DENSE EXTERIOR INSULATION SYSTEM BUILDING

Abstract

A building having an insulation system is provided. The building can have an inner structure forming an interior space of the building, a plurality of standoff brackets extending parallel to an outer surface of the inner structure and spaced a spacing distance outward from the inner structure, exterior cladding attached to the standoff brackets, an insulation cavity formed between the inner structure and the exterior cladding, and insulation provided in the insulation cavity. The building can have a plurality of top standoff brackets and a plurality of side standoff brackets. The building can have a corner standoff bracket provided spaced outwards from a corner of the inner structure, extending the insulation cavity from one side of the inner structure, around the corner, and to an adjacent side of the inner structure. In a further aspect, a frame can support the inner structure.

Claims

1. A building comprising: an inner structure forming an interior space of the building; a plurality of standoff brackets extending parallel to an outer surface of the inner structure and spaced a spacing distance outward from the inner structure; exterior cladding attached to the standoff brackets; an insulation cavity formed between the inner structure and the exterior cladding; and insulation provided in the insulation cavity.

2. The building of claim 1, wherein the plurality of standoff brackets are dimensional lumber.

3. The building of claim 1, further comprising a plurality of top standoff brackets extending parallel to a top of the inner structure and a plurality of side standoff brackets extending parallel to a side of the inner structure.

4. The building of claim 1, further comprising legs connected between the standoff brackets and the inner structure, the legs spacing the plurality of standoff brackets the spacing distance from the inner structure.

5. The building of claim 1, wherein the spacing distance is one of: 12 inches; and, 24 inches.

6. The building of claim 1, further comprising bottom standoff brackets extending parallel to a bottom of the inner structure and spaced downwards from the bottom of the inner structure to form an insulation cavity below the inner structure.

7. The building of claim 1, further comprising a corner standoff bracket provided spaced outwards from a corner of the inner structure, the corner standoff bracket extending the insulation cavity from one side of the inner structure, around the corner, and to an adjacent side of the inner structure.

8. The building of claim 3, further comprising an edge standoff bracket spaced outwards from an edge between one of the sides of the inner structure and the top of the inner structure, the edge standoff bracket extending the insulation cavity from the one of the sides of the inner structure to the top of the inner structure.

9. The building of claim 1, further comprising at least one of: a window; and, a door passing through the exterior cladding and the inner structure.

10. The building of claim 9, wherein the window comprises: an inner window positioned proximate the inner structure; and, an outer window positioned proximate an outer surface formed by the exterior cladding.

11. The building of claim 1, wherein the inner structure, the insulation, and the exterior cladding are all supported by a frame.

12. The building of claim 11, wherein the frame is made of steel.

13. The building of claim 11, wherein the frame comprises a plurality of vertically extending support columns.

14. The building of claim 13, wherein the frame comprises four support columns provided on a square.

15. The building of claim 13, wherein each support column includes a column upper plate at a top of the column and a column lower plate at a bottom of the column.

16. The building of claim 15, further comprising thermal isolators provided on top of the column upper plates and on the bottom of the column lower plates.

17. The building of claim 14, further comprising a column connection strut running between a pair of width-spaced support columns and a long wall upper column strut braces running between a pair of length-spaced support columns.

18. The building of claim 13, further comprising a wall trough running horizontally and connected to an inside surfaces of a pair of adjacent support columns to support a side walls of the inner structure.

19. The building of claim 18, wherein the wall trough is welded to the inner surfaces of the pair of adjacent support columns.

20. The building of claim 18, further comprising side braces running diagonally from the pair of adjacent support columns to the wall trough.

21. The building of claim 20, comprising long side braces and short side braces, the long side braces attached to the support columns higher than the short side braces.

22. The building of claim 13, further comprising screw piles, the screw piles connected to bottom ends of the columns.

23. The building of claim 13, wherein bottom ends of the support columns extend below bottom standoff brackets extending parallel to a bottom of the inner structure and spaced downwards from the bottom of the inner structure.

