Insulating Device for Building Foundation Slab
20180127944 ยท 2018-05-10
Assignee
Inventors
Cpc classification
E02D27/02
FIXED CONSTRUCTIONS
Y02A30/00
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02B30/90
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
E04B2001/7679
FIXED CONSTRUCTIONS
E04C3/34
FIXED CONSTRUCTIONS
E04C5/01
FIXED CONSTRUCTIONS
E02D31/00
FIXED CONSTRUCTIONS
E04C5/03
FIXED CONSTRUCTIONS
International classification
E02D31/00
FIXED CONSTRUCTIONS
E04C3/34
FIXED CONSTRUCTIONS
E04B1/16
FIXED CONSTRUCTIONS
E04B1/74
FIXED CONSTRUCTIONS
E04B1/30
FIXED CONSTRUCTIONS
E04C5/01
FIXED CONSTRUCTIONS
Abstract
A device for insulating the slab foundation of a building, said device comprising: a generally horizontal insulating section disposed between the slab foundation and a footer of a building, said horizontally disposed insulating section comprising a generally elongated cuboid shape having at least one cutout through which a concrete column is disposed; said prefabricated device further comprising a generally vertical insulating section disposed adjacent to said horizontal insulating section and attached to said building.
Claims
1. A device for insulating the slab foundation of a building, said device comprising: a generally horizontal insulating section disposed between the slab foundation and a footer of a building, said horizontally disposed insulating section comprising a generally elongated cuboid shape having at least one cutout through which a concrete column is disposed; said prefabricated device further comprising a generally vertical insulating section disposed adjacent to said horizontal insulating section and attached to said building.
2. The device of claim 1, wherein the device is prefabricated and comprises a material selected from the group consisting of extruded foam, polyisocyanurate foam, expanded foam, insulated foil bubble wrap, and blown insulation.
3. The device of claim 1, wherein the material comprises an additive selected from the group consisting of an insecticide, an herbicide, a fungicide, and a water repellant.
4. The device of claim 1, wherein the vertical insulating section further comprises a semi rigid external sheath.
5. The device of claim 1, further comprising a vertical metal bar disposed through at least one column, where the bar comprises a material selected from the group consisting of steel, iron, and metal alloy.
6. The device of claim 1, further comprising a horizontal metal bar disposed across the device through and perpendicular to the at least one column, where the bar comprises a material selected from the group consisting of steel, iron, and metal alloy.
7. The device of claim 1, wherein each concrete column is capable of bearing a vertical load of at least about 20,000 pounds.
8. The device of claim 1, wherein the device has an R-value of at least about 5 per inch of material thickness.
9. A device for insulating the slab foundation of a building, said device horizontally disposed between the slab foundation and footer of a building, said device comprising a generally elongated cuboid shape having at least one cutout through which a concrete column is disposed.
10. The device of claim 9, wherein the device is prefabricated and comprises a material selected from the group consisting of extruded foam, polyisocyanurate foam, expanded foam, insulated foil bubble wrap, and blown insulation.
11. The device of claim 9, wherein the material comprises an additive selected from the group consisting of an insecticide, an herbicide, a fungicide, and water repellant.
12. The device of claim 9, further comprising a vertical metal bar disposed through at least one column, where the bar comprises a material selected from the group consisting of steel, iron, and metal alloy.
13. The device of claim 9, further comprising a horizontal metal bar disposed across the device through and perpendicular to the at least one column, where the bar comprises a material selected from the group consisting of steel, iron, and metal alloy.
14. The device of claim 9, wherein each concrete column is capable of bearing a vertical load of at least about 20,000 pounds.
15. The device of claim 9, wherein the device has an R-value of at least about 5 per inch of material thickness.
16. A method of insulating the slab foundation of a building, said method comprising the steps of: providing a footer for a building; providing a horizontally disposed insulating device, said device comprising a generally elongated cuboid shape having at least one vertically disposed cutout therethrough; pouring a concrete slab foundation for the building such that structurally supportive columns for the slab are created through the cutouts.
