IPC분류정보
국가/구분 |
United States(US) Patent
등록
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국제특허분류(IPC7판) |
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출원번호 |
US-0901175
(2007-09-13)
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등록번호 |
US-8322097
(2012-12-04)
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발명자
/ 주소 |
- Schiffmann, Glenn P.
- Schiffmann, Gerhard P.
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출원인 / 주소 |
- Composite Panel Systems, LLC
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대리인 / 주소 |
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인용정보 |
피인용 횟수 :
6 인용 특허 :
124 |
초록
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A method of constructing a building or building appurtenance, optionally without structural use of concrete except for floor slabs. The method contemplates excavating a hole to establish a natural base on which the structure is to be constructed, establishing layout locations where upright walls or
A method of constructing a building or building appurtenance, optionally without structural use of concrete except for floor slabs. The method contemplates excavating a hole to establish a natural base on which the structure is to be constructed, establishing layout locations where upright walls or other supports of the structure are to be erected, establishing a fabricated footer, optionally a fiber-reinforced polymeric footer, along the laid-out locations of the supports, placing pre-fabricated load-bearing fiber-reinforced polymeric building panels or other supports on the fabricated footer, and connecting the pre-fabricated wall panels or other supports to each other according to the structure plan thereby developing load-bearing walls or other supports, and erecting overlying structure on the load-bearing walls or other supports.
대표청구항
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1. A method of constructing a building which shelters an area, the method comprising: (a) excavating a hole, as necessary, to establish a natural base on which to construct the building,(b) establishing layout locations where upright walls of the building are to be erected, thereby to generally defi
1. A method of constructing a building which shelters an area, the method comprising: (a) excavating a hole, as necessary, to establish a natural base on which to construct the building,(b) establishing layout locations where upright walls of the building are to be erected, thereby to generally define an outer perimeter of the building to be constructed, as well as to generally define locations where any interior walls will extend upwardly from the natural base,(c) establishing a fabricated load-bearing footer along the laid-out locations of the upright walls,(d) placing pre-fabricated building panels, having tops, bottoms, lengths, heights, inwardly-facing surfaces, and outwardly-facing surfaces, on the fabricated footer, and(e) connecting the pre-fabricated building panels to each other to thereby develop foundation walls, a given such foundation wall comprising(i) a first outermost fiber-reinforced polymeric layer defining an outwardly-facing surface of the foundation wall,(ii) an innermost fiber-reinforced polymeric layer defining at least a portion of an inwardly-facing surface of the foundation wall,(iii) a space between the first and second outermost layers, and(iv) a plurality of studs, spaced along the length of the foundation wall and extending away from the foundation wall, including extending away from one of the innermost and outermost layers and away from the space between the innermost and outermost layers; and(f) erecting overlying structure on the foundation walls thereby to shelter the area. 2. A method as in claim 1 wherein a given such building panel comprises a plurality of structurally-reinforcing members extending along substantially an entirety of the height of the building panel, and extending from locations at or proximate the first outermost layer to locations at or proximate the second outermost layer. 3. A method as in claim 2 wherein the first and second outermost layers comprise reaction curable resin compositions which have been cured. 4. A method as in claim 3 wherein at least one of the second outermost layer and the first outermost layer has a nominal thickness between about 0.03 inch thick and about 0.15 inch thick. 5. A method as in claim 1 wherein the foundation wall comprises thermally insulating foam elements comprising closed cell foam having densities of about 1 pound per cubic foot to about 12 pounds per cubic foot. 6. A method as in claim 2 wherein substantially all of the foundation wall is below grade. 7. A method as in claim 1 wherein the studs have end panels remote from the innermost layer, further comprising channels between said studs, the channels having open sides extending along the full lengths of the respective studs and wherein the foundation wall comprises a top plate providing a top surface of the foundation wall and comprising fiber-resin composite material extending generally continuously between top ends of the end panels of the studs and a top end of the outermost layer, and over such open channels. 8. A method as in claim 1 wherein each of the innermost layer, the outermost layer, and the studs is a fiber-resin composite wherein the fiber component is greater than 45 percent by weight, wherein the innermost and outermost layers are at least 0.07 inch thick, and wherein the foundation wall has a vertical crush resistance capacity of at least 4000 pounds per lineal foot length of such foundation wall. 9. A method as in claim 1 wherein each of the innermost layer, the outermost layer, and the studs is a fiber-resin composite wherein the fiber component is greater than 45 percent by weight, wherein the innermost and outermost layers are at least 0.07 inch thick, and wherein the foundation wall has a horizontal point loading bending moment resistance corresponding to at least about 2000 pounds per square foot. 10. A method as in claim 2 wherein the innermost layer, the outermost layer, and the structurally reinforcing members comprise fiberglass-reinforced polymeric structures. 