U.S. patent application number 11/800530 was filed with the patent office on 2008-05-22 for prefabricated buildings, components and methods of erection of prefabricated buildings.
Invention is credited to David Groppe.
Application Number | 20080115432 11/800530 |
Document ID | / |
Family ID | 39365068 |
Filed Date | 2008-05-22 |
United States Patent
Application |
20080115432 |
Kind Code |
A1 |
Groppe; David |
May 22, 2008 |
Prefabricated buildings, components and methods of erection of
prefabricated buildings
Abstract
This invention is a new concept in prefabricated buildings,
components and methods of making the components and methods of
erecting the buildings. A typical wall of the new building consists
of a plurality of alternately positioned wall panels and support
columns, where each support column is situated between two adjacent
facing side edges of two wall panels. Coupling elements connect the
support column to the two panels, and a single activation element
on the support column causes these coupling elements to pull the
wall panels into correct elevation and secure engagement with the
support column and also secures the support column to an anchor pin
in the foundation directly below the support column. This support
column consists of an outer tube and a shaft slidable within the
tube. First coupling elements extending from each side edge of the
support column, and mating second coupling element are situated in
the side edges of each panel for cooperation with the first
coupling elements. Drawing the shaft upward causes mutual
engagement of the first and second coupling elements and causes
secure engagement of the support column with the anchor pin.
Inventors: |
Groppe; David; (Arnold,
CA) |
Correspondence
Address: |
ABELMAN, FRAYNE & SCHWAB
666 THIRD AVENUE, 10TH FLOOR
NEW YORK
NY
10017
US
|
Family ID: |
39365068 |
Appl. No.: |
11/800530 |
Filed: |
May 3, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60857732 |
Nov 7, 2006 |
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Current U.S.
Class: |
52/220.2 ;
52/261; 52/745.19; 52/745.2 |
Current CPC
Class: |
E04B 1/24 20130101; E04B
1/6162 20130101; E04B 2001/249 20130101; E04B 2001/2481
20130101 |
Class at
Publication: |
52/220.2 ;
52/745.19; 52/261; 52/745.2 |
International
Class: |
E04G 21/00 20060101
E04G021/00 |
Claims
1. A prefabricated wall comprising: a. a plurality of wall panels
and a plurality of columns for supporting said wall panels, where
each of said columns and panels has top and bottom parts, inner and
outer surfaces and opposite side edges, and said panels and columns
are adapted to be alternately spaced and joined together with each
of said columns situated between two of said panels to form a wall
section, b. coupling means for each of said wall sections for
releasably attaching one side edge of each of said two panels to
each side edge of said column, and c. activating means on said
column of each of said wall sections for activating each of said
coupling means, wherein each of said coupling means comprises: (1)
at least one 1.sup.st coupling element situated on one side edge of
said column, and (3) at least one 2.sup.nd coupling element on the
side edge of the panel being coupled thereto, said column and
panels being laterally movable relative to each other until said
1.sup.st and 2.sup.nd coupling elements of said column and of said
wall panels respectively come into engagement, said activating
means being adapted to drive said 1.sup.st coupling element
generally vertically which drives said 2.sup.nd coupling elements
generally horizontally, thus driving said side edges of said panels
and column toward each other.
2. A prefabricated wall according to claim 1 wherein said column of
each of said wall sections comprises: a. an outer tube having top
and bottom parts and a bore extending lengthwise, and b. an inner
shaft having top and bottom parts and opposite side edges and being
axially slidable upwardly in said outer tube bore, C. said
activating means being adapted to drive said inner shaft axially
between an initial open position to a closed position where said
wall panels are drawn toward said column.
3. A prefabricated wall according to claim 2, wherein (a) said
activating means of each of said wall sections comprises an
external lead screw on said top part of said inner shaft and a
mating threaded nut at said top part of said outer tube whereby
rotation of said nut draws said shaft upward.
4. A prefabricated wall according to claim 2, wherein a. said first
coupling element of each of said wall sections comprises: a 1st
wing that is: (1) fixed to each of said side edges of said inner
shaft and extending laterally outward therefrom and terminating in
and end part which includes a cam surface inclined inwardly toward
said inner shaft, and (2) movable upward when said inner shaft is
driven upward, and b. said side edge of said wall panel defines a
recess extending inward into said panel and thus extending away
from said shaft, and c. said second coupling element comprises a
pin fixed in said recess in said wall panel and extending in the
inside-to-outside direction, said cam surface of said first
coupling element, when said inner shaft is driven upwardly by said
activating means, camming said pin and associated wall panel toward
to said inner shaft.
5. A prefabricated wall according to claim 4, further comprising a
second wing situated on said side edge of said outer tube axially
above said first wing on said inner shaft, said first wing when
driven upward by upward movement of said inner shaft, capturing
said pin between it and said second wing fixed to said outer
tube.
6. A prefabricated wall according to claim 4, adapted to be erected
on and attached to a foundation which includes anchor means secured
in said foundation, wherein: (d) said column outer tube comprises
walls extending from said top part of said column downward to and
engaging said foundation, and (e) said activating means driving
said inner shaft upward relative to said outer tube, puts said
inner shaft in tension relative to said outer tube and puts said
outer tube walls in compression relative to said foundation, said
upward movement of said inner shaft relative to said outer tube
also lifts said 1.sup.st wing and its cam surface therein which
cams said pin and panel attached to said pin inwardly toward said
inner shaft.
7. A prefabricated wall according to claim 2 adapted to be erected
on and attached to a foundation which includes anchor means secured
in said foundation, wherein, a. said inner shaft further comprises
1.sup.st first means for engaging said anchor means, b. said outer
tube comprises 2.sup.nd means fixed to said outer tube for engaging
and driving said inner shaft upward relative to said outer tube,
which puts said inner shaft in tension and creates an opposite
downward force on said outer tube when it is urged against said
when outer tube against said foundation, and c. where said upward
movement of said inner shaft and 1.sup.st coupling element thereon
creates a cam force for urging said 2.sup.nd coupling element
laterally inward toward said outer tube when said inner shaft is
moved upward.
8. A prefabricated wall according to claim 1, wherein said wall
panel end edge defines therein a recess with said pin mounted in
said recess, and said 1.sup.st coupling element is extendable into
said recess to engage said pin.
9. A prefabricated wall according to claim 1, wherein said 1.sup.st
coupling element includes an inclined cam surface for driving said
pin laterally toward said column when said shaft is driven
upwardly.
10. A prefabricated wall according to claim 2, wherein said outer
tube is formed by walls, two of which form said opposite side edges
of said column, each of these two walls defining therein an
elongated slot through which said 2.sup.nd coupling element carried
by said inner shaft can extend, and said wing is fixed to said side
wall of said outer tube above said slot.
11. A prefabricated wall according to claim 1, wherein said wall
panel is formed as a laminate having length in said top-to-bottom
direction, width in said side-to-side direction, thickness in said
inner-to-outer direction and has exposed side edges, each of said
side edges having a plurality of pocket-like recesses extending
inwardly and spaced apart along said length, and said wall panel
further comprises in each of said recesses a pin situated inward of
said side edge and extending in said inner-to-outer direction, said
pin configured to be engagable by said 1.sup.st coupling element
extending from said inner shaft.
12. A prefabricated wall according to claim 11, wherein each of
said wall panels comprises: a. a generally rectangular frame formed
by top, bottom and side edge beams which define between then a
central space, b. a core of heat insulation material substantially
filling said central space and secured therein, and c. inner and
outer skins covering said inner and outer sides respectively of
said frame and core.
13. A prefabricated wall according to claim 12 wherein for each of
said wall panels: a. said frame is injection molded of plastic, b.
said core comprises heat insulating expandable urethane, and c.
said skins comprise fiber glass, Kevlar.RTM. carbon fiber or other
composite.
14. A prefabricated wall according to claim 4, wherein said top
wing has a bottom surface that is generally horizontal extending
outward from said outer tube and then tapers upward at its end part
to easily receive said pin in said wall panel recess.
15. A prefabricated wall according to claim 4, wherein on each side
edge of said outer tube and adjacent side edge of said inner shaft
said top wing and bottom wing are displaced relative to each other
in the inner-to-outer direction.
16. A prefabricated wall according to claim 4, wherein said top
wing on one side edge of said outer tube is displaced forward of
said top wing on the opposite side edge of said outer tube, and
said bottom wing is displaced rearward of said bottom wing on the
opposite side edges of said inner shaft.
