U.S. patent number 3,640,039 [Application Number 04/821,761] was granted by the patent office on 1972-02-08 for building structure.
This patent grant is currently assigned to Ball Corporation. Invention is credited to James K. Chastain, James R. McKee.
United States Patent |
3,640,039 |
McKee , et al. |
February 8, 1972 |
BUILDING STRUCTURE
Abstract
An assembly structure for building panels having undercut
channels in the end portions thereof wherein a key is inserted into
a plurality of such channels to loosely join the panels, and
resilient inserts are thereafter driven into spaces between the
panels to render the junction rigid, and a method of joining the
assembly by progressively positioning the inserts.
Inventors: |
McKee; James R. (Muncie,
IN), Chastain; James K. (Gaston, IN) |
Assignee: |
Ball Corporation (Muncie,
IN)
|
Family
ID: |
25234244 |
Appl.
No.: |
04/821,761 |
Filed: |
May 5, 1969 |
Current U.S.
Class: |
52/281;
52/396.04; 52/586.2; 52/464 |
Current CPC
Class: |
F16B
5/0052 (20130101); E04B 1/6158 (20130101) |
Current International
Class: |
E04B
1/61 (20060101); F16B 5/00 (20060101); E04c
001/10 () |
Field of
Search: |
;52/281,403,747,586,580,464,468,285,286,582 ;287/2.92E,2.92K |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Abbott; Frank L.
Assistant Examiner: Burke; Sam D.
Claims
What is claimed is:
1. In a rigid, load-bearing, weatherproof joint structure
comprising at least two building units having undercut channels
defined therein, each of said channels having a shoulder and at
least one of said channels being located at an end of one of said
units, a key member having a web portion and spaced-apart flanges
behind and engageable with said shoulders, said key member being
disposed in the channels to fasten the building units together in a
spaced-apart relationship whereby spaces are provided on opposite
sides of said key member, and resilient inserts snugly positioned
in the spaces between the building units and on opposite sides of
said key member for holding the flanges of said key member in
engagement with said shoulders.
2. A joint structure as set forth in claim 1 wherein both of the
undercut channels are located at the end portions of the two
building units and the key member is of an "I" cross-sectional
shape.
3. A joint structure as set forth in claim 2 wherein each of the
resilient inserts is a rubber strip.
4. A joint structure as set forth in claim 2 wherein the building
unit comprises a foam core and nonporous, solid outer wall
portions.
5. A joint structure as set forth in claim 2 wherein each of the
channels is of a "T" cross section.
6. A corner assembly of building units comprising two building
units having undercut channels defined in the end portions thereof,
each of said channels having a shoulder, a corner key member having
side portions and protrusions including flange portions behind and
engageable with said shoulders, said protrusions extending
outwardly from said side portions and being shaped complementary to
the channels, disposed at an angle to each other and positioned one
each loosely within the channels wherein spaces are provided
between the side portions of the corner key member and the units,
said corner key member loosely fastening said building units
together, and separate resilient inserts snugly positioned in the
spaces between the units and the side portions of the corner key
member for holding the flange portions of said protrusions in
engagement with the shoulders of said channels so as to provide
rigidity to the assembly.
7. An assembly of building units comprising a first building unit
and a second building unit each having undercut channels defined
therein, each of said channels including a shoulder, the first
building unit having the channel in the end portion thereof and the
second building unit having a channel in the sidewall thereof, a
key member having a web portion and spaced-apart flanges shaped
complementary to the channel and positioned behind and engageable
with said shoulders, said flanges being disposed in and between the
two channels to fasten the first building unit loosely in a
position normal to the wall surface of the second building unit but
spaced apart therefrom, and a pair of resilient inserts snugly
positioned between the two building units and on opposite sides of
said key member for holding the flanges of said key member in
engagement with said shoulders.
