG. 7 is an extracted cross sectional broken away perspective view of the above ground wall taken from dash lines 7 of FIG. 1 ;

FIG. 8 is an extracted cross sectional broken away perspective view of the of the above ground wall take from dash lines 8 of FIG. 1 ;

FIG. 9 is an extracted cross sectional broken away perspective view of the of the above ground wall take from dash lines 9 of FIG. 1 ;

FIG. 10 is cross sectional broken away view of the window or door jamb assembly; and

FIG. 11 is an extracted cross sectional broken away perspective view of a commercial building wall similar to FIGS. 4-9 .

DETAILED SPECIFICATION

Referring to FIG. 1 , an illustrated 1200 square foot house 20 with a basement 30, with drainage rock and back fill removed may be seen. Firstly in building the house 20, the basement space 5 is excavated. The house is then built on a below ground poured cement foundation 9.
As shown in FIGS. 1-5 , the wall core 36 is comprised of spaced apart parallel boards 40, 42 and mechanical fasteners 44 therebetween, as commonly known as the TSTUD® 36. The TSTUD® 36 forms the assembly core illustratively used in the foundation walls 30, above ground wall 70 and the roof 110.
The foundation or basement walls 30 sit on footer plates 32 and are anchored thereto by anchors 34 imbedded into the poured cement foundation 9. Footer L-brackets (not shown) may also be used to secure the basement walls 30 to the cement foundation 9. The wall core T-shaped studs or TSTUD® 36 includes an opposing wide board 40 and a parallel spaced narrow board 42. Mechanical fasteners or wood dowels 44 pass through the boards 40, 42 and are glued in place.
In the prefabrication of the modular walls 30, 70 and roof assemblies 110 at a manufacturing sight, the walls are built in horizontal layers in a jig or mold suitably in 8′×4′ panels. Depending the size of the building to be built, the panel may be dramatically larger in dimensions, such as 10′×4′ or 12′×6′ panels. Firstly, the exterior skin 46 is pre-made or may be commercially available materials in sheets that are placed horizontally in the mold or jig. The skin 46 may be made of a variety materials including fiberglass, cementious sheets, metal, masonite board or composite sheets. As illustrated below, when made, the outside of skin 46 should have an attractive exterior building material look that may be corrugated fiberglass or wood exterior for a nice appearance that may be painted or treated otherwise. In many cases, the external skin 46 may have a weather water resistance coating such as a gel coat.
The skin 46 is placed exterior side down within the jig or mold to build the modular walls 30, 70 and roof assemblies 110 in very similar, if not the same, manner. Next, an array of TSTUDS® 36 suitably 24″ on center are suspended above the skin. The distance above the skin 46 is dependent on how thick the finish panels to-be-walls 30, 70 and 20 are meant to be. For a standard wall, 1½″ to 2″ away from the skin 46 is good for a 6″ finished wall. Next, the expanding foam 54 is poured into the mold or jig to expand and cover the inside of the skin 46, the wide board 40, and the mechanical fasteners 44 and general half way up and covering a portion of the narrow board 42. After the foam 54 becomes rigid and forming a panel, the skin and TSTUDS® 36 with the rigid foam 54 are removed from the mold or jig. Next horizontal holes 56 may be drilled in the exposed TSTUDS® 36 or the holes 56 may be pre-drilled in the narrow exposed narrow board 42 of the TSTUDS® 36 before they are placed in the mold. This arrangement allows for assembly of wiring, conduits, fixtures and the like within foundation walls 30. These bare wood portions of the narrow boards 42 are also used to join adjacent basement wall panels 30 with framing screws approximately spaced vertically 12″ apart vertically with 3⅛″ #8 framing screws. This methodology for joining panels also works for above ground walls 70 or roof panel assemblies 110.
FIG. 3A shows a cross sectional view through the house 20 of FIG. 1 taken along lines 3A-3A. Basement walls 30 are assembled on footer plates 32 and anchored thereto and into cement 9 with anchors 34. As described above, wall core 36 comprises TSTUDS® 36 which also may be secured to footer plates 32 and cement foundation 9 with L-brackets (not shown). The TSTUDS® 36 include wide board 40 and opposing narrow board 42 both connected together with mechanical fasteners 44. The exterior skin 46 maybe of a fiber glass, high performance thixotropic or isophalic resin which may have a gel coat outer finish thereby water and weather proofing the skin 46.
FIG. 3B illustrates a second embodiment roof 111 of the present invention comprised of a stacked double TSTUDS® 37 with a central narrow board 43 with upper and lower mechanical fasteners 45 joining spaced apart wide boards 47, 49. Exterior cover skin 51 may be in pre-formed sheets resembling shingles or shakes or be of fiber glass or metal. Poured in foam 53 is poured into the upside down double stacked TSTUDS® 37 as to fill the space from the exterior skin 51, around the upper wide boards 47, the mechanical fasteners 45 and partially over the central narrow board 43. Open space 55 thus provides open space 55 for wiring and fixtures. Dry wall 57 is then attached to the lower wide boards 49.
FIGS. 4 and 5 show that the TSTUDS® 36 wide boards 40 have L-shaped fiber glass brackets or fasteners 52 secured to the TSTUDS® 36 with screws and glued to the skin 46 with fiber glass adhesive. This will prevent delamination of the skin 46. Once in the mold or jig, the expanding foam 54 is poured into the mold or jig to expand and cover the inside of the skin 46, the wide board 40, and the mechanical fasteners 44 and general half way up and covering a portion of the narrow board 42. After the foam 54 finishes expanding, becomes rigid, and forming a panel, the skin 46 and TSTUDS® 36 with the rigid foam 54 are removed from the mold or jig. Next, horizontal holes 56 may be drilled in the exposed TSTUDS® 36 or the holes 56 may be pre-drilled in the narrow exposed narrow board 42 of the TSTUDS® 36 before they are placed in the mold. Again, these bare wood portions of the narrow boards 42 are also used to join adjacent basement panels 30 with framing screws approximately spaced vertically 12″ apart vertically with 3⅛″ #8 framing screws. Lastly, sheet rock or dry wall 60 is nailed or screwed to the exposed ends of the narrow boards. 42. Header plates 62 may then be added to the basement wall 30. As shown in FIG. 4 , 2×4′ or 2×6′ dimensional lumber 64 or other TSTUDS® 36 variations or sizes may be used in place of the TSTUDS® 36. Next, flooring 66 is built on top of the basement walls 30. Flooring structures 66 may be seen in applicant's U.S. Pat. No. 10,731,332.
Cost savings:

TABLE 1

Foundations

Traditional Block	Approx Cost	Innovated Structure	Approx Cost

Footing	Same	Footing	Same
Foundation Block	$ 8,000	Insulated Foundation	$ 12,000
Mastic	$ 1,000	Mastic	$ 500
Build wall inside	$ 4,000
Insulate	$ 2,500	Insulate	Pre-Insulated
	$ 15,500		$ 12,500

Average R Value	16	Average R Value	40
Time to complete	42 hours	Time to complete	4 hours
		Improved R Value	250%
		Savings	$ 3,000

100 lineal feet ×8′ tall

FIGS. 1-3A, 3B and 6 illustrate above grade walls 70 and roof assembly 110. Again, the core assembly is the TSTUDS® 36 which can be secured to the floor 66 with L-brackets (not shown) and includes exterior skin 46, opposing wide boards 40, narrow boards 42 and mechanical fasteners 44. Exterior skin 46 may be of cementious or OSB board, molded cedar shake-like 74 looking materials that may resemble half rounds, random squares or octagons. Also, unitary molded fiber glass, plastic or metal sheets of 4×8′ may also be use.
Cost savings:

TABLE 2

Wall and Rim Assembly

Traditional 2 × 6 construction with and R	Innovated Sructures

Insulate rim	$ 1,000		$ 100
Build walls	$ 10,800		$ 16,500
		Stand walls	$ 1,500
Insulate walls	$ 1,800		$ —
Attach sheathing	$ 506		$ —
Attach WRB	$ 234		$ —
Attach siding	$ 8,800	Finish	$ 1,000
	$ 23,140		$ 19,100