24. The building of claim 13, further comprising a lift frame connectable to tops of the support columns, the lift frame having lift lugs and operative to lift the building.

25. The building of claim 24, wherein top ends of the support columns extend above top standoff brackets extending parallel to a top of the inner structure and spaced upwards from the top of the inner structure.

Description

DESCRIPTION OF THE DRAWINGS

[0009] A preferred embodiment of the present invention is described below with reference to the accompanying drawings, in which:

[0010] FIG. 1 is a schematic view of a building without exterior cladding;

[0011] FIG. 2 is top view of a frame for a building;

[0012] FIG. 3 is a side view of the building of FIG. 1;

[0013] FIG. 4 is a perspective view of the frame shown in FIG. 2;

[0014] FIG. 5 is a schematic view of the building shown in FIG. 1 and screw piles to support the building;

[0015] FIG. 6 is a schematic illustration of the building shown in FIG. 1 being placed on lower column isolator stub brackets;

[0016] FIG. 7 is a close up view of a connection between a top of a screw pile and a lower column isolator stub bracket;

[0017] FIG. 8 is schematic illustration of a lift frame;

[0018] FIG. 9 is a schematic illustration of a close up view of a utilities trench leg that allows utilities to be run into and out of the building; and

[0019] FIG. 10 is a schematic illustration of a building with adjacent structures.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

[0020] FIG. 1 shows a building 1 without exterior cladding. The building 1 can be a semi-permanent building, such as a home, but it can also be offices or other types of buildings.

[0021] Referring to FIGS. 1-6, the building 1 can have an inner structure 50 that forms the interior space of the building 1. This inner structure 50 can be supported by a frame 60. Standoff brackets 2, 44, 11, 12 can be provided, spaced outward from the inner structure 50 to form an insulation cavity 4, where insulation can be installed, before exterior cladding 22 is attached to the standoff brackets 2, 44, 11, 12. This results in the building 1 having exterior cladding 22, with insulation behind in the insulation cavity 4, insulating the inner structure 40; all of which is supported by the frame 60. The building 1 can be fully insulated on all sides using standoff brackets 2, 44, 11, and 12 to create an insulation cavity 4 enclosing the inner structure 50 on all sides and sufficiently sized to accept the amount of insulation required to reach a desired R value.

[0022] The building 1 can have a length (with the long sides) and a width (with the short sides).

[0023] Windows 5 and entry doors 6 can be provided in the building 1, passing through the exterior cladding 22 and the inner structure 50. In one aspect, each window 5 can have an inner window positioned proximate the inner structure 50 and an outer window positioned proximate the outers surface formed by the exterior cladding 22 to reduce or eliminate ambient air effects on the inner window.

[0024] Referring to FIGS. 2-4, the building 1 can be supported by the frame 60, with the inner structure 50, the insulation and the exterior cladding 22 all supported by this frame 60. While the inner structure 50 and the exterior cladding 22 may be wood, the frame 60 can be made of steel and have a plurality of vertically extending support columns 7. In one aspect, four (4) support columns 7 can be used with these four support columns 7 provided on a square, as shown best in FIG. 2.

[0025] Referring to FIG. 4, Each column 7 can have a column upper plate 9 at the top of the column 9 and a column lower plate 52 provided at the bottom of the column 7. Thermal isolators 53 can be provided on top of the column upper plate 9 to act as a thermal break, lessening heat transfer into and out of the column 7 through the column upper plate 9. This is especially beneficial if the column 7 is made up of a material with better thermal conductivity than the material making up of the inner structure 50.

[0026] Column connection struts 8 can be provided with each column connection strut 8 running between a pair of width-spaced support columns 7 to support the pair of support columns 7 in place. Long wall upper column strut braces 14 can be provided with each long wall upper column strut brace 14 running between a pair of length-spaced support columns 7. In this manner, the column connection struts 8 and the long wall upper column strut braces 14 can secure the positioning of the support columns 7.