8. An assembly of building units comprising at least three building
units having undercut channels defined at the end portions thereof,
each of said channels including a shoulder, two of said building
units being positioned in an end-to-end, spaced-apart relationship
with the channels confronting one another, and the other of said
building units being positioned normal to the confronting building
units with the channel positioned adjacent to but spaced apart from
the space between the two confronting building units, a key member
having web portions and spaced-apart flanges behind and engageable
with said shoulders, said key member being positioned in all three
channels to loosely fasten the building units in the described
relationship, a first separate resilient insert snugly positioned
within the space between the confronting building units, a second
separate resilient insert snugly positioned within the space
between said other building unit and one of said confronting
building units and a third separate resilient insert positioned
within the space between said other building unit and the other
confronting building unit so as to hold the flanges of said key
member in engagement with the shoulders of said channels whereby
said inserts provide rigidity to said assembly.
9. An assembly of building units comprising four building units
having undercut channels defined at the end portions thereof, each
of said channels having a shoulder, two of said building units
being positioned in an end-to-end, spaced-apart relationship with
the channels confronting one another, and the other two of said
building units being positioned normal to and on opposite sides of
the confronting building units with the channels therein positioned
adjacent to but spaced apart from the space between the two
confronting building units, a key member having web portions and
spaced-apart flanges behind and engageable with said shoulders,
said key member being positioned in all four channels to loosely
fasten the building units in the described relationship, and at
least four separate resilient inserts snugly positioned within the
spaces between the building units for holding the flanges of said
key member in engagement with the shoulders of said channels so as
to provide a rigid assembly, two of said inserts being positioned
on one side of said confronting building units and on opposite
sides of said key member and the other two of said inserts being
positioned on the other side of said confronting building units and
on opposite sides of said key member.
10. An assembly of building units comprising at least two building
units having end portions each of which defines an undercut channel
having a shoulder, a key member having a web portion and
spaced-apart flanges behind and engageable with said shoulders,
said key member being disposed in both of said channels for loosely
fastening said units and for positioning said end portions in
confronting but spaced-apart relationship, and at least two
elongated resilient inserts each of which when in an undeformed
state includes at least one portion having a transverse thickness
greater than the distance between the confronting end portions,
said inserts being positioned on opposite sides of said key member
and snugly held in the spaces between the confronting end portions
in a deformed state for holding the flanges of said key member in
engagement with the shoulders of said channels, whereby said
inserts add rigidity to the assembly.
Description
This invention relates to structural assemblies for building
construction. More particularly, this invention relates to a means
of assembling preconstructed, load-bearing panels in a secure and
efficient manner.
Modern construction techniques have largely utilized a load-bearing
skeleton to which inter and outer walls and other building members
are attached. Basically, the visible portions of buildings
employing such construction are supported by an internal
skeleton.
For instance, residential construction generally utilizes a wooden
stud skeleton in the vertical wall to which the inner plaster or
wallboard is attached and to which the outer sheathing or other
covering such as masonary is secured. Similarly, high-rise
buildings employ strong metal skeletons as the framework to which
the enclosing portions of the building are attached.
One basic drawback to such construction is that it must usually be
assembled piecemeal at the building site. Therefore, the
construction process and personnel are exposed to the elements.
Also, since equipment must be distributed between all of the active
building sites, only simple, relatively inefficient equipment is
employed.
The attractiveness of a centralized, protected, and specialized
location for the preassembly of units to be assembled on site into
a building has long been recognized. In addition to the convenience
and comfort afforded the workmen, this procedure also permits the
use of more specialized equipment, such as jigs, to produce more
accurately sized equipment than can be produced on a job site.
With the discovery of lightweight foam panels only inches thick
which display all of the insulating properties of walls many times
such thickness, the advantages of a preassembled building unit
become even more apparent. Module sections of buildings can be
produced by such materials by foaming polymers, for instance
urethanes, with the door openings, window openings, and other
needed features integral with the unit. Such compact and complete
units may then be conveniently shipped to a construction site and
rapidly assembled.
However, one drawback has been the inability to produce a joint
structure which is structurally sound, weathertight, durable, and
which may be quickly and efficiently assembled. Since the units
must be readily assembled and since the joining structure must be
internal of the unit surface, it is very difficult to gain
compressive forces at the joint. One approach has been to key or
slide the units together. However, when sufficient forces are
provided to produce a strong and weathertight joint, the force
required to join such units together is prohibitive. For this
reason, a simple, tight, tongue-in-groove type joint is not
satisfactory for such large building units.