17. A prefabricated wall according to claim 1 adapted to be erected
on and attached to a foundation which is secured in the ground and
includes anchor means fixed in said foundation and spaced apart to
locations corresponding to each of said columns, where each of said
columns comprises an outer tube with a bore extending lengthwise,
and an inner shaft axially slidable upward in said outer tube bore,
said inner shaft having a bottom end adapted to releasably engage
one of said anchor means, and said inner shaft when pulled upwardly
relative to said column, pulls upwardly on said anchor means
causing tension on said inner shaft and a downward force of said
outer tube on said foundation as said wall panels are drawn toward
said column.
18. A wall according to claim 17, wherein said activating means
further comprises adjustment means (a) to allow upward movement of
said inner shaft while said inner shaft draws inward said wall
panels toward said column, and thereafter (b) to couple said inner
shaft to said anchor means which resists further upward movement of
said inner shaft, which thereafter goes into tension as said outer
tube walls go into compression.
19. A wall according to claim 18, wherein said adjustment means
comprises a blade with an elongated axial slot therein connected to
said anchor, and a pin mounted to said inner shaft and extending
transversely through said slot, where axial movement of said inner
shaft moves said pin to the top end of said slot.
20. A kit for constructing a prefabricated wall, said kit
comprising: a. a plurality of wall panels and a plurality of
columns for supporting said wall panels, where each of said columns
and panels has top and bottom parts, inner and outer surfaces and
opposite side edges, and said panels and columns are adapted to be
alternately spaced and joined together, with each of said columns
situated between two of said panels to form a wall section, b.
coupling means for each of said wall sections for releasably
attaching one side edge of each of said two panels to each side
edge of said column, and c. activating means on said column of each
of said wall sections for activating each of said coupling means,
wherein each of said coupling means comprises: (1) at least one
1.sup.st coupling element situated on one side edge of said column,
and (2) at least one 2.sup.nd coupling element on the side edge of
the panel being coupled, said column and panels being laterally
movable relative to each other until said 1.sup.st and 2.sup.nd
coupling elements of said column and of said wall panels
respectively come into engagement, and said activating means being
adapted to drive said 1.sup.st coupling element generally
vertically which drives said 2.sup.nd coupling elements generally
horizontally, thus driving said side edges of said panels and
column toward each other.
21. A kit for a prefabricated building adapted to be erected above
a floor area which includes anchor elements spaced apart and
secured in said floor area, said kit comprising a plurality of wall
panels and columns for constructing walls as defined in claim 18,
each of said walls having opposite ends which are releasably
joinable to define an enclosure, and said inner shafts of said
columns of said walls being releasably connectible to said anchor
elements.
22. A kit according to claim 20, wherein said 2.sup.nd coupling
element comprises a pin mounted in said wall panel, said pin being
engagable by said 1.sup.st coupling element.
23. A generally rectangular prefabricated building erected on a
floor area and attached to anchor means in said floor area,
comprising: a. four walls as defined in claim 2, where each of said
walls extends upright and laterally to predetermined lengths
respectively and terminates in opposite ends, b. corner columns for
joining adjacent ends of two walls, and c. a roof secured to said
top parts of at least two of said walls, and d. for each of said
walls each of said inner shafts has a bottom end engagable to one
said anchor elements and a top part adapted to be pulled upward
relative to said outer tube top part, thereby causing said inner
shaft to be in tension and said outer tube bottom part to press
downward against said floor area, and said 1st coupling elements to
be urged upward, thus driving said wall panels toward said
column.
24. A prefabricated building according to 23 wherein, each of said
columns comprises: (1) an outer tube, (2) an inner shaft axially
movable within said outer tube, (3) 1.sup.st means at the bottom
part of said inner shaft adapted to engage one of said anchors, (4)
2.sup.nd means carried by said inner shaft and adapted to engage
said adjacent panels, and when driven upward to pull said engaged
panels laterally inward toward said inner shaft, and (5) 3.sup.rd
means adapted to draw said 2.sup.nd means upward while bearing
downward against said outer tube, thereby putting said inner shaft
in tension and urging said outer tube downward against said
foundation when said inner shaft is pulled upward and said adjacent
wall panels are pulled laterally toward said outer tube.
25. A building according to claim 23 further comprising a roof
truss formed of a plurality of roof beams extending across said
building between the tops of two opposite walls, each of said roof
beams releasably coupled to one of said columns at the top part in
a haunch connection comprising: a. a threaded rod extending upward
from said inner shaft and freely through said nut plate, b. an
apertured transverse plate fixed to said outer tube, c. a nut
drawing said threaded rod and inner shaft upward, and d. said rod
extending further upward and through an aperture in said end of
said roof beam, and a further nut to secure same.
26. A building according to claim 23, wherein each of said corner
columns comprises an outer tube and inner shaft wherein said side
edges of said outer tube are 90 degrees apart, and side edges of
said inner shaft correspond to said side of said outer tube.
27. A method of manufacturing a wall panel having inner and outer
sides with an injection mold having inner and outer covers and edge
covers, at least one edge cover including an injection inlet means
and at least one edge cover including outlet vent means, comprising
the steps: a. positioning a generally rectangular frame having
inner and outer sides corresponding to said inner and outer sides
of said wall panel in said mold, said frame defining within it a
central cavity, b. positioning inner and outer skins adjacent the
inner and outer sides of said frame to enclose said central cavity,
c. covering said skins with said front and rear covers of said
mold, d. securing said inner and outer covers and said edge covers
onto said mold, e. injecting expandable urethane plastic into said
cavity, f. venting said cavity via apertures in said frame and
mold, g. bonding said skins to said frame, h. cooling said mold and
molded panel therein, i. opening said covers, and j. removing said
panel from said mold.
28. A method of manufacturing a wall panel comprising the steps: a.
providing a book-like mold having movable front and rear covers for
defining between them a mold space that corresponds generally to
the length, width and thickness of a panel to be made, b.
positioning a generally rectangular frame in said mold space, said
frame defining within it a central cavity, c. positioning front and
rear skins adjacent the front and rear sides of said frame to
enclose said central cavity, d. covering said skins with said front
and rear covers of said mold, e. covering ends of said frame and
closing said mold with end plates, f. securing said front and rear
covers and said end plates onto said mold, g. injecting expandable
urethane plastic into said cavity, h. venting said cavity via
apertures in said frame and mold, i. bonding said skins to said
frame, j cooling said mold and molded panel therein, k. opening
said covers and end plates, and l. removing said panel from said
mold.
29. A method of manufacturing a wall panel according to claim 27,
comprising the steps: a. positioning 1.sup.st, 2.sup.nd and
3.sup.rd production lines for simultaneously producing 1.sup.st and
2.sup.nd skins and one frame every minute, b. directing from said
1.sup.st, 2.sup.nd and 3.sup.rd production lines, every minute, two
skins and one frame to a final mold station where each panel is
made in a few seconds, and c. directing the output of panels from
said final mold station sequentially at the rate of one per minute
to 1.sup.st-10.sup.th cooling stations, so that after ten minutes
the panel at the 1.sup.st cooling station is completed and this
station is ready to receive a new panel to begin its 10 minute
cooling phase, thus producing from 10 cooling stations together,
one cooled panel every minute.
30. A method of manufacturing a wall panel according to claim 27,
comprising the steps: a. a. positioning 1.sup.st, 2.sup.nd and
3.sup.rd production lines for simultaneously producing "x" quantity
of 1.sup.st and 2.sup.nd skins and one frame every minute, b.
directing from said 1st, 2.sup.nd and 3.sup.rd production lines
every minute, "x" number of 1st and 2.sup.nd skins and one frame to
a final mold station where each panel is made in a few seconds, and
c. directing the output of "x" quantity of panels per minute from
said final mold station sequentially at the rate of "x" per minute
to "y" quantity of cooling stations, so that after "y" minutes the
panel at the 1.sup.st cooling station is completed and this station
is ready to receive a new panel to begin its "y" minute cooling
phase, thus producing from said final mold station "x" panels per
minute and producing in the aggregate from said Y cooling stations
"x" cooled panels per minute.