11. A method as in claim 1 wherein the studs extend from the innermost layer a distance of about 1 inch to about 6 inches. 12. A method as in claim 1 wherein the foundation wall comprises thermally insulating foam extending from the innermost layer to the outermost layer, the foam being bonded to the innermost layer and to the outermost layer. 13. A method as in claim 1, including using, in the fabricated footer, one or more fiber-reinforced reaction cured polymeric footer pads. 14. A method of fabricating a building comprising: (a) excavating a hole, as necessary, to establish a natural base on which to construct the building;(b) establishing layout locations where upright walls of the building are to be erected, thereby to generally define an outer perimeter of the building;(c) creating a footer, including placing one or more footer pads on the natural base, as footer elements, along the outer perimeter of the building;(d) placing pre-fabricated fiber-reinforced load-bearing polymeric building panels on the fabricated footer;(e) connecting the pre-fabricated building panels to each other to thereby develop load-bearing walls, wherein a given such load-bearing wall has a length and a height, and comprises (i) an outermost fiber-reinforced polymeric layer defining an outwardly-facing surface of the load-bearing wall,(ii) an innermost fiber-reinforced polymeric layer defining at least a portion of an inner surface of the load-bearing wall, and(iii) a plurality of studs, spaced along a length of the wall, the studs protruding from the innermost layer, including extending away from one of the innermost and outermost layers; and(f) erecting overlying structure on the load-bearing walls, the overlying structure, in combination with the load-bearing walls, sheltering an area to be sheltered by the building. 15. A method of constructing an appurtenance to a building, the building being defined by a generally enclosing outer perimeter, the appurtenance being located outside the generally enclosing outer perimeter, the method comprising: (a) excavating one or more below-grade holes outside the outer perimeter of the building to establish a natural base on which to construct the appurtenance,(b) establishing at least first and second locations where supports are to be erected in the one or more holes thereby to establish support locations for supporting such appurtenance,(c) creating appurtenance footers, including placing appurtenance footer pads on the natural base, as appurtenance footer elements, the appurtenance footers being displaced from the building footer and outside the outer perimeter, and compatible with collectively supporting the appurtenance through overlying-support structure, and(d) mounting overlying support structure on the one or more footers, the support structure comprising one or more uprightly-oriented fiber-reinforced reaction cured polymeric support posts, adapted and configured to support the appurtenance, on corresponding ones of the appurtenance footer pads, the method further comprising cutting the one or more of the fiber-reinforced reaction cured polymeric support posts off to a desired height, thus to define one or more supports each comprising a such appurtenance footer pad and at least one such fiber-reinforced polymeric support post, each such post extending as an elongate structure having a post side wall extending from a bottom of the post to a top of the post, an outer surface defining an outer perimeter of the post at the post top,further comprising installing, on a respective such fiber-reinforced polymeric support post, a fiber-reinforced polymeric structural cap which overlies the support post at the top of the support post and wherein such structural cap comprises a single-piece top wall extending about the outer perimeter of the post, and a skirt, integral with the cap top wall about substantially the entirety of the perimeter of the post, and extending down from the top wall, and(e) mounting an overlying appurtenance to the support structure, as desired, to develop suitable features in the appurtenance; and(f) back-filling the excavation. 16. A method as in claim 15 wherein such cap comprises a structural fiberglass-reinforced polymeric structure wherein the top wall transmits the overlying load generally uniformly about the perimeter of the side wall of the post, and the skirt interfaces with the outer surface of the post side wall about substantially the entirety of the perimeter of the post in providing lateral support to the appurtenance. 17. A method of constructing a building to shelter an area, the method comprising: (a) excavating a hole to establish a natural base on which to construct the building;(b) establishing layout locations where upright walls of the building are to be erected;(c) establishing a fabricated footer along the laid-out locations of the upright walls;(d) placing pre-fabricated load-bearing fiber-reinforced polymeric building panels on the footer;(e) connecting the pre-fabricated building panels to each other and thereby developing load-bearing walls; and(f) erecting overlying structure on the load-bearing walls, such overlying structure comprising a first innermost surface layer and a second opposing outermost fiber-reinforced polymeric surface layer and a space between the first innermost and second outermost surface layers, and a plurality of studs, spaced from each other along the overlying structure and protruding from one of the innermost and outermost surface layers and away from the space between the innermost and outermost surface layers. 