초록 ▼

A system for forming structures, such as buildings, including the forming of a foundation slab, attaching flexible wall panels to the periphery of the foundation in a serial overlap configuration, installing prefabricated windows and doors, draping and attaching a membrane over the top of the wall p

A system for forming structures, such as buildings, including the forming of a foundation slab, attaching flexible wall panels to the periphery of the foundation in a serial overlap configuration, installing prefabricated windows and doors, draping and attaching a membrane over the top of the wall panels, inflating the membrane upwardly to form a surface upon which to spray a foam substance, and spraying the foam to either the interior or exterior surfaces of the structure, including the roof membrane, so that an economical and energy efficient building can be provided at a low cost.

대표청구항 ▼

1. A method for forming a structure comprising the steps of: (a) Forming a foundation, (b) Attaching panels to said foundation to form an assembled panel construction, (c) Installing at least a door in said panels, (d) Fabricating an unshaped flexible membrane having a middle portion and furth

1. A method for forming a structure comprising the steps of: (a) Forming a foundation, (b) Attaching panels to said foundation to form an assembled panel construction, (c) Installing at least a door in said panels, (d) Fabricating an unshaped flexible membrane having a middle portion and further having a peripheral portion, (e) Draping said flexible membrane over the upper portion of said assembled panel construction, such that the middle portion of said membrane hangs down within said panel construction lower than the peripheral portion of said membrane, adjusting said membrane such that the draped mode of said membrane will be the reverse of the desired shape of the roof of the structure, thereafter attaching the peripheral portion of the membrane to the upper portion of the panel construction, and thereafter (f) Inflating said membrane with air pressure, (g) Applying foam to a surface of said panels, (h) Applying foam to a surface of said membrane, (i) Applying a fire barrier to the interior or exterior exposed side of said foam, and (j) Applying an exterior sealant to any exterior exposed foam surfaces, Whereby structures of various sizes and configurations can be constructed and modified without the necessity of an extensive structural framework. 2. The method of claim 1 wherein step (e), draping and attaching, further includes, draping said fabricated membrane from a top edge of all said panels such that central portions of said membrane hang lower than said top edges of said panels, adjusting the distance said central portions and peripheral portions of said membrane hang to appropriate levels so that when inverted upwardly said membrane forms the upper limit of a desired configuration of a roof for said structure, and making said membranes and said panels contiguous by attaching and sealing said membrane to at least one of outer or inner upper portions of said panels proximate to said upper edges of said panels. 3. The method of claim 1 wherein step (f), inflating said membrane, further includes, closing and sealing all orifices in said structure except one, and placing inflation means in the one remaining open orafice to force outside air into the interior of said structure creating a high pressure area therein which inflates said membrane upwardly creating a formed surface of a desired configuration upon which to spray foam. 4. The method of claim 1 wherein step (g), applying foam to a surface of said panels, further comprises, applying foam by means of spraying to a desired thickness upon the interior surfaces of said panels attached to said foundation, whereby said foam forms the interior walls of the said structure. 5. The method of claim 1 wherein step (h), applying foam to a surface of said membrane, further includes, applying foam by means of spraying to a desired thickness upon an interior surface of said membrane, whereby said foam forms a roof for said structure. 6. The method of claim 1 wherein step (i), applying a fire barrier, further includes, applying a coat of a fire barrier medium in a contiguous fashion on the interior or exterior surfaces of said structure, whereby said foam is isolated from direct exposure to the interior or exterior space of said structure. 7. The method of claim 1 wherein, step (j), applying exterior sealant, further includes, applying an exterior sealant medium to any exterior foam surfaces whereby said surfaces are thereby protected from elemental deterioration. 8. The method of claim 1 wherein steps (g) and (h), applying foam to surfaces of said panels and said membrane, further include, applying foam by means of spraying to a desired depth upon exterior surfaces of said panels and said membrane, whereby said structure is formed from applying foam to exterior surfaces rather than interior surfaces. 9. The method of claim 1 wherein steps (g) and (h), applying foam to said panels and said membrane, further include, applying foam by means of spraying to a desired depth upon both interior and exterior surfaces of said membrane and said panels, thereby forming said structure by means of a foam-sandwich construction. 10. A method for forming a structure comprising the steps of: (c) Forming a foundation, (b) Attaching panels to said foundation, (c) Installing windows and doors in said panels, (d) Fabricating a flexible membrane, (e) Draping and attaching said flexible membrane to said assembled wall panels, (f) Inflating said membrane with air pressure, (g) Applying foam to a surface of said panels, (h) Applying foam to a surface of said membrane, (i) Applying a fire barrier to the interior or exterior exposed side of said foam, and (j) Applying an exterior sealant to any exterior exposed foam surfaces, Whereby structures of various sizes and configurations can be constructed and modified without the necessity of an extensive structural framework; and wherein step (a), forming a foundation, further includes, pouring a concrete slab within the confines of a two piece form such that a narrow, contiguous transverse step is formed along the periphery of said/slab, and retaining an upper contiguous portion of said two piece form which comprises a vertically disposed peripheral baseboard surrounding an upper edge portion of said slab above said step. 11. A method for forming a structure comprising the steps of: (a) Forming a foundation, (b) Attaching panels to said foundation, (c) Installing windows and doors in said panels, (d) Fabricating a flexible membrane, (e) Draping and attaching said flexible membrane to said assembled wall panels, (f) Inflating said membrane with air pressure, (g) Applying foam to a surface of said panels, (h) Applying foam to a surface of said membrane, (i) Applying a fire barrier to the interior or exterior exposed side of said foam, and (j) Applying an exterior sealant to any exterior exposed foam surfaces, Whereby structures of various sizes and configurations can be constructed and modified without the necessity of an extensive structural framework; and wherein step (b), attaching panels to the foundation, further includes, fastening a first, inner panel to said baseboard above said step such that panel conforms generally to the configuration of said baseboard and said slab, fastening a first outer panel to an outer surface of said first inner panel so that said second panel half-laps said first panel, fastening a second said inner panel to an inner surface of said first outer panel with vertical edges of said first and second inner panel in abutting engagement, and serially continuing the fastening of further said inner and outer panels to said baseboard and to one another around the periphery of said slab forming vertical wall forms. 