31. A method of erecting a prefabricated building using
prefabricated walls, columns and corner columns as defined in claim
26, comprising the steps: a. establishing a floor area on which to
erect said building, b. securing anchor means in said floor area at
predetermined locations, c. positioning and erecting a corner
column at a corner location for said building above a corresponding
anchor means and engaging said inner shaft of said corner column to
said anchor means, d. positioning said first wall panel with one of
its end edges adjacent one side edge of said corner column, moving
said wall panel laterally until said is 1.sup.st and 2.sup.nd
coupling elements of said corner column enter said recesses of said
first wall panel, and elevating said inner shaft to engage and
draw-in said wall panel to said column, e. positioning and erecting
a first of said columns ("first column") adjacent said opposite
side edge of said first wall panel and positioned above said anchor
means corresponding to said first column, engaging said inner shaft
of said first column to said anchor means, and positioning said
first coupling elements of said first column in recesses in said
opposite side edge of said first wall panel, f. elevating said
inner shaft of said first column for its first coupling elements to
engage and draw together said opposite side edge and said first
column, and to simultaneously secure said first column to its
anchor means, and g. successively similarly attaching columns and
wall panels to complete said walls of predetermined length and
included corner columns to define a building enclosure.
Description
RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. 119, 120
based upon applicant's Provisional Application, Ser. No.
60/857,732, filed Nov. 7, 2006.
I. BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention is in the field of prefabricated buildings
and methods of erection of prefabricated buildings.
[0004] 2. Background
[0005] There is a worldwide need for buildings of all types,
including homes, hospitals, school and factories, this need being
particularly acute in areas of natural disasters such as occurred
with the Tsunami and Hurricane Katrina and in war-torn areas. The
need is also great in many under-developed areas and countries and
even in developed countries where cost, speed and ease of
construction have become great concerns. Thus, a first set of basic
objectives is for prefabricated homes that have low cost, safe and
secure construction, good insulation from heat and cold and
durability. Obviously, an attractive appearance would be quite
desirable since many prior art prefabricated buildings have
nondescript or poor appearance. Fireproofing is a still further
objective, but difficult and expensive because conventional
materials are primarily wood and wood products.
[0006] Vast amounts of wood materials are used and thus consumed in
worldwide home and building construction for framing, inner and
outer walls, floors and roofs. Thus, a worldwide wood consumption
cycle is well along with no end in sight, as forests are being
destroyed and wood from demolished and replaced homes is often
burned or otherwise disposed of without useful recycling. Another
problem in prefabricated building construction is the time to
manufacture components, to transport and erect the components, and
a requirement for skilled persons with professional equipment and
power tools to achieve assembly and erection of the buildings.
Finally, the economics of high volume usually precludes much
variety or esthetic considerations.
II. OBJECTS AND SUMMARY OF THE NEW INVENTION
[0007] This present invention includes a new prefabricated building
concept, components, sub-assemblies, fully erected buildings and a
method of assembly or erection of such buildings. A principal
object of this invention is to provide buildings that can be
erected very quickly and easily and by persons who may not be
professionals in this field and who may have little or nor power
equipment, and/or who may be erecting such buildings in remote and
primitive regions.
[0008] A further object of this invention is to provide buildings,
and housing type buildings in particular, that are extremely
inexpensive as regards cost of components and labor.
[0009] Another object of this invention is to provide prefabricated
housing that can be erected by persons who do not need to be
trained and experienced carpenters, bricklayers, plumbers,
electricians, painters, etc.
[0010] A still further object of this invention is to provide
prefabricated housing which is strong, safe, well insulated from
heat and cold and is fireproof.
[0011] An additional object of this invention is to provide
prefabricated houses that do not require wood as a basic
construction component, which helps conserve the world's forests
from destruction.
[0012] A related object of this invention is to provide housing
having such good insulation characteristics at a reasonably low
cost, that there will be a greatly reduced need for heating fuel,
be it from wood, wood products, coal, oil, gas, or even electrical,
and wind power. Such reduced fuel needs conserve natural resources,
reduce environmental pollution from combustion and reduce
operational costs of living in such buildings.
[0013] A still further object of this invention is for the
components of such new buildings, particularly the modular wall,
roof and floor panels, to be light weight and thus easy and
inexpensive to transport and to handle during erection of the
buildings.
[0014] An additional object of this invention is to use components,
particularly wall, roof and floor panels, which can be manufactured
in factories that can be easily set up near the locations where the
building will be erected.
[0015] A further object of this invention is for the coupling
elements that join wall panels and other components to be simple to
understand and easy to use.
[0016] An additional object is for these buildings to be adapted
for assembly in rural or even remote and undeveloped areas,
including deserts and jungles, where conventional roads, machinery,
equipment and skilled artisans are few or non-existent.
[0017] These and other objects of the invention will be further
understood and appreciated by those skilled in the art by reference
to the following written specification, claims and appended
drawings.
III. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a partially cut-away top perspective view of a
prefabricated building of this invention,
[0019] FIG. 2 is an exploded view of a typical wall panel as used
in the building of FIG. 1,
[0020] FIG. 3 is a perspective view of the wall panel of FIG. 2 in
its final assembled state,
[0021] FIG. 4 is a fragmentary sectional view taken along line 4-4
in FIG. 3 showing the pocket and pin arrangement in the edge of the
panel of FIGS. 2 and 3,
[0022] FIG. 4A is a sectional elevation view taken along line 4A-4A
in FIG. 4,
[0023] FIG. 5 is a fragmentary and exploded perspective view of two
wall panels as seen in FIGS. 2 and 3 positioned to be coupled to a
Drawlock column between their adjacent edges,
[0024] FIG. 6 is a fragmentary perspective view of the two panels
of FIG. 5 after they have been drawn to and coupled with the
column,
[0025] FIG. 7 is a fragmentary exploded perspective view of a
column of FIG. 5 to which wall panels are attached,
[0026] FIG. 7A is a fragmentary top front perspective view of the
column of FIG. 7 connected to a foundation,
[0027] FIG. 7B is a fragmentary top perspective view of the column
of FIG. 7 to which roof truss beams are coupled,
[0028] FIGS. 8-10 show the column in progressive stages of its
coupling with wall panels, where FIG. 8 is a fragmentary elevation
view showing schematically how draw pins in edge pockets of
opposite wall panels approach coupling wings of the column,
[0029] FIG. 9 is a fragmentary perspective view of the column of
FIG. 8 showing how the draw pins of the opposite wall panels have
been drawn inward to the column and upward to their final
location,
[0030] FIG. 10 is a fragmentary elevational sectional view taken
along line 10-10 in FIG. 9 further showing the side panels fully
coupled to the column and showing the position of the draw bar
within the column,
[0031] FIG. 10A is a side elevation view in section of the column
of FIG. 6 showing schematically a force diagram of forces applied
to the draw bar, the column, the foundation and the draw pin,
[0032] FIG. 11 is a fragmentary sectional view taken along line
11-11 in FIGS. 1 and 10 showing the draw pins in side panel pockets
fully coupled with the wing tabs of the draw bar and of the
column,
[0033] FIG. 12 is a fragmentary elevational sectional view taken
along line 12-12 in FIG. 10, showing the coupling of the bottom end
of the draw shaft with the anchor,
[0034] FIG. 13 is a fragmentary elevational view in section,
partially similar to FIG. 10, showing the top end of the draw shaft
within the column when opposite wall panels are drawn-in and
coupled to the columns,
[0035] FIG. 14 is a fragmentary sectional elevational view taken
along line 14-14 in FIG. 13, showing the column and its coupling to
roof truss beams,
[0036] FIG. 14A is a top sectional view along line 14A-17A in FIG.
14,
[0037] FIG. 14B is a top perspective view of the roof truss
coupling to a wall column,
[0038] FIG. 15 is a fragmentary sectional plan view along line
15-15 in FIG. 1, showing the coupling of two wall panels to a
column forming the corner construction of the building,
[0039] FIG. 16 is a fragmentary sectional view taken along line
16-16 in FIG. 1, showing a set of adjacent roof panels coupled to a
column between them,
[0040] FIG. 17 is a fragmentary sectional view taken along line
17-17 in FIG. 1, showing the junction of the top ends of adjacent
roof panels at the peak of the roof,
[0041] FIG. 18 is a fragmentary sectional elevation view,
corresponding to FIG. 12, but showing a second embodiment of
connection of the bottom of the column and draw shaft to the
foundation;
[0042] FIGS. 19-21 show a sequence of stages of assembly or
erection of a typical wall of wall panels and columns, and
[0043] FIG. 22 is an exploded perspective view of a bookend mold
module for manufacture of a wall panel.