Average R Value	18	Average R Value	40
Time to complete	42 hours	Time to complete	4 hours
		Improved R Value	222%
		Savings	$ 4,040

indicates data missing or illegible when filed

TABLE 3

Roof Assembly

	Traditional roof trusses	Innovated Structures

Roof trusses	$ 3,675	Assembly	$ 10,800
Sheathing installed	$ 2,250		$ —
Tar paper	$ 500	Stand walls	$ —
Shingles	$ 2,500		$ —
Insulate	$ 5,000		$ —
	$ —	Finish	$ 500
	$ 13,925		$ 11,300
Average R Value	48	Average R Value	60
Time to complete	42 hours	Time to complete	4 hours
		Improved R. Value	125%
		Savings	$ 2,625

TABLE 4

HVAC System

Traditonal heating	$ 4,500	MiniSplit	$ 5,500
Traditional air condition	$ 4,000	Or Air Heat Pump	$ —
Metal ductwork	$ 1,500	Plastic duct work	$ 500
Air to Air exchanger	$ 2,500	Air to Air exchange	$ 3,500
Dehumidification	$ 1,500	Dehumidification	$ 1,500
Controls	$ 500	Controls	$ 1,000
	$ 14,500		$ 12,000
		Savings	$ 2,500

	TABLE 5

	Total savings	$ 12,165
	Labor hours	96
	Labor savings days	12
	HERs score	100 vs 39ish
	BTU consumption	~50% to ~75%
	ACH
	3 vs 5ish

	indicates data missing or illegible when filed

FIG. 7 introduces a new concept of exterior treatment of 4×8′ sheets of fibrous or cementious materials of a batten-style skin or panel 80 with simulated battens to cover up the seams 84 between 4×8′ sheets with fasteners 86. The inside wall of the sheets 80 has a layer of wire mesh 90 held in place by tacks or the poured in foam. The mesh is designed to stop flying debris such as debris during a hurricane or tornado from piecing the building walls and roof assemblies. The assemblies will stop a 2×4″ 12′ long traveling at 120 miles per hour from piecing the building. Also the wire mesh will hold the building together during an earthquake or seismic occurrences.
FIG. 8 shows another exterior skin 96 treatment resembling 4×8′ sheets of simulated vertical wood panels with battens 97 and fasteners 98.
FIG. 9 shows the stretched steel-like mesh 100 fastened to the outside of the TSTUDS® 36 wide board 40 suitably with U-shaped wire tacks. Also, simulated horizontal lap boards 102 are shown.
FIG. 10 illustrates a jamb construction 116 for windows and doors 118 that fit into opening 119, which are part of the present invention. Adjacent to window/door opening 119 are two touching TSTUDS® 120 (king and striker) for supporting the Jamb 116. An external jamb section 122 with a U-channel 123 to receive and support siding can be sealed with mastic 124 and fastened on the outside of the building 20 adjacent to the TSTUDS® 120 with screw 126. Jamb extension 128 is positioned between the external jamb section 122 and the L-bracket or J-channel 132 thereby capturing the dry wall and secured thereat with screws 130, 136. Window casing or door trim 138 is then fastened in place with screw 4.
FIG. 11 illustrates a commercial wall 150 made in accordance with the present invention. Metal stud 152 is spaced from the sound and/or fire board 154 and secured thereat with metal fastener or screw 156. After which, the board 154 screwed to the metal stud 156 with screw 156 is placed into the jig or mold. Then the foam is poured into the space between the stud 152 and the sound/fire board 154 as well as substantially around the metal stud 156.
The above embodiments are for illustrative purposes and the scope of this invention is described in the appended claims below.

Claims

What is claimed:

1. Prefabricated, modular, foundation, wall and roof assemblies are used to build inexpensively energy efficient houses and commercial buildings, the assemblies comprising:

a.) a panel of preform weather resistant exterior skin;

b.) above and away from the skin are suspended an array of parallel studs; and

c.) between the studs, between the studs and skin and partially around the studs is an expanding poured foam layer forming a complete rigid thermal break between the skin and the stud.

2. The assemblies of claim 1, further comprising apertures in the stud portion not covered with foam to provide for the mounting of wiring through the studs.