[0027] Wall troughs 10 can be provided running horizontally, with each wall trough 10 connected to inside surfaces of a pair of support columns 7 on one side of the building 1. The wall troughs 10 can be provided near a bottom end of the support columns 7 to support side walls of the inner structure 50. In one aspect, the wall troughs 10 can be welded to the inner surfaces of the support columns 7.

[0028] The column connection struts 8, the long wall upper column strut braces 14 and the wall troughs 10 can all work together to keep the support columns 7 in their squared position.

[0029] Optionally, side braces 15 can be provided running diagonally from the support columns 7 to the wall troughs 10 to further support the wall troughs 10. In one aspect, both long side braces 15 and short side braces 15 could be used with the long side braces 15 being attached to the support columns 7 at a higher point than the short side braces 15.

[0030] Referring again to FIGS. 1-4, the wall troughs 10 can support the inner structure 50. In one aspect, floor beams (not shown) can be provided running between the wall troughs 10 and the side walls of the inner structure 50 can be provided extending upwards from the wall troughs 10.

[0031] The inner structure 50 can be made of flooring, drywall and other standard interior finishing materials, however, in one aspect, the inner structure 50 can be made up of wood. For example, the inner structure 50 could be formed of mass timber panels or conventional framing. If the inner structure 50 is conventional framing, sheeting such as a plywood, etc. can be provided in the inners side and outer side of this framing.

[0032] On the outside of the inner structure 50, vapor barrier 13 can be provided. In one aspect, the vapor barrier 13 can be 12 mil polyethylene that is glue sealed on all sides, roof and underside of the inner structure 50.

[0033] Referring again to FIG. 1, a plurality of standoff bracket 2, 44 can be provided spaced a spacing distance outwards from an outer surface of the inner structure 50 along the top and sides of the inner structure 50. These standoff brackets 2, 44 can be dimensional lumber, such as 24s, and extend along its length, parallel to the outer surface of inner structure 50. The size of the insulation cavity 4 between the inner structure 50 and the exterior cladding 22 is determined by the spacing distance.

[0034] Top standoff brackets 2 can be provided extending parallel to a top of the inner structure 50 and side standoff brackets 44 can be provided extending parallel to sides of the inner structure 50.

[0035] In one aspect, top standoff brackets 2 can extend from a front of the building 1 to a back of the building 1 (the width of the building), perpendicular to the length of the building 1. In one aspect, the side standoff brackets 44 can extend a height of the building 1.

[0036] Legs 3 can be connected between the standoff brackets 2, 44 and the inner structure 50 used to space the standoff brackets 2, 44. The length of the legs 3 will determine the spacing distance outwards from the outer surface of the inner structure 50, In aspects, the distance the standoff brackets 2, 44 are spaced from the inner structure 50 could be 12or 24.

[0037] Bottom standoff brackets 11 can be provided running below the inner structure 50 to form an insulation cavity 4 below a bottom or floor of the inner structure 50. These bottom standoff brackets 11 can be dimensional lumber, such as 24s.

[0038] Corner standoff brackets 12 can be provided spaced out from the corners of the inner structure 50 so that the insulation cavity 4 extends around the corners of the inner structure 50. These corner standoff brackets 12 can be dimensional lumber, such as 24s. The corner standoff brackets 12 can be installed between the standoff brackets 44 on one side of the building 1 and the standoff brackets 44 of an adjacent side of the building 1. Exterior cladding 22 can be installed along the standoff brackets 44 on the one side of the building 1 to the corner standoff bracket 12 and exterior cladding 22 can be installed along the standoff brackets 44 on the adjacent side of the building 1 to the same corner standoff bracket 12. In this manner, the insulation cavity 4 can extend from one side of the inner structure 50, around the corner of the inner structure 50, under the corner standoff bracket 12, to the adjacent side of the inner structure 50.