18. A method of fabricating a building, comprising: (a) excavating a hole, as necessary, to establish a natural base on which to construct the building;(b) establishing layout locations where upright walls of the building are to be erected, thereby to generally define an outer perimeter of the building to be constructed;(c) creating a footer, including placing one or more fiber-reinforced polymeric reaction-cured footer pads on the natural base, as footer elements, along the outer perimeter of the building;(d) placing pre-fabricated fiber-reinforced load-bearing polymeric building panels on the fabricated footer;(e) connecting the pre-fabricated building panels to each other to thereby develop load-bearing walls, wherein a given such load-bearing wall has a length and a height, and comprises (i) an outermost fiber reinforced polymeric layer defining an outwardly-facing surface of the load-bearing wall,(ii) an innermost fiber-reinforced polymeric layer defining at least a portion of an inner surface of the load-bearing wall, and(iii) thermally-insulating foam between the outermost layer and the innermost layer; and(f) erecting overlying structure on the load-bearing walls, the overlying structure, in combination with the load-bearing walls, sheltering an area to be sheltered by the building,further comprising a plurality of studs, spaced along the length of the wall, the studs protruding from the innermost layer, including extending away from one of the innermost and outermost layers, the studs being integral parts of the building panels. 19. A method of fabricating a building comprising: (a) excavating a hole, as necessary, to establish a natural base on which to construct the building;(b) establishing layout locations where upright walls of the building are to be erected, thereby to generally define an outer perimeter of the building to be constructed;(c) establishing a footer along the laid-out locations of the upright walls;(d) placing pre-fabricated fiber-reinforced load-bearing polymeric building panels on the footer;(e) connecting the pre-fabricated building panels to each other to thereby develop load-bearing walls, wherein a given such load-bearing wall has a length and a height, and comprises (i) an outermost fiber-reinforced polymeric layer defining an outwardly-facing surface of the load-bearing wall,(ii) an innermost fiber-reinforced polymeric layer defining at least a portion of an inner surface of the load-bearing wall,(iii) thermally-insulating foam between the first and second outermost layers, and(iv) further comprising a plurality of studs, spaced along a length of such wall, the studs protruding from the innermost layer, including extending away from one of the innermost and outermost layerswherein a such polymeric building panel comprises a pultruded structure which defines the innermost layer and the outermost layer, and wherein such building panel further comprises structurally reinforcing members which extend from the innermost layer to the outermost layer, and which are integral with at least one of the innermost layer and the outermost layer; and(f) erecting overlying structure on the load-bearing walls, the overlying structure, in combination with the load-bearing walls, sheltering an area to be sheltered by the building, further comprising a plurality of studs, spaced along a length of the wall, the studs protruding from the innermost layer, including extending away from one of the innermost and outermost layers. 20. A method as in claim 1 wherein the studs extend from the innermost layer and away from the space between the outermost layer and the innermost layer. 21. A method of fabricating a building comprising: (a) excavating a hole, as necessary, to establish a natural base on which to construct the building;(b) establishing layout locations where upright walls of the building are to be erected;(c) establishing a footer along the laid-out locations of the upright walls;(d) placing pre-fabricated fiber-reinforced load-bearing polymeric building panels on the footer;(e) connecting the pre-fabricated building panels to each other to thereby develop load-bearing walls, wherein a given such load-bearing wall has a length and a height, and comprises (i) an outermost fiber-reinforced polymeric layer defining an outwardly-facing surface of the load-bearing wall,(ii) an innermost fiber-reinforced polymeric layer defining at least a portion of an inner surface of the load-bearing wall, and(iii) a plurality of studs, spaced along a length of the wall, the studs protruding from the innermost layer, including extending away from one of the innermost and outermost layers, and wherein the studs are mounted to the innermost layer; and(f) erecting overlying structure on the load-bearing walls, the overlying structure, in combination with the load-bearing walls, sheltering an area to be sheltered by the building. 22. A method as in claim 1 wherein the constructed building applies a downwardly directed load on the footer, further comprising placing a deformable and curable bridging material on the footer, and placing the pre-fabricated building panels on the footer, over the bridging material such that at least a portion of the bridging material is between the footer and the pre-fabricated building panels, the deformable bridging material being deformed by the placement of the building panels on the footer, and subsequently effecting curing of the curable bridging material such that the bridging material, after curing, is a load-bearing material which transfers corresponding portions of the overlying load from the building panel to the footer. 