Residential homes having tensioned curved wall panels

• US 6,722,091 B1
• Filed: 12/17/1999
• Issued: 04/20/2004
• Est. Priority Date: 12/18/1998
• Status: Expired due to Fees

• Current Assignee: International Building Concepts, Ltd.
• Original Assignee: Robert J. Leslie
• Inventors: Leslie, Robert H., Leslie, Robert J.
• Primary Examiner(s): Yip, Winnie S.
• Application Number:
  US09/465,713
• Time in Patent Office: 1,586 Days
• Field of Search: 522/45, 522/46, 522/47, 522/48, 52/794, 52/82, 522/49, 52/801, 428/106-109
• US Class Current: 52/246
• CPC Class Codes: E04B 1/2604 Connections specially adapted therefor shear dowels E04B1/486, E04B1/49
• CPC Class Codes: E04B 1/2608 Connectors made from folded sheet metal E04B1/2612 takes precedence
• CPC Class Codes: E04B 2001/0061 Buildings with substantially curved horizontal cross-section, e.g. circular
• CPC Class Codes: E04B 2001/2656 Bent or curved bolts
• CPC Class Codes: E04G 21/10 Devices for levelling, e.g. templates or boards smoothing tools E04F21/16, E04F21/24
• CPC Class Codes: E04H 1/02 Dwelling houses; Buildings for temporary habitation, e.g. summer housessmall erections for limited occupation E04H1/12 ; collapsible, erectable or rotatable buildings E04B1/343
• CPC Class Codes: Y10T 428/24066 Wood grain
• CPC Class Codes: Y10T 428/24074 Strand or strand-portions

Abstract

A tensioned structure such as a house is disclosed. The house includes at least one wall panel placed under tension by bending the wall panel from a flat form to a curved form. The tension provides rigidity and thus strength to the wall panel. In a preferred form, the house includes two tensioned wall panels with the concave faces of the wall panels confronting each other such that a generally circular residential house is formed. A counter to oppose the tension engages the wall panels. The counter may include a roof or rafter support network, a portion of the floor or floor support, the wall panels themselves where the end edges of the wall panels are engaged to each other, or stainless steel straps running about the wall panels. The wall panel may be include material such as oriented strand board, steel, cement, plastic, or organic material such as grass. Further disclosed are methods for constructing the house and for bending without breaking material such as oriented strand board where the material is bent from a flat form to a curved form to place the material under tension so as to provide rigidity and strength to the structure having the tensioned sheet of material.

Claims

1. A residential house having a floor and a roof, comprising, in combination:

a) at least one wall panel, with the wall panel;

i) having upper and lower edges, wherein the lower edges are at the floor of the residential house and wherein the upper edges are at the roof of the residential house, and wherein the wall panel has sufficient rigidity between the upper and lower edges to support a roof load and to further support a live roof load;

ii) having a pair of end edges running between the upper and lower edges, with a distance between the end edges along the wall panel being greater than 19½

feet when the wall panel is in a nontensioned form and such that a length of said wall panel is greater than a height of the wall panel;

iii) being one-piece;

iv) being in a generally curved form and having a concave face and a convex face, with the concave face being oriented toward an interior of the residential house;

v) having an outward tension, with the outward tension being from the concave face to the convex face; and

vi) comprising a sheet of oriented strand board, wherein the oriented strand board is a wood product, wherein the oriented strand board is not particle board, wherein the oriented strand board is not flakeboard, wherein the oriented strand board comprises wood strands sliced from wood in a direction of a grain of the wood such that inherent tree strength is maintained in the oriented strand board, wherein the sheet of oriented strand board comprises a first face layer of wood strands, a second face layer of wood strands, and a core layer of wood strands between the first and second face layers, wherein the wood strands of the face layers are aligned in one direction, and wherein said one direction is a vertical direction running between the floor and the roof;

b) a counter engaged to the wall panel to oppose the outward tension to fix the wall panel in the generally curved form;

c) wherein the roof is on the wall panel so as to form the residential house; and

d) wherein the residential house is studless.

