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, consisting essentially of:
 extruding a first partial wall panel section and a second partial wall panel section, each partial wall panel section 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 partial wall panel adjacent the first partial wall panel section and abutting a longitudinal edge of the second partial wall panel section with an adjacent longitudinal edge of the first partial wall panel section;   permanently bonding the second partial wall panel section to the first partial wall panel section along the abutted edges thereof to produce a finished foundation wall; and   placing the finished 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 partial wall panel section to the edge of the first partial wall panel section includes a process selected from the group consisting of:
 ultrasonic welding;   solvent welding;   gluing with an adhesive;   plate welding;   friction stir welding;   thermal bonding; and   extruder/wire feed welding.   
     
     
         3 . The method of  claim 2 , wherein said first and second partial wall panel sections are cut to produce finished foundation walls of a desired height. 
     
     
         4 . The method according to  claim 1  further consisting of cutting at least one wall panel section, along a longitudinal direction, to produce a finished foundation wall having a desired linear dimension. 
     
     
         5 . The method according to  claim 1  wherein at least one additional element is permanently affixed to the finished foundation wall. 
     
     
         6 . The method according to  claim 5 , wherein the additional element is selected from the group consisting of:
 a sill plate;   a top plate;   a window frame member;   an expansion joint;   a vertical seam;   wall/column supports;   an electrical box assembly;   a window frame;   a door frame;   a beam pocket;   a mechanical device pass-through;   an a vertical end cap; and   a masonry ledge   
     
     
         7 . A method of manufacturing a polymeric wall panel, comprising:
 (a) extruding a first polymeric wall section, said first wall section having a predefined longitudinal length;   (b) extruding at least one additional polymeric wall section, said additional wall section having about the same predefined longitudinal length;   (c) positioning the first polymeric wall section adjacent, along a longitudinal edge, and co-planar with the additional polymeric wall section; and   (d) permanently bonding the first polymeric wall section to the additional polymeric wall section to assemble the polymeric wall panel.   
     
     
         8 . The method according to  claim 7 , further comprising repeating steps (b) through (d) to form an extended polymeric wall panel. 
     
     
         9 . The method according to  claim 7  wherein at least one dimension of the polymeric wall panel is modified by sawing the polymeric wall panel. 
     
     
         10 . The method according to  claim 7  wherein permanently bonding includes a process selected from the group consisting of:
 ultrasonic welding;   solvent welding;   gluing with an adhesive;   plate welding;   friction stir welding;   thermal bonding; and   extruder/wire feed welding.   
     
     
         11 . The method according to  claim 7  wherein at least one additional element is permanently affixed to the polymeric wall panel. 
     
     
         12 . The method according to  claim 11 , wherein the additional element is selected from the group consisting of:
 a sill plate;   a top plate;   a window frame member;   an expansion joint;   a vertical seam;   wall/column supports;   an electrical box assembly;   a window frame;   a door frame;   a beam pocket;   a mechanical device pass-through;   an a vertical end cap; and   a masonry ledge   
     
     
         13 . The method according to  claim 7  further including cutting the polymeric wall panel sections to the predefined longitudinal length. 
     
     
         14 . The method according to  claim 7 , wherein cutting the polymeric wall panel sections is accomplished with a technique selected from the group consisting of: water jet cutting, heated knife cutting and wire cutting. 
     
     
         15 . The method according to  claim 7 , further comprising placing the polymeric wall panel in a below-grade location, wherein at least an exterior surface of the polymeric wall panel withstands a sustained lateral load applied thereto. 
     
     
         16 . The method according to  claim 11 , wherein the additional element is a sill plate affixed along the bottom of the polymeric wall panel; and
 where the method further comprises placing the polymeric wall panel in a below-grade location, where at least an exterior surface of the polymeric wall panel withstands a sustained lateral load applied thereto.