U.S. patent number 3,641,724 [Application Number 04/872,272] was granted by the patent office on 1972-02-15 for box beam wall construction.
Invention is credited to James Palmer.
United States Patent |
3,641,724 |
Palmer |
February 15, 1972 |
BOX BEAM WALL CONSTRUCTION
Abstract
A wall construction for homes and the like developed for the
construction of wall sections at locations removed from the
building into which includes an integral box beam construction at
the upper portions thereof with insulating and reflective material
being provided as integral elements within the wall section. The
box beam construction is built directly into the wall section and
provides a strengthening factor to permit the placement of doors
and windows at any point and permits the placement of truss rafters
at any point along the wall.
Inventors: |
Palmer; James (Excelsior,
MN) |
Family
ID: |
25359225 |
Appl.
No.: |
04/872,272 |
Filed: |
March 29, 1969 |
Current U.S.
Class: |
52/793.11;
52/407.3; 156/78 |
Current CPC
Class: |
E04C
2/386 (20130101) |
Current International
Class: |
E04C
2/38 (20060101); E04c 002/46 () |
Field of
Search: |
;52/615,309,204,210,407,481 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Murtagh; John E.
Claims
What is claimed is:
1. A wall section including:
a. at least a pair of spaced upright support members;
b. means joining the lower ends of said support members;
c. intermediate header means joining said members at a
predetermined distance from the upper end thereof;
d. upper header means joining said members at the upper ends
thereof;
e. a pair of continuous surface members secured to opposite sides
of said upright supports and extending therebetween and secured to
said intermediate and upper header means to thereby form a closed
box construction at the upper portion of said support member;
f. each of said upright members being of a first predetermined
transverse dimension along a first longitudinal portion thereof and
being of a predetermined smaller transverse dimension along a
second longitudinal portion thereof to provide a shoulder to
receive and position one of said continuous surface members
thereagainst; and,
g. the other of said continuous surfaces being of a size to extend
over and be secured to said lower end joining means, said upright
supports and said upper header means.
2. The structure set forth in claim 1 and the other of said
continuous surfaces being of a size to extend a predetermined
dimension above said upper header means.
Description
In the past, various modular wall sections have been suggested for
off-the-site preparation wherein the individual wall sections are
shipped to the site and simply assembled into the proper
arrangement. Although the need and financial considerations for
such factory preassembled sections is well known, to date, the
problems that have existed in this art have subtracted greatly from
the success which the industry would like to obtain. One of the
major problems in utilizing these free-constructed wall sections is
the lack of flexibility to obtain an esthetically desirable home
and further, the final houses produced in this manner are often
thought to be poorly constructed from structural or strength
standpoints.
Applicant has provided herein a new and unique concept for
providing modular preassembled wall sections wherein a box beam
arrangement is formed directly within the wall section which
provides a great deal of strength to the wall unit to thereby
overcome some of these objections to structural situations and has
further provided a wall unit which is a complete wall structure
having the necessary insulation and reflective materials directly
provided therein which materials are so arranged and utilized as to
provide proper spacing for the installation of electrical wiring
and the like at the jobsite. This particular arrangement of
applicant's wall-forming materials, then provides a certain degree
of flexibility which permits the wall framework to be completely
erected and thereafter provided with proper wiring and the
like.
With applicant's concept, the box beam header situation is further
enhanced with the type of assembly methods utilized. Applicant
provides a completely glued and nailed structure which presents a
nonrackable arrangement of the elements contained therein such that
no shifting of the various parts can occur in transportation or the
like and which, therefore, maintains the units in proper plumb
condition. This, obviously, prevents misalignment of parts and
simplifies the assembly at the jobsite.
It is therefore an object of applicant's invention to provide a
wall section of modular form including a box beam construction
integrally arranged therewith.
It is a further object of applicant's invention to provide a wall
section construction arranged for modular sizing which includes a
frame structure having heat-insulating and heat-reflective means
incorporated therein.
It is a further object of applicant's invention to provide a wall
structure arranged for modular sizing which incorporates insulating
and reflective materials in selected portions thereof to permit
additional elements to be mounted in cavities or airspaces provided
therein.
