U.S. patent number 3,717,964 [Application Number 05/053,502] was granted by the patent office on 1973-02-27 for module frames.
This patent grant is currently assigned to Behring Corporation. Invention is credited to Victor E. Brown, Raul L. Mora, Evans T. Morton.
United States Patent |
3,717,964 |
Brown , et al. |
February 27, 1973 |
MODULE FRAMES
Abstract
The method of making frames and frame units for modules of
modular buildings includes steps of punching perimeter beams to
form stops on the beams where cross-beams are to be located, and
assembling the cross-beams with a pair of the perimeter beams by
butting the ends of the cross-beams against corresponding stops to
position the cross-beams without using jigs or fixtures to
establish their positions. Retainers may be formed in the perimeter
beams next to the stops to temporarily retain the cross-beams in
place until they are welded to the perimter beams. In some frame
units, the perimeter beams and cross-beams are metal channels, and
the beams are assembled flange-to-flange and web-to-web. One weld
is made to connect each abutting pair of flanges next to the webs,
and another weld is made at a point separated farther from the webs
so that the webs reinforce each other and the flanges reinforce
each other. Cross-beams may also be welded to the stops on the
perimeter beams. The invention includes the frame units, part of
the strength and load handling capabilities of which are derived
from particular arrangements of stops and welds.
Inventors: |
Brown; Victor E. (Fort
Lauderdale, FL), Mora; Raul L. (Fort Lauderdale, FL),
Morton; Evans T. (Pompano Beach, FL) |
Assignee: |
Behring Corporation (Ft.
Lauderdale, FL)
|
Family
ID: |
21984735 |
Appl.
No.: |
05/053,502 |
Filed: |
July 9, 1970 |
Current U.S.
Class: |
52/79.1; D25/61;
52/236.9; 52/664; 52/690 |
Current CPC
Class: |
E04B
2/767 (20130101); E04B 1/3483 (20130101); E04B
1/24 (20130101); E04B 5/10 (20130101); E04B
2001/2448 (20130101); E04B 2001/2436 (20130101); E04B
2001/2457 (20130101) |
Current International
Class: |
E04B
1/24 (20060101); E04B 1/348 (20060101); E04B
2/76 (20060101); E04B 5/10 (20060101); E04b
001/34 () |
Field of
Search: |
;52/715,664,666,690,696,650,663,633,236 ;182/228 ;287/189.36B
;29/513,469,155,429 ;219/107 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
966,578 |
|
Aug 1957 |
|
DT |
|
694,018 |
|
Jun 1930 |
|
FR |
|
1,011,917 |
|
Apr 1965 |
|
GB |
|
Primary Examiner: Murtagh; John E.
Assistant Examiner: Raduazo; Henry E.
Claims
Having thus described our invention, we claim:
1. A frame unit for a module of a modular building including in
combination, a pair of metal perimeter beams in the form of
channels which are parallel to each other and spaced apart by a
cross-dimension of a frame unit, each of said perimeter beams
having a plurality of tabs punched out from and integral with the
channel web thereof and projecting between the channel flanges,
said tabs being spaced all along the length of said perimeter beams
and located at predetermined positions for cross-beams, a plurality
of cross-beams in the form of channels spaced all along and
extending between said perimeter beams parallel to each other and
having ends butting against respective ones of said tabs to
position the same, each of said cross-beams having the channel
flanges thereof respectively abutting the channel flanges of said
perimeter beams and the web thereof abutting the webs of said
perimeter beams to form corners, and each abutting pair of flanges
having a first spot weld joining the same at a corner next to the
webs of said beams and a second spot weld joining the same at a
point spaced diagonally along said pair of flanges from said corner
so that the webs of said perimeter beams and said cross-beams
reinforce each other and the flanges of said perimeter beams and
said cross-beams reinforce each other.
2. The frame unit as claimed in claim 1 in which the webs of said
cross-beams are spot welded to said tabs.
3. A frame unit for a module of a modular building including in
combination, a pair of angled metal perimeter beams which are
parallel to each other and spaced apart by a cross-dimension of a
frame unit, said perimeter beams having a web and at least one
flange, each of said perimeter beams having a plurality of tabs
integral therewith and projecting along a flange thereof, said tabs
being spaced at intervals all along the length of said perimeter
beams to provide stops for positioning cross-beams, a plurality of
angled metal cross-beams spaced all along and extending between
said perimeter beams parallel to each other, said cross-beams
having a web and at least one flange, each of said cross-beams
having the web thereof abutting a pair of said tabs on said
perimeter beams and forming a corner with the webs of the perimeter
beams, each cross-beam also having at least one flange thereof
respectively fitting inside and abutting the flanges of said
perimeter beams, and each abutting pair of flanges having a first
spot weld interconnecting the same at a corner next to the webs of
said beams and a second spot weld spaced diagonally along said pair
of flanges from said first spot weld and separated farther than
said first weld from the webs of said beams so that the webs of
said perimeter beams and said cross-beams reinforce each other and
the flanges of said perimeter beams and said cross-beams reinforce
each other.
