WO1998049403A2

WO1998049403A2 - Building structures fabricated from stressed-skin panels

Info

Publication number: WO1998049403A2
Application number: PCT/US1998/008495
Authority: WO
Inventors: Robert Noble; James F. Mahoney
Original assignee: Kiva Advanced Environmental Technologies Corporation
Priority date: 1997-04-30
Filing date: 1998-04-28
Publication date: 1998-11-05
Also published as: AU7563198A; WO1998049403A3

Abstract

The present invention provides a building structure comprising a pair of opposed substantially vertical end walls (38), each wall having a substantially straight base side and a substantially continuous arch side extending from one end of the base side to the other end of the base side in each end wall (38); and arcuate roof/wall member (36) formed from at least one curvilinear stressed-skin panel, the radius of curvature corresponding to the arch side of the end walls (38) and extending from one end of the base side to the other end of the base side.

Description

Building Structures Fabricated from Stressed-skin Panels

Technical Field

The present invention relates to building structures and shelters, especially for temporary and rapid deployment uses, made from stressed-skin panels. The structures of the invention are fabricated from easily transportable components to be readily erected or disassembled on site and are particularly useful for the military and for temporary and low-cost accommodation.

Background of the Invention The structures of the invention have a Quonset hut type shape. Quonset-type huts are known. They generally comprise semi-circular opposing, vertical end walls separated by integral wall and roof elements that form a substantially continuous arc from the ground on one side of the structure to the ground on the other side of the structure and following the shape of the end walls. However, the prior art structures have suffered from one or more disadvantages that this invention addresses. Commonly, the prior art structures are formed from an arcuate frame or skeleton upon which is mounted the outer arcuate surface walls and roof. Thus, such structures rely upon such a skeleton or frame for their structural integrity, rather than on the outer skin of the wall/roof itself. Examples of such structures are found in U.S. Patents Nos.: 3,968,604; 4,347,690; 5,295,335; and

5,333,421. These types of structures suffer from the disadvantages of being relatively cumbersome or complicated to fabricate and erect, and usually may not be disassembled readily, if at all. Further, such structures tend to be relatively expensive and inefficient, in terms of their relatively thick and heavy structure and/or complex mode of construction.

Structures have been proposed that do not rely on a frame for their structural integrity. See, for example, U.S. Patent Nos. 4,649,676 and 4,700,514. However, such structures tend to rely upon a corrugated, wave form or bent plate wall and/or roof to provide structural integrity. If such structures are made with substantially flat panels, without such corrugation, wave form or bent plate, they would tend to collapse.

Of course, panels have been used in building structures for many years. Wall panels are known that do not require a frame or superstructure for support. See, for example, U.S. Patent No. 4,702,058. However, such panels tend to be of specialist applications in conventional flat walled structures. Structural panels are also known to comprise an internal honeycomb structure laminated between outer panels, such as U.S. Patent Nos.: 4,910,928; 4,931,340; and 5,184,439. Further, it is known to produce molded stressed-skin panels, such as in U.S. Patent Nos. : 4,702,870; 4,753,713; 5,198,236; 5,277,854; and 5,314,654; and PCT published Application No.

WO92/21499.

However, there still exists a need for low-cost structures that are relatively light-weight, low cost, easily transportable and simple to erect and disassemble. There is also a need for thin, more efficient structures which use less material and volume.

Disclosure of the Invention

The present invention provides an outdoor building structure comprising a pair of opposed, substantially vertical end walls, each wall having a substantially straight base side and a substantially continuous arch side extending from one end of the base side to the other end of the base side in each end wall; and an arcuate roof/wall member formed from at least one curvilinear stressed-skin panel, the radius of curvature corresponding to the arch side of the end walls and extending from one end of the base side to the other end of the base side. In embodiments having a plurality of stressed-skin panels forming the curvilinear roof/wall member, the panels will typically be joined to the end walls, and joined end-to-end and side-to-side, in forming the roof/wall member.

