Structural Member And Building Embodying Same

Abstract

A substantially rectangular prefabricated structural member that includes a core of rigid material that has two transversely aligned rectangular panels secured to opposite longitudinally extending surfaces thereof. The structural members when disposed side by side and situated between a foundation supported sill and an elongate plate situated vertically thereabove, cooperate to define a wall structure. The panels are of greater height and width than the core with which they are associated, and cooperate with the core to define first and second horizontal channels that interlock with the sill and plate to hold the structural member in a fixed transverse position relative thereto. The panels on each structural member project outwardly from a first vertically extending side surface of the core to cooperate with said first side surface to define a third vertically extending channel. A first vertically extending section of the core extends outwardly from the first and second panels, with this outwardly extending section having a second vertical side surface defined thereon. When the structural members are interlocked with a sill and plate and disposed side by side, the vertically extending section of one structural member is disposed within the third channel of the structural member situated adjacent thereto, and the structural members cooperating to provide a continuous vertically extending wall. Nails, staples or the like may be driven through the lower and upper longitudinal edge portions of the panels to firmly secure the same to the plate and sill, to prevent longitudinal movement of the structural members relative thereto. The prefabricated structural members above described may be used to not only form the exterior walls of a building, but the interior partitions as well, and also the floor of the building. The panels may also be used to define the roof structure of the building if desired. The core is preferably a rigid material that has good heat and sound insulating qualities. Honeycomb material or other reticulated material, both with and without heat and sound insulating composition filling the voids therein, have been found satisfactory for use as cores. Structural members using such cores have been found by tests to have extremely high compression resistant qualities as well as being capable of withstanding exceptional high wind loading. The exterior longitudinally extending surfaces of the structural members above described preferably have means included as an integral part thereof that permit stucco or other cementitious material to bond thereto when applied by conventional methods, and without the use of wire screen, mesh or the like.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

Rectangular structural members capable of interlocking with one another when disposed side by side to provide a dimensionally stable wall that may form either an exterior or interior portion of a building. The structural members when disposed side by side in interlocking relationship may also be used to define a floor or roof of a building of either a single or multistory design.

2. Description of the Prior art

In the past, various types of prefabricated rectangular structural members have been proposed and used to a limited extent in forming the wall of buildings. However, such prior art structural members have the operational disadvantages that they provide no satisfactory and simple interlock therebetween, and are difficult to incorporate into the frame of a building.

The present structural members overcome the operational disadvantages of prior art devices in that they easily interlock with one another, as well as sills and plates to define both exterior and interior walls, as well as floors and roofs of buildings.

SUMMARY OF THE INVENTION

A rectangular structural member formed from a core of rigid material, preferably having good heat and sound insulating qualities, and to which core two transversely aligned rectangular panels are secured. The core and panels are so arranged relative to one another that they cooperate to define first and second horizontal channels that interlock with a foundation supported sill and an elongate plate situated at an elevated position thereabove. Third vertically extending channels are formed in the structural members that permit the latter to engage corner posts, fasteners, and the like, as well as vertically extending sections that project outwardly from the structural members situated adjacent thereto.

The structural members used in forming an exterior wall have means incorporated in the exterior wall defining portions thereof to permit stucco or other cementitious material to be applied directly to the structural member and bond thereto. Stucco or other cementitious material when applied to the structural members forms a continuous water and weather proof surface thereon.

A major object of the present invention is to provide a rectangular structural member defined by a rectangular rigid core to which transversely aligned rectangular panels are so secured that they cooperate with the core to define first, second and third channels, and the first and second channels serving to interlock with portions of the framing of a building to hold the structural members in fixed relationship thereto. The structural members due to the third channels and projecting sections of the core interlock with one another to form a continuous exterior or interior wall, as well as a floor or roof of a building.

A further object of the invention is to supply rectangular structural members that have substantial compressive strength and high resistance to wind loading, can be fabricated from standard commercially available materials, may be delivered to the job in a prefabricated condition, are weather resistant, and due to their low cost of manufacture may be used to provide housing at substantially less cost than by conventional methods now in use.

Yet another object of the invention is to furnish structural members that may be fabricated on the job site for subsequent incorporation into a building structure.

