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

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. Thefoam76 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 alonglines3A-3A ofFIG.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 fromdash lines4 ofFIG.1;
• FIG.5 is a cross sectional broken away view taken along lines5-5 ofFIG.4;
• FIG.6 is an extracted cross sectional broken away perspective view of the roof taken fromdash lines6 ofFIG.1;
• FIG.7 is an extracted cross sectional broken away perspective view of the above ground wall taken fromdash lines7 ofFIG.1;
• FIG.8 is an extracted cross sectional broken away perspective view of the of the above ground wall take fromdash lines8 ofFIG.1;
• FIG.9 is an extracted cross sectional broken away perspective view of the of the above ground wall take fromdash lines9 ofFIG.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 toFIGS.4-9.
DETAILED SPECIFICATION
• Referring toFIG.1, an illustrated 1200square foot house20 with abasement30, with drainage rock and back fill removed may be seen. Firstly in building thehouse20, thebasement space5 is excavated. The house is then built on a below ground pouredcement foundation9.
• As shown inFIGS.1-5, thewall core36 is comprised of spaced apartparallel boards40,42 andmechanical fasteners44 therebetween, as commonly known as theTSTUD®36. TheTSTUD®36 forms the assembly core illustratively used in thefoundation walls30, aboveground wall70 and theroof110.
• The foundation orbasement walls30 sit onfooter plates32 and are anchored thereto byanchors34 imbedded into the pouredcement foundation9. Footer L-brackets (not shown) may also be used to secure thebasement walls30 to thecement foundation9. The wall core T-shaped studs orTSTUD®36 includes an opposingwide board40 and a parallel spacednarrow board42. Mechanical fasteners or wood dowels44 pass through theboards40,42 and are glued in place.
• In the prefabrication of themodular walls30,70 androof assemblies110 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, theexterior skin46 is pre-made or may be commercially available materials in sheets that are placed horizontally in the mold or jig. Theskin46 may be made of a variety materials including fiberglass, cementious sheets, metal, masonite board or composite sheets. As illustrated below, when made, the outside ofskin46 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, theexternal skin46 may have a weather water resistance coating such as a gel coat.
• Theskin46 is placed exterior side down within the jig or mold to build themodular walls30,70 androof assemblies110 in very similar, if not the same, manner. Next, an array ofTSTUDS®36 suitably 24″ on center are suspended above the skin. The distance above theskin46 is dependent on how thick the finish panels to-be-walls30,70 and20 are meant to be. For a standard wall, 1½″ to 2″ away from theskin46 is good for a 6″ finished wall. Next, the expandingfoam54 is poured into the mold or jig to expand and cover the inside of theskin46, thewide board40, and themechanical fasteners44 and general half way up and covering a portion of thenarrow board42. After thefoam54 becomes rigid and forming a panel, the skin andTSTUDS®36 with therigid foam54 are removed from the mold or jig. Nexthorizontal holes56 may be drilled in the exposedTSTUDS®36 or theholes56 may be pre-drilled in the narrow exposednarrow board42 of theTSTUDS®36 before they are placed in the mold. This arrangement allows for assembly of wiring, conduits, fixtures and the like withinfoundation walls30. These bare wood portions of thenarrow boards42 are also used to join adjacentbasement wall panels30 with framing screws approximately spaced vertically 12″ apart vertically with 3⅛″ #8 framing screws. This methodology for joining panels also works forabove ground walls70 orroof panel assemblies110.
• FIG.3A shows a cross sectional view through thehouse20 ofFIG.1 taken alonglines3A-3A.Basement walls30 are assembled onfooter plates32 and anchored thereto and intocement9 withanchors34. As described above,wall core36 comprisesTSTUDS®36 which also may be secured tofooter plates32 andcement foundation9 with L-brackets (not shown). TheTSTUDS®36 includewide board40 and opposingnarrow board42 both connected together withmechanical fasteners44. Theexterior skin46 maybe of a fiber glass, high performance thixotropic or isophalic resin which may have a gel coat outer finish thereby water and weather proofing theskin46.