Thus, the primary structure of the envelope of the building structure of the invention is an assembly of arcuate or curvilinear stressed-skin panels carrying the bending (from spanning) loads and lateral loads due to wind, earthquake, impact or the like, without dependence on a primary structural skeleton. The curvilinear cross-section vaulted segments formed in the structures of the invention are preferably in a generally semi-circular cross-section. In a preferred embodiment of the invention, there is provided a modular structure of the type described in which further vault modules can be added to produce a shelter of substantially any desired length between the vertical end walls.

In a preferred embodiment of the invention there is provided such a structure with a low thickness to span ratio. By that is meant the ratio of the thickness of the roof panel from interior to exterior, to the span or vault distance between internal supports in a direction substantially parallel to the end walls. In this embodiment of the invention, the ratio is generally from about 1/80 to 1/480, preferably from 1/100 to

1/320, and more preferably 1/120 to 1/240, as determined, for example, by panels with a 10 foot span and a thickness from 3/4 inch to 1.2 inches.

In another preferred embodiment of the invention, the structure is provided with internal support panels which are preferably spaced at every or every other panel joint in the longitudinal direction of the structure between the end walls, to provide intermediate support for this span and additional vertical load bearing capacity and resistance to lateral loads due to wind, earthquake or impact and the like. More preferably, internal shear support panels are used which are substantially parallel to the end walls and which extend vertically from the floor or ground to the ceiling of the structure, and along every or every other panel joint laterally from a point that is spaced apart from the internal wall as it approaches the ground, to accommodate a plenum or chase that is described in another preferred embodiment below, to a point that leaves between each pair of shear walls a suitable span distance. Alternatively, posts or columns may be used instead of, or in combination with, such panels. Such internal support panels or posts may be reinforced by means of a tension wire or cable or a rod strung between them, preferably at their peaks, across the span and in the direction substantially parallel to the end walls and to the ground or the panels adjacent the ground on the other side of each post or column.

In another embodiment of the invention, an internal, substantially vertical panel extends from the base or floor of the structure to the ceiling thereof and adjacent to the curvilinear vault as it approaches the ground. Preferably, this panel extends along the length of the structure between the end walls. This panel not only provides additional support to the structure but also creates a plenum or chase between the panel and the vaulted roof/ wall panels. More preferably, this internal panel extends along the edges of the vertical support panels that are spaced apart from the vaulted primary structure.

This space accommodates mechanical, electrical and plumbing equipment. It also provides a plenum through which air can be supplied to rooms within the building structure for heating and/or cooling purposes. The plenum can provide a passage for air ducts or perform as a continuous air duct without the need for additional duct materials. Passages of adjacent modules will align so that these functions can pass through multiple modules. One advantage of this feature of the invention is that it provides for the simple introduction of such equipment or ducting and, when the structure is to be disassembled, the equipment in such spaces can readily be extracted. The panels in the structures of the invention are connected side-to-side and end- to-end, preferably by means of connecting devices such as brackets, plates or, more preferably, members such as blocks or dowels or the like that fit into appropriately sized recesses in the edges of the panels and, when placed therein, extend beyond the panel edge and into a corresponding aligned recess in an adjacent panel. These connection devices may be inserted either in the manufacturing facility or on site, and generally fill voids formed in an open cell structure in the stressed-skin panel.

Preferably, they are screwed or bolted to the panel. Preferably, the panel joints are finally sealed by means of tape, usually both on the outside and inside of the panels.

In accordance with the invention, there is thus provided a means of low cost housing or shelter in a "break down" design which is very portable. While modules and/or sections of the building of the invention may be shipped as assembled sections to the constructions side, it is preferred that the structure be supplied as a kit comprising the curvilinear panels, end wall components, the shear panels or posts and other internal supports, and connection devices and joint seals. This kit may be supplied in a relatively low volume container in which the curvilinear panels nest with one another minimizing the overall volume of the containers. Also, because the components of the building structures of the invention are light weight, handling of the kit and erection of the structures if facilitated.