2. The residential house according to claim 1 wherein the residential house comprises first and second wall panels, with the concave faces of each of the wall panels being oriented to face each other and being fixed in such an orientation.

3. The residential house according to claim 1 wherein the roof comprises a support network and wherein the counter comprises at least a portion of the support network.

4. The residential house according to claim 1 and further comprising a floor level support for the residential house, wherein the counter comprises at least a portion of the floor level support.

5. The residential house according to claim 1 wherein the counter comprises a fastener engaged to an end edge of the wall panel.

6. The residential house according to claim 2 where the counter comprises the first and second wall panels themselves, with respective end edges of the first and second wall panels being engaged to each other.

7. The residential house according to claim 1 wherein the counter comprises a strap.

8. The residential house according to claim 2 wherein the counter comprises a pair of straps surrounding the first and second wall panels, with one of the straps being disposed at a generally upper section of the first and second wall panels and with the other of the straps being disposed at a generally lower section of the first and second wall panels.

9. The residential house according to claim 2 wherein the end edges of the first wall panel confront the end edges of the second wall panel such that the first and second wall panels form generally the shape of a circle.

10. The residential house according to claim 2 wherein the end edges of the first wall panel are spaced from the end edges of the second wall panel, and further comprising wall sections between respective end edges of the first and second wall panels.

11. The residential house according to claim 2 wherein one end edge of the first wall panel confronts one end edge of the second wall panel and wherein the other edge of the first wall panel is spaced from the other edge of the second wall panel, and further comprising a door engaged between said other edges which are spaced from each other.

12. The residential house according to claim 1 and further comprising a door opening in the wall panel.

13. The residential house according to claim 1 and further comprising a window opening in the wall panel.

14. A residential house having a floor and a roof, comprising, in combination:

a) at least one wall panel, with the wall panel;

i) having upper and lower edges, wherein the lower edges are at the floor of the residential house and wherein the upper edges are at the roof of the residential house, and wherein the wall panel has sufficient rigidity between the upper and lower edges to support a roof load and to further support a live roof load;

ii) having a pair of end edges running between the upper and lower edges, with a distance between the end edges along the wall panel being greater than 19½

feet when the wall panel is in a nontensioned form and such that a length of said wall panel is greater than a height of the wall panel;

iii) being one-piece;

iv) being in a generally curved form and having a concave face and a convex face, with the concave face being oriented toward an interior of the residential house;

v) being tensioned outwardly;

vi) being fixed in the generally curved form;

vii) comprising a sheet of oriented strand board, wherein the oriented strand board is a wood product, wherein the oriented strand board is not particle board, wherein the oriented strand board is not flakeboard, wherein the oriented strand board comprises wood strands sliced from wood in a direction of a grain of the wood such that inherent tree strength is maintained in the oriented strand board, wherein the sheet of oriented strand board comprises a first face layer of wood strands, a second face layer of wood strands, and a core layer of wood strands between the first and second face layers, wherein the wood strands of the face layers are aligned in one direction, and wherein said one direction is a vertical direction running between the floor and the roof;

b) wherein the roof is on the wall panel so as to form the residential house; and

c) wherein the residential house is studless.