It is therefore an object of the instant invention to provide a
method of strongly and securely joining building units.
Another object of this invention is to provide a means for quickly
and efficiently joining building units.
Still another object of this invention is to provide a building
unit joint which provides a weathertight seal.
Yet still another object of this invention is to provide a building
unit joint which is durable.
Still yet another object of this invention is to provide a building
joint which may be assembled and made secure on a building site
without benefit of complex tools.
Other objects of this invention will be apparent from the drawings
and following discussion.
According to this invention, building units are securely joined
together by first securing two units together relatively loosely by
inserting a key into integral channels at the end portions of each
of the units. While the key provides a very strong joint with
regard to longitudinal forces attempting to pull the joint apart,
it does not in anyway jam the ends together and, in fact, permits a
rather substantial clearance between the units. A resilient insert
is then progressively inserted into the clearance between the units
on each side. This insert securely seals the joint in a
weatherproof manner and also lends a stiffening effect to the unit
which results in a strong, rigid joint between the units.
The significance of the separate resilient insert will be
appreciated upon consideration of what appears to be an equivalent
arrangement, but which arrangement is, in fact, unworkable. That is
an arrangement in which the resilient seals are made integral with
the unit ends and the compressive forces on the seals supposedly
generated by the key as it is driven into the channels. However,
the force required to drive the key into the channels is so high as
to render this approach unworkable. On the other hand, if the key
is first inserted into the channels with a loose fit, the rubber
inserts may be driven in locally by first inserting a small portion
of the strip at, for instance, the top of the joint groove and then
pounding the strip into the groove locally in a progressive manner
until the entire resilient strip is within the groove. While the
high pressures necessary for sealing are produced, high forces are
not involved because the pressures are only localized.
The invention will be more readily understood with reference to the
drawings in which:
FIG. 1 is a perspective, exploded view of a typical series of joint
assemblies according to this invention;
FIG. 2 is a top view of a building unit as used in the instant
invention;
FIG. 3 is a top view of a key as used in the instant invention;
FIG. 4 is an end view of an insert as used in the instant
invention;
FIG. 5 is a cross-sectional representation of a simple butt joint
according to the instant invention;
FIG. 6 is a cross-sectional representation of a corner joint
according to the instant invention;
FIG. 7 is a cross-sectional representation of a T-joint according
to the instant invention;
FIG. 8 is a cross-sectional representation of a combination butt
joint and T-joint;
FIG. 9 is a cross-sectional representation of a combination butt
joint and two T-joints.
As can be seen from FIG. 1, building units 10 are joined by means
of keys 12 inserted in channels 14 defined in units 10. Resilient
inserts 16 are then inserted between the units 10 to lend strength
and rigidity to the joint and to render the joint weatherproof.
The nature of building unit 10 will be more readily appreciated
with reference to FIG. 2 wherein it may be seen that channel 14 is
more specifically defined in an end section 18 which may be of
metal, polymer, or other material, and is preferably extruded. End
sections 18 may preferably be employed in the production of
building units 10 by securing one wall 20 within projections 22 of
end section 18. An insulating material, such as formed-in-place
urethane is then placed between walls 20 to form core 24. Core 24
adheres to walls 20 and end section 18 to form an integral unit. If
desired, a decorative outer surface 28 may be adhered to wall 20.
Decorative surface 28 may be of stone, wood, or facsimile brick, or
other desired finish as may be appropriate for exterior or interior
use.
Key 12, as shown in FIG. 3, is of a relatively simple configuration
which is readily extruded from, for instance, polymers or metals,
though aluminum extrusions are preferred for strength and ease of
handling.
Resilient insert 16 shown in FIG. 4 includes several projections 30
on each side thereof to enhance sealing. Also, projections 30
enable the resilient insert 16 to be readily positioned in the
finished unit and to generate the desired lateral forces to provide
rigidity in the joint.