17. The device of claim 16, wherein the device is prefabricated and comprises a material having an R-value of at least about 5 per inch of thickness and wherein the material is selected from the group consisting of extruded foam, polyisocyanurate foam, expanded foam, insulated foil bubble wrap, and blown insulation.
18. The device of claim 16, wherein the material comprises an additive selected from the group consisting of an insecticide, an herbicide, a fungicide, and water repellant.
19. The device of claim 16, further comprising: a vertical metal bar disposed through at least one column; and a horizontal metal bar disposed across the device through and perpendicular to the at least one column, where the bars comprise a material selected from the group consisting of steel, iron, and metal alloy.
20. The device of claim 16, wherein each concrete column is capable of bearing a vertical load of at least about 20,000 pounds.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] The present invention will be understood more fully from the detailed description given hereinafter and from the accompanying drawings of exemplary embodiments of the present invention. However, the drawings and descriptions herein should not be taken to limit the invention; they are for explanation and understanding only.
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[0063] Like reference numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0064] The present invention will be discussed hereinafter in detail in terms of the preferred embodiment according to the present invention with reference to the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be obvious, however, to those skilled in the art that the present invention may be practiced without these specific details. In other instance, well-known structures are not shown in detail in order to avoid unnecessary obscuring of the present invention.
[0065] The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word exemplary or illustrative means serving as an example, instance, or illustration. Any implementation described herein as exemplary or illustrative is not necessarily to be construed as preferred or advantageous over other implementations.
[0066] All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. In the present description, the terms upper, lower, left, rear, right, front, vertical, horizontal, and derivatives thereof shall relate to the invention as oriented in
[0067] Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
[0068] Referring to
[0069] As shown in
[0070] Referring still to
[0071] One problem with the prior art system shown in
[0072] Referring now to
[0073] Referring again to
[0074] Referring again to
[0075] Much like the prior art slab insulation system of
[0076] A second problem with the prior art system shown in
[0077] Referring now to
[0078] Referring again to
[0079] As further illustrated in
[0080] Those of skill in the art will appreciate that a number of materials may be used for sheathing layer 300, including extruded foam, polyisocyanurate foam, expanded foam, and insulating foil bubble wrap material or similar material.
[0081] Referring again to
[0082] Referring still to
[0083] As shown in
[0084] As further illustrated in
[0085] Referring now to
[0086] Referring now to
[0087] Referring still to
[0088] Referring again to
Dr. Energy Saver Home Services, Rigid Insulation Board: R-value Packed into a Rigid Foam Panel, available at http://www.drenergysaver.com/insulation-materials/rigid-insulation-board.html (last visited Dec. 27, 2012).
[0090] However, persons of ordinary skill in the arts of building construction or thermal insulation will appreciate that any convenient insulation material will suffice as long as it meets or can be adapted to meet the configuration of the present invention and any applicable construction regulations. Preferably, exterior insulating member 5100 is of semi-rigid construction.
[0091] As shown in
[0092] Referring still to
[0093] Turning to
[0094] As shown in
[0095] Any desired number, shape, and size of void 5300 may be used in the present invention. The determination of those parameters is based on the material properties of the slab and footer and the desired weight that the slab is intended to hold. For example, medium grade concrete holds about 4,000 pounds per square inch. As illustrated in
[0096] A prototype of the above described embodiment of the president invention was produced for testing by Home Innovation Research Labs (HIRL), an independent laboratory located at 400 Prince George's Blvd. Upper Marlboro, Md. 20774, to determine the structural safety of using the present invention as described herein. In general, the prototypes tested by HIRL were as described herein and shown in
[0097] The voids or cutouts in the footer insulation member of the slab insulation device provide a path for 3-inch diameter cylindrical support piers between the turndown slab and the footer when the concrete slab is poured. The support piers are nominally spaced at 2 feet on center.
[0098] For all test specimens the follow process was used to cast the specimens. The footer section was cast on May 30, 2013 and the slab section was cast the following day to simulate typical production scheduling. No adhesion enhancement was done when casting the cold joint between the footer and the slab portion of the test specimen. Commercial ready-mix concrete specified at 3500 psi (slump<5) was used for both the footer and slab portions. A pencil vibrator was used to assist in filing out the forms. Concrete cylinders were cast and tested by a third-party testing firm. All the test specimens were allowed to cure for 28 days before testing began.