4. The frame unit as claimed in claim 3 in which the ends of said
cross-beams and said tabs have a spot weld connecting them
together.
5. A box module for a modular building consisting of a plurality of
frame units as claimed in claim 3 having the perimeter beams
thereof welded together at corners to form the box module, the
frame units including horizontal ceiling and floor frame units and
a plurality of vertical side frame units.
Description
BACKGROUND OF THE INVENTION
One particular type of modular building has modules which include
metal frames made with beams and various other parts for doors,
windows, wiring, plumbing, etc. Preferably, frame units for walls,
floors and ceilings are constructed separately, and are then
assembled in an assembly line and secured together to form a
module. The positioning and retention of beams in constructing such
frame units can result in large dimensional variations from unit to
unit unless jigs and fixtures are used to accurately locate the
beams. However, a manufacturer of modular homes ordinarily wishes
to supply several different models of a given type of home, and due
to design variations from one home model to another, different jigs
and fixtures would be required for each model. This complicates
production as well as requiring substantial investment in jigs and
fixtures.
SUMMARY OF THE INVENTION
The present invention provides a method of making frames for
modules wherein positioning of certain beams is accomplished in a
self-jigging manner. Stops are provided on perimeter beams where
cross-beams are to be located. This may be done by sequential
punching in a programmed punch press to allow easy variation in the
location of stops from one beam to another. Cross-beams are placed
between two perimeter beams against corresponding stops. In some
beams, retainers cooperate with the stops to temporarily hold the
cross-beams. Then the cross-beams are welded to the perimeter beams
to form frame units. Ultimately these frame units are assembled to
form complete frames for modules and are welded together.
The frame units and frames are part of the invention and derive
part of their effectiveness from particular arrangements of stops
and welds. Cross-beams may be welded to the stops on the perimeter
beams, and this helps to unitize the frame units so that when loads
are applied they are well distributed. Perimeter beams and
cross-beams in floor and ceiling units are channels which are
welded together flange-to-flange and web-to-web so that the webs
reinforce each other and the flanges reinforce each other. This
helps to prevent web crippling even when relatively thin gauge
materials are used.
Accordingly, it is an object of the invention to provide a method
of making module frames which method is at least partly
self-jigging.
Another object of the invention is to facilitate variation in beam
locations from one module frame to another.
A further object of the invention is to construct a frame unit for
a module so that it will distribute loads effectively.
Another object of the invention is to strengthen frames for modules
by particular arrangements of welds.
Other objects of this invention will appear from the following
description and appended claims, reference being had to the
accompanying drawings forming a part of this specification wherein
like reference characters designate corresponding parts in the
several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a module for a modular home;
FIG. 2 is a perspective view of a frame for the module of FIG. 1,
the frame not being completed with door openings, window openings
and the like;
FIG. 3 is a sectional view taken along line 3--3 of FIG. 2 and
looking in the direction of the arrows;
FIG. 4 is a sectional view taken along line 4--4 of FIG. 2 and
looking in the direction of the arrows;
FIG. 5 is a sectional view taken along line 5--5 of FIG. 2 and
looking in the direction of the arrows;
FIG. 6 is a fragmentary perspective view of one cross-beam member
extending between two perimeter beams in a wall frame unit included
in the frame of FIG. 2;
FIG. 7 is a fragmentary sectional view taken along line 7--7 of
FIG. 6;
FIG. 8 is a fragmentary perspective view of a portion of a
perimeter beam for a floor frame unit or a ceiling frame unit;
FIG. 9 is a schematic view of a punch press useful in performing a
punching operation in carrying out the method of the invention;
FIG. 10 illustrates a step of assembling cross-beams between two
perimeter beams and placing the cross-beams against stops on the
perimeter beams;
FIG. 11 further illustrates the placing of the cross-beams against
stops on the perimeter beams;
FIG. 12 is a fragmentary perspective view illustrating the step of
welding the cross-beams to the perimeter beams;
FIG. 13 is an elevational view of two wall frame units stacked
vertically as may be done in constructing multistory buildings;
FIG. 14 is a sectional view taken along line 14--14 of FIG. 13;
FIG. 15 is a perspective view of a floor frame unit or ceiling
frame unit as the case may be;
FIG. 16 is a sectional view taken along line 16--16 of FIG. 15;
FIG. 17 is a fragmentary perspective view of a portion of the floor
frame unit before assembly thereof showing in particular the
assembling of a cross-beam with a perimeter beam; and
FIG. 18 is a fragmentary perspective view illustrating the step of
welding the cross-beam and the perimeter beam together as well as
showing the final arrangement of stops and welds.