A still further object of the invention is to supply a structural member that has a high strength weight ratio, good insulating qualities, is water and fire resistant, is bug and vermin proof, has a long life expectancy, and is unlimited as to the designs that may be achieved therewith.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a building in which the walls, roof and floor are formed from prefabricated rectangular structural members;

FIG. 2 is a fragmentary vertical cross sectional view of a first form of slab and wall structure of the building shown in FIG. 1 taken on the line 2--2 thereof;

FIG. 3 is a fragmentary vertical cross sectional view of a second form of slab and wall structure embodying a termite shield;

FIG. 4 is a fragmentary vertical cross sectional view of a third form of slab and wall structure;

FIG. 5 is a fragmentary vertical cross sectional view of a fourth form of slab and wall structure particularly adapted for an interior partition in the building shown in FIG. 1;

FIG. 7 is a fragmentary horizontal cross sectional view of the building shown in FIG. 1 taken on the line 6--6 thereof;

FIG. 7 is a fragmentary horizontal cross sectional view of a corner wall detail for a building;

FIG. 8 is a fragmentary horizontal cross sectional view of the intersection of two interior partition walls;

FIG. 9 is a horizontal cross sectional view of the joint between two wall defining structural members taken on the line 9--9 of FIG. 1.

FIG. 10 is a vertical cross sectional view of a door joint structure taken on the line 10--10 of FIG. 1;

FIG. 11 is a vertical cross sectional view of a window sill structure taken on the line 11--11 of FIG. 1;

FIG. 12 is a vertical cross sectional view of a jamb structure taken on the line 12--12 of FIG. 1;

FIG. 13 is a vertical cross sectional view of the wall and roof structure taken on the line 13--13 of FIG. 1;

FIG. 14 is a transverse cross sectional view of the ridge portion of the roof taken on the line 14--14 of FIG. 1;

FIG. 15 is a transverse cross sectional view of the ridge portion of the roof and a partition extending downwardly therefrom;

FIG. 16 is a horizontal cross sectional view of two wall defining structural members spliced together;

FIG. 17 is a vertical cross sectional view of a two story bearing partition;

FIG. 18 is a side elevational view of one of the rectangular structural members;

FIG. 19 is an end elevational view of the structural member shown in FIG. 18;

FIG. 20 is a horizontal cross sectional view of the structural member shown in FIG. 18 taken on the line 20--20 thereof;

FIG. 21 is a front elevational view of a window defining structural member that has a portion thereof cut away to illustrate the interior thereof;

FIG. 22 is a front elevational view of a first wall defining structural member cooperating with a second structural member to provide a window opening of greater length than the width of one of said panels;

FIG. 23 is a front elevational view of a door defining structural member;

FIG. 24 is a front elevational view of a wall defining structural member containing a portion of an electrical conduit system;

FIG. 25 is a transverse cross sectional view of a wiring harness system embodied in one of the structural members;

FIG. 26 is a cross sectional view of the adjacent end portions of the structural wall defining members that embody conduit, and a connector that extends between said conduit.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The prefabricated structural member A shown in FIGS. 18, 19 and 20 may be used to not only form the walls B of a building C as shown in FIG. 1 but the roof D and floor E as well.

Each structural member A includes a rectangular rigid core 10 that is preferably defined by expanded resin impregnated honeycomb kraft paper having a cell size of 1 1/2 inches, and the paper weighing 99 pounds per ream (3,000 square feet). The core 10 is preferably 3 5/8 inch in depth. The impregnating resin is 18 percent by weight of the honeycomb core.

First and second rectangular rigid panels 12 and 14 are provided that are of greater width and height than the core 10. Panels 12 and 14 are transversely aligned and bonded to opposite longitudinal sides of the core 10 in such a manner as to cooperate therewith to define first and second horizontal channels 16 and 18 and a vertical channel 20. A vertical section 22 of the core 10 projects outwardly from the panels as illustrated in FIGS. 18 and 20. First and second panels 12 and 14 are secured to opposite longitudinal sides of the core 10 by an adhesive such as "Cascophen RS-240MD" which has a phenol resorcinol base and is manufactured by Borden Inc. The adhesive conforms to Federal Specification MMM A-181b.

The building C shown in FIG. 1 includes a concrete foundation F that is in the shape of a hollow rectangle. A section of foundation F is shown in FIG. 2 in which it will be seen to include a pad 26 and a curb 28 extending upwardly therefrom. Pad 26 includes a flat horizontal surface 30 on which an edge portion of one of the structural members A rests to partially define the floor E. A number of longitudinally spaced J-bolts 24 have the lower ends thereof embedded in the concrete defining the curb 28.

