Residential construction method and apparatus

Abstract

Home residential construction based on the use of panels made of metal cladding with expanded polystyrene therebebetween. The metal cladding is preferably 26-gauge galvanized steel and the thickness of the panels is approximately six inches. Such a panel is strong enough to serve as a roof panel, a wall panel or a floor panel and will be dimensionally similar to the roofs, walls, and floors of existing homes. A pitched roof is formed of roof panels, supported by a bar joist at the peak. Walls are formed of wall panels joined using trays for their bottom ends and caps for their top ends and sides. A residence constructed using the present materials and methods is stronger than conventional “brick and stick” homes and can be constructed more quickly and cheaply, and is less expensive to heat and cool.

Description

[0001] Generally, the present invention relates to residential construction. In particular, it relates to a material for use as wall material and methods for using that material. [0002] Historically, homes, some apartments and smaller offices are built on the jobsite using bricks and lumber, plus other materials such as shingles and insulation panels. These materials can be used to construct an endless variety of residences, from simple tract homes to elaborate custom-built homes. [0003] Although great strides have been made in pre-assembling some components, such as roof trusses and windows and doors, in factories where they can be made more quickly and cheaply, still most of residential construction is made at the jobsite, laying one brick and nailing one “2 by 4” at a time. As a result, a significant component of residential construction cost is for labor. [0004] Another disadvantage of residential construction that is related to the fact that homes are largely built on site is t...

AI Technical Summary

Benefits of technology

"The present invention is a method and apparatus for constructing residences using panels made of metal cladding with expanded polystyrene between. These panels are strong and can be used as roof panels, walls, or floors without needing further modifications. The panels are supported and joined to form strong, weather-tight, energy-efficient structures. The use of insulated panels made of expanded polystyrene, particularly those made with air, results in much higher energy efficiency ratings than conventional materials. The use of a bar joist eliminates the need for roof trusses, providing more usable space under the roof. The use of trays and caps in combination with the panels provides a rigid structure for a roof, wall, or floor. The use of EPS several inches thick makes the method and materials especially attractive in very cold and very warm climates."

Problems solved by technology

These panels are known in warehouse construction as “freezer panels.” Some types of freezer panels, namely those with urethane between the cladding, are unsuitable for residential construction because of the gases given off by the urethane.

However, those that are made of expanded polystyrene (EPS, known more commonly under the trademark STYROFOAM), preferably those made of EPS foamed with air, are unknown in residential construction.

Roof trusses work well in traditional homes but make attic space largely unusable other than for storage of boxes because the existence of the trusses require those walking around in an attic to keep their heads low to avoid injury.

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