Before explaining the present invention in detail, it is to be
understood that the invention is not limited in its application to
the details of construction and arrangement of parts illustrated in
the accompanying drawings, since the invention is capable of other
embodiments and of being practiced or carried out in various ways.
Also, it is to be understood that the phraseology or terminology
employed herein is for the purpose of description and not of
limitation.
As Shown on the Drawings:
Referring first to FIGS. 1 through 8, a modular building such as a
home, apartment or other building, may consist of two or more
modules which are constructed in a factory, transported to the
building site, assembled together, and secured to each other and to
a foundation. A module 20 is shown in FIG. 1 to illustrate a
typical module for one type of home, but it is to be understood
that the invention is not limited in application to this particular
module.
A basic frame structure 22 for a module such as the module 20 is
shown in FIG. 2. It is to be understood that this frame structure
illustrates the invention, but it is incomplete in that doors,
windows, interior walls, and many other accessory structures have
been omitted. The frame 22 includes a floor frame unit 24 and a
roof frame unit 26. There are three wall frame units 28, 30 and
32.
The wall frame unit 28 consists basically of two perimeter beams 34
and 36 which are each in the form of an angle beam, and a plurality
of cross-beams 38 extending parallel to each other between the
perimeter beams 34, 36. The cross-beams 38, known as studs, are
preferably in the form of channel beams, as may be seen more
clearly for example in FIG. 6.
On the other side of the frame 22, the wall frame unit 30 consists
of two perimeter beams 40 and 42, each in the form of an angle
beam, and a plurality of cross-beams 44 extending parallel to each
other between the perimeter beams 40, 42. The cross-beams 44, known
as studs, are channels identical to the channels 38. The other wall
32 likewise has two perimeter beams and cross-beams and is of the
same construction as walls 28 and 30. The fourth wall has been
omitted from FIG. 2 but is the same.
The floor frame unit 24 includes two perimeter beams 46 and 48,
which are in the form of channels, and cross-beams or joists 50
which are also in the form of channels. The cross-beams 50 extend
parallel to each other between the perimeter beams 46 and 48. There
may also be perimeter beams at the ends of the floor frame unit 24
such as the perimeter beam 52.
The roof or ceiling frame unit 26 is substantially identical to the
floor frame unit 24 and includes perimeter beams 54 and 56 in the
form of channels, and cross-beams or joists 58 also in the form of
channels. There may be perimeter beams at the ends of the frame
unit 26 such as the perimeter beam 60.
All of the beams described and illustrated in connection with FIG.
2 are made of metal, preferably high strength steel. It may be
noted that the floor frame unit 24 and the roof or ceiling frame
unit 26 are recessed within the wall frame units 28, 30 and 32. The
perimeter beams 34 and 36 together with the studs 38 are welded to
the perimeter beams 54 and 46. Similarly, the perimeter beams 40
and 42 together with the studs 44 are welded to the perimeter beams
56 and 48. By having the floor frame unit 24 and the roof frame
unit 26 welded to the inside faces of the wall frame units 28, 30
and 32, additional rigidity and strength is obtained in the final
structure because there is less hinging action at the welded
joints. This feature of the frame construction is described and
claimed in a co-pending application Ser. No. 38,100 filed on May
18, 1970 by John M. Evans and Evans T. Morton and assigned to the
present assignee.
In accordance with one aspect of the present invention, the
perimeter beams of the various frame units are provided with stops
which may be in the form of tabs, and the cross-beams which extend
between the perimeter beams butt against these stops. Referring
first to FIG. 3, it may be seen that the cross-beam 44 of the wall
frame unit 32 butts against a stop or tab 62 formed in the
perimeter beam 40. The lower end of cross-beam 44 likewise butts
against an identical stop formed in the lower perimeter beam 42. In
the roof frame 26, the end of a cross-beam 58 shown in FIG. 3 butts
against two stops or tabs 64 and 66 formed in the perimeter beam
56. The same elements are shown in FIG. 4 from a different
angle.