The panels in the building structure of the invention are preferably stressed-skin structural panels containing open cell grids. The panels preferably have at least one stressed-skin layer integrally molded with open cell grids. Preferably, the panels comprise a pair of stressed-skin layers on opposite side of the panel each integrally bonded to a cell structure which has preferably been formed as two half panels and then bonded together at the center by mating matching cells together. The panels are preferably fabricated out of cellulose material, such as wood fibers or agricultural fibers, recycled paper and wood products, and the like, or the fibers can be noncellulose materials, including animal fibers, such as wool or textile fibers, such as cotton or synthetic fibers, such as various plastics and fiberglass as well as mineral fibers, and the like.

Further advantages and applications will become apparent to those skilled in the art from the following detailed description of the preferred embodiments and the drawings referenced herein, in which like numerals refer to like elements, the invention not being limited to any particular embodiment.

Brief Description of the Drawings

Figure Figures 1-5 comprise a sequence of schematic side elevation views, in section, illustrating the formation of panels to be used in the present invention;

Figure 6 is a side elevation view, in section, illustrating a panel to be used in the present invention;

Figure 6A is a detailed sectional view of a flange and rib in production in a panel to be used in the present invention;

Figure 7 is a bottom plan view of the panel of Figure 6, illustrating flanges extending over a portion of the surface area of the open cells of the grid of the panel; Figures 8-12 comprise a sequence of schematic drawings, in section, illustrating curvilinear panels for use in the present invention;

Figures 13-15 comprise a sequence of schematic drawings, in section, illustrating curvilinear panels for use in the present invention;

Figure 16 is a perspective view of a building structure of the invention, illustrating one module thereof;

Figure 16A is a perspective view of a building structure of the invention, illustrating multiple modules connected together to form a larger structure of the invention;

Figure 17 is a top plan view of the building structure of the invention shown in Figure 16, illustrating some internal components of the structure in phantom;

Figure 17A is a top plan view of the building structure of the invention shown in figure 16A, illustrating some internal components of the structure in phantom;

Figure 18 is a cross-sectional view of a building structure of the invention shown in Figure 17 A and taken along the line 18-18; Figure 18A is a cross-sectional view of a building structure of the invention, as shown in Figure 18, and illustrating an alternative interior support system to that shown in that figure;

Figure 19 is a perspective view of a building structure of the invention, partially cut away to illustrate a plenum wall according to a building structure of the invention; Figure 20 is a part cross-sectional view of the joint between two curvilinear panels in a building structure of the invention, illustrating a mode of connection of the panels;

Figure 20A is a perspective view of a curvilinear panel to be used in a building structure of the invention and showing connection devices for connecting the panel to adjacent panels;

Figure 21 is a schematic perspective view, part cut away, illustrating the nesting of panels for a building structure of the invention in a kit form for shipment;

Figure 22 is a schematic cross-sectional view of a sill for mounting a building structure of the invention on the ground;

Figure 22A and 22B are schematic cross-sectional views of alternative sills for mounting a building structure of the invention to a slab;

Figure 23 is a schematic cross-sectional view of a base tray for mounting a building structure of the invention to a slab and showing conduit, wiring and a duct; Figure 24A is a schematic cross-sectional view, part cut away, of a chase region of a building structure of the invention, showing ducting for air; and

Figure 24B is a schematic cross-sectional view, part cut away, of a plenum region of a building structure of the invention, showing a mode of supply of heated or cooled air.

Detailed Description of the Invention

The present invention provides a building structure comprising a pair of opposed substantially vertical end walls, each wall having a substantially straight base side and a substantially continuous arch side extending from one end of the base side to the other end of the base side in each end wall; and an arcuate roof/ wall member formed from at least one curvilinear stressed-skin panel, the radius of curvature corresponding to the arch side of the end walls and extending from one end of the base side to the other end of the base side.

