Lightweight, prefabricated building structures

Claim 2

A lightweight, prefabricated building structure comprising the following elements: a plurality of wall panels having upper and lower sections and having positive attachment means for attaching each of said wall panels to a foundation, and friction lock means for joining said wall panels; said positive attachment means comprising a plurality of com-lock fasteners, each of said com-lock fasteners having a female insert about every six to eighteen inches of the periphery of and fixedly attached to said foundation, at least one male insert molded within said lower section of each of said plurality of wall panels for locking with said female insert, said male insert comprising a moveable hook to be in registry with a corresponding one of said female inserts, whereby when each of said movable hooks is driven into said corresponding one of said female inserts, the positive attachment means provides sufficient strength for the resulting building structure to withstand severe winds; and a plurality of roof panels joinable to said upper sections of said wall panels by friction lock means.

Claim 3

The structure of claim 1 wherein said wall panels and roof panels comprise rigid polyurethane foam.

Claim 4

The structure of claim 1 wherein said attachment means also comprises an adhesive.

Claim 5

The structure of claim 2 wherein said moveable hook consists essentially of a metal, engineering plastic and injection molded nylon.

Claim 6

The structure of claim 1 wherein said friction lock means comprises lap joints, lap splices, dove tail joints, dowel joints, pin fitting joints, compression fitting joints, tenon and mortise, and tongue and groove.

Claim 7

The structure of claim 1 wherein additional elements comprise a plurality of corner panels having friction lock means for joining said corner panels to said wall panel.

Claim 8

The structure of claim 6 wherein said wall panels and said corner panels are joined to each other by tongue and groove friction lock means comprising a tongue along one side edge and a groove along the other side edge of said panels, said wall panels and corner panels are joined to roof panels and said roof panels are joined to each other by said tongue and groove friction lock means.

Claim 9

The structure of claim 1 wherein each of a plurality of overhang roof panels is joinable to each of said roof panels.

Claim 10

The structure of claim 8 wherein each of said overhang roof panels has a grooved channel to serve as a gutter.

Claim 11

The structure of claim 9 wherein at least one downspout is connected to one grooved channel.

Claim 12

The structure of claim 6 wherein each of said wall panels and corner panels has an interior wall and an exterior wall.

Claim 13

The structure of claim 11 wherein additional elements comprise a plurality of interior wall panels and a plurality of combination interior-exterior wall panels and wherein an interior side edge of each combination interior-exterior wall panel is joinable to one side edge of said interior wall panels by friction lock means and each exterior side edge is joinable between a side edge of each of said wall panels adjacent to said combination interior-exterior wall panel by friction lock means.

Claim 14

The structure of claim 12 wherein said additional elements also comprise at least one wall panel to accommodate a window.

Claim 15

The structure of claim 13 wherein said additional elements also comprise at least one door mounted between two wall panels.

Claim 16

The structure of claim 14 wherein said plurality of elements form a single story residential building.

Claim 17

The structure of claim 15 wherein each of the plurality of elements have dimensions of length, width and thickness which are compatible for shipment via a single shipping pallet.

Claim 18

The structure of claim 11 wherein said plurality of elements form a multi-story residential building.

Claim 19

The structure of claim 6 wherein an additional element comprises at least one door panel mounted between two wall panels.

Claim 20

The structure of claim 18 wherein said plurality of elements form a single story commercial building.

Claim 21

The structure of claim 18 wherein said plurality of elements form a multi-story commercial building.

Claim 22

A lightweight, prefabricated building structure comprising the following elements consisting of rigid polyurethane foam: a plurality of wall panels, each of said wall panels having a length in the range of about one to 50 feet, a width in the range from about six inches to about 20 feet, a thickness in the range from about one to about six inches, a top edge, a bottom edge having positive attachment means for attaching said wall panel to a foundation, a first side edge having a tongue extending along substantially the entire length of said panel and a second side edge having a groove extending along substantially the entire length of said panel for receiving a tongue of a first side edge of one of said wall panels to another of said wall panels and for joining said wall panels one to another, said positive attachment means comprising a plurality of com-lock fasteners, each of said com-lock fasteners having a female insert about every six to eighteen inches of the periphery of and fixedly attached to said foundation, at least one male insert molded within said lower section of each of said plurality of wall panels for locking with said female insert, said male insert comprising a movable hook to be in a registry with a corresponding one of said female inserts, whereby when each of said movable hooks is driven into said corresponding one of said female inserts, the positive attachment means provides sufficient strength for the resulting building structure to withstand severe winds; at least four corner panels each having a top edge, a bottom edge having said attachment means, a first corner side having a tongue extending along substantially the entire length of said panel for joining to a groove of said first side edge one of said wall panels and a second corner side having a groove extending along substantially the entire length of said panel for receiving a tongue of a first side edge of another of said wall panels and for joining to said wall panels; and a plurality of roof panels joinable by tongue and groove and those roof panels adjacent to said wall panels and said corner panels joinable to the respective top edge of said wall panel and said corner by tongue and groove.