FIG. 5 is a sectional view taken through the other wall frame unit
28, and shows a cross-beam 38 having its upper end butting against
a stop or tab 68 formed in the perimeter beam 34 and having its
lower end butting against a stop or tab 70 formed in the perimeter
beam 36. FIG. 5 also shows the left ends of two cross-beams 50 and
58. It may be seen that the end of cross-beam 58 butts against two
stops or tabs 72 and 74 formed in the perimeter beam 54 of the roof
frame unit. Similarly, the end of cross-beam 50 butts against two
stops or tabs 76 and 78 formed in the perimeter beam 46 of the
floor frame unit.
FIG. 6 illustrates how the cross-beams or studs of the wall frame
units 28, 30 and 32 may be welded to the perimeter beams. In FIG.
6, the perimeter beams 34 and 36 are shown together with a
cross-beam 38. It may be seen that there is a spot weld 80 between
a flange of stud 38 and the inside flange of perimeter beam 34.
There is another weld 82 connecting the web of stud 38 to the stop
or tab 68. Likewise, at the lower end of stud 38 a weld 84 connects
the inside flange of stud 38 to the inside flange of perimeter beam
36, and another spot weld 86 connects the web of stud 38 to the
stop or tab 70. It is not essential to provide two welds at each
end of the studs 38. For example, the welds 80 and 84 could be used
alone or the welds 82 and 86 could be used alone.
FIGS. 6 and 7 illustrate retainer prongs 88 and 90 formed in the
perimeter beam 34 directly adjacent the tab 68. It will be
understood that there are identical prongs formed in the perimeter
beam 36 directly adjacent and on opposite sides of the tab 70. As
may be seen in FIG. 7, the web of the stud 38 fits between the
prongs 88 and 90 and the tab 68. The studs can be forced over the
prongs such as 88 and 90 when the studs are being placed against
the stops such as stops 68. The prongs will yield to allow the end
of the stud to pass and then spring back to retain the stud against
the tab 68 until the stud is welded in place. This considerably
simplifies the positioning of the studs, and saves a great deal of
equipment which would otherwise be required for clamping and
holding the studs in place.
FIG. 8 merely illustrates in greater perspective the configuration
of the tabs 76 and 78 in the perimeter beam 50.
FIGS. 9 through 12 illustrate basic steps in the method of the
invention. The invention includes a step of providing perimeter
beams with stops located at predetermined positions spaced along
the length thereof at which cross-beams are to be located. FIG. 9
illustrates how this may be accomplished. A perimeter beam 34 is
shown passing through a punch press 91 which sequentially punches
stops or tabs in the perimeter beam 34. The press 91 has die sets
92 and 94 which are designed to form both the tabs 68 and the
retainer prongs 88,90 in a single punching step. The specific
position of a given tab 68 and retainer 88,90 on the perimeter beam
34 can be controlled very accurately. The press 91 may be of the
numerically controlled type. Thus, the locations of all of the tabs
68 for a given beam can be programmed into the press, and specific
locations can be selected by feeding input information into the
press such as from punched cards. Then as the beam 34 passes
through the press, tabs 68 and retainer prongs 88 are punched at
precisely located position where cross-beams are to be placed in
the ultimate frame unit. It is easy to vary the spacing from one
tab to another within a given beam merely by proper selection of
the input information for the punch press. It is also easy to
change the location of tabs from one beam to another.
It may be seen that by forming the stops on the perimeter beams at
preselected positions on the beams as by a punching operation, a
considerable investment in jigs and fixtures is saved. If it were
necessary to rely upon jigs and fixtures to position the
cross-beams, different fixtures would have to be provided for
different positions of beams. The setup time for a given frame unit
would be considerably increased, and there would be considerably
more labor involved also.
FIGS. 10 and 11 illustrate the step of assembling the cross-beams
38 with two perimeter beams 34 and 36 and placing the ends of the
cross-beams 38 against the stops or tabs 68 and 70 to position the
cross-beams without requiring jigs or fixtures to establish those
positions. The beams 38 (and 44) are assembled vertically. FIG. 11
in particular shows the upper end of a cross-beam 38 being forced
over the prongs 88 into position against a tab 68. FIG. 12
illustrates the lower end of the cross-beam 38 after it has been
butted against the tab 70, and after the retainer prongs have
returned to hold the lower end of the stud 38 in place.
FIG. 12 also shows the welds 86 and 84 which may be used to weld
the stud 38 to the perimeter beam 36, and thus illustrates the step
of welding the studs to the perimeter beams. All of the wall frame
units are made by essentially the same sequence of steps.
The floor frame unit 24 and the roof frame unit 26 are made by the
sequential steps illustrated in FIGS. 15 through 18. A floor frame
unit 24 is shown in FIG. 15 including the perimeter beams 46,48 and
the cross-beams or joists 50. FIG. 16 shows the manner in which the
joists 50 fit inside the channel flanges of the perimeter beams 46
and 48.