It is a further object of applicant's invention to provide wall
sections designed and arranged for modular sizing which includes
strengthening elements integral therewith which afford a
longitudinal strengthening factor for load-carrying purposes
entirely therealong.
It is still a further object of applicant's invention to provide a
complete rigid wall section for use in construction which, due to
its specific design, provides a substantially rigid and strong
element which is easily modified and varied to provide a variety of
forms to be produced through the utilization of multiples of such
elements.
These and other objects and advantages of the invention will more
fully appear from the following description made in connection with
the accompanying drawings, wherein like reference characters refer
to the same or similar parts throughout the several views; and in
which:
FIG. 1 is a perspective view illustrating the framing and
application of an exterior 2 a wall section embodying the concepts
of applicant's invention;
FIG. 2 is a perspective view taken from the opposite side of
applicant's wall structure illustrating the insulating and the
reflective-surface techniques and box beam assembly techniques
utilized in applicant's concept;
FIG. 3 is an elevation of a wall section embodying applicant's
concepts;
FIG. 4 is a vertical section taken substantially along line 4--4 of
FIG. 3; and,
FIG. 5 is a sectional view taken through a pair of adjacent wall
structures illustrating the method for joining the same.
In accordance with applicant's concept, and in accordance with the
accompanying drawings, a wall module generally designated 10
includes a wall framework section which considering FIG. 1 provides
a plurality of upright studs, 11, 12, 13 and 14, attached at one
end to a lower baseplate 15 and at the other end to an upper header
16. As illustrated in FIG. 1, the outer stud members 11-14, are
full length while the interior stud members 12-13 are substantially
shorter to provide an intermediate header member 17 extending
between the outer studs 11-14 and attached thereto with shorter
stud sections designated 12a, 13a in aligned relation to the inner
studs 12-13, arranged on the opposite side of the intermediate
header 17. To provide and illustrate this structure, applicant has
utilized standard wooden 2.times.4' s, but it is obvious that other
sizes of structural elements may be utilized.
As illustrated in FIG. 1, the outer studs 11-14 are notched at the
upper end thereof such as at 18 to provide a shoulder 19 and the
sizes of the short stud sections 12a, 13a above the intermediate
header 17 are all in corresponding relation to this notched member
to provide the interfitting of an additional member therein as will
be discussed hereinafter.
As illustrated in FIG. 1, an exterior cover member designated 20 is
provided which is of a predetermined dimension such that the upper
end 20a thereof may be slightly above the upper end of the upper
header 16 to provide a top plate partial housing section. This
exterior cover member 20 is also offset slightly on one of the
outer studs 11 or 14 such that an overlap as will be discussed
hereinafter in connection with FIG. 5 is provided. This exterior
member 20 is rigidly connected to the framework provided through
the utilization of glue and nailing. This gluing and nailing
process provides a rigid structure having a tremendous advantage
over a simply nailed member.
To complete the framework structure, a discussion of FIG. 2 is now
made wherein the framework as illustrated in FIG. 1 is turned over
to now present a plurality of cavities bounded respectively by the
structural members. The process of providing insulation and
reflective materials into these cavities includes as illustrated, a
foaming process using foaming urethanes which may be applied
through a mixing gun 21 directly into the cavities and thereby
provide filling thereof to a desired depth with complete adhesion
to the members forming the cavities. These cavities are filled to
approximately two-thirds of the depth of the cavity and this
foaming in place urethane material 22 will not only provide an
insulating effect, but will greatly increase the rigidity of the
entire structure. After foaming and while the foaming material is
still in a liquid or semiliquid state, a reflective material 23 is
layed directly thereover and may be pressed thereto as in the form
shown by a roller 24 being applied against the outer surface
thereof. This particular reflective material 23 provides in its
most preferred form, both a vapor barrier source and a reflective
source such that heat will be reflected back into the building and
thereby provide a guard against heat loss. By bonding this material
23 directly to the foam, it is obvious that a superior situation is
provided as to those arrangements wherein the reflective material
is simply nailed to the individual structural elements.
