U.S. patent number 3,665,662 [Application Number 05/056,363] was granted by the patent office on 1972-05-30 for structural member and building embodying same.
Invention is credited to A. Lynn Castle, Robert L. Timbrook.
United States Patent |
3,665,662 |
Timbrook , et al. |
May 30, 1972 |
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.
Inventors: |
Timbrook; Robert L.
(Northridge, CA), Castle; A. Lynn (Zephyr Core, NV) |
Family
ID: |
22003900 |
Appl.
No.: |
05/056,363 |
Filed: |
July 20, 1970 |
Current U.S.
Class: |
52/210; 52/211;
52/270; 52/294; 52/262; 52/97; 52/101; 52/281; 52/220.2; 52/293.1;
52/92.1 |
Current CPC
Class: |
E04B
1/10 (20130101); E04B 1/26 (20130101); E04B
2001/2684 (20130101) |
Current International
Class: |
E04B
1/02 (20060101); E04B 1/26 (20060101); E04B
1/10 (20060101); E04B 1/00 (20060101); E04b
007/02 () |
Field of
Search: |
;52/92 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Lawson; Patrick D.
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.
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.
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