The first step is to punch the perimeter beams 46 and 48 to form
the stops where cross-beams are to be located. Retainer prongs may
be formed in the perimeter beams 46 and 48 if desired, but they are
not necessary in all cases since the floor frame units are usually
fabricated in a horizontal position. In FIG. 17, a single stop or
tab 77 replaces the two stops 76 and 78 shown for example in FIG.
8. A retainer prong 100 is also shown. The stops 77 are punched at
precise locations for cross-beams in exactly the same manner
described in connection with FIG. 9. Then a plurality of the
cross-beams 50 are assembled with the perimeter beams extending
parallel between the perimeter beams. The ends of the cross-beams
are placed against the stops 77 to position the cross-beams without
requiring jigs or fixtures for their positioning. Next, the
cross-beams are welded to the perimeter beams.
A specific arrangement of welds which is unexpectedly strong is
shown in FIG. 18. It may be seen that the web 102 of beam 50 is
welded to the tab 77 at 104 and 106. The tab 77 is perpendicular to
the flanges 108 and 110, and the tab 77 thus provides a corner at
112 which stiffens the web 114 of beam 46. By having the tab 77
welded to the web 102, the two webs 114 and 102 reinforce each
other.
Also, the flange 108 is welded to flange 116 and flange 110 is
welded to flange 118 in a desirable manner. There are welds at 120
and 122 which are very close to the two webs 102 and 114, these
welds being very close to the corner formed by the two webs 102 and
114. There are two other welds 124 and 126 separated farther from
the webs 102 and 114 than the welds 120 and 122, and these welds
are spaced diagonally from welds 120 and 122.
Thus, welds 120 and 122 effectively weld the two beams together
web-to-web, and the two welds 124 and 126 effectively weld the two
beams 50 and 46 together flange-to-flange. This means that the webs
102 and 114 reinforce each other and the flanges 116 and 118
respectively reinforce the flanges 108 and 110.
After the frame units have all been assembled and welded, the
various frame units 24, 26, 28, 30 and 32 are assembled together
into a generally cubicle shape and are welded together in
accordance with the previous description. The frame units are
ordinarily finished with surfacing material and other structure
before they are welded together. In a commercial production
facility, the frame units may be completed in subassembly bays, and
then assembled together and welded on a final production line. FIG.
18 shows that the cross-beams 50 of the floor frame unit 24 may be
filled or partially filled with sound deadening material such as
sand cement 130 to help to deaden the sound of the cross-beams 50.
The cement 130 adds weight to the cross-beams and changes their
natural frequency to a relatively low frequency which does not have
unpleasant qualities.
As previously mentioned, the particular arrangement of welds shown
in FIG. 18 gives unexpected strength to the floor and roof frame
units 24 and 26. The webs of the various beams reinforce each other
and the flanges of these beams also reinforce each other. As a
result, it is possible to use relatively thin gauge material for
the beams and still achieve frame units of high compressive and
tensile strength. Similarly, the welding of the cross-beams or
studs 38 and 44 in the wall frame unit to the tabs or stops such as
the tabs 68 and 86 shown in FIGS. 11 and 12 increases the strength
and load distributing characteristics of the wall frame unit. This
is illustrated particularly in FIGS. 13 and 14. In FIG. 13, two
wall frame units 28 and 28' are shown stacked one above the other
as they would be arranged if two frames 22 were placed one above
the other. This happens in construction of multi-story buildings.
It may be seen that if some of the studs 38 and 38' were shorter
than others, there would be a possibility of the perimeter beams 34
and 36' becoming distorted with a resultant uneven distribution of
loads. However, by welding the studs 38 and 38' to the tabs such as
tabs 68 and 70, the wall frames are unitized so that loads are
distributed uniformly. This distribution of loads is facilitated by
providing compressible material such as styrofoam at 132 between
the perimeter beams 34 and 36' as shown in FIG. 14. The styrofoam
will compress to conform to the beams 34 and 36' and thus take up
any irregularities in these beams.
It is apparent that the invention provides module frames and a
method of making module frames wherein certain positioning steps
are self-jigging. This considerably speeds up production, reduces
investment in jigs and fixtures, saves labor and conserves floor
space in an assembly operation. Furthermore, the welding of the
various beams to the stops which are used for self-jigging imparts
strength to the structures and improves load distribution. A
particular arrangement of welds is provided for the floor and roof
frame units which imparts unexpectedly high strength to these
structures. The floor frame unit can be sound deadened in an
extremely simple manner.
* * * * *