Thus, the primary structure of the envelope of the building structure of the present invention is an assembly of curvilinear stressed-skin panels carrying the bending (from spanning) loads and lateral loads due to wind, earthquake, impact or the like, without dependence on a primary structural skeleton.

The panels in the building structure of the invention are preferably stressed-skin structural panels containing open cell grids. The basic configuration for panels useful in the structures of the invention can be formed in accordance with methods established in the prior art, such as embodied in U.S. Patent Nos. 4,702,870; 4,753,713; 5,198,236; 5,277,854; and 5,314,654, the entire disclosures of which are incorporated herein by this reference.

The panels preferably have at least one stressed-skin layer integrally molded with open cell grids. Preferably, the panels comprise a pair of stressed-skin layers on opposite side of the panel each integrally bonded to a cell structure which has preferably been formed as two half panels and then bonded together at the center by mating matching cells together. The panels are preferably fabricated out of cellulose material, such as wood fibers or agricultural fibers, recycled paper and wood products, and the like, or the fibers can be non-cellulose materials, including animal fibers, such as wool or textile fibers, such as cotton or synthetic fibers, such as various plastics and fiberglass as well as mineral fibers, and the like. Alternatively, mixtures of cellulose and non-cellulose fibers will also be found useful in such panels.

Figures 1-5 illustrate a preferred method of forming panels for use in the structures of the invention in which a porous carrier or screen 10 has mounted thereto blastomeric pads 12 which define by their geometry and spaces there between the configuration of the grid in the structural panels. The blastomeric pads 12 are preferably hexagonal in cross section, so as to form hexagonal cells in the grid of the panels (see Figure 7). However, other shaped pads and therefore other shaped cells can be used. Referring to Figure 1, a ratio of the nominal dimension diameter of the bottom of the pad b to the dimension of the diameter of the top t, or b/t, is preferably about 1.0 to 1.7, most preferably about 1.4. In the cross section shown in Figure 1, the top of the pad has a height "h" measured from the carrier which is preferably at least about 85 % of the width "b" of the base of the pad. Generally, the dimensional width of the pad top will be less than the base dimension "b". Preferably, the height to base width ratio (h/b) is about 0.85 to 2.00, most preferably about 0.95 to 1.50. The pads are preferably spaced apart evenly and from 0.050 to 0.200 inches or more apart, more preferably 0.130 to 0.180 inches. Preferably, the pads have a concave or bangalore profile in which the general curvature is defined by two substantially linear sections forming two angles measured relative to the longitudinal axis of the pad.

Referring now to Figure 2, fiber dispersed in a liquid medium 11 is disposed on the porous carrier 10 and between and on top of the blastomeric pads 12. The liquid is preferably water and the fiber is preferably cellulose material, such as wood fibers, recycled paper, and wood products and the like, agricultural, animal, or textile fibers. Most preferably recycled paper products or agricultural fibers are used as the source of fiber.

As shown in Figure 3, a porous top plate 14 completes a mold which upon compression, as shown in Figure 4, deforms the pads 12, which are made of blastomeric material such as silicone. Preferably, the pads have a Shore A hardness of from 15 to 45, more preferably from 20 to 35. With the application of pressure and heat, the fibers are consolidated into a panel member 18, as shown in Figure 5, that comprises a surface skin 20 on one side and on the other side integrally formed ribs 22 terminating in flanges 24. As illustrated in Figure 6 and 6A, compression of the elastomeric pads 12 enhances the formation of ribs 22 and their flanges 24. Preferably, as shown in Figure 6A, the relationship between the flange overhang "r" to the distance between the pads "s" is such that the ratio (r/s) is greater than 0.1 and more preferably from 0.3 to 0.45.

