Building Construction

Abstract

A building construction suitable for employment in low cost modular housing including a major structural element adapted to serve as a grade beam with provision for heating, cooling, and ventilating means as well as a raceway for electrical wiring. Such grade beam is designed to engage and support wall and floor members or panels to form a cooperative assembly therewith in a manner facilitating expeditious erection with a minimum use of skilled labor.

Description

BACKGROUND OF THE INVENTION

There is a rapidly developing need for large scale low cost housing in this country which will nevertheless be flexible in design and of high quality to avoid rapid obsolescence. At the present time there has been a large increase in the manufacture of so-called "mobile homes" which, however, do not lend themselves readily to varied architectural designs or truly permanent neighborhood planning. The usual prefabricated houses are available in only a limited number of floor plans and designs and still require a substantial amount of on-site labor of a skilled type, not only to assemble the components but also to incorporate the necessary electrical wiring, plumbing, heating and ventilating equipment, and the like.

It has therefore appeared that the most effective solution to the problem would be the development and adoption of modular systems which would afford the desired flexibility of design and could be erected rapidly by unskilled labor. Many efforts have been made in this direction, as illustrated for example in U.S. Pat. No. 3,420,016, but a thoroughly practical construction which would enable the rapid assembly of all components necessary for a livable dwelling has been lacking.

It is accordingly an important object of this invention to provide a novel structural element in the form of a grade beam designed and adapted to serve as a conduit for heating, cooling and ventilating air as well as providing a raceway for electrical wiring.

Another object is to provide such grade beam for ready assembly with modular floor and wall panels to index and support the same.

Still another object is to provide a novel building construction incorporating such grade beam as a perimeter support for the floor and walls thereof in a manner to facilitate rapid assembly of all components and yet afford complete flexibility in the location of air inlets, air outlets, electrical receptacles and the like.

Other objects of the invention will appear as the description proceeds.

To the accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter fully described, the following description and the annexed drawings setting forth in detail certain illustrative embodiments of the invention, these being indicative, however, of but a few of the various ways in which the principles of the invention may be employed.

THE DRAWING

In the annexed drawing:

FIG. 1 is a semi-diagrammatic vertical cross-section taken longitudinally through a building construction incorporating the present invention.

FIG. 2 is a vertical section taken transversely through the building construction of FIG. 1 on the line 2--2.

FIG. 3 is a fragmentary isometric detailed view of a grade beam and floor and wall panel assembly embodying principles of the invention.

FIG. 4 is an enlarged transverse cross-section taken on the line 4--4 on FIG. 3.

FIG. 5 is a further enlarged transverse cross-section through the grade beam and panel assembly of this invention showing a preferred modification thereof.

DESCRIPTION OF THE INVENTION

Referring first to semi-diagrammatic FIGS. 1 and 2 of the drawing, it is contemplated that the grade beam 1 of this invention will be adapted to rest directly upon fairly widely spaced concrete piers such as 2, 3, 4, and 5, the upper ends of which are at or slightly above grade 6. Rigid floor panels such as 7 are adapted to rest upon the grade beam which also supports the vertical wall panels 8. The ceiling panels 9 (which may also comprise the roof of the structure) rest upon and are supported by the wall panels 8 to which they may be secured by appropriate brackets 10 (see FIG. 5). While a wide variety of different panels may be utilized in accordance with the invention, and the particular form of panel illustrated herein is not per se a part of such invention, a preferred panel construction nevertheless comprises spaced thin parallel steel sheets 11 and 12 having layers 13 of foamed insulating resin applied to their inner surfaces and a central honeycomb core 14. Such panels may be very strong and rigid and therefore suitable as flooring as well as for wall and roof members. The entire structure is rigidified not only by employment of brackets such as 10 but also by resin bonding of adjacent panels together and to the grade beam 1.

Such grade beam 1 may comprise an elongated sheet steel member of general rectangular cross-section having a continuous longitudinally extending slot in its upper surface defined by two upstanding side flange portions 16 and 17. Such flanges thus extend upwardly for a distance slightly greater than the thickness of a floor panel 7 which is adapted to rest upon the inner ledge portion 18 of the grade beam and abut against upstanding flange 17. The upper edge portion 19 of flange 17 and the upper edge portion 20 of flange 16 are turned inwardly toward each other, thus to provide a partially enclosed upstanding channel or raceway above the lower wider portion of the grade beam 1.