Claim 23

A lightweight, prefabricated building structure comprising the following elements consisting of rigid polyurethane foam: a plurality of wall panels, each of said wall panels having a length in the range of about one to 50 feet, a width in the range from about six inches to about 20 feet, a thickness in the range from about one to about six inches, a top edge, a bottom edge having positive attachment means for attaching said wall panel to a foundation, a first side edge having a tongue extending along substantially the entire length of said panel and a second side edge having a groove extending along substantially the entire length of said panel for receiving a tongue of a first side edge of one of said wall panels to another of said wall panels and for joining said wall panels one to another, said positive attachment means comprising a plurality of com-lock fasteners, each of said com-lock fasteners having a female insert about every six to eighteen inches of the periphery of and fixedly attached to said foundation, at least one male insert molded within said lower section of each of said plurality of wall panels for locking with said female insert, said male insert comprising a movable hook to be in a registry with a corresponding one of said female inserts, whereby when each of said movable hooks is driven into said corresponding one of said female inserts, the positive attachment means provides sufficient strength for the resulting building structure to withstand severe winds; at least four corner panels each having a top edge, a bottom edge having said attachment means, a first corner side having a tongue extending along substantially the entire length of said panel for joining to a groove of said first side edge one of said wall panels and a second corner side having a groove extending along substantially the entire length of said panel for receiving a tongue of a first side edge of another of said wall panels and for joining to said wall panels; and a plurality of roof panels joinable by tongue and groove and those roof panels adjacent to said wall panels and said corner panels joinable to the respective top edge of said wall panel and said corner by tongue and groove.

Claim 24

The structure of claim 21 wherein an adhesive is applied between said foundation and the bottom edge of said wall panels.

Claim 25

The structure of claim 21 wherein said moveable hook consists essentially of a metal, engineering plastic and injection molded nylon.

Claim 26

The structure of claim 21 wherein each of a plurality of overhang roof panels is joinable to each of said roof panels.

Claim 27

The structure of claim 24 wherein each of said overhang roof panels has a grooved channel to serve as a gutter.

Claim 28

The structure of claim 25 wherein at least one downspout is connected to one grooved channel.

Claim 29

The structure of claim 21 wherein each of said wall panels and corner panels has an interior wall and an exterior wall.

Claim 30

The structure of claim 27 wherein additional elements comprise a plurality of interior wall panels and a plurality of combination interior-exterior wall panels and wherein an interior side edge of each combination interior-exterior wall panel is joinable to one side edge of said interior wall panels by tongue and groove and each exterior side edge is joinable between a side edge of each of said wall panels adjacent to said combination interior-exterior wall panel by tongue and groove.

Claim 31

The structure of claim 28 wherein said additional elements also comprise at least one wall panel to accommodate a window.

Claim 32

The structure of claim 29 wherein said additional elements also comprises at least one door panel mounted between two wall panels.

Claim 33

The structure of claim 30 wherein said plurality of elements form a residential building having at least one story.

Claim 34

The structure of claim 31 wherein said plurality of elements form a single story residential building.

Claim 35

The structure of claim 32 wherein each of the plurality of elements are compatible for shipment via a single shipping pallet.

Claim 36

The structure of claim 33 wherein an additional element comprises at least one door panel mounted between two wall panels.

Claim 37

The structure of claim 34 wherein said plurality of elements form a commercial building having at least one story.

Claim 38

The structure of claim 35 wherein said plurality of elements form a multi-story commercial building.

Claim 39

A panel for assembly of lightweight building structures comprising an interior wall, an exterior wall, a first side edge, a second side edge, a top edge and a bottom edge, said interior wall being separated from said exterior wall by a thickness of at least one inch, said first side edge having a groove along substantially the entire length of said first side edge and having a depth of slightly greater than the thickness of said panel and a tongue along substantially the entire length of said second side edge for mating with said groove, said top edge joinable to a roof by tongue and groove, and positive attachment means for attaching to a foundation within said bottom edge, said positive attachment means comprising a plurality of com-lock fasteners, each of said com-lock fasteners having a female insert about every six to eighteen inches of the periphery of and fixedly attached to said foundation, at least one male insert within said lower section of each of said plurality of wall panels for locking with said female insert, said male insert comprising a moveable rod to be in registry with a corresponding one of said female inserts, whereby when each of said movable hook is driven into said corresponding one of said female inserts, the positive attachment means provides sufficient strength for the resulting building structure to withstand severe winds.

Claim 40

A panel for assembly of lightweight building structures comprising an interior wall, an exterior wall, a first side edge, a second side edge, a top edge and a bottom edge, said interior wall being separated from said exterior wall by a thickness of at least one inch, said first side edge having a groove along substantially the entire length of said first side edge and having a depth of slightly greater than the thickness of said panel and a tongue along substantially the entire length of said second side edge for mating with said groove, said top edge joinable to a roof by tongue and groove, and positive attachment means for attaching to a foundation within said bottom edge, said positive attachment means comprising a plurality of com-lock fasteners, each of said com-lock fasteners having a female insert about every six to eighteen inches of the periphery of and fixedly attached to said foundation, at least one male insert within said lower section of each of said plurality of wall panels for locking with said female insert, said male insert comprising a moveable rod to be in registry with a corresponding one of said female inserts, whereby when each of said movable hook is driven into said corresponding one of said female inserts, the positive attachment means provides sufficient strength for the resulting building structure to withstand severe winds.

Claim 41

The panel of claim 37 wherein said panel comprises rigid polyurethane foam.

Claim 42

The panel of claim 38 wherein said moveable hook consists essentially of a metal, engineering plastic and injection molded nylon.

Claim 43

The panel of claim 37 wherein said top edge is joinable to a roof panel by tongue and groove.

Claim 44

The panel of claim 37 wherein said top edge is joinable to a floor panel by tongue and groove.