[0044] The features of the invention will become apparent from the
following description of the exemplary embodiments taken in
conjunction with the accompanying drawings.
IV. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] For convenience and clarity in describing the preferred
embodiments, similar elements or components appearing in different
figures and in different embodiments will have the same reference
numbers.
[0046] FIGS. 1 to 22 illustrate my new prefabricated building
invention which includes: (a) an assembled prefabricated building,
(b) the subassembly of a single wall or wall section formed of key
structural components of wall panels and support columns, (c) a
method of assembly or erection of such a building, (d) a new wall
panels alone, and (e) the method of making the new wall panel.
A. General Description of the Prefabricated Building
[0047] A typical building 10 constructed according to this
invention comprises side and end walls 11 formed of alternately
spaced wall panels 12 and support columns 14. Such walls are
secured to a floor 22 or other foundation and support a roof 15
comprising a roof truss and roof panel 18. More specifically, each
side wall 11 is formed of alternately positioned upright wall
panels 12 and upright support columns 14, where each column 14 is
situated between and releasably coupled to facing side edges 12A of
two adjacent wall panels 12. A typical wall panel has width of four
feet and height of eight, ten or more feet in height. Obviously, a
complete wall 11 comprising many wall panels 12 may vary in length
and height, and may include doors and windows as desired. Also, as
discussed later, wall panels 12, as modular units of wall 11, may
have customized sound and heat insulation properties, customized
esthetic interior and exterior surfaces and built-in HVAC, plumbing
and electrical components. Roof 15 is constructed in a manner
generally similar to that of the walls, with roof panels 18
releasably coupled to roof beams 20 situated between facing side
edges of adjacent roof panels. Optionally, other roof structure is
possible, but such would not necessarily employ and take advantage
of the present invention. The building also has floor 22 and anchor
23 components, and may utilize floor panels, generally similar to
wall panels but having properties appropriate for a floor. The
support columns structurally integrate the walls, roof and floor as
will be described in later sections.
B. Wall Construction of Wall Panels and Support Columns
[0048] As noted above and as seen in FIGS. 1 and 5-11, walls 11 of
the new prefabricated building are constructed of alternately
spaced wall panels 12 and support columns 14. For convenience, this
description and the claims will refer when appropriate to a
coupling means 1 which comprises coupling elements 2 and 3 for
connecting wall panels 12 to a support column 14, anchor connection
means 4 for securing a support column 14 to the anchor means 23,
and actuation means 5 for actuating said coupling means 1.
[0049] (1) Support Column
[0050] A typical support column 14 as seen in FIGS. 5-11 comprises
an outer tube 14A and a shaft or draw bar 25 slidable in tube 14A.
Said outer tube 14A has top part 14T, bottom part 14B and opposite
side walls 14E. Tube 14A also has front or inside wall 14C and rear
or outside wall 14D that correspond respectively to interior and
exterior surfaces of walls 12 of building 10.
[0051] The above mentioned coupling means 1 comprises first
coupling elements 2 on each side edge of each support column 14 and
second coupling elements 3 on each wall panel 12. As further
described, each support column 14 has on each side edge 14E five
axially spaced coupling elements 3, each comprising a set of wings
or jaws 29, 30. The five coupling elements 2 (designated 2A-2E) on
each side edge of column 14A are adapted to cooperate with five
coupling elements 3 (designated 3A-3E) on the side edge 12A of each
wall panel 12. As illustrated, each coupling element 2 comprises a
set of wings, where wing 29 is fixed to side edge 14E of outer tube
14 and wing 30 is carried by shaft 25 and movable to approach wing
29 when shaft 25 is drawn upward relative to outer tube 14A. The
actual number, size and form of coupling elements may vary from the
preferred constructions illustrated herein.
[0052] For cooperation with these five first coupling elements
2A-2E on each side edge 14A of each support column 14 are five
second coupling elements (3A-3E), each second coupling element
comprises a recess 26 and a pin 43 in the side edge of a typical
wall panel.
[0053] Each of coupling elements 2A-2E on support column 14 engages
and locks onto a pin 43 of a corresponding coupling element 3A-3E
of a panel when the panel is positioned for engagement and
connection to the support column.
[0054] (2) Wall Panel
[0055] As seen in FIG. 2 particularly and in FIG. 2A, each wall
panel 12 has side edges 12A, and in each side edge 12A is a series
of coupling elements 3A-3E, each consisting of a pocket or recess
26 and a pin 43 fixed in the pocket. Each recess 26 and pin 43
fixed therein functions as a coupling element 3 of coupling means 1
for connecting a wall panel to a support column 14. These recesses
are axially spaced apart to correspond to and receive said axially
spaced apart first coupling elements 2A-2E, each consisting of a
set of wings 29, 30. The central core of panel 12 is urethane foam
38.
[0056] For each set of wings the movable wing 30 includes a
hook-like groove 30A. For coupling of a wall panel 12 to the
support column 14, each set of wings extends laterally from the
support column 14 into a recess 26 in the side edge of wall panel
12 and engages and releasably couples with pin 43 in the panel.
Thus, the panel is maneuvered into position until each of the five
recesses on one side edge receives therein one set of wings, with
pins 43 moving between each said two wings of each set and into
said locking groove 34.
[0057] As seen in FIGS. 7, 7A and 7B, in a typical set of wings the
fixed upper wing 29 (a) has a tapered top edge 29A for easily
entering a corresponding recess 26 in a panel side edge 14A, and
(b) has a generally flat or horizontal bottom edge 29B that has
with a slight upward taper 29C at the outer end 29D. As seen in
FIGS. 11 fixed or top wing 29 is displaced laterally behind movable
wing 30 and toward the exterior side of column 14. The movable wing
30 of each set of wings is situated below top wing 29 and is
axially movable within an axial slot 31 in the side wall 14A of
column 14.
[0058] Below each fixed wing 29 is movable wing 30 attached to and
moved by draw bar 25. At the top edge of wing 30 is a groove 30A
creating a hook-like recess to receive and capture a pin 43 of
coupling element 3 of wall panel 12.
[0059] As noted above, each column 14 comprises an inner shaft or
draw bar 25 slidable within said outer tube 14A. As seen in FIG. 8
and also in FIGS. 7, 7A and 7B, draw bar 25 has its own axial slots
32 to receive hook elements 33 of each lower wing 30. When
assembling wings 30 onto draw bar 25, each wing 30 is moved
laterally until its two hook elements 33 enter and pass through
slot 31 on the side edge of outer tube 14A of support column 14,
and thence each element 33 enters a slot 32 of draw bar 25 and
drops down into full engagement. Later, upward movement of draw bar
25 will drive all hook elements 33 upward so that the edge of
groove 30A in the top edge of hook element 33 will approach the
bottom edge 29B of fixed wing 29 and capture pin 43 there
between.
[0060] To achieve this arrangement of draw bar, wings and outer
tube components, movable wings 30 are attached after draw bar 25 is
situated within the bore of outer tube 14A and slot 32 is aligned
with slot 31 of outer tube 14. As seen, draw bar 25 has five
axially spaced (movable) wings 30 on each side, which operate with
five fixed wings 29 on each side of outer tube 24, thus producing
five sets of wings on each side of column 14. Each set of wings is
one of the coupling elements 2A-2E. Axial movement upward of draw
bar 25 within outer tube 14A will move each top and bottom end beam
39 and wing 30 upward toward corresponding fixed wing 29 of outer
tube 14A.
[0061] Before describing how a panel 12 is coupled to column 14,
first note the panel structure as seen in FIGS. 2, 3, 4 and 5.
Panel 12 consists primarily of inner frame 40 having side beams 41
with pockets 42 spaced along the length of each side beam 41. Each
pocket 42 is formed by a generally triangular cup with pin 43
extending transversely across and fixed in each cup. In a
manufacturing process to be described later, sheets or skins 44A,
44B are attached to frame 41 and become the inside and outside
surfaces of wall panel 12.