[0039] Edge standoff brackets 17 can be provided spaced out from an edge between one of the sides of the inner structure 50 and the top of the inner structure 50 so that the insulation cavity 4 extends around the edge the inner structure 50, causing the interior cavity 4 to extend from the one of the sides of the inner structure 50 to the top of the inner structure 50. Exterior cladding 22 can be installed along the side standoff brackets 44 along the one of the sides of the inner structure 50 to the edge standoff bracket 17 and exterior cladding 22 can be installed along the top standoff brackets 2 on the top of the inner structure 50 to the same edge standoff bracket 17. In this manner, the insulation cavity 4 can extend from the one side of the inner structure 50, around the edge, under the edge standoff bracket 17, to the top of the inner structure 50.

[0040] These edge standoff brackets 17 can be dimensional lumber, such as 24s.

[0041] Bottom edge standoff brackets 21 can be provided spaced out from an edge between one of the sides of the inner structure 50 and the bottom of the inner structure 50 so that the insulation cavity 4 extends around the edge the inner structure 50, causing the interior cavity 4 to extend from the one of the sides of the inner structure 50 to the bottom of the inner structure 50. Exterior cladding 22 can be installed along the side standoff brackets 44 along the one of the sides of the inner structure 50 to the bottom standoff bracket 21 and exterior cladding 22 can be installed along the bottom standoff brackets 11 on the bottom of the inner structure 50 to the same bottom edge standoff bracket 21. In this manner, the insulation cavity 4 can extend from the one side of the inner structure 50, around the edge (under the bottom edge standoff bracket 21), to the bottom of the inner structure 50.

[0042] These edge standoff brackets 21 can be dimensional lumber, such as 24s.

[0043] In this manner, the inner structure 50 can be enclosed on all sides by insulation.

[0044] Referring to FIG. 5, in one aspect, the building 1 can be installed onto screw piles 17, avoiding the need for concrete piling or a concrete foundation. The screw piles 17 can be installed in the ground at a location where it desired to have the building 1. The screw piles 17 can be installed in the ground so that the tops of the screw piles 17, extending above the ground surface, correspond to the column lower plate 52 of the support columns 7 of the building 1.

[0045] Rather than connecting the bottoms of the support columns 7 directly to the tops of the screw piles 17, lower column isolator stub brackets 25 can be provided between the tops of the screw piles 17 and the column lower plate 52 of the corresponding column 7. The support columns 7 can extend so that the column lower plate 52 of each column 7 extends below the bottom standoff brackets 11 and these the column lower plate 52 can be connected to the tops of the screw piles 17. Thermal isolators (not shown) can be provided between the lower column isolator stub brackets 25 and the bottoms of the support columns 7 to create a thermal break between the column 7 and the lower column isolator stub bracket 25 to prevent heat transfer between the column 7 and the lower column isolator stub bracket 25.

[0046] In one aspect, the top plates 19 of the screw piles 17 can have no bolt holes. Instead, a connector can be used to attach the bottoms of the lower column isolator stub bracket 25 to the tops of the top plates 19 of the screw piles 17. FIG. 7 illustrates a connector 57 to connect a lower column isolator stub bracket 25 to a top plate 19 of screw pile 17 that does not have bolt holes.

[0047] The connector 57 can have a pair of screw pile clamps 20 that can be bolted under sides of the screw pile top plate and bolted to the lower column isolator stub bracket 25 bottom plate 18 to secure the lower column isolator stub bracket 25 to the top plate 19 of the screw pile 17 that does not have bolt holes.

[0048] Alternatively, the building can be mounted on blocks with a block supporting each column lower plate 52 of a column 7.

[0049] Referring to FIG. 6, mesh can be installed (such as stapled) to the outside of the standoff brackets 2, 12, 11 to form the insulation cavities 4 that insulation can be installed into.

[0050] With insulation installed in the insulation cavities 4, exterior cladding 22 can be installed on all sides, the roof and the bottom.

[0051] Referring again to FIG. 1, built in deck attachments 31 can be provided on the building 1 under the doors 6 in the structure to provide an attachment point for a deck once the building 1 is installed in a location.

[0052] Solar shade brackets 32 can be provided above the windows 5 to allow a solar shade to be easily installed above the windows 5 when the building 1 is installed in a location. The solar shades can reduce daytime heating in summer months.