The longitudinally extending slot defined by edge portions 19 and 20 may be covered by sheet metal cover plates 21 which may be provided with ventilating registers 22 and electrical receptacles 23 at desired intervals. An electrical wiring harness 24 may be clipped to the inner side of the upstanding flange portion 17, as shown, with appropriate connections to the electrical receptacles 23 and to light switches such as S provided where required.

Grade beam 1 will desirably be lined with appropriate insulating material 25, such as foamed polyurethane, which may define an enclosed conduit as shown, such conduit being readily apertured where desired as at 26 (FIG. 4) opposite registers 22 for the inlet or outlet of ventilating air.

The floor panels 7 will desirably be decked with large sheets of plywood 27 cemented thereto, and carpeting 28 or other appropriate floor covering material may then be applied thereto. In the FIG. 3 and 4 embodiment, such carpeting or other floor cover will normally abut and terminate against the downwardly curved edges of cover plates 21, but in the preferred FIG. 5 embodiment described below such carpeting may extend into contact with the wall panels 8, being apertured only in the areas where the registers and electrical receptacles are located.

In addition to cementing or bonding the wall panels 8 to the grade beam 1, such wall panels may desirably be riveted to upstanding flange portion 16 as at 29, and the outer ledge or shoulder portion of the grade beam may be provided with a longitudinally extending upstanding rib 30 formed therein adapted mechanically to interengage with the lower edges of such panels. A sheet metal flashing strip 31 is adapted to be engaged beneath the lower edges of panels 8 and extend downwardly a short distance in close engagement with the outer side 15 of the grade beam.

In the preferred embodiment of the invention illustrated in FIG. 5 of the drawing, the foamed polyurethane insulating material 32 within the lower rectangular portion of grade beam 1 may extend only along the bottom and sides of the latter since such insulation is relatively unimportant in the upper region thereof. The upstanding flange portions 16' and 17' are of a vertical extent substantially equal to the thickness of floor panels 7 and the plywood decking 27' may be apertured where desired to accommodate the ventilating registers 33 and electrical receptacles 34, the carpeting or other floor covering 28' being similarly apertured for the same purpose. A longitudinally extending sheet metal channel 35 is bonded or riveted to upstanding flange portion 16' as shown to define therewith an enclosed wireway or raceway to contain the electric wiring 36 connected to such receptacles. The under side of the plywood 27' is covered with a thin metal sheet or foil F in the region above channel 35. In this embodiment of the invention the need for the metal cover plates 21 is thus eliminated. Sheet metal straps 37 may be welded at intervals across the gap defined by upstanding flanges 16' and 17' further to rigidify and strengthen the structure while nevertheless permitting free air flow to registers 33 at whatever points the latter may be located. Such straps or bars also assist in supporting channel 35 and, indeed, can be the sole support therefor. Channel 35 may be installed within the grade beam proper at the factory or later at the site. The above described construction enables maximum use to be made of the floor space while permitting the registers and electrical receptacles to be located wherever they may be desired.

It is contemplated that the grade beams of this invention may be formed in single lengths to extend along the entire side of a structure so that they will be required to be joined together only at the corners of the latter as by welding or bolting with suitable reinforcing angle members. A strong rigid frame is thereby provided for the entire building, and a divider may be positioned where desired within the grade beam so that ventilating air under pressure may be introduced into one section thereof for admission into the building through the registers and air may be withdrawn through similar registers at the opposite side of a room, for example, to provide for positive circulation of such air.

It will accordingly be seen that I have achieved the objects of the invention in a manner to permit the expeditious assembly of the building construction with unskilled labor but without sacrifice of quality. Because the air registers and electrical receptacles may be located and relocated at will, the construction design is also very flexible and readily altered to a new plan. The problems ordinarily encountered in installing wiring, air ducts, and the like in the usual walls and partitions are avoided and it is also feasible to place water piping within the beam for convenient access where needed. The electric wiring may desirably be in the form of a pre-assembled harness which is simply placed within the raceway. Separate metal or plastic conduit is not required although they may, of course, be utilized where required by building codes.

The metal section of my new beam is readily produced by roll-forming or brake-forming and may be produced in a variety of sizes and lengths. In some installations where aluminum is a suitable material, the beam may be an extruded section. All components are readily susceptible of mass production, so that both factory and on-site operations are relatively simple and inexpensive.

