Static structures (e.g. – buildings) – Processes – Fabrication of member – module – etc.
Reexamination Certificate
2000-06-22
2001-12-25
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
Processes
Fabrication of member, module, etc.
C052S742130, C052S309700, C264S046700
Reexamination Certificate
active
06332304
ABSTRACT:
BACKGROUND—FIELD OF INVENTION
The object of the invention was to improve the fabricating procedure used in manufacturing prefabricated panelize housing panels. The inventor's objective was to produce superior panels, with a greater insulation “R” factor in a small amount of wall thickness space for the exterior wall and ceiling panels. He was also intent on increasing the strength of the exterior wall panels against earthquake and wind, to produce them easier, faster, easier field installation and at a lower cost.
BACKGROUND—DESCRIPTION OF PRIOR ART
The inventor was already producing a similar product with the use of open framed jig fixtures, which assembled the steel framed wall panels. After the framework was complete the drywall and electrical was installed, then the Polyurethane insulation was sprayed into the walls. The exterior siding was generally installed at the site. While his current process produced good quality at a lower cost it still did not satisfy the inventor. The most important part of housing panels is the exterior panels, walls and ceilings. They produce the envelope within which the resident lives. In order to obtain a higher “R” factor, above R-13, builders were forced to make thicker walls. Most builders, both factory and site builders, use Fiberglass insulation. Its “R” factor is much lower than that of Polyurethane foam spray. The high density Polyurethane foam spray used herein, has an “R” factor of 7.69 per inch of thickness, whereas fiberglass bats have an “R” factor of approximately 3.58 per inch of thickness. The inventor's present system has certain drawbacks which lowered the cost effectiveness of the current method.
This prompted the inventor to develop a procedure for producing the panels in a far superior manner. He designed and developed the Clamshell Jig Fixture. The Clamshell Jig Fixture is designed to improve all phases of production of the wall panels except the assembly of the framework.
SUMMARY
The Clamshell Jig Fixture solved all of the inventor's problems, including some he hadn't thought of, as relates to the production of a higher quality exterior housing panel.
OBJECTIVE AND ADVANTAGES
The objective is to produce exterior housing panels with a greater insulation “R” factor in the standard wall size of 3⅝ inches thick, more moisture resistant, fire resistant, termite and bug resistant, and with superior strength. The Clamshell Jig Fixture did just that. After the steel framework is completely assembled in an open squaring jig fixture, per applicable building code, the framework is placed into the Clamshell Jig Fixture. The Fixture is then closed tight. Then the Polyurethane Foam is injected into the Clamshell Jig Fixture from the top and other areas as needed. The Polyurethane foam expands as it is injected into the Clamshell, filling all areas except that which the steel occupies. The panel becomes what is known as an Encapsulated assembly. In addition to filling all the cavities of the wall panels, the framework is positioned with spacers, so that the foam places ½ inch to ⅝ inch of foam on the inside of the exterior walls and ¾ inch to 1″ on the outside of the framework. This eliminates the need for drywall on the inside and sheathing on the outside. After the foam is cured, which take only minutes, the Encapsulated frame assembly is removed from the Clamshell Jig Fixture. The frame assembly is trimmed of excessive foam and readied for the prehung doors and window assemblies, if required. When a wall panel is to receive one or more door or window assemblies, a door or window filler block is installed into the Clamshell Jig Fixture prior to inserting the framework into the Clamshell. This filler block prevents foam from filling the door and/or window cavity while injecting the foam.
The Clamshell Jig Fixtures may be fabricated in any size, thickness or shape, height or length, depending upon the manufactures requirements. Ceiling panels are produced in the same manner similar to the wall panels. It is recommended that the panels be designed as 8 feet high, 8 feet long and using a steel framework of 3⅝ inches thick. This will result in a standard wall. This height and length are easier to handle. As a comparison, a wooden 3⅝ inch thick frame wall 8 feet high and 8 feet long, with ⅝ inch drywall on the inside, R-13 fiberglass insulation, and a ½ inch sheathing on the outside weighs approximately 1,163.53 pounds. A steel wall of the same size manufactured under the inventor's current system weighs approximately 496.62 pounds and the same size panel using the Clamshell Encapsulation process weighs approximately 346.77 pounds. This is approximately 70% less than a wood framed panel, and 30% less than the inventor's current system.
The difference in the amount of the “R” factor is much greater than that of wood. A 3⅝ inch thick steel framework with ⅝ inches of foam on the inside replacing the drywall and 1 inch of foam on the outside, produces an encapsulated 5¼ inch thick wall panel. This results in an “R” factor of 40.37 as compared to an R-13 in a standard wooden wall or an R-19 in a 6 inch thick wall.
The cost difference in comparison is as follows: Comparing identical “R” factor walls. A wooden wall panel of the size specified, 3⅝″×8′×8′, costs approximately $15.22 per linear foot. A steel Encapsulated wall panel of the same size and with the same “R” factor costs $8.44 per linear foot. To achieve the “R” factor of the encapsulated wall assembly the wooden wall would cost approximately $47.33 per linear feet. This computes to a savings of approximately 68%.
The Polyurethane referred to herein is a Class 1 Isofoam Polyisocyanate. It is free from Formaldehyde and CFC's or HCFCS. It repels water and is self extinguishing. It has an “R” factor of 7.69 per square or cubic inch after curing. It has a compressive strength of 40 pounds per square or cubic inch. It readily bonds to drywall and steel and many other building products including wood. Because of the compression strength of the Polyurethane foam, it increased the structural integrity of the ceiling and wall panels. A 3⅝ inch steel frame assembly with a ⅝ inch inside foam sheath and a 1 inch outside foam sheath comprising a total wall thickness of 3⅝ inches, 8 feet tall and 8 feet long will occupy 48,384 cubic inches of foam insulation. The vertical strength of the encapsulated wall panel one inch long across the full thickness, 5¼ inches, of the wall panel 8 feet high, will provide a total compressive strength of 20,160 pounds, 96 inches×5¼ inches=504 cubic inches×40 lbs/sq. inch. The vertical strength of the entire 8 foot long encapsulated wall will produce a total compressive strength of 1,935,360 pounds, 96 inches×20,160. This does not include the vertical compressive strength of the steel stud members, which will vary from as small as 7,500 lbs per inch to 25,000 lbs per sq inch, depending upon the steel thickness. A wooden frame gains no strength from the fiberglass insulation bats, and the wooden studs have a compressive strength of 1,200 lbs per sq. inch. Thus the Polyurethane foam insulation greatly increases to the wall strength.
Advantages
1. The exterior housing panels, ceiling and wall, constructed using the Encapsulated method of fabrication will provide a much greater energy savings as compared to a standard wood frame panel system with fiberglass insulation. The encapsulated panels provide approximately a 311% greater insulating advantage.
2. Additionally, the Encapsulation process also prevents air infiltration through the electrical receptacles and switch boxes.
3. The ½ inch to ⅝ inch of foam insulation replacing the drywall on the inside of the Encapsulated wall panel enhances the insulating factor by as much as 7.69 times and the foam does not shatter as easily as drywall. The foam is also compatible with the use of joint plasterin
Friedman Carl D.
Slack N.
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