[0053] The building 1 can be moved into place by a crane (not shown) and installed on the screw pile 17. Referring to FIG. 8, a lift frame 80 can be provided that can be connected to the top of the building 1 and used to lift the building 1 with the crane. The lift frame 80 can have a number of spreader bars to distribute the lifting forces applied to building 1. Referring to FIGS. 1, 4, and 8, top ends of the support columns 7 can extend past the top standoff brackets 12, so that the top ends of the support columns 7 are higher than the top standoff brackets 12 or even flush with the top standoff brackets 12. The lifting frame 80 can have four (4) connection points 82 that can be bolted to the upper plates 9 of the support columns 7 (with the thermal isolators 53 in between to act as a thermal break).

[0054] Lifting lugs 16 can be provided on top of the lift frame 80 that are connectable to a crane and can be used to lift the lift frame 80 and the building 1 connected to the lift frame 80.

[0055] To move the building 1 into place on the screw piles 17, the lift frame 80 can be connected to the top of the building 1 and, specifically, the connection points 82 on the lift frame 80 connected to the top plates 9 of the support columns 7. The lifting lugs 16 can then be connected to a crane and the crane used to lift the lift frame 80 and the building 1, such as from a trailer or other transport means for the building 1. With the crane lifting the lift frame 80 and the building 1, the crane can maneuver the building 1 into a desired location, such as on top of the screw piles 17 and lower the building 1, by the lift frame 80 down into position. The support columns 7 can then be connected to the screw piles 17. With the building 1 in the desired position, the crane can be disconnected from the lift frame 80 and the lift frame 80 can be removed from the top of the building 1. Alternatively, the lift frame 80 can be left on the building 1 and used as the framework for solar panels or other elements.

[0056] The building 1 is easily relocatable and the site the building 1 was placed on easily remedial by removing the building 1 from the screw piles 17 (or blocks) and then removing the screw piles 17 (or blocks).

[0057] The building 1 can be ready for a solar array to be added, with the solar array attached to the column upper plates 9 at the top of the support columns 7 rather than the roof of the building 1. In one aspect, the lift frame 80 can be left on the building 1 and form a frame for a solar array. Solar panels can be mounted to this lift frame 80 with the lift frame 80 mounted above and not attached to the roof of the building 1.

[0058] With the building 1 installed on the screw piles 17 and supported above these screw piles 17 by the lower column isolator stub brackets 25, a crawl space can be created below the building 1 allowing access to ducting, plumbing, utilities, etc. below the building 1. This allows easy service and prevent the necessity of breaking the vapor barrier 13 to gain access.

[0059] Referring to FIGS. 5 and 9, a utilities trench leg 26 can be provided running from the ground where the utilities are running and up into the building 1 to allow utilities like water, sewer and electricity to be supplied into the building 1. The utilities trench leg 26 can be made up of two hollow cylinders 90, 92 sized so that one cylinder 90 is larger than the other cylinder 92. One of the cylinders 90 can be attached to the building 1 and the other cylinder 92 can be provided running out of the ground with the smaller cylinder 92 inserted into the larger cylinder 90, allowing the cylinders 90, 92 to slide relative to one another. This will allow the utilities trench leg 26 to move/adjust should the ground move due to frost heaving, soil settling etc.

[0060] The utilities trench leg 26 can be sealed to prevent the entrance of radon gas into the utilities trench leg 26.

[0061] A sewage line 29, a fresh water line 30, and other possible utilities lines can be run through this utilities trench leg 26 so handle removing sewage from the building 1, supplying the building 1 with water, etc.

[0062] Additionally, a room air closed loop 28 can be provided running through the utilities trench leg 26 and an air fan 27 can circulate air from inside the building 1 through the room air closed loop 28. This room temperature air can keep the utilities from freezing in the utilities trench leg 26, such as water in the fresh water line 30 or sewage in the sewage line 29.