[0062] Now, note that FIG. 5 shows two panels 12 being moved, as
indicated by arrows 45, toward both opposite sides of a support
column 14. Coupling elements 3A-3E, each comprising a pocket 26 and
pin 43 are generally aligned with coupling elements 2A-2E, each
comprising a set of upper and lower wings 29, 30. FIG. 6
illustrates a section of wall 11 where two wall panels 12 have
converged laterally against a column 14. FIG. 8 indicates
schematically how two wall panels (not shown) of FIG. 5 approach
opposite side edges of a column 14 and become coupled thereto. In
FIG. 8 the wall panels are not shown, but representing each wall
panel is a circle 43A representing pin 43 as the wall panel is
moved toward column 14. If a wall panel's elevation is not properly
aligned with space 46 between upper and lower wings 29, 30, then
taper edge 29C of upper wing 29 will guide pin 43A into space 46
and then downward into groove 30A.
[0063] FIGS. 8, 9, and 10 illustrate schematically two wall panels
12 moving and moved into engagement with both sides 14A of a single
support column 14. The two wall panels are not shown; however, pins
43A or 43B represents one of the coupling elements 2A-3G in a
typical wall panel. Once wall panel 12 and its pin 43 (this pin
representing the five coupling elements 3A-3E) moves sufficiently
inward toward column 14, pin 43 will reach the position indicated
by 43B. At this time, upward movement of draw bar 25 has driven
lower wing 30 upward, and tapered edge 30B of wing 30 has driven or
cam pin 43 (43B) further inward toward column 14. Full upward
movement of draw bar 25 drives pin 43 upward against bottom edge
29B of fixed upper wing 29, which thus positions panel 1 2 at the
correct elevation relative to column 14. This guidance and capture
of pin 43 by wings 29, 30 positions and secures wall panels 12 to
support columns 14, creating walls of desired length. Because the
proper alignment of each panel 12 is predetermined, the coupling
means 1 cannot overdraw or damage pin 43 or the panel in which it
is fixed.
[0064] Activation of draw bar 25 within outer tube 14A of each
column 25 achieves a plurality of functions: (a) engaging and
pulling the panels to be closely adjacent the column, (b) moving
the panels to the correct elevation and orientation relative to the
column and (c) securing the panels to the column. Said activation
also releasably secures the column and attached panels to the
anchor, floor or other foundation 22.
[0065] As seen in FIGS. 5, 6 and 1, each column 14 has a bottom end
14B that becomes secured to the floor 22, anchor or other
foundation component and a top end 14T that becomes coupled to and
supports roof 15. Each column 14 serves a plurality of different
functions with simplicity, efficiency and security, as described
below.
C. Operation of Draw Bar for Securing Wall Panels and Urging the
Support Column Downward Against Foundation
[0066] FIGS. 9, 10, 10A and 12 illustrate a first embodiment 4A of
the anchor coupling 4, and FIG. 18 illustrates a second embodiment
4B of such coupling. As seen in these figures coupling 4A consists
of rod 51 having hook 52 at the bottom that engages horizontal
anchor pin 53 that is securely embedded or otherwise fixed in the
floor 22 or in a jack stand 100 (FIG. 9) secured in the ground. In
the course of erecting a building 10, draw bar 25 is coupled via
rod 51 and hook 53 to anchor pin 53, which will anchor to the
ground the connected components (draw bar 25, support column 14 and
attached wall panels 12), as further explained below.
[0067] As seen in FIGS. 9, 10 and 12, draw bar 25 has at its lower
end, below wings 30, variable length coupling 4A which consists of
rod 51 whose lower end is pivotably coupled to anchor pin 53 and
whose threaded top end is fixed via locking nuts 57 to blade 56. In
FIG. 18 there is a variation in the form of an upward extending rod
55 whose top end is similarly fixed to blade 56, but whose bottom
end is fixed in the floor or foundation 22 with no pivoting
capability. In both of these embodiments blade 56 is secured to rod
51 or 55 respectively. With locking nuts 57 the elevation of blade
56 can be adjusted so that slot 58 in blade 56 will have its top
and bottom ends located at predetermined elevations relative to
anchor pin 53 or to the top reference surface 100A of the anchor
pad or jack stand, whichever is established as the basic reference
elevation.
[0068] As seen in FIG. 12, at the top end of slot 58 is pin 59
fixed to the lower end of draw bar 25. Further, as seen, draw bar
25 is in its uppermost or second position, since pin 59 is barred
from further upward movement by the top end of slot 58. In this
upper position draw bar 25 has pulled adjacent wall panels 1 2
closely and securely against the support column 14.
[0069] More specifically, when upright support column 14 is
positioned directly above rod 51, and draw bar 25 (slidable within
column 14) has its lower end coupled to rod 51, draw bar 25 is then
slidable within support column 14 within the limit of length L of
slot 58.
[0070] This movement of draw bar 25 is coordinated with movable
wings 30 secured thereto, so that upward movement of draw bar 25 to
its limit per slot 58, will bring each wing 30 to the predetermined
correct elevation below wing 29 to pull wall panels 12 inwardly to
the correct tightness against column 14 and to the correct
elevation relative to foundation or floor 22.
D. Actuation Means "5" To Actuate Coupling Means "1"
[0071] As described briefly earlier, actuation means 5 actuates
coupling means 1 which pulls draw bar 25 upward and draws panels 12
inward against support column 14. The actuation means 5 includes
(a) main nut 74 on threaded rod 66 extending from the top of draw
bar 25, and (b) block 68 fixed to a top portion of 14T of support
column 14. As seen in FIGS. 13, 14 and 14A, draw bar 25 is drawn
upward relative to outer tube 14A by rotating main nut 74. As will
be further described, the engagement of the bottom of draw bar 25
via coupling 4A to the anchor means 23, simultaneously secures
outer tube 14A of column 14 to the floor 22 and secures two wall
panels 12 at the correct elevation and tightness to column 14,
while barring over tightening forces that might be applied to pins
43 in the wall panels.
[0072] Coupling 4A has a height adjustment available via the set of
locking nuts 57, whereby variations in the elevation of the floor
or foundation 22 and length of rod 51 or 55 can be easily
accommodated, so that all draw bars 25 in the various support
columns 14 and all wall panels 12 will be at the same
elevation.
E. Anchor Connection with Support Column
[0073] As seen in FIG. 13, the top end of tube 14A of column 14
includes fixed block 68. The top end of draw bar 25 includes fixed
block 65. Threaded rod 66 coupled to block 65 extends through bore
67 in block 68, and rotation of main nut 74 on rod 66 pulls draw
bar 25 upward relative to outer tube 14A. As seen in FIGS. 13 and
14, outer tube 14A of column 14 in this embodiment is a rectangular
tube having side walls 14E, front or inner wall 14C and rear or
outer wall 14D. Block 68 fixed to outer tube 14A of support column
14 is supported by resting on cut-out edges, 14X, 14Y of front and
rear walls 14C, 14D where it sits between side walls 14E.
Consequently, any downward pressure on edges 14X, 14Y, urges the
support column 14 downward against the foundation 22.
[0074] Tightening of main nut 74 in a single step "locks down"
column 14 against the floor or foundation 22 and simultaneously
pulls upward on draw bar 25 and draws inward panels 12. More
specifically, lock down nut 74 when rotated by a wrench, bears
downward on block 68 which bears downward on edges 14X, 14Y of
outer tube 24 of column 14 which has its bottom end 14B driven
downward against the foundation 22.
[0075] The reason downward force on column 14 is achieved is that
rotation of nut 74 causes pulling upward on rod 66. As described
earlier, rod 66 is fixed to the top end of draw rod 25 whose bottom
end is coupled to the fixed floor or anchor. Also, as described
earlier, pulling upward initially causes draw bar 25 to move
upward, as wall panels 12 are drawn inward to and against column
14. Continued upward pulling on draw bar 25: (a) cannot further
lift the draw bar because such is barred and limited by slot 58 in
anchor connection 5, and (b) can only apply further downward force
on outer tube 14A of column 14 against the foundation. Lock nut 74
is then torqued to the proper final force for this assembly.