Surfaces 30, 32 and 34 of the foundation F have a layer of water proof mastic 36 applied thereto. A sill 38 of rectangular transverse cross section that has a number of vertical bores 40 formed therein through which bolts 24 may extend is disposed on curb 28 as shown in FIG. 2. The sill 38 is held in a fixed position on curb 28 by nuts 42 that threadedly engage the bolts 24.

Building C includes a number of corner parts 44 of square transverse cross section as shown in FIG. 6, and these corner posts having elongate plates 46 extended therebetween after the structural members A have been disposed to form a wall. The elongate plates are shown in FIG. 13. Foundation F has a longitudinally extending recess 48 formed on the upper outer portion of curb 28 as shown in FIG. 2.

When a structural member A is to be used as a part of an exterior wall B, the first panel 12 that is exteriorly disposed is 1/2 inch gypsum siding. The second panel 14 that is interiorly disposed is 1/2 inch gypsum board. First panel 12 on the exterior surface thereof is coated with a dry layer 50 of polyvinyl acetate, Polyco 2119, manufactured by Borden Inc. for reasons that will later be explained.

To erect the wall B one of the structural members A-1 is vertically disposed for first channel 16 thereof to engage sill 38 and third channel 20 to engage the corner post 44 as shown in FIG. 6. The panels 12 and 14 are secured to the sill 28 and corner post 44 by staples 52 and a layer of glue (not shown).

Structural members A-2 to A-6 as shown in FIG. 2 are sequentially positioned to interlock with one another and with sill 38 to form one wall B of the building C. Structural member A-6 is formed with two vertical grooves 20 to permit this panel to interlock with structural member A-5 as well as with a corner post (not shown). After the panels A-1 to A-6 have been disposed in a wall defining configuration as shown in FIG. 1, an elongate plate 46 is extended between the corner posts 44, with the plate engaging the second recesses 18 of the structural members. The structural members A-1 to A-6 are now interlocked with one another, as well as with sill 38 and plate 46 and as a result provide a stable vertical wall B.

A second wall of the building C is provided by structural members. In FIG. 6 it will be seen that a vertically extending wood cleat 52 is secured to the second panel 14 of structural member A-1. Cleat 52 is engaged by third channel 20 of structural member A-7. The first panel 12 of structural member A-7 is of sufficient width as to extend across corner post 44 as well as the end extremity of first panel 12 of structural member A-1.

The first and second panels 12 and 14 are preferably four feet by eight feet to permit commercially available sheet material to be used in the fabrication of the structural members A. After the structural members A have been assembled in the interlocking relationship shown in FIG. 1 as previously described, the exterior panels 12 have the joints therebetween sealed with waterproof tape (not shown) that is bonded to the panels by the use of "Wonderbond No. 901" adhesive manufactured by Borden, Inc.

The exterior panels 12 may now have a layer of stucco, which is cement plaster containing Borden, Inc. Polyco 2119 applied thereto to a depth of one-half inch to 1 inch. The Polyco 2119 is a dry polyvinyl acetate. Polyco 2119 is contained in the wet stucco in an amount of between 10 to 15 percent of the Portland cement portion thereof. When the stucco material is applied to the panels having the dry layer 50 of polyvinyl acetate thereon, the polyvinyl acetate is activated and creates an excellent bond with the stucco containing the same Polyco 2119 material. Thus, the exterior surface of the first panels 12 as shown in FIG. 1 may have a protecting layer of stucco J applied thereto without wire mesh screen or the like being used to effect a bond between the stucco and the panels. The stucco J when applied to the walls B provides a continuous layer thereon that is water tight and weatherproof.

In FIG. 2 it will be seen that the floor E of the building C is defined by a number of structural members A that are horizontally disposed, and each of the structural members include a honeycomb core 10 and first and second panels 12 and 14.

The structural member A-11 shown in FIG. 2 that serves as a part of the floor E has the panels 12 and 14 thereof formed of plywood, preferably one-half inch thick. The structural member A-11 has cross pieces 54 in the end portions thereof, which cross pieces are lapped by the first panel 12. The second panel 14 is in abutting contact with the cross piece 54. A layer of high shear adhesive 56 serves to join the first panel 12 and second panel 14 to the cross piece 54.