[0063] A thermostat (not shown) can be used to control the operation of the air fan 27, circulating warm air from inside the inner structure 50 through the room air closed loop 28 when the temperature in the utilities trench leg 26 is low, providing a heat source in the utilities trench leg 26 and preventing freezing of the utilities passing through the utilities trench leg 26 in colder climates. With the building 1 supported above a ground surface, the migration of radon gas from into the building 1 from the ground is prevented since there is no direct connection between the ground and the interior of the building 1.

[0064] In one aspect, rather than having a building 1 with a single level, buildings 1 can be stacked with one building 1 installed on top of another building 1. The first building 1 can be installed on screw piles 7 as described herein and then the lift frame 80 can be connected to the top of a second building 1 and the second building 1 lifted, with a crane, on top of the first building 1.

[0065] The lower plates 52 on the support columns 7 of the second building 1 can be lined up with upper plates 9 on the support columns 7 on the first building 1 and the lower plates 52 of the support columns 7 of the second building 1 connected to the upper plates 9 of the first building 1 so that the second building 1 is secured to above the first building 1 and the support columns 7 of the buildings 1. In this manner, the weight of both the buildings 1 are transferred through the support columns 7 of the buildings 1 to the screw piles 17 or other foundation of the first building 1.

[0066] In one aspect, lower column isolator stub brackets 25 can be provided between the support columns 7 of the first building 1 and the support columns 7 of the second building 1.

[0067] Stacking of buildings 1 allows even more housing to be provided at a location. For example, a location with space for four buildings 1 can be become an eight unit complex by stacking each building 1.

[0068] Referring to FIG. 10, in a further aspect, a building 101, such as building 1 shown in FIG. 1, can be expanded using the positioning of the four support columns 103, such as support columns 7 in building 1, of the buildings 101 and adding additional columns 104 on screw piles (or other foundation) to support one or more additional structures around the building 101, such as roofs for shaded decks, car ports, etc.

[0069] These additional support columns 104 can provided so that they form a square with two of the support columns 103 of the building 101, where the square formed by the additional support columns 104 and the two support columns 103 of the building 101 match the size of a square formed by the four support columns 103 of the building 101. The support columns 103 form a lift bar mounting frame 102 with standard dimensions. This allows a lift frame, such as lift frame 80 shown in FIG. 8, or other structures, that can be attached to the four support columns 103 of the building 101 to also be attached between the building 101 and two additional support columns 104. For example, this allows a lift frame 80 that can be used to lift the building 101 into place to be repurposed as additional structures surrounding the building 101 because the connection points 82 of the lift frame 80 can be used to connect to two additional support columns 104 and two support columns 103 of the building 101 that form a square that corresponds to the connection points 82 of the lift frame 80.

[0070] In FIG. 10, a lift frame 105 can be left on the top of the building 101 to allow a solar panel array to supply electricity to the building 101 to be installed above the building 101 on this lift frame 105. However, additional lift frames 106, 107, 108, 109 can also be provided to form a cover for shaded deck areas, car ports, etc.

[0071] A lift frame 106 can be provided on the left side of the building 101 utilizing the two left support columns 103 of the building 101 as two connections points and then two additional support columns 104 as the other two connection points. This lift frame 106 can form a roof for a deck, car port, etc.

[0072] A lift frame 107 can be provided on a front side of the building 101 utilizing the two front support columns 103 of the building 101 as two connections points and then two additional support columns 104 as the other two connection points. This lift frame 106 can form another roof for a deck, car port, etc.

[0073] A lift frame 108 can be provided on the right side of the building 101 utilizing the two right support columns 103 of the building 101 as two connections points and then two additional support columns 104 as the other two connection points. This lift frame 108 can form also a roof for a deck, car port, etc.

[0074] A lift frame 109 can be provided on a rear side of the building 101 utilizing the two rear support columns 103 of the building 101 as two connections points and then two additional support columns 104 as the other two connection points. This lift frame 109 can form another roof for a deck, car port, etc.

[0075] In this manner, structures can be provided adjacent to the building 101 that use the same spacing as the lift bar mounting frame 102 of the building 101.

[0076] The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous changes and modifications will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all such suitable changes or modifications in structure or operation which may be resorted to are intended to fall within the scope of the claimed invention.