U.S. patent number 3,879,908 [Application Number 05/365,538] was granted by the patent office on 1975-04-29 for modular building panel.
Invention is credited to Victor P. Weismann.
United States Patent |
3,879,908 |
Weismann |
April 29, 1975 |
Modular building panel
Abstract
An improved prefabricated modular building panel includes a
three-dimensional lattice fabricated of a plurality of rod-like