As shown in FIG. 5, two building units 10 are joined by positioning
key 12 in channel 14 of each building unit 10. Key 12 provides a
loose, flexible joint between building units 10. The joint is
rendered strong and rigid by inserting resilient inserts 16 into
gaps 32 between building units 10. In this manner, key 12 provides
great longitudinal strength in the joint while resilient inserts 16
stiffen the joint and preclude bending of the joint in the
direction normal to the wall surfaces.
When in place, inserts 16 are preferably flush and present the
appearance of a carefully caulked joint. Alternatively, other outer
surfaces may be presented by insert 16 including a curved rib or
even a surface similar to decorative surface 28.
As shown in FIG. 6, corner sections may be assembled in a similar
manner. Building units 10 are loosely assembled by inserting corner
member 34, and specifically keylike projections 36-- which may be
disposed at various angles-- of corner member 34 into the channels
14 of building units 10. A resilient spacer 38 is positioned at the
inside juncture of building units 10. Resilient inserts 16 are then
positioned between corner member 34 and building units 10 to
complete the joint. The integrity and strength of such a corner
joint will be readily apparent.
FIG. 7 illustrates the simple T-joint between building units 10 in
the form of an external wall and an internal wall. This joint
utilizes key 12, channel 14 and insert 16 in a manner analogous to
the above-discussed butt joint. However, a channel 40 analogous to
channel 14 is provided in outside building unit 10 at the location
at which the junction is desired by means of an insert 42 which is
molded into building unit 10 as discussed above.
FIG. 8 illustrates a T-joint between three building units 10 where
two are butt joined together and the third joint in a T fashion and
the butt joint. This type of joint utilizes a special key 44 which
is adapted to engage the channels 14 of all three building units
10. The special key 44, of course, provides a loose joint between
the three building units and resilient inserts 16 are utilized to
lend rigidity to the joint.
Still another complicated joint illustrating the flexibility of
this invention is shown in FIG. 9. In this joint, four building
units 10 are joined in a manner discussed above utilizing variant
keyway 46. As in the other examples, variant keyway 46 is inserted
into channel 14 of each building unit 10. Because of the discussed
clearances, this step is readily accomplished. Then, resilient
inserts 16 are driven into the appropriate gaps to complete the
joint.
EXAMPLE
A steel frame was fabricated to form a simulated foundation of a
12.times. 12.times. 8 foot building. The building was constructed
of 4.times. 8.times.21/4 foot structural panels as described
herein. Facing on the panels was 1/8-inch hardwood on the inside
and 1/8 -inch cement asbestos board covered with 1/8 -inch epoxy
matrix and No. 2 marble chips on the outside. The core of the panel
was a 2-pound per cubic foot poured-in-place polyurethane foam.
Channels as shown in the drawings surrounded the perimeter of the
panels, and the panels were assembled as shown in the drawings and
discussed herein.
Loading was applied to the simulated windward face of the building
by three identical hydraulic jacks which were interconnected
through a manifold to equalize the pressure to each jack. A timber
grillage was set at the face of each of the loaded panels between
the wall panel and the jack to distribute the load so as to provide
the proper relationship between maximum shear and maximum bending
moment. Strain gauges were located at three points, 4 inches below
the tops of each windward panel, to measure the deflection of the
panels from true vertical. Pressures applied to the building wall
were correlated to wind loadings. The wall was tested with
pressures corresponding to winds of 75 m.p.h. loading, 150 m.p.h.
loading, and 250 m.p.h. loading. The test was repeated with the
building rotated 90.degree.. In none of the tests was there a
failure or permanent distortion of the panel and securing
structure. Maximum deflections were less than 1 inch at the 7 foot
8 inch height of the center panel and not over one-half inch at
either end panel during the 250 m.p.h. test.
From the above discussion and example, it will be apparent that the
instant invention provides a structure and method whereby
prefabricated panels may be easily and conveniently assembled on
site utilizing ordinary tools. Further, the junction assembly
provides excellent structural strength and weather seal.
It will be apparent from the above description and drawings that
various modifications of the structure and method may be made
within the scope of the invention. Therefore, the invention is not
intended to be limited to the particular examples or illustrations
employed except as may be required by the following claims.
* * * * *