The floor E above described is preferably formed as a part of the building C prior to the structural members A-1 to A-10 being disposed to define a part of the walls B as shown in FIG. 1. The building C shown in FIg. 1, will have two sets of walls (not shown), that are similar to the two walls illustrated in this figure.

The structural member A-2 as shown in FIG. 1 includes a window G as a part thereof. The detailed structure of this panel is illustrated in FIG. 21. The structural member A-2 utilizes the same elements as structural member A shown in FIG. 18, but in addition includes a cut-out central portion 58 for the window G. The cut-out portion 58 is defined by a rough window frame 60 and a sill member 62, both of which will normally be formed from two-by-fours. The rough frame 60 is held in position within the confines of the structural member A-2 by two splicing pieces 64 as shown in FIG. 21, and two downwardly projecting extensions 66 of the side portions of said frame.

Structural members A-4 and A-5 as may best be seen in FIG. 1 cooperate to not only form a part of one of the walls B, but as a support for a window G' that is of greater width than either of the panels A-4 or A-5. The elements of the structural member A-4 are shown in FIG. 22. The structural member A-4 is similar to the structural member A-2 other than the rough window frame 60 extends to the right through the vertical sections 22 of the core 10. The structural member A-5 is similar to the structural member A-4, and differs primarily therefrom in that the structural member A-5 has a vertical channel (not shown) formed in the left hand edge portion thereof as viewed in FIG. 1 that interlocks with the vertical sections 22 shown in FIG. 22.

Structural member A-8 has a door H associated therewith. In detail, the structural member A-8 has a cut-out central portion that is defined by two-by-fours that form a rough door frame 68 that is normally closed by the door H shown in FIG. 1. The structural member A-8 interlocks with the structural member A-7 and A-9 as previously explained in detail as well as interlocking with the elongate plate 46. FIG. 9 shows in detail the structural members A-9 and A-10 interlocking with one another. In FIG. 9 it will be seen that the vertical section 22 is disposed within the channel 20 and the section bonded to the panels 12 and 14 of the structural member A-9 by layers of adhesive 69 that are situated on the interior surfaces of the panels 12 and 14 of the structural member A-9 and the adjoining faces and 14 of structural member A-9 and the adjoining faces of the vertical section 22 of structural member A-10.

The elongate longitudinal plates 46 support the roof D that is formed from structural members A as may best be seen in FIG. 13. The upper surface 70 of the plate 46 slopes upwardly and inwardly and serves as a support for the structural members A-12 that are disposed side by side. The elongate plate 46 is situated within the confines of the channel 18 of structural member A-3 as shown in FIG. 13 and is secured thereto on each side by a layer of adhesive 68. Two metal angle pieces 72 covers the upper extremities of the panels 12 and 14. A longitudinally extending casing bead 74 of inverted L-shaped transverse cross section serves as the upper limit for the layer of stucco J that is secured to the exterior surface panel 12. The layer of stucco J continues downwardly and terminates in the recess 48 of foundation F as shown in FIG. 2. A wood block 76 extends longitudinally through each of the panels A-11, and is vertically aligned with one of the plates 46. Lag screws 78 extend downwardly through bores 80 in block 76 to engage plate 46 and secure each of the panels A-11 to the latter. A metal clip piece 82 is secured to the end extremity of structural member A-12 as shown in FIG. 13. The metal piece 82 engages a clip 84. The upper portion of metal piece 82 is secured to the structural member A-12 by nails or staples 86. The metal clip piece 82 includes an upwardly extending doubled over portion 82a that serves as a stop for a layer of tar 88 and gravel 90 that overlies panel A-12 and provides a waterproof roof covering. If desired a reinforcing member 92 may be provided in structural member A-12 that is parallel to block 76 and spaced outwardly therefrom as shown in FIG. 13. Staples 92 serve to secure structural member A-3 to plate 46, as well as clip piece 84 to panel 12. Tape 94 is provided that is adhered to the upper interior surface of second panel 14 of structural member A-3 as shown in FIG. 13, with the tape also adhered to the under surface of second panel 14 of the roof structural member A-12. The under surface of second panel 14 to the right of structural member A-3 as viewed in FIG. 13 defines the ceiling of building C. The ceiling preferably has an acoustic texture defining material 96 applied as a layer thereto.

