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 cap for use with basement walls having at least one generally vertical surface, comprising: 
 a generally longitudinal horizontal top surface providing an interface between different construction materials, said horizontal top surface consisting essentially of a polymeric material; and    a flange, connected to and extending downward from the top surface adjacent and parallel to the vertical surface of the wall, said flange connected to said horizontal top surface along an edge thereof;    said cap resisting a flow of air in said basement wall.    
     
     
         2 . The cap of  claim 1 , further comprising a decorative face on said flange.  
     
     
         3 . The cap of  claim 1 , where said cap is greater in width than a width of the basement wall.  
     
     
         4 . The cap of  claim 1 , wherein said cap supports a sustained compressive load applied thereto.  
     
     
         5 . The cap of  claim 1 , further comprising a hollow channel along at least one edge thereof.  
     
     
         6 . The cap of  claim 5 , wherein said hollow channel further comprises a removable cover.  
     
     
         7 . The cap of  claim 1 , wherein said polymeric material includes polyvinyl chloride.  
     
     
         8 . The cap of  claim 1 , wherein said polymeric material includes a reinforcement additive.  
     
     
         9 . The cap of  claim 8 , wherein said reinforcement additive includes glass fiber.  
     
     
         10 . The cap of  claim 1 , wherein said cap transfers at least a portion of a sustained lateral load imparted by backfill against the basement wall to the upper structural member.  
     
     
         11 . A cap for use with basement walls having first and second generally vertical surfaces, comprising: 
 a generally longitudinal horizontal top surface consisting essentially of a polymeric material;    first and second flanges, connected to and extending downward from the top surface adjacent and parallel to the respective first and second surfaces of the wall, at least one of said flanges connected to said horizontal top surface along an outer edge thereof;    said cap being affixed to said basement wall using an adhesive; and    means for attaching an upper structural member to said cap to provide an interface between different construction materials.    
     
     
         12 . The cap of  claim 11 , wherein said means for attaching includes a mechanical fastener.  
     
     
         13 . The cap of  claim 11 , wherein said means for attaching includes an adhesive.  
     
     
         14 . The cap of  claim 1 , wherein said adhesive is pre-applied to said cap horizontal surface and exposed before attaching the upper structural member.  
     
     
         15 . The cap of  claim 11 , further comprising a gap-filling insulation member providing a seal between the cap and the upper structural member.  
     
     
         16 . The cap of  claim 11 , further comprising a decorative face on at least one of said first and second flanges.  
     
     
         17 . The cap of  claim 11 , where said cap is greater in width than a width of the basement wall.  
     
     
         18 . The cap of  claim 11 , further comprising a hollow channel along at least one edge thereof.  
     
     
         19 . The cap of  claim 18 , wherein said hollow channel further comprises a removable cover.  
     
     
         20 . The cap of  claim 11 , wherein said polymeric material includes a reinforcement additive.  
     
     
         21 . The cap of  claim 20 , wherein said reinforcement additive includes glass fiber.  
     
     
         22 . The cap of  claim 11 , wherein said cap transfers at least a portion of a sustained lateral load imparted by backfill to the basement wall to the upper structural member.  
     
     
         23 . The cap of  claim 11 , wherein the basement wall is formed from a polymeric material.  
     
     
         24 . A cap for use with a polymeric foundation wall, the wall having first and second generally vertical surfaces, comprising: 
 a generally longitudinal horizontal top surface consisting essentially of a polymeric material;    first and second flanges, connected to and extending downward from the top surface adjacent and parallel to the respective first and second surfaces of the wall, at least one of said flanges connected to said horizontal top surface along an outer edge thereof, and at least one of said flanges being permanently affixed to the adjacent panel surface;    said cap being attached to said foundation wall using an adhesive; and    means for attaching an upper structural member to said cap to provide an interface between the polymeric foundation and an alternative construction material.    
     
     
         25 . The cap of  claim 24 , further comprising a decorative face on at least one of said first and second flanges.  
     
     
         26 . The cap of  claim 24 , where said cap is greater in width than a width of the basement wall.  
     
     
         27 . The cap of  claim 24 , wherein said cap supports a sustained compressive load applied thereto.  
     
     
         28 . The cap of  claim 24 , wherein said polymeric material includes a reinforcement additive.  
     
     
         29 . The cap of  claim 28 , wherein said reinforcement additive includes glass fiber.  
     
     
         30 . The cap of  claim 24 , wherein said cap transfers at least a portion of a sustained lateral load imparted by backfill to the basement wall to the upper structural member.  
     
     
         31 . The cap of  claim 24 , wherein at least one of said first and second flanges includes a load-bearing structure extending therefrom.  
     
     
         32 . The sill cap of  claim 31 , wherein said load-bearing structure supports a brick face.  
     
     
         33 . The cap of  claim 24 , wherein the basement wall is formed from a polymeric material.