As illustrated in Figure 7, the resultant panel has flanges 24 that cover a portion 26 of the surface area of each cell in the grid 22 of panel 18. The portion 26 of the surface area so covered will be bounded by the edge 28 of the flange and the wall 30 of the rib which forms a portion of the grid 22. The remaining portion 32 of the surface area of the cell is that through which elastomeric pad 12 projected and will thus remain uncovered. The amount of cell surface area covered by flange 24 can vary widely, for example from at least 10% of the surface area and up to about 90% of the surface area, preferably about 15-40%, more preferably about 15-20% of the surface area. This panel represents a sub-or half-panel for the building structures of this invention and is attached to another sub- or half-panel by means of the flanges 24 to form a complete panel, as described below.

As noted previously, the primary structure of the envelope of the building structure of the present invention is an assembly of curvilinear stressed-skin panels carrying the bending loads and lateral loads. The curvilinear cross-section vaulted segments formed in the structures of the invention are preferably formed in a generally semi-circular cross-section, in order to optimize the height of the interior space of the structure. In figures 8-12, there is schematically illustrated a general process for the formation of a curvilinear panel for use in the building structures of the invention. As shown in Figure 8, a sub-panel 18 is applied in the direction of the arrows shown to a mold 33 having a curvilinear mold surface 34 so that the stressed-skin surface of the panel is in contact with the mold surface. Referring to Figure 9, the sub-panel 18 is conformed to the curvilinear mold surface 34 by using a sub-panel from the process described above, which are generally malleable but can be treated with moisture to increase their malleability, and/or by the application of heat. Referring now to Figure 10, another sub-panel 35 is then applied to the curvilinear sub-panel 18 with the grid structures of each sub-panel facing one another and to which there is applied adhesive shown by the arrows in Figure 10 to form a complete panel 36 for the structures of the invention. The adhesive is allowed to set or cure and the panel 36 is then released from the mold as illustrated in Figure 12. Alternatively, a pair of sub-panels may be curved or flexed by appropriate male and female molds and then bonded together after shaping. Alternatively, at least a portion of the porous carrier 12 may be curvilinear to impart a corresponding curve to the panel formed thereon by the process illustrated in

Figures 1-5.

As shown in Figure 13, the ribs and flanges alignment in mating sub panels will not usually match or register exactly, due in part to the different radii of curvature established in the sub panels. However, it has been found that the overlap and the resultant matching of the ribs is generally sufficient to maintain adequate structural integrity particularly along the neutral axis 37 of the grid panel shown in Figure 14. In the event that additional bond surface is considered desirable, molds of different radii of curvature may be used to form a pair of sub-panels designed to provide a different radii of curvature, so that the ribs will remain in substantial alignment when the sub- panels are bonded together as shown in Figure 15.

Referring now to Figure 16, there is illustrated therein a building structure according to the invention. The structure is formed by a first, substantially vertical end wall 38 and a similar end wall at the other end of the structure, shown in phantom. Each end wall is preferably substantially semicircular in shape, and formed by flat panels produced by the process described above, but with the laminations of sub-panels being flat, rather than curvilinear. Between the end walls, the outer structure is completed by a number of curvilinear panels 36 joined end to end and side to side, preferably by the means described below. At least one of the end walls is provided with a door 39 in frame 39a below transom 39b and the remainder of the end wall is made up of panels similar to those of the arcuate vaulted portion of the structure, but being flat instead of curvilinear. The vaulted structure may be attached to the end wall by any suitable means such as by screws and/or bolts through the curvilinear panels and extending into hard points or blocks in the panels forming the end walls. Windows may be provided in the end walls and/or curvilinear panels as desired. Preferably three panels 37 are used per vault. The module illustrated in Figure 16 can serve as a basis for making building structures according to the invention of any desired length. Usually, the length of a module will be of two panel widths. Typical panels may be ten feet long by four feet wide, but obviously other sizes such as five feet by ten feet, four feet by eight feet or five feet by eight feet, could be used. Thus, as illustrated in Figure 16A, as many modules as desired may be connected together end to end so as to increase the separation between the end walls to form a building structure of desired size. It is also apparent that one or more intermediate walls may be included in the structure, between the end walls, thereby providing a means to partition the interior space of the structure into separate rooms.