23. A method as in claim 1 wherein one or more elongate fiberglass-reinforced reaction cured polymeric footer pads extend along the length of the foundation, as the footer, for at least a portion of the length of the footer, and support a downwardly directed load, applied by the foundation, of at least 5000 pounds per lineal foot of the footer. 24. A method as in claim 10 wherein at least one of the studs is aligned with a corresponding one of the structurally reinforcing members. 25. A method as in claim 1 wherein the studs are mounted to the innermost layer. 26. A method as in claim 1, further comprising placing a deformable and curable bridging material on the footer such that, as the building panels are placed on the footer, the bridging material is deformed, and is disposed between the footer and the bottoms of the building panels and curing the bridging material after the building panels are placed on the footer. 27. A method of fabricating a building, comprising: (a) excavating a hole, as necessary, to establish a natural base on which to construct the building;(b) establishing layout locations where upright walls of the building are to be erected, thereby to generally define an outer perimeter of the building to be constructed, as well as to generally define locations where any interior walls will extend upwardly from the natural base;(c) establishing a load bearing footer along the laid-out locations of the upright walls;(d) placing pre-fabricated fiberglass-reinforced infusion molded load-bearing polymeric building panels on the footer;(e) connecting the pre-fabricated building panels to each other to thereby develop load-bearing walls, wherein a given such load-bearing wall has a length and a height, and comprises (i) a first outermost fiberglass-reinforced polymeric layer defining an outwardly-facing surface of the load-bearing wall,(ii) an innermost fiberglass-reinforced polymeric layer defining at least a portion of an inner surface of the load-bearing wall,(iii) a space between the first and second outermost layers, and(iv) a plurality of studs, spaced along a length of the wall, the studs extending away from one of the innermost and outermost polymeric layers and extending away from the space between the first and second outermost layers; and(f) erecting overlying structure on the load-bearing walls, the overlying structure, in combination with the load-bearing walls, sheltering an area to be sheltered by the building. 28. A method as in claim 27 wherein a given such building panel comprises a plurality of structurally-reinforcing members spaced along the length of the respective wall and extending along substantially an entirety of the height of such wall, and extending from locations at or proximate the first outermost layer to locations at or proximate the second outermost layer, at least one of the studs comprising first and second legs (128) spaced from each other along the length of the wall and extending from the innermost layer in a direction away from the outermost layer to end panels (130), a given leg (128), of a given stud overlying a respective such structurally-reinforcing member, and extending along the length of such structurally-reinforcing member. 29. A method as in claim 27 wherein the innermost and outermost layers comprise reaction curable resin compositions which have been reaction cured. 30. A method as in claim 27, further comprising selecting, as the pre-fabricated building panels, building panels wherein the respective building panel further comprises thermally insulating foam elements extending from one of the first and second outermost layers to the other of the first and second outermost layers. 31. A method as in claim 27 wherein the foundation wall has a vertical crush resistance capacity of at least 4000 pounds per lineal foot of length of such foundation wall. 32. A method as in claim 27 wherein the foundation wall has a horizontal point load bending moment resistance corresponding to at least about 2000 pounds per square foot. 33. A method as in claim 27 wherein the studs are mounted to the innermost layer. 34. A method as in claim 14 wherein the establishing of the layout locations where upright walls are to be erected includes defining locations where interior walls will extend uprightly from the footer. 35. A method as in claim 14 wherein the footer pads are fiber-reinforced polymeric reaction-cured footer pads. 36. A method as in claim 14, further comprising thermally-insulating foam between the first and second outermost layers. 37. A building, having an outer perimeter, and comprising: (a) a footer, including footer pads on a natural base, as footer elements, along the outer perimeter of said building;(b) pre-fabricated fiber-reinforced load-bearing polymeric building panels on the fabricated footer;(c) the building panels being connected to each other to thereby develop load-bearing walls, wherein a given such load-bearing wall has a length and a height, and comprises (i) an outermost fiber-reinforced polymeric layer defining an outwardly-facing surface of said load-bearing wall,(ii) an innermost fiber-reinforcing polymeric layer defining at least a portion of an inner surface of said load-bearing wall, and(iii) a plurality of studs, spaced along a length of said wall, said studs protruding from the innermost layer, including extending away from one of said innermost and outermost layers; and(d) overlying structure on said load-bearing walls, said overlying structure, in combination with the load-bearing walls, sheltering an area to be sheltered by said building.
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