Claims

We therefore particularly point out and distinctly claim as our invention:

1. A grade beam comprising an elongated rigid sheet metal structure having a main portion of generally rectangular cross-section and two parallel spaced upstanding flange portions on its upper side defining a longitudinally extending slot therebetween, said flange portions being positioned inwardly from the respective sides of said main portion of said structure to provide shoulders outwardly thereof, floor members supported on one said shoulder, and wall members supported on the other said shoulder, and access means between the interior of said rectangular cross-section and said slot.

2. A building assembly comprising a structural beam of elongated rigid sheet metal having a main portion of generally rectangular cross-section and two parallel spaced upstanding flanges on its upper side defining a longitudinally extending slot therebetween, said flanges being positioned inwardly from the respective sides of said main portion to provide shoulders outwardly thereof; vertical wall panels resting on one said shoulder and mounted to said beam; and horizontal floor panels having end portions resting on the other said shoulder and supported thereby.

3. The building assembly of claim 2, wherein said wall panels are of a thickness substantially equal to the width of said shoulder supporting the same.

4. The building assembly of claim 2, wherein said floor panels are of a thickness slightly less than the vertical extent of said flange portions, such slot is provided with cover plates, and floor covering on said floor panels is of a thickness to bring the top surface thereof generally level with the top surface of said cover plates.

5. The building assembly of claim 2, wherein at least certain of said cover plates are provided with air passages therethrough, and at least certain of said cover plates have electrical outlets therein.

6. The building assembly of claim 5, wherein electric wiring connected to said outlets is disposed within said slot between said flanges, and said air passages are in communication with said main portion of said beam.

7. The building assembly of claim 2, wherein said beam is supported upon spaced piers.

8. The building assembly of claim 2, wherein said beam extends around substantially the entire perimeter of the building, constituting the primary support for the same.

9. The building assembly of claim 2, wherein said panels are bonded together and to said beam.

10. The building assembly of claim 2, wherein the lower edge portions of said wall panels are mechanically inter-engaged with a protuberance on the shoulder supporting the same.

11. A building beam of general hollow box cross-section, an upstanding longitudinally extending channel portion on the upper side thereof in communication with the interior of said beam, said channel portion being of substantially less width than said hollow box beam portion to provide shoulders on said beam to each side thereof, floor members supported on one said shoulder, and wall members supported on the other said shoulder.

12. The beam of claim 11, wherein said channel portion is provided with removable cover members.

13. A building beam of general hollow box cross-section, an upstanding longitudinally extending channel portion on the upper side thereof adapted to serve as a raceway for electric wiring, passages through said channel portion in communication with the interior of said beam for delivery of air to or from such interior, said channel portion being of substantially less width than said hollow box beam portion to provide shoulders on said beam to each side thereof, floor members supported on one said shoulder, and wall members supported on the other said shoulder.

14. The building beam of claim 11 further comprising a raceway for electric wiring within said channel portion, and passages downwardly through said channel portion in communication with the interior of said beam.

15. The building assembly of claim 2, wherein an upturned channel of less width than said slot is connected to one of said flanges, said channel acting as a raceway for electrical wiring.

16. The building assembly of claim 15, wherein the remaining portion of said slot is in communication with said main portion of said structural beam, said remaining portion of said slot and said main portion of said structural beam acting as a passage for air flow.

17. The building assembly of claim 16, wherein said floor panels are of a thickness substantially equal to the vertical extent of said flanges.

18. The building assembly of claim 17, wherein floor decking covers said floor panels and slot, said floor decking having a plurality of aligned apertures for both air registers in communication with said remaining portion of said slot and electrical receptacles connected to said wiring.

19. A grade beam comprising a first elongated hollow structure having a flat upper surface and a pair of spaced upstanding flanges on said upper surface, said flanges being positioned inwardly of the lateral sides of said first structure to provide shoulders outwardly thereof, floor members supported on one said shoulder, and wall members supported on the other said shoulder.

20. The grade beam of claim 19, wherein electrical wiring is carried between said flanges and access means are provided in said upper surface at spaced longitudinal intervals to establish fluid communication between the hollow interior of said first structures and the space between said flanges for air passage therethrough.

21. The grade beam of claim 20, wherein the space between said flanges is provided with both electrical receptacles connected to said wiring and air registers to control air flow from said second structure.