The arrangement of the panels 36 in the building structures of Figures 16 and 16A may be seen more clearly in corresponding plan views in Figures 17 and 17A, respectively.

In a preferred embodiment of the invention, shown in Figure 18, the vaulted arch structure between the ends walls is supported internally by shear panels 40 extending vertically from the ground or the base of the building structure to the ceiling and consist of panels aligned in a plane substantially parallel to that of the end walls. These panels are separated across the long central longitudinal axis of the building structure by a span distance "S" and/or also separated from the vaulted structure in the areas where it approaches the ground one either side of the building so that there is formed between the shear panels 40 and the outer walls spaces 42. Preferably, as shown in phantom in Figures 17 and 17A, these shear walls are located adjacent to the joints between adjacent curvilinear panels that form the vaulted structure and are located adjacent to each of such joints or, more preferably, under alternating joints (as shown). Preferably the ratio of the thickness of the panels of the vaulted structure to the span distance "S" is generally from about 1/80 to about 1/480, preferably from about 1/100 to about 1/320, more preferably from about 1/120 to about 1/160 or 1/240. For example, for a 10 foot span and a panel having thickness of 3/4" the ratio is 1/160. These are unusually low ratios that indicate a large internal span despite a relatively thin structure. This feature contributes to the lightness of the structure and its high structural integrity without further support or skeletal structure.

Alternative internal bracing and support may be provided by the embodiment shown in Figure 18A whereby posts or columns 43 take the place of shear panels 40 shown in Figure 18. Yet further support may be provided by a tensioned wire cable or rod 44 extending between the post or columns 43, and between the columns or posts and each base of the vaulted roof/wall element.

Referring now to Figure 19, there is shown therein a building structure of the invention with one lower side portion between the sidewalls cut away to reveal an internal panel or wall 41 extending the length of the building structure of the invention between the end walls. In this embodiment of the invention, wall 41 creates between it and the adjacent vaulted structure, a space more clearly shown as 42 in Figure 18 that provides a plenum or chase into which may be provided mechanical, electrical or plumbing equipment (not shown) or, by means of ducts (not shown) means for providing a supply of heated or air conditioned air. Space 42 may be open at least one end to accommodate entry of electrical, plumbing or other mechanical fittings, or may be sealed to form a plenum for circulation of air in the structure.

Of course, when a building structure of increased size is created, or a structure with intermediate walls between the end walls, it will ordinarily be desirable to align the plenum spaces to provide continuity for the air circulation or the auxiliary equipment and conduit included within the space.

The panels in the structures of the invention are typically connected side-to-side and end-to-end, preferably by means of connecting devices such as brackets, plates or, more preferably, members such as blocks or dowels or the like that fit into appropriately sized recesses in the edges of the panels and, when placed therein, extend beyond the panel edge and into a corresponding aligned recess in an adjacent panel. With reference to Figure 20, there is shown a partial cross-section of a joint between abutting curvilinear panels 36 in the structure of the invention by a connecting device 45 extending between the adjoining panels and into correspondingly shaped recesses in each panel. Those recesses may be conveniently provided by a void between the faces of the stress skin panel formed by the open grid structure. Such connecting devices may be installed either in the manufacturing facility or on site and preferably secured by screws or bolts 46. To minimize the number of holes in the outer surface of the building structure that may conduct water from weathering into the panels and degrade the integrity of the panels, such screws or bolts are predominantly directed from the interior of the building structure.