• FIG.3B illustrates asecond embodiment roof111 of the present invention comprised of a stacked double TSTUDS®37 with a central narrow board43 with upper and lowermechanical fasteners45 joining spaced apartwide boards47,49.Exterior cover skin51 may be in pre-formed sheets resembling shingles or shakes or be of fiber glass or metal. Poured infoam53 is poured into the upside down double stacked TSTUDS®37 as to fill the space from theexterior skin51, around the upperwide boards47, themechanical fasteners45 and partially over the central narrow board43.Open space55 thus providesopen space55 for wiring and fixtures.Dry wall57 is then attached to the lowerwide boards49.
• FIGS.4 and5 show that theTSTUDS®36wide boards40 have L-shaped fiber glass brackets orfasteners52 secured to theTSTUDS®36 with screws and glued to theskin46 with fiber glass adhesive. This will prevent delamination of theskin46. Once in the mold or jig, the expandingfoam54 is poured into the mold or jig to expand and cover the inside of theskin46, thewide board40, and themechanical fasteners44 and general half way up and covering a portion of thenarrow board42. After thefoam54 finishes expanding, becomes rigid, and forming a panel, theskin46 andTSTUDS®36 with therigid foam54 are removed from the mold or jig. Next,horizontal holes56 may be drilled in the exposedTSTUDS®36 or theholes56 may be pre-drilled in the narrow exposednarrow board42 of theTSTUDS®36 before they are placed in the mold. Again, these bare wood portions of thenarrow boards42 are also used to joinadjacent basement panels30 with framing screws approximately spaced vertically 12″ apart vertically with 3⅛″ #8 framing screws. Lastly, sheet rock ordry wall60 is nailed or screwed to the exposed ends of the narrow boards.42.Header plates62 may then be added to thebasement wall30. As shown inFIG.4, 2×4′ or 2×6′dimensional lumber64 orother TSTUDS®36 variations or sizes may be used in place of theTSTUDS®36. Next, flooring66 is built on top of thebasement walls30.Flooring structures66 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 and6 illustrate abovegrade walls70 androof assembly110. Again, the core assembly is theTSTUDS®36 which can be secured to thefloor66 with L-brackets (not shown) and includesexterior skin46, opposingwide boards40,narrow boards42 andmechanical fasteners44.Exterior skin46 may be of cementious or OSB board, molded cedar shake-like74 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 orpanel80 with simulated battens to cover up theseams84 between 4×8′ sheets with fasteners86. The inside wall of thesheets80 has a layer ofwire mesh90 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 anotherexterior skin96 treatment resembling 4×8′ sheets of simulated vertical wood panels withbattens97 andfasteners98.
• FIG.9 shows the stretched steel-like mesh100 fastened to the outside of theTSTUDS®36wide board40 suitably with U-shaped wire tacks. Also, simulatedhorizontal lap boards102 are shown.
• FIG.10 illustrates ajamb construction116 for windows anddoors118 that fit intoopening119, which are part of the present invention. Adjacent to window/door opening119 are two touching TSTUDS®120 (king and striker) for supporting theJamb116. Anexternal jamb section122 with a U-channel123 to receive and support siding can be sealed withmastic124 and fastened on the outside of thebuilding20 adjacent to theTSTUDS®120 withscrew126.Jamb extension128 is positioned between theexternal jamb section122 and the L-bracket or J-channel132 thereby capturing the dry wall and secured thereat withscrews130,136. Window casing ordoor trim138 is then fastened in place withscrew4.
• FIG.11 illustrates acommercial wall150 made in accordance with the present invention.Metal stud152 is spaced from the sound and/orfire board154 and secured thereat with metal fastener orscrew156. After which, theboard154 screwed to themetal stud156 withscrew156 is placed into the jig or mold. Then the foam is poured into the space between thestud152 and the sound/fire board154 as well as substantially around themetal stud156.
• The above embodiments are for illustrative purposes and the scope of this invention is described in the appended claims below.

Claims (2)

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

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