F. Anchor and Foundation
[0076] As seen in FIGS. 10, 10A, 12, and as described in Sections C
and D above, the lower part of draw bar 25 engages a foundation or
floor 22 or anchor 23 in the ground by anchor connection 4
comprising rod 51 extending downward to anchor pin 53. As seen, rod
51 has a bottom hook end 52 that engages fixed pin 53 and a
threaded top end. Also shown is anchor plate 54 whose neck is
situated inside the bottom end of outer tube 14A to stabilize it
from horizontal slippage. As seen in FIG. 10A, tightening lock-down
nut 74 atop block 65 fixed to outer tube 14A of column 14, pulls
draw bar 25 upward, thus, affecting an upward force F1 in rod 66,
seen as force F1'in draw bar 25, and seen as force F1'' in anchor
rod 51 and thus also on anchor pin 53. This upward force generates
a reaction downward force F2, F2' in the walls of outer tube 14A of
column 14, which downward forces becomes applied to the foundation
or floor 22. Also, as previously described, the upward force F1
applies force vectors F3 and F4 to pin 43 for drawing the wall
panels inward and upward.
[0077] A number of different foundations or floors may be employed
depending on the land conditions, equipment and materials available
or still other factors. For example, there may be a poured concrete
floor covering the entire area of the building to be erected, or
there may be only individual pilings or jack stand foundations
situated at the site of each upright support column, or some
combination of the above. In all cases it is necessary to establish
a very strong fixed anchor element at each location below an
upright support column.
[0078] FIGS. 7, 7A, 9, 10 and 12 illustrate a horizontal anchor pin
53 embedded in jack stand 100 (FIGS. 7, 7A, and 9) or embedded in
floor 22 (FIGS. 10 and 12). Engaged to anchor pin 53 in each figure
is hook 52 at the bottom end of rod 51. Because of the relationship
of the generally round cross-section of hook 52 and round
cross-section of the hook, rod 51 can easily angulate in all
directions from straight to accommodate any failure of a column 14
to be situated directly over the center of pin 53 and rod 51.
[0079] The later connection of the top end of rod 51 to the bottom
end of draw bar 25 has been described above. FIG. 12 shows how the
slot 58 in blade 56 and pin 59 in slot 58 arrangement allows
further angulation of rod 51, if necessary. FIG. 18 illustrates a
rod 55 fixed in a foundation, but including blade 56, slot 58 and
pin 59. A typical jack stand, as seen in FIG. 7A, has a truncated
pyramid shape with a seven inch square plate at the top, and
eighteen inch square plate at the bottom, and a twenty-four inch
height.
G. Roof Assembly and Connection to Side Walls
[0080] FIGS. 1, 7B, 13, 14, 14A and 14B illustrate the haunch
coupling of the roof truss to support columns 14. In this roof
truss system horizontal roof beams 80 span the space between side
walls 11, with each end portion 80A of a beam 80 removably coupled
to the top portion of one upright support column 14. As seen in
FIGS. 14 and 14A, end portion 80A of beam 80 rests upon block 68
which rests on cut-out ledges 14X, 14Y of the front and rear walls
14C, 14D respectively of outer tube 14A of column 14. Rod 66
extends upward from block 65 in draw bar's clearance hole 68A in
block 68. Lock down nut 74, when rotated, pulls draw bar 25 upward
to its maximum height set by slot 58 situated at the bottom of
outer tube 14A (see FIG. 12). In this upward position, with nut 74
tightened down, adjacent wall panels 12 will be drawn in to their
connect position of elevation and closeness to column 14. This
fixes and stabilizes the wall panels to the column and locks down
that column and panels to the floor or anchor.
[0081] Horizontal beams 80 join and support the opposite side walls
11. Each inclined roof beam 81 is situated between the facing side
edges of two adjacent roof panels 18, which are drawn securely
toward beam 81 by an internal draw bar similar to draw bars 25
employed in the side wall construction. Roof panels 18 are
sufficiently light weight that they can be easily lifted,
positioned and secured to roof beams 81. As evident in FIG. 13, the
single lock down nut 74 secures the wall panels into a wall
construction, and the single lock down nut 82 secures roof beams
80, 81 to the wall structure.
[0082] Roof beams 81 are partially similar to support columns 14,
in that each includes a slidable draw bar and sets of fixed and
movable wings for engaging pins in pockets of roof panels 12, which
are generally similar to wall panels 12. A series of alternatively
spaced roof panels 18 and roof beams 20 create a roof section 70.
As seen in FIG. 16, which is a sectional view taken from FIG. 1,
each two adjacent roof panels 18 joined by a roof beam 20 have
additional sealing strip elements 71, 72 which extends from one
panel toward the other and include internal gasket 74. When two
adjacent roof panels 18 are drawn and secured to a roof beam 20, as
seen in FIG. 16, seal strip 71 automatically slides over and
resiliently locks by the hook part 73 onto seal strip 72. FIG. 17
shows an additional seal 75 for adjacent top edges of two roof
sections.
[0083] The alternative roof truss system of FIG. 1 includes lower
horizontal roof beams 90, inclined roof beams 91, longitudinal roof
truss header beam 92, and side wall header beams 93 which
interconnect the top parts of support columns 14 of the side walls.
With this roof truss system that is independent of the roof panels,
the roof section is assembled of panels 18 and support beams 20,
one-after-another, into a roof section that lies upon and is
supported by the basic roof truss system.
[0084] This arrangement demonstrates another aspect of the present
invention which reduces labor, parts, and cost and thus speeds
erection of the building, while assuring a reliable seal.
H. Corner Wall Structure
[0085] As seen in FIGS. 1 and 15, the corner construction of side
walls 11 and end walls employs a corner upright support column 101
and draw bar 102 generally similar to a column 14 and draw bar 25,
except that the wings 29, 30 in this corner embodiment extend at a
right angle to each other, so that they can engage and couple to
the side and end wall panels 11 respectively. Pulling up on draw
bar 102 will cause wings 29, 30 to connect with pins 43 of the
respective panels and to draw these panels inward against column
101.
I. Floor
[0086] The floor 22 as seen in FIG. 1 is poured concrete or other
material with anchor or hold-down rods 51 or 55, as seen in FIGS.
12 and 18 respectively, embedded or secured in the floor. The floor
may be as primitive as bare dirt, so long as the anchor elements 23
are strong enough and sufficiently embedded to securely hold down
and stabilize the walls attached to said anchor elements.
[0087] The floor may alternatively be constructed of floor panels
in a manner generally similar to construction of a wall 11, with
floor beams and draw bars between facing side edges of adjacent
floor panels.
[0088] Strength, heat and sound insulation properties would be
designed into floor, wall and roof panels as desired. These panels
may also include modular segments of HVAC, electrical
telecommunication wiring, plumbing, etc. so that assembly of the
panels into floor, wall and roof sections automatically creates the
basic network of HVAC, electrical, telecommunicating and plumbing
systems.
J. Steps in Erection of Building
[0089] For this description of the building erection procedure, it
shall be assumed that a variety of preliminary steps have been
completed, namely:
[0090] (a) that the components are constructed and are readily
available at the erection site, these components including all the
wall panels 12, roof panels 18, support column and draw bar units
14/25, and roof beams and corresponding draw bar units 20, and
[0091] (b) that all the anchor pins 53 and upward extending anchor
rods 51 are positioned and secured either in a poured concrete
floor or in pilings, jack stands or in other foundation means, all
at the reasonably accurate elevation and distances from each
other.
[0092] The next steps in the preferred method of erection of the
building are as follows; however, numerous variations are
possible:
[0093] 1. Position a corner wall support column 101 as seen in
FIGS. 15 and 1) this support column has two panel-engaging sides
90.degree. apart, above the anchor pin in the corner location;
[0094] 2. Bring the side edge of a side wall panel into close
proximity with each of said panel-engaging sides of said corner
column, until each set of first coupling elements (2A-3E), namely
each set of upper and lower wings 29, 30 on each panel-engaging
side of the corner column enters a corresponding recess 42 of one
of the second coupling elements 3A-3E in a side edge of the panel,
until the coupling pin 43 in each recess is correctly in the space
46 between said wings. If necessary the tapered edges of wings 29
will guide or cam pin 43 to the correct elevation, thus correctly
positioning the panel as regards its orientation and elevation, see
FIG. 8. Both panels 12 oriented 90.degree. apart are now in initial
engagement with corner support column 101. It is assumed at this
time that the lower end 14B of draw bar 102 is properly connected
to the anchor pin directly below support column 101.
[0095] 3. Pull upward draw bar 102 (FIG. 15) until each pins 43 is
securely positioned between each set of wings 29, 30, and the
panels are drawn into proper position and secure engagement with
column 101, the column being securely connected to anchor pin 43
below the column.