12. A method for forming a structure comprising the steps of: (a) Forming a foundation, (b) Attaching panels to said foundation, (c) Installing windows and doors in said panels, (d) Fabricating a flexible unshaped membrane having a middle portion and further having a peripheral portion, (e) Draping said flexible unshaped membrane over the panels, such that the middle portion of said membrane hanges down within said panels lower than the peripheral portion of said membrane, adjusting said membrane such that the draped mode of said membrane will be the reverse of the desired shape of the roof of the structure, thereafter attaching the peripheral portion of the membrane to the panels, and thereafter (f) Inflating said membrane with air pressure, (g) Applying foam to a surface of said panels, (h) Applying foam to a surface of said membrane, (i) Applying a fire barrier to the interior or exterior exposed side of said foam, and (j) Applying an exterior sealant to any exterior exposed foam surfaces, Whereby structures of various sizes and configurations can be constructed and modified without the necessity of an extensive structural framework; and wherein step (c), installing windows and doors, further includes, cutting out portions of said vertical walls to receive windows and doors, framing said cut-out portions, and installing the windows and doors therein. 13. A method for forming a structure comprising the steps of: (a) Forming a foundation, (b) Attaching panels to said foundation to form an assembled panel construction, (c) Installing at least a door in said panels, (d) Fabricating an unshaped flexible membrane, (e) Attaching and draping said flexible membrane to an upper portion of said assembled panel construction, (f) Inflating said membrane with air pressure, (g) Applying foam to a surface of said panels, (h) Applying foam to a surface of said membrane, (i) Applying a fire barrier to the interior or exterior exposed side of said foam, and (j) Applying an exterior sealant to any exterior exposed foam surfaces, Whereby structures of various sizes and configurations can be constructed and modified without the necessity of an extensive structural framework, and wherein step (d), fabricating a flexible membrane, further includes, fabricating a contiguous, large, flexible, relatively light membrane large enough to overlie said panels on said foundation with substantial excess in all directions, and spraying said membrane with a sealant if necessary to make said membrane relatively impervious to air flow therethrough. 14. A method for forming a structure comprising the steps of: (a) Forming a foundation, (b) Attaching panels to said foundation to form an assembled panel construction, (c) Installing at least a door in said panels, (d) Fabricating an unshaped flexible membrane having a middle portion and further having a peripheral portion, (e) Draping said flexible unshaped membrane over the panels, such that the middle portion of said membrane hangs down within said panels lower than the peripheral portion of said membrane, (f) adjusting said membrane such that the draped mode of said membrane will be the reverse of the desired shape of the roof of the structure, (g) thereafter attaching the peripheral portion of the membrane to the panels, and thereafter (h) Inflating said membrane with air pressure, (i) Applying foam to a surface of said panels, and (j) Applying foam to a surface of said membrane. 15. A method for forming a building structure, comprising the steps of: (a) Providing a foundation; (b) Providing inner and outer upstanding panels, each of which has respective upper and lower portions and respective vertical side edges, and arranging the respective panels in an overlapping relationship relative to the respective vertical side edges of the panels; (c) Securing the lower portions of the panels to the foundation; (d) Providing a membrane, and attaching said membrane to the upper portions of the panels; (e) providing at least one access opening in the panels; and (f) applying foam to at least one of the interior and exterior surfaces of the building structure. 16. The method of claim 15, wherein a first inner panel is secured to the foundation; wherein a first outer panel is arranged in an overlapping relationship with respect to the first inner panel and is secured thereto, and wherein the sequence is continued to form an assembled panel structure. 17. The method of claim 15, wherein the membrane is flexible and made sufficiently non-porous and is draped over the panels, and wherein the membrane is inflated by air pressure prior to applying the foam. 18. The method of claim 15, wherein the step of forming at least one access opening comprises the step of forming a door and at least one window in the building structure. 19. The method of claim 15, wherein the panels are made of plywood, and wherein the step of attaching the membrane to the upper portion of the panels includes the step of attaching a thin strip to the respective tops of the plywood panel, to retain the membrane. 20. A method of forming a building structure, comprising the steps of: (a) Providing a foundation; (b) Providing inner and outer upstanding panels, each of which has respective upper and lower portions and respective vertical side edges, and arranging the respective panels in an overlapping relationship relative to the respective vertical side edges of the panels; (c) Securing the lower portions of the panels to the foundation and to each other; (d) Providing a substantially flexible membrane, (e) Draping the membrane over the assembled panel structure, and attaching the membrane to the upper portions of the assembled panels; (f) Providing at least one access opening in the assembled panels; (g) Substantially sealing the interior of the building structure; (h) Inflating the membrane with air pressure; (i) Applying foam to a surface of said membrane; and (j) Applying foam to a surface of said panel structure. 21. The method of claim 20, wherein the foam is applied to both interior and exterior surfaces of the membrane and the panels. 22. The method of claim 21, further including the step of providing a fire barrier on the interior foam surface.