Modular structure for building panels and methods of making and using same

Abstract

The present invention is a polymeric panel system and method for production and use thereof, enabling the rapid construction of a building foundation wall or other structure and in particular a below-grade foundation. The polymeric foundation system includes polymeric wall panels and other components suitable for withstanding lateral and end compression loads. The walls include two parallel faces separated by a series of webs or ribs, where the webs and faces of the wall panels may be formed of a similar polymer material such as polyvinylchloride (PVC). The wall panels and / or other components may be extruded so as to enable the rapid production of sections of wall panels, where the panels may be cut to length and then affixed to adjacent panels to form a foundation wall. The method of affixing adjacent panels may include welding, gluing or other techniques and may be performed on the job site or in a pre-fabrication facility. Furthermore, the wall panels may be co-extruded with an insulating material inserted in the voids between the parallel faces so as to provide improved thermal performance of the foundation as well.

Description

[0001] This is a Divisional Application of, and priority is claimed from, co-pending U.S. patent application Ser. No. 10 / 683,229, for a “MODULAR STRUCTURE FOR BUILDING PANELS AND METHODS OF MAKING AND USING SAME,” filed Oct. 10, 2003 by R. Douglas, which claims the benefit of U.S. Provisional Application No. 60 / 417,904 for a “MODULAR STRUCTURE AND MANUFACTURING METHOD FOR BUILDING PANELS,” by Robert B. Douglas, filed Oct. 11, 2002, both of which are hereby incorporated by reference in their entirety.[0002] This invention relates generally to the structure and manufacture of building panels and components, as well as methods of using such panels and components, and more particularly to building panels produced primarily of a polymeric material and being suitable for use in the construction of buildings and structures such as below-grade and load-bearing construction and building foundations. BACKGROUND AND SUMMARY OF THE INVENTION [0003] The present invention is directed to an improv...

AI Technical Summary

Problems solved by technology

However, use as structural components that are suitable for withstanding or bearing lateral loads as below-grade foundations, as well as concurrent, compressive end loads (i.e., applied along the longitudinal length of the structure) does not appear to be taught in the prior art.

While known components fulfill their particular objectives and requirements, the prior art components do not appear to provide an integrated system capable of withstanding the required loads for an extended period of time without failure or unacceptable deflection, or a method of manufacture and use of such a system, or the associated components, particularly as load-supporting foundation elements.

Prior art foundation systems generally preclude easy shipping and assembly of foundations, or are labor intensive.

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