To enhance the structural integrity of the building and to keep water out of the joint 47 between adjoining panels, tape 48 extends along the seam or joint between the panels on the exterior surface of the building. It has been found that duct tape such as 3M^® Tartan silver colored contractor grade cloth tape, 1" or 2 wide may be used.

Similarly, a tape 49 along the interior of the joint and covering screws 46 may be used to improve the internal cosmetic appearance. However, both tapes, and in particular external tape 48, contribute to the structural integrity of the building structure. The external tape 48 should be ultraviolet, water and temperature resistant so as to preserve the integrity of the joint and the panel. Preferably, such connection devices are spaced apart by about one to two feet along the relevant panel edges. It has been found that such spacing serves to appropriately connect the panels in sufficient alignment to allow the tape and/or other sealant to minimize ingress of water into the panel joints from exposure of the building to the weather. As shown in Figure 20A, the connecting devices 45 are spaced at regular intervals along the edges of the panel 36. Other advantages of such tape are its low cost and ease of removal for disassembly of the structure. If desired, one end of the connecting devices may be permanently secured in the panel by adhesives or the like. However, the other end should remain unattached in the panel of the structure so that the building may be disassembled. The connecting devices 45 are preferably internal to the panels and may be blocks, dowels, pegs, splines or the like, but could also be other means of connection that may be external to the panels in the form of plates, angles, clips, channels and the like.

While the butt-joining of adjacent panels is preferred for simplicity and low cost, it will be apparent that alternative joints could be used, such as tongue and groove, mating ridged, segmented or continuous designs. To make the panels 36 weatherproof, they are preferably coated with an appropriate sealing or coating such as polyurethane. Suitable polyurethanes include AMF^® Polyureseal BP (5006 clear, 5086 satin or 5016 white) from American Formulating and Manufacturing in San Diego, Narathane^® Liquid Plastic SD93 Clear Satin from Flecto Company, Inc. of Oakland, California (Catalog No. 129).

One significant feature of the building structures of the invention is their easy portability in low volume and their ready transportability in view of those features and the overall lightweight characteristics of the panels. As shown in Figure 21, the curvilinear panels 36 may be nested one upon the other together with flat panels 50 that may form the end walls, the plenum panel 41 depicted in Figure 19 and/or the shear wall 40 depicted in Figure 18. In a particular example where the panels are four feet wide and ten feet long, a typical module can be enclosed in a box 51 having an overall dimension of ten feet by four feet by two feet.

The building structure of the invention may be placed on the ground or on a preformed slab or footing, but the ends of the panel generally need some form of protection to prevent ingress of water and subsequent degradation thereof. Accordingly, the ends of the panels adjacent the ground may be sealed with Polyureseal or Narathane or rubberized with any suitable setting rubber material as will be apparent to one of ordinary skill in the art. In preferred embodiments of the invention, the lower extremities of the structure of the invention may be fitted into a channel 52 of a sill plate 53, as shown in Figure 22 or onto a portion of a base tray made from metal, plastic, wood or other appropriate material.

As shown in Figures 22 A and 22B, the lower perimeter 54 of the building structure of the invention formed by panels 36 may be mounted to a sill plate 55 depicted in Figure 22A or angle plate 56 depicted in Figure 22B to a slab or foundation 57. Alternatively, such slab or foundation could be a wood floor. The panels may be mounted by means of screws or rivets 58 or other suitable fastening means and the plate (55 or 56) may be mounted to the slab or foundation 57 by bolts 59 or other suitable fastening means. The sill or angle plate preferably comprises a horizontal portion 60, attached to slab or foundation 57, and a substantially vertical portion 61, attached to the panels 36. Preferably the vertical portion is sized to fill the space between the stressed-skins of the panels 36, as shown in Figure 22A, or, where it does not, as shown in Figure 22B, the space is sealed with sealant or caulk 62.

With reference to Figure 23, the space 42 in the building structures of the invention is also shown to be provided with wires 63 for electrical supply, to outlets

63a (as shown in Figures 23 and 24A and 24B in Wall 41), conduits 64 for supply of electricity or water or the like and a modular chase or duct 65 for conducting conduit, wire or air.

