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.

1 . A method for producing a below-grade foundation wall, comprising: 
 extruding a first wall panel and a second wall panel, each wall panel including a hollow frame member with first and second face sheets generally parallel to one another and connected by a plurality of ribs spanning a space therebetween;    positioning the second wall panel adjacent an edge of the first wall panel;    permanently affixing the second wall panel to the edge of the first wall panel to produce a foundation wall; and    placing the foundation wall in a below-grade location, wherein at least an exterior surface thereof withstands a sustained lateral load applied thereto.    
     
     
         2 . The method of  claim 1 , wherein said method of permanently affixing the second wall panel to the edge of the first wall panel includes a process selected from the group consisting of: 
 ultrasonic welding;    solvent welding;    gluing with an adhesive;    plate welding;    friction stir welding;    thermal bonding;    extruder/wire feed welding; and    mechanical fastening.    
     
     
         3 . The method of  claim 2 , wherein said extruded hollow frame members of the first and second wall panels are cut to produce wall panels of varying heights.