Structural member A-12 may be used with either the roof ridge structure K shown in FIG. 14 or a second roof ridge structure L illustrated in FIG. 15. In both the first and second roof ridge structures K and L the structural members A-12 have transverse inner cross members 98 formed as an integral part thereof. The cross members 98 define vertical faces 100 when the structural members A-12 of which they form a part are positioned at predetermined angles relative to the horizontal, and serve to support the panel 12.

In the first roof ridge shown in FIG. 14, the adjacent faces 100 are bonded together by a layer of adhesive 102, which adhesive is preferably one with a phenol resorcinol base manufactured by Borden, Inc. that has an accelerator and catalyst No. FM124D also manufactured by Borden, Inc. added thereto. Nails 104 are cross driven into the cross members 98 to assist the adhesive 102 in holding them together. The layers of tar 88 and gravel 90 is continued upwardly over the roof ridge K as shown in FIG. 14. Roof ridge K has tape 106 secured to the adjacent edge portions of the second panels 14 as shown in FIG. 14 to mask the junction line 108 therebetween. The tape 106 and the inner surface of the second panels 14 as shown in FIG. 14 are covered with a layer of the acoustic texture defining material 96.

The second form L of the roof ridge defining structure shown in FIG. 15 is used when a supporting wall or partition M is situated directly under the cross members 98 and parallel thereto. The partition M is defined by structural members A-13 that are disposed side by slide in interlocking relationship and have the second channels 18 thereof engaged by an elongate plate 110 that has two upper surfaces 112 that extend downwardly and outwardly in opposite directions, and are parallel to the lower exterior surfaces 114 of second panels 14 as shown in FIG. 15. A number of spaced lag screws 116 extend downwardly through bores 118 in one of the cross members 98 to engage plate 110 as shown in FIG. 15. Metal L-pieces 120 are secured by nails or staples 122 to the upper ends of first and second panels 12 and 14 of structural member A-13 as shown in FIG. 15, which pieces 120 define bearing surfaces.

When the foundation F is a flat concrete slab, the walls B may be erected thereon and secured thereto as shown in FIG. 3. Sills 38 of rectangular cross section are secured to edge portions of the foundation F by bolts 24. Sheet metal termite shields 124 have center portions 124a thereof sandwiched between the undersides of the sills 38 and the upper edge surfaces of foundation F. Each shield includes an inner portion 124b that extends upwardly in abutting contact with the inner vertical surface of sill 38. An outer portion 124c of the shield 124 extends downwardly in recess 48 and then outwardly to conduct rain and runoff water away from the wall B. The layer of stucco J terminates in abutting contact with shield portion 124c. The layer of stucco J is adhered to the exterior surface of a building member A as shown in FIGS. 18, 19 and 20, which building member has the first channel 16 thereof in engagement with sill 38.

FIG. 4 is illustrative of the floor and wall structure of a building B in which the floor E is defined by a concrete slab 126 that has a curb 128 extending upwardly from the outer edges thereof. Curb 128 has an elongate sill 38 secured thereto in the same manner shown in FIG. 2. Structural members A have the first channels 16 thereof in engagement with sill 38, and the structural members interlocking with one another to define a continuous wall as previously described in detail. The panels 12 and 14 in the structural member A shown in FIG. 4 are both formed from plywood.

FIG. 5 illustrates the details of an interior partition wall B-1 that is capable of sustaining a downwardly directed load. The partition wall B-1 includes a sill 38 secured to the upper surface of slab 126 by bolts 24 as previously described, and the sill being engaged by the first channel 16 of a structural member A. Structural member A is illustrated in FIG. 5 as formed from a honeycomb core 10 and panels 12 and 14, which panels are both defined by gypsum board. A strip of mastic 128 is sandwiched between the sill 38 and slab 126 on which the sill is supported. Layers of adhesive 130 bond the exterior vertical surfaces of the sill 38 of the adjoining interior surfaces of panels 12 and 14.