As further illustrated in FIG. 2, the last element of the box beam
is afforded and is properly attached into position after completion
of the insulating and reflective installation. This element is
designated 25 and includes a member to extend and fit properly into
the aforementioned notched area 18 and abut with the shoulder 19.
This box beam element again is attached into its position through
proper nailing and gluing procedures and at this point, the entire
box beam element is formed and includes the intermediate header 17
and upper header member 16 as the flanges of the beam with the
exterior surface member 20 the interior member 25 serving as the
webs of the box beam structure. It should be noted that this box
beam extends entirely along any one of the individual sections and
therefore affords a proper and sufficiently strong header for
heading above window sections, other openings and for the
installation of truss supports or truss rafters at any position
along a wall section rather than locating them with particular
reference to a vertical stud or providing solid beam headers over
window openings with the trusses positioned on the solid
headers.
It should be noted in FIG. 2 that as the foam material 22 and the
reflective material 23 assumes approximately two-thirds of the
depth of each of the cavities that an additional area is afforded
on the inner side of the wall to permit the proper placement of
wiring or the like therein. This is particularly visible in FIG. 4
wherein this space is designated 26 and it should be noted that
this area will permit the installation of wiring or other
mechanical necessities without disturbing either the insulating
material or the vapor barrier and reflective material.
The wall structure as illustrated in FIG. 2 represents the
utilization of the concept when openings must be provided for
windows or the like. In this particular case the box beam area
designated 27 extends entirely across the wall module 10 with the
window opening 28 being provided therein through the utilization
being provided therein through the utilization of a window header
29 below the window opening with vertical studs 30-31 located
thereunder. In the form shown in FIG. 3, there is a difference in
the structure utilized although it should be obvious that the
structure necessary to afford a window opening must essentially be
different than that utilized to provide a solid wall section.
In the form shown, in FIG. 4, the extending exterior member 20 is
illustrated with the added length 20a to provide an area 32 into
which the top plate which functions to join sections may be layed
and nailed. By providing such a continuous exterior surface and
resulting containing area a stronger relationship for adjacent
sections is provided than when the normal top plate is simply layed
on top of the top header 16. In other words, by providing a
two-sided containing area more strength, nailing area and rigidity
is therefore provided to connect adjacent sections to one
another.
FIG. 5 illustrates the method of section joining wherein the
exterior surfacing members 20 are in overlapped relation and it
should be noted that as previously stated, this member will lap
joints between adjacent exterior studs 11-14 upon adjacent
sections.
In the structures of FIGS. 4 (in dotted lines) and 5, an interior
decorative surface is suggested and is designated 33. This
particular interior surface is installed at the jobsite, but it
should be noted that this member again adds rigidity to the box
beam arrangement by completely enclosing the same while still
providing the area 26 necessary for mechanical installations.
Applicant has also found that when utilizing a desirable surface
member such as a decorative redwood or the like for the exterior
surfacing member 20, it is not necessary to provide any additional
exterior sheeting. Obviously, if other decorative effects are
desired for the exterior of the house, then the surfacing sheet 20
is simply a structural member rather than being decorative and
structural.
Applicant has provided herein a unique modular wall construction
which utilizes a unique combination of available elements to
provide a box beam header member entirely along the top area of a
wall section and it is well known in structural analysis that such
beams provide substantial strength to support loads and applicant
accomplishes this effect without providing solid header members or
without incorporating steel beams into his structure.
As should also be obvious with applicant's structure, highly
effective insulating and heat-reflective barrier is provided which
through its positioning will not be damaged by the installation of
mechanical or electrical features into the wall panel as an area
for such devices is maintained therein. Although applicant has
illustrated the insulating concept as an in place foaming process,
it should be obvious that proper size urethane blocks may be cut
and glued into the afforded cavities with the reflective material
then being applied and glued directly thereto. This latter process
is certainly ideal for mass assembly situations, but it should be
obvious that proper fitting of these elements would be necessary
which might slightly slow down the assembly arrangement. Applicant,
therefore, has chosen as a preferred form, the foaming in place
process.
It should be obvious that the wall structure provided herein
affords a wide variety of wall areas and by simply providing
multiples of the modulars and shifting these to meet the required
needs, any type of wall can be constructed.
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