15. A method for building a residential house having a floor, a wall and a roof, comprising, in combination, the steps of:

a) choosing first and second sheets of tensionable material for said wall of the residential house, with each of the sheets of tensionable material having ends, with each of the sheets of tensionable material being flexible between a generally flat form having potential tension and a generally curved form having a tension biased toward the generally flat form, wherein each of the first and second sheets runs from the floor of the residential house to the roof of the residential house, wherein said sheets have sufficient rigidity on edge to support a roof load and to further support a live roof load, wherein each of said sheets includes a length of more than 19½

feet when said sheet is in a nontensioned form and such that a length of said wall panel is greater than a height of the wall panel, and wherein the step of choosing comprises the step of selecting sheets of oriented strand board as the first and second sheets of tensionable material, wherein the oriented strand board is a wood product, wherein the oriented strand board is not particle board, wherein the oriented strand board is not flakeboard, wherein the oriented strand board comprises wood strands sliced from wood in a direction of a grain of the wood such that inherent tree strength is maintained in the oriented strand board, wherein the sheet of oriented strand board comprises a first face layer of wood strands, a second face layer of wood strands, and a core layer of wood strands between the first and second face layers, wherein the wood strands of the face layers are aligned in one direction, and wherein said one direction is a vertical direction running between the floor and the roof;

b) bending each of the sheets into the generally curved form so as to form a generally concave face and so as to produce tension in the generally curved form;

c) countering the tension in the sheets when the sheets are in the generally curved form, fixing the sheets in the generally curved form, and orienting the sheets relative to each other such that the concave faces are oriented toward each other and such that the each of the ends of one sheet confronts one end of the other sheet to make an enclosure; and

d) placing the roof on the sheets to form the residential house.

16. A method for bending without breaking a panel of oriented strand board, with the panel having two end edges, with the method comprising, in combination, the steps of:

a) selecting a panel of oriented strand board, wherein the oriented strand board is a wood product, wherein the oriented strand board is not particle board, wherein the oriented strand board is not flakeboard, wherein the oriented strand board comprises wood strands sliced from wood in a direction of a grain of the wood such that inherent tree strength is maintained in the oriented strand board, wherein the panel of oriented strand board comprises a first face layer of wood strands, a second face layer of wood strands, and a core layer of wood strands between the first and second face layers, and wherein the wood strands of the face layers are aligned in one direction, wherein the panel of oriented strand board comprises end edges, wherein the end edges run in said one direction;

then

b) drawing the end edges toward each other to form a curved panel of oriented strand board; and

then

c) fixing the curved panel of oriented strand board in place.

17. The method of claim 16 wherein the panel includes a medial portion, wherein the step of initiating a bend in the panel comprises the step of initiating a bend in the panel at a location in the medial portion, and wherein the step of continuing to bend the panel incrementally comprises the step of continuing to bend the panel in each of two direction, with one of the directions being from the location to one of the end edges and with the other of the directions being from the location to the other of the end edges.

18. A residential house having a roof and comprising:

a) a sheet, wherein the sheet includes a height sufficient to serve as a wall of the residential house;

b) wherein the sheet includes a length, with the length being defined by the upper and lower edges, wherein the sheet has sufficient rigidity between the upper and lower edges to support a roof load and to further support a live roof load;

c) wherein the sheet is one-piece;

d) wherein the sheet is in a generally curved form;

e) wherein the sheet is tensioned so as to be biased toward a flat form;

f) wherein the sheet is fixed in the generally curved form;

g) wherein the sheet is a sheet of oriented strand board, wherein the oriented strand board is a wood product, wherein the oriented strand board is not particle board, wherein the oriented strand board is not flakeboard, wherein the oriented strand board comprises wood strands sliced from wood in a direction of a grain of the wood such that inherent tree strength is maintained in the oriented strand board, wherein the sheet of oriented strand board comprises a first face layer of wood strands, a second face layer of wood strands, and a core layer of wood strands between the first and second face layers, wherein the wood strands of the face layers are aligned in one direction, wherein the sheet of oriented strand board comprises end edges, wherein the end edges run in said one direction, wherein the end edges of the sheet have been drawn towards each other to form the generally curved form; and

h) wherein the roof is on the sheet so as to form the residential house.

19. The residential house of claim 18, wherein the length runs a distance greater than the height of the sheet.

20. The residential house of claim 18, wherein the sheet includes a length, wherein the length is greater than 19½

feet when the sheet is in the flat form.