[0096] 4. Two wall panels 11 (FIG. 15,1) at 90.degree. to each
other are now upstanding and coupled to the corner column 101, and
each of these wall panels has an exposed opposite side edge remote
from the side edge coupled to the corner column. Adjacent each of
said exposed side edges of the panels is positioned a new support
column 14. The draw bar 25 of each new support column is coupled to
an anchor pin below it, which may require tilting of the column and
may require momentarily sliding the bottom end of draw bar 25 out
of the bottom end of the outer tube 14A. For convenience, the
above-mentioned first wall panel forming the corner will be
designated Panel 1. The new support column adjacent to the exposed
edge of Panel 1 will be designated Column 1.
[0097] 5. In addition to connecting Column 1 to its anchor pin,
Column 1 is adjusted in position and orientation so that its
coupling elements (2A-3E), namely wings 29, 30 are maneuvered into
coupling elements (3A-3E), namely pockets or recesses 2 in the
exposed side of Panel 1; however, coupling of Column 1 and Panel 1
is not yet complete.
[0098] 6. A new wall Panel 2 is now positioned adjacent the other
side of Column 1, until the coupling elements (2A-2E) namely, the
sets of wings of Column 1, enter corresponding coupling elements
(3A-3E) namely recesses 42 in the adjacent side edge of Panel
2.
[0099] 7. Next, draw bar 25 within Column 1 is pulled upward which
draws Column 1 toward Panel 1 and draws Panel 2 toward Column 1,
until Panel 2 is upright and properly aligned, consistent with
Panel 1.
[0100] 8. As seen in FIGS. 19, 20, and 21, this procedure is
repeated for the length of the side wall, followed by attachment of
another corner column, followed by attachment of "end" wall
panels.
[0101] 9. With the walls 10 essentially complete, horizontal roof
beams 80 are positioned with their ends 80A coupled into the top
ends of opposite columns 14 in opposite side wall 10. The
upstanding rod 66 of each column 14 extends through holes in said
ends of roof beams 80.
[0102] 10. Next, an inclined roof beam 81, which includes a draw
bar assembly for engaging roof panels, is positioned with its lower
end positioned adjacent the end 80A of beam 80 top wall column. Rod
66 extends through both beams, and lock-down nut 82 is installed to
secure both beams to column 14. The upper ends of roof beams are
supported by a header beam 92 extending lengthwise of the building,
FIG. 1.
[0103] 11. Next, a first roof panel 18 is positioned with one side
edge and its recesses closely adjacent a first roof beams, until
the sets of wings enter the pockets in the side edge of the first
roof panel. The draw bar in beam 81 is pulled axially until roof
panels on both sides are drawn-in and properly and snugly
positioned.
[0104] 12. Additional roof beam/draw bar component and roof panels
are consecutively placed in a manner generally similar to the
erection of a side wall and is continued to complete one side of a
gabled roof.
[0105] 13. A variety of subsequent finishing steps will be executed
as selected, including connection of electrical, water and HVAC
components through panels and columns. Various details associated
with individual components and discussed above, such as connecting
the bottom of each draw bar to the corresponding anchor pin, have
not been described again. Also, not described here are methods of
accurately positioning and establishing the correct elevation of
jack stands and anchor pins.
K. Construction of a Wall Panel
[0106] Wall panels as seen in FIGS. 2-6, having the dimensions and
physical properties required for a prefabricated building as
described herein, may be made by numerous manufacturing processes;
however, the preferred process which is consistent with concepts of
the present invention:
[0107] (a) uses non-wood materials such as plastics, fiberglass and
composites which reduce consumption of forests, and which have good
heat and cold insulation properties and thus further reduce the
consumption of wood and other natural resources and energy for
heating and cooling,
[0108] (b) uses methods and manufacturing equipment that can be
easily transported, set up and used to produce wall panels and
support columns at very high speed and low cost,
[0109] (c) produces panels that are strong yet extremely light
weight so that transport, storage, and assembly will not require
heavy equipment, and
[0110] (d) produces panels which can have a great variety of
textured, colored, aesthetic and functional external and internal
surfaces.
[0111] The new panels seen in FIGS. 2 and 4 are manufactured by a
method using a mold shown schematically in FIG. 22 which includes
the following steps:
[0112] Step 1: The skins 44A, 44B of each panel are fabrics which
comprise two layers of fiberglass and/or Kevlar carbon fiber (matte
and unidirectional) with polyester resin which (a) may be wetted
out by hand, or (b) may be wet from prepregnated resin, or (c) may
have resin injected into a closed mold which already contains the
fabric sheets. These panels have a Class 1 fire rating.
[0113] Step 2: The internal frame 40 of each panel comprises two
identical side legs 44, each having equally spaced pockets 42 and
top and bottom end legs 39 whose ends are joined to the side legs
to form a picture frame; however, the top leg includes a rake angle
from front to rear to accommodate the slope of the roof. Thus, the
inside of the picture frame and the inside skin 44A will be
slightly taller than the outside skin 44B, as seen in FIG. 4A.
Instead of joining side and end legs, the legs of this picture
frame can be formed in a single step mold. This frame may be made
of a fiber glass and resin combination or of any other materials
having suitable strength characteristics for the temperature and
environmental conditions of molding and of use in buildings.
[0114] Step 3: A mold, as seen in FIG. 22, holds the fabric sheets
and frame of a single panel. Urethane foam 38 is injected into the
space within the frame and between the skins, the skins are bonded
to the frame, and a unitary one-piece panel is created. Thereafter,
holes are drilled or machined to receive pins 43 for coupling to
the previously described support column/draw bar subassemblies 14.
Optimally, pins 43 may be placed within the mold before
injection.
[0115] Step 4: The top and bottom legs 39 of each frame include
holes 86 along their length to receive injection nozzles (not
shown) for entry of the urethane foam that expands 1200% in 40
seconds. Hole size depends on the volume of the cavity and the
speed of the urethane. After injection, the nozzles are retracted
and the holes are sealed. Heat from and during injection is about
100.degree. F. which is maintained for about 45 seconds.
[0116] Step 5: For each panel, injection cycle time is one minute
and cure time is 10 minutes. The fiberglass skin may be manually
placed in the mold, or with a PFE (Precision Feed End Effector) the
skin can be laid up in the mold with optional wet, dry or prepreg
gel coat, or the gel coat may be sprayed inside the mold before the
skin is situated therein. Preferably a robot will apply the gel
coat since it is highly combustible and the robot is sufficiently
explosion-proof. Also, the robot can maneuver into confined
compartments or unfriendly environments and can move molds with gel
coat to safer location.
[0117] Step 6: The fiber glass and epoxy mold 83 in a preferred
embodiment opens like front and rear book covers 83A open from the
core pages of a book.
[0118] End plates 84 of the mold overlie the top and bottom beams
39 of the picture frame 40. Holes 85 in end plates 84 are aligned
with holes 86 in said top and bottom beams 39 of frame 40, so that
injected foam can pass through the mold end plates and the frame
end wall, into the panel cavity 87. The skins 44A, 44B will become
bonded to frame 40.
[0119] Step 7: High Speed Manufacturing Sequences:
[0120] With selected number and sequencing of molds, panels can be
made at the rate of one per minute or theoretically 43, 200 per
month with this arrangement:
[0121] (a) skins are made at the rate of one per minute,
[0122] (b) frames are made at the rate of one per minute,
[0123] (c) two skins and one frame converge to form a panel
cartridge (with injection and 1200% expansion in 4 seconds) and
movement of mold to a cooling line for ten minutes, and
[0124] (d) with ten cooling lines, each taking ten minutes, a
staggered arrangement will produce one panel every minute. This is
illustrated in attached Appendix A.
[0125] This is all robot controlled and thus requires essentially
no human labor except for basic supervision and maintenance. This
panel construction is applicable for wall, roof and/or floor
panels. Panel shape may be flat, curved or otherwise. Surface
texture, color, graphics or other esthetic on interior and exterior
panel surface is possible.