[0099] The support piers need to support not only the dead load and live load of the building, they also need to resist compression load that may result from shear loading on the walls. The worst-case combination of loads is likely to be in a corner. The testing was designed to simulate a worst-case corner construction.
[0100] Three specimens were constructed. Each specimen had a 3 diameter circular support pier supporting a 66 section of a slab turndown. The turndown was 11.25 thick. A #3 rebar was placed vertically in the center of the support pier and contained a 90-degree bend as if it were entering the slab. See, for example,
[0101] Each test specimen was loaded into Home Innovation Labs's large universal testing machine (UTM). The specimen was loaded through a 3.53.5 square steel plate located where the bottom plate in typical construction would be located. This location placed the load slightly eccentric to the support pier. The compression load was applied at a rate of 0.0525 inches/minute. This rate was determined by testing concrete cylinders per ASTM C39 and using the same rate as appropriate for that test method. The specimen was loaded until failure. In the test, the failure of all three specimens was due to failure of the slab portion of the specimen due to the slightly eccentric loading. The table below shows the results of the compression testing:
TABLE-US-00004 Specimen # Ultimate Load (pounds) 1 53565 2 56312 3 51571 Mean 53816 Standard Deviation 2380
[0102] For the three shear test specimens that were prepared, a 4-foot-long footer section 10 wide by 16 deep was formed and cast with one #3 rebar protruding upward where the center of each support pier would be cast as part of the slab. See, for example,
[0103] After curing for one day, the thermal barricade foam insulation was placed on top of the footer section 2.5 from the end of the footer. The test specimen contained two support piers spaced 2 feet apart with the first pier centered 6 from the end of the footer. A turned down slab section that began 4 from the end of the footer measuring 6 wide by 44 long by 11.25 deep was cast on top of the thermal barricade. Two #4 rebars were placed horizontally through the turned down section and zip tied to the vertical #3 rebars protruding from the footer.
[0104] A piece of 26 nominal lumber was glued to each side of the footer and were used as lifting points to transfer the specimen in and out of the test setup. The lumber was not intended to be part of the test nor was it part of the thermal barricade system. Each test specimen was mounted in Home Innovation's shear wall test apparatus. A typical ASTM E72 test set up was used. Per ASTM E72 a hold down structure was used to limit uplift as the shear load was applied.
[0105] The shear load was applied via a 56 steel plate placed on the end of the slab section. This set up was designed to cause failure at the support piers. The load was applied at a rate of 0.1 inches/minute. Each specimen was instrumented to record slip and uplift. In order to better observe the failure mode as it occurred, the foam thermal barricade was removed from the third specimen prior to testing.
[0106] The shear testing resulted in an initial failure of the support pier followed by bending and yielding of the rebar as the displacement continued. The table below summarizes the results of the shear testing at the initial failure of the support pier.
TABLE-US-00005 Displacement at Load at initial failure initial failure Specimen # (pounds) (inches) 1 4100 0 (see discussion) 2 8832 0 3 10467 0 Mean 7800 0 Standard Deviation 3307 0
[0107] Referring again to
[0108] As shown in
[0109] Again, as shown in
[0110] Of course, those of skill in the art will appreciate that each of the components of slab insulating device 5000 may be used independently if desired.
[0111] Referring now to
[0112] Referring now to
[0113] Referring now to
[0114] The above-described embodiments are merely exemplary illustrations set forth for a clear understanding of the principles of the invention. Many variations, combinations, modifications, or equivalents may be substituted for elements thereof without departing from the scope of the invention. It should be understood, therefore, that the above description is of an exemplary embodiment of the invention and included for illustrative purposes only. The description of the exemplary embodiment is not meant to be limiting of the invention. A person of ordinary skill in the field of the invention or the relevant technical art will understand that variations of the invention are included within the scope of the claims.