In Figure 24A there is shown one embodiment of the invention for air circulation whereby a duct 65 conducts air to a diffuser 66 set into chase wall 41.

Obviously, a plurality of such diffuses will usually be used to adequately circulate air in the structure.

Alternatively, as described above, the plenum 42 formed by wall panels 36 and internal wall 41 may itself be used to conduct air, as shown in Figure 24B from an air heater and/or conditioner 67. The general circulation path of the air in this embodiment is shown by the arrows in Figure 24B. The advantage of this embodiment is the elimination of the duct 65, shown in Figure 24 A, and the cost thereof.

All patents and patent applications cited in this specification are hereby incorporated by reference as if they had been specifically and individually indicated to be incorporated by reference. Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity and understanding, it will be apparent to those of ordinary skill in the art in light of the disclosure that certain changes and modifications may be made thereto without departing from the spirit or scope of the appended claims.

Claims

Claims:

1. A building structure comprising

(a) a pair of opposed substantially vertical end walls, each wall having a substantially straight base side and a substantially continuous arch side extending from one end of the base side to the other end of the base side in each end wall; and

(b) an arcuate roof/wall member formed from at least one curvilinear stressed-skin panel, the radius of curvature corresponding to the arch side of the end walls and extending from one end of the base side to the other end of the base side.

2. A building structure as recited in claim 1 further comprising

(c) at least one substantially vertical panel extending from the base of the structure to approximately the interior ceiling of the roof/wall member thereof and positioned adjacent to the roof/ wall member as it approaches the base of the structure.

3. A building structure as recited in claim 2 wherein the panel extends along substantially the length of the structure spanning the end walls, thereby providing additional support to the structure and creating a plenum between the panel and the roof /wall member.

4. A building structure as recited in claim 1 further comprising

(d) at least one internal support panel positioned in the longitudinal direction of the structure between said end walls and spanning a sufficient portion of the distance from the roof/wall member to the base of the structure to thereby provide intermediate support for the roof/ wall member.

5. A building structure as recited in claim 4 wherein said internal support panel comprise an internal shear support panel which is positioned substantially parallel to the end walls and which extends substantially vertically from the base of the structure to the inner ceiling of the roof /wall member.

6. A building structure as recited in claim 1 wherein the thickness-to-span ratio of the roof/wall member, measured in a direction substantially parallel to the end walls, is in the range of from approximately 1/80 to approximately 1/480.

7. A building structure as recited in claim 6 wherein the thickness-to-span ratio in the range of from approximately 1/100 to approximately 1/320.

8. A building structure as recited in claim 6 wherein the thickness-to-span ratio in the range of from approximately 1/120 to approximately 1/240.

9. A building structure as recited in claim 1 further comprising

(e) a plurality of connecting members which are configured to engage with appropriately sized recesses in the edges of each of the roof/wall member panels and the end wall panels and, when placed therein, extend beyond the panel edge and into a corresponding aligned recess in an adjacent panel, thereby providing releasable engagement between the individual panels comprising the building structure.

10. A building structure as recited in claim 1 wherein at least one of said panels in the building structure comprises a stressed-skin structural panel containing open cell grids.

11. A building structure as recited in claim 10 wherein the stressed-skin structural panel comprises at least one stressed-skin layer integrally molded with at least one open cell grid.

12. A building structure as recited in claim 10 wherein the stressed-skin panel comprises a pair of stressed-skin layers on opposite side of the panel each integrally molded to an open cell grid.

13. A building structure as recited in claim 10 wherein the stressed-skin panel comprises fiber material.

14. A building structure as recited in claim 13 wherein at least a portion of said fibers are cellulosic.

15. A building structure as recited in claim 13 wherein at least a portion of said fibers are non-cellulosic.