V. SUMMARY
[0126] This invention discloses a variety of embodiments of the new
prefabricated building structure, components and methods of
manufacture, including:
[0127] (a) a whole building comprising walls, roof and floor or
foundation,
[0128] (b) the subassembly of a single wall or portion of one
wall,
[0129] (c) the sub-assembly of a single support column and one or
two attached panels,
[0130] (d) a single support column and slidable internal shaft,
[0131] (e) roof and floor sub-assemblies,
[0132] (f) a method of erecting a building constructed of the new
panels and support columns,
[0133] (g) a method of manufacturing a single wall panel, and
[0134] (h) a kit components for assembling or erecting a building,
or a wall, or a wall section.
[0135] Summaries of certain ones of the above-described embodiments
of this invention are presented below.
[0136] A first embodiment of the present invention is a
prefabricated wall comprising:
[0137] (a) a plurality of wall panels and a plurality of columns
for supporting said wall panels, where each of said columns and
panels has top and bottom parts, inner and outer surfaces and
opposite side edges, and said panels and columns are adapted to be
alternately spaced and joined together, with each of said columns
situated between two of said panels to form a wall section,
[0138] (b) coupling means for each of said wall sections for
releasably attaching one side edge of each of said two panels to
each side edge of said column, and
[0139] (c) activating means on said column of each of said wall
sections for activating each of said coupling means, [0140] wherein
each of said coupling means comprises: [0141] (1) at least one
1.sup.st coupling element situated on one side edge of said column,
and [0142] (2) at least one 2.sup.nd coupling element on the side
edge of the panel being coupled, said column and panels being
laterally movable relative to each other until said 1.sup.st and
2.sup.nd coupling elements of said column and of said wall panels
respectively come into engagement, and
[0143] said activating means being adapted to drive said 1.sup.st
coupling element generally vertically which drives said 2.sup.nd
coupling elements generally horizontally, thus driving said side
edges of said panels and column toward each other.
[0144] A second embodiment of the present invention is a
prefabricated wall as described in said first embodiment,
wherein
[0145] (a) said first coupling element of each of said wall
sections comprises: a 1st wing: [0146] (1) fixed to each of said
side edges of said shaft, [0147] (2) extending laterally outward
therefrom and terminating in and end part which includes a cam
surface inclined inwardly toward said shaft, and [0148] (3) movable
upward when said shaft is driven upward, and
[0149] (b) said side edge of said wall panel defines a recess
extending inward into said panel and thus extending away from said
shaft, and
[0150] (c) said second coupling element comprises a pin fixed in
said recess in said wall panel and extending in the
inside-to-outside direction, said cam surface of said first
coupling element, when said shaft is driven upwardly by said
activating means, camming said pin and associated wall panel toward
to said column.
[0151] A third embodiment is a prefabricated wall according to said
second embodiment, adapted to be erected on and attached to a
foundation which includes anchor means secured in said foundation,
wherein: [0152] (a) said column outer tube comprises walls
extending from said top part of said column downward to and
engaging said foundation, [0153] (b) said inner shaft extends
axially in said outer tube, and [0154] (c) said activating means
driving said inner shaft upward relative to said tube, which puts
said shaft in tension relative to said tube and puts said tube
walls in compression relative to said foundation, where said
lifting said shaft lifts said 1.sup.st wing and its cam surface
therein cams said pin and panel attached to said pin inwardly
toward said shaft.
[0155] A fourth embodiment is a prefabricated wall according to
said first embodiment, wherein each of said wall panels
comprises:
[0156] (a) a generally rectangular frame formed by top, bottom and
side edge beams which define between then a central space,
[0157] (b) a core of heat insulation material substantially filling
said central space and secured therein, and
[0158] (c) inner and outer skins covering said inner and outer
sides respectively of said frame and core.
[0159] A fifth embodiment is a prefabricated wall according to said
first embodiment adapted to be erected on and attached to a
foundation which is secured in the ground and includes anchor means
fixed in said foundation and spaced apart to locations
corresponding to each of said columns, where each of said columns
comprises an outer tube with a bore extending lengthwise, and an
inner shaft axially slidable upward in said outer tube bore, said
inner shaft having a bottom end adapted to releasably engage one of
said anchor means, and said inner shaft when pulled upwardly
relative to said column, pulls upwardly on said anchor means
causing a downward force of said outer tube on said foundation and
tension on said inner shaft, as said wall panels are drawing toward
said column.
[0160] A sixth embodiment is a kit for constructing a prefabricated
wall, said kit comprising:
[0161] (a) a plurality of wall panels and a plurality of columns
for supporting said wall panels, where each of said columns and
panels has top and bottom parts, inner and outer surfaces and
opposite side edges, and said panels and columns are adapted to be
alternately spaced and joined together, with each of said columns
situated between two of said panels to form a wall section,
[0162] (b) coupling means for each of said wall sections for
releasably attaching one side edge of each of said two panels to
each side edge of said column, and
[0163] (c) activating means on said column of each of said wall
sections for activating each of said coupling means,
[0164] wherein each of said coupling means comprises: [0165] (1) at
least one 1.sup.st coupling element situated on one side edge of
said column, and [0166] (2) at least one 2.sup.nd coupling element
on the side edge of the panel being coupled, said column and panels
being laterally movable relative to each other until said 1.sup.st
and 2.sup.nd coupling elements of said column and of said wall
panels respectively come into engagement, and [0167] said
activating means being adapted to drive said 1.sup.st coupling
element generally vertically which drives said 2.sup.nd coupling
elements generally horizontally, thus driving said side edges of
said panels and column toward each other.
[0168] A seventh embodiment is a generally rectangular
prefabricated building erected on a floor area and attached to
anchor means in said floor area, comprising:
[0169] (a) four walls as defined in said second embodiment, where
each wall extends upright and laterally to predetermined lengths
respectively and terminates in opposite ends,
[0170] (b) corner coupling for joining adjacent ends of two
walls,
[0171] (c) a roof secured to said top parts of at least two of said
walls, and
[0172] (d) each of said columns of each of said walls having an
internal shaft with a bottom end engagable to said anchor element
and a top part adapted to be pulled upward relative to said column
top at, thereby causing said shaft to be in tension, said column
bottom part to press downward against said floor area, and said
coupling means thereon to be urged upward.
[0173] An eight embodiment is a method of manufacturing a wall
panel with an injection mold having front and rear and edge covers,
where at least one edge cover includes an injection inlet means,
and at least one edge cover includes outlet vent means, comprising
the steps:
[0174] (a) positioning a generally rectangular frame having inner
and outer sides in said mold, said frame defining within it a
central cavity,
[0175] (b) positioning inner and outer skins adjacent the inner and
outer sides of said frame to enclose said central cavity,
[0176] (c) covering said skins with said front and rear covers of
said mold,
[0177] (d) securing said front and rear covers and said end plates
onto said mold,
[0178] (e) injecting expandable urethane plastic into said
cavity,
[0179] (f) venting said cavity via apertures in said frame and
mold,
[0180] (g) bonding said skins to said frame,
[0181] (h) cooling said mold and molded panel therein,
[0182] (i) opening said covers and end plates, and
[0183] (j) removing said panel from said mold.
[0184] A ninth embodiment is a method of erecting a prefabricated
building according to said seventh embodiment, comprising the
steps:
[0185] (a) establishing a (generally horizontal) floor area on
which to erect said building,
[0186] (b) securing anchor means in said floor area at
predetermined locations and a generally common elevation,
[0187] (c) positioning and erecting a corner column at a corner
location for said building above a corresponding anchor means and
engaging said shaft of said corner column to said anchor means,
[0188] (d) positioning said first wall panel with one of its end
edges adjacent one side edge of said corner column, moving said
will panel laterally until said coupling elements of said corner
column enter said recesses of said first wall panel, and elevating
said shaft to engage and draw-in said wall panel to said
column,
[0189] (e) positioning and erecting a first column adjacent said
opposite side edge of said first wall panel and positioned above
said anchor means corresponding to said first column, engaging said
shaft of said first column to said anchor means, and positioning
said first coupling elements of said first column in recesses in
said opposite side edge of said first wall panel, and
[0190] (f) elevating said shaft of said first column for its first
coupling elements to engage and draw together said opposite side
edge and said first column, to simultaneously secure said first
column to its anchor means.
[0191] While the invention has been described in conjunction with
several embodiments, it is to be understood that many alternatives,
modifications, and variations will be apparent to those skilled in
the art in light of the foregoing description. Accordingly, this
invention is intended to embrace all such alternatives,
modifications, and variations which fall within the spirit and
scope of the appended claims.
* * * * *