An inside exterior wall structure is shown in FIG. 7 that includes a vertical corner post 132 that has a first nailer strip 134 secured thereto. The corner post 132 and nailer strip are situated within a third channel 20 of a first structural member A. A second nailer strip 136 is secured to panel 12 as shown in FIG. 7 and in alignment with post 132. The second nailer strip 136 engages channel 20 of the second panel A. An extension 14a of panel 14 of second structural member A extends over surface 132a of post 132 and an end edge 14a of panel 14. Layers of adhesive 140, nails 142 and staples 144 hold the above described assembly together as shown in FIG. 7. A layer of stucco J is applied to the exterior surfaces of panels 12 in the same manner as previously described in connection with FIG. 2. An L-shaped metal reinforcing member 138 is embedded in the stucco J to prevent the cracking of the stucco at the corner defined thereby.

When a first partition wall B-1 abuts against a second partition wall B-2 as shown in FIG. 8, the structural member A forming a part of the second partition has an elongate vertical wood member 146 incorporated as a part thereof. A nailer strip 148 is transversely aligned with member 146 and secured to panel 12 by nails 150 that extend into member 146. The nailer strip 148 engages channel 20 of the structural member A that forms a part of the partition wall B-1, and serve to hold the partition wall B-1 at a fixed position relative to wall B-2. Nailer strip 148 is secured to the interior surfaces of panels 12 and 14 of structural member A in partition wall B-1 by layers of adhesive 152.

FIG. 10 illustrates in detail how a prehung door 154 and metal frame 156 therefor may be incorporated into structural member A-8. The structural member A-8 has a wood door buck 154 made integral therewith.

The manner by which a preformed conventional metallic window structure G is incorporated into the structural member A-2 is illustrated in detail in FIG. 11.

Should it be desired to use the structural members A for the floors E and walls B of a multiple story building C, the construction illustrated in FIG. 17 may be employed. The second floor E' of the building is defined by a horizontal structural member A that has a transverse wood block 156 included as a part thereof, with this block being axially aligned with an elongate plate 158 that engages the second channel 14 of a vertical structural member A-1. A number of spaced screws 160 are extended downwardly through panel 14 and block 156 of structural member A to engage plate 158. Structural member A of second floor E' has an elongate sill 162 secured thereto by nails 164, with the sill being vertically aligned with block 156. The sill 162 is engaged by the first channel 16 of a second structural member A-2 that forms a part of the second story of the building. Layers of adhesive 166 are employed to hold the above described assembly together.

In the event it should be necessary to splice two of the structural members A together, the construction shown in FIG. 16 may be employed. The two structural members A are disposed to form a portion of a wall, roof or floor and have the channels 20 thereof adjacent one another. Two elongate wood key members 168 are positioned within channels 20 and are bonded to the panels 12 and 14 of the structural members A by layers of adhesive 170. Staples 172 hold the panels 12 and 14 in abutting contact with the key members 168 until the adhesive has set. The space between the key members is filled with a section of the honeycomb core 10.

FIG. 25 illustrates the manner by which sheathed electrical cable 174 may be extended along the upper surface of core 10 of a structural member A and within the second channel 18 prior to the channel being engaged by a plate 46.

Structural members A are illustrated in FIG. 24 in which electrical conduit 176 is embedded in the core 10 and connected to a wall fixture outlet box 178, wall switch 180 and wall receptacle or pull boxes 182.

A tubular connector 184 is shown in FIG. 26 that extends between the adjacent end portions of conduit 176 in two structural members A that define a portion of a wall B. The center portion 186 of the connector 184 is corrugated to permit the connector to effect a snug fit with the conduits 176. Connector 184 has interior tapered end surfaces 188 to prevent wire (not shown) being pulled through conduit 176 being hung up on the connector. The connector 184 is preferably formed from an inexpensive material having some resiliency such as plastic or the like.

The erection of a building C by use of the structural members A previously described is as follows. The foundation F is poured, and the configuration of the walls B laid out thereon, including the modular spacing marks. The sills 38 are then secured to the foundation in the manner previously described. Corner posts 44 are then erected, and braced in a vertical position. The exterior surface of each corner post is coated with a layer of adhesive, just prior to one of the structural members A being caused to engage the sill 38, and the portions of the structural member A that define channel 20 therein being brought into engaging contact with the corner post. The structural members A have the portions thereof defining the first channels 16 coated with adhesive, and these adhesive coated surfaces are slid downwardly over the sill 38 and in abutting contact therewith. Staples or nails are driven through the lower portions of the structural members A to hold them in contact with the sill 38, until the adhesive has bonded the structural members A to the sill.

The erection of the structural members A is so continued until the complete wall B has been effected. As the structural members A are placed in a wall B defining position, the vertical sections 22 of the cores 10 are caused to engage the channels 20 of the structural members A adjacent thereto, and the structural members bonded to one another. After the structural members A have been erected to define a wall as previously described, the electrical harness 174 is extended along the upper surface of the walls 10 in the structural members A. The location for receptacles, switches, and fixtures are marked on one of the panels defining a structural member A, and the panel cut to permit the insertion of the receptacles, switches, and fixtures therein at the cut-out location. Conduit is extended through the core to the desired location as shown in FIG. 24, and the electrical harness 174 pulled or extended therethrough to make suitable connections to the receptacles, switches, and fixtures.

Other lines and rough plumbing may be extended through the cores 10 in the same manner as conduit is extended therethrough, with the plumbing connections being made by cutting openings in either the panel 12 or 14. The portions of the structural members A that define the second channels 18 have the interior surfaces thereof coated with an adhesive, and when so coated are engaged by an elongate plate 46. The structural members A defining the roof D are then secured to the plates 46 as previously described in detail. Similarly, when the structural members A are to be used to define a floor E, these structural members are laid side by side in interlocking relationship and adhered to one another by both staples and nails and adhesive. The exterior surface of the panels 12 are coated with a dry layer 50 of polyvinyl material, that is activated when a layer of stucco or other cementitious material containing the same additive is applied thereto as a protective layer. Thus, the exterior surface of the building may have stucco applied thereto, without the additional expense of placing wire netting or other material thereon, to hold the stucco in place. Prior to the stucco being applied to the exterior surface of the building C, the cracks or junction lines between the panels or the structural members A are taped to effect a water tight seal. The prehung doors and frames, as well as the prehung windows, are now installed as previously described. Also, the standard plumbing fixtures (not shown) are installed, as well as shop fabricated mill work which also is not shown. The interior surfaces of the structural members are now finished either by painting, plastering or the like.

When stucco containing polyvinyl acetate is applied to a panel having a film of the Polyco 2119 thereon, an extremely durable structural member is provided. The moisture in the stucco activates the vinyl acetate film to bond the layer of stucco to the panel. The vinyl acetate in the film of stucco cooperates with the cement therein to provide a material that has a great resistance to cracking either by weathering or sudden forces being applied thereto. The film of polyvinyl acetate on the panel is preferably applied to be an integral part of the structural members, prior to the members being assembled to define part of a wall structure. However, if desired, the polyvinyl acetate may be sprayed or otherwise applied to the panels after the structural members of which they form a part are assembled to define a wall.

Claims

We claim:

1. In combination with a foundation supported sill and an elongate horizontal plate vertically aligned therewith and situated at a fixed elevation thereabove, a plurality of rectangular structural members that cooperate with said sill and plate to define at least a portion of a wall, each of said structural members being of the type that includes a rectangular rigid core of slightly greater width than that of said sill and plate and of such height as to substantially span the vertical distance between said sill and plate, and first and second rectangular rigid panels of greater width and height than said core bonded to opposite sides thereof, and each of said structural members being characterized by said first and second panels thereof being so positioned relative to said core as to cooperate therewith to define first and second horizontal channels, a third vertically extending channel, and a vertically extending exposed section of said core that extends into said third channel of said structural member adjacent thereto to interlock therewith, with the adjacent vertical edges of said structural members in abutting contact when said structural members are in engagement with said sill and plate, and in addition:

a. first means for maintaining each of said structural members at a fixed longitudinal position relative to said sill and plate; and

b. second means integral with at least the exposed surfaces of said first panels, for bonding a continuous coating of plastic cement containing material thereto that spans said exposed surfaces and extends over the junction lines between said structural members.

2. The combination as defined in claim 1 in which said core of each of said structural members is a non-metallic honeycomb material that has substantial heat and gypsum insulating qualities, and said first panel is waterproof gypsum sheathing.

3. The combination as defined in claim 1 in which said first means are a plurality of layers of adhesive that coat the interior surfaces of the portions of said first and second panels that partially define said first and second channels, with said layers of adhesive being in bonding contact with said sill and plate.

4. The combination as defined in claim 1 in which said second means is:

c. a dry layer of polyvinyl compound that covers the exterior surface of said first panel; and

d. said polyvinyl compound mixed with said cement containing material in a sufficient quantity that when said cement containing material is applied to said exterior surface as a coating thereon, said polyvinyl compound layer is activated to hold said coating in place.

5. The combination as defined in claim 1 in which said sills, plates and structural members cooperate to define a continuous sequence of walls that are substantially normally disposed to one another, with at least two of said walls being laterally spaced and parallel, and said combination in addition including:

c. at least one vertical corner post of substantially square transverse cross section that extends upwardly from said sill, with said corner post engaging a third channel in a first end positioned structural member of a first of said walls;

d. third means for securing said first end positioned structural member to said corner post;

e. a vertical nailer strip of rectangular transverse cross section secured to an exterior surface of said first end positioned structural member, said nailer strip vertically aligned with said post, and said nailer strip being engaged by a third channel of a second end positioned structural member of a second of said walls; and

f. fourth means for securing said second end positioned structural member to said nailer strip.

6. The combination as defined in claim 1 in which said sills, plates and structural members cooperate to define a continuous sequence of walls that are substantially normally disposed to one another, with at least two of said walls being laterally spaced and parallel, and said sills being supported on curbs that form a part of a foundation, with said combination in addition including:

c. a plurality of vertical corner post assemblies that extend upwardly from said sills and interlock with third channels in end positioned structural members in said walls to define corners; and

d. a plurality of horizontal second structural members of substantially the same structure as said first structural members, said second structural members extending between said curbs and having the third channels and sections thereof interlocking to define a floor.

7. The combination as defined in claim 1 in which said sills, plates and structural members cooperate to define a continuous sequence of walls that are substantially normally disposed to one another, with at least two of said walls being laterally spaced and parallel, and said sills being supported on curbs that form a part of a foundation, with said combination in addition including:

c. a plurality of vertical corner post assemblies that extend upwardly from said sills and interlock with third channels in end positioned structural members in said walls to define corners; and

d. a plurality of second structural members of substantially the same structure as said first structural members, said second structural members extending between and at least partially supported by said sills that form a part of said parallel walls, and said second structural members defining a roof.

8. A combination as defined in claim 7 which in addition includes:

e. at least one layer of waterproof material supported on the upper surfaces of said second structural members.

9. The combination as defined in claim 4 in which said sills, plates and structural members are arranged in a configuration to define the walls of a building having a plurality of sides, which combination in addition includes:

c. a foundation that includes a continuous upwardly extending curb, said curb supporting said sills on the upper surface thereof, and said curb having a longitudinal recess in the upper outer part thereof into which said cement containing material is extended to effect a water tight seal with said curb.

10. The combination as defined in claim 9 in which said curb defines an interior flat horizontal surface, which combination in addition includes:

d. a plurality of said structured members that are horizontally disposed and have edge portions thereof supported on said flat surfaces, said horizontal structural members having said sections and third channels thereof in interlocking engagement, and said horizontal structural members defining a floor for said building.

11. The combination as defined in claim 9 which in addition includes:

d. elongate electrical conducting means that rest on the upper surfaces of said cores and are adjacently disposed to said plates;

e. electrical outlets in the second panels of at least a part of said structural members; and

f. third electrical conducting means extending through said cores from said electrical conducting means to said electrical outlets.

12. The combination as defined in claim 9 which in addition includes:

d. a plurality of axially aligned tubular conduits embedded in said cores and extending transversely through said structural members; and

e. a plurality of tubular connectors that removably engage adjacent ends of said conduits, said connectors formed from a resilient material, with each of said connectors having interior tapered end surfaces to prevent wire being hung up on said connectors as said wire is pulled therethrough.

13. The combination as defined in claim 12 in which each of said connectors has a corrugated central portion to permit limited deformation of said connector to effect a connection between said conduits with which said connector is in engagement.

14. The combination as defined in claim 5 in which at least first and second of said structural members have wood framed first and second openings therein, and said combination in addition including:

g. a preformed window assembly mounted in said first framed opening and secured thereto; and

h. a preformed door assembly mounted in said second framed opening and secured thereto.

15. The combination as defined in claim 14 which in addition includes:

i. a plurality of said structural members that extend between said plates and define a roof, said roof defining structural members disposed side by side with said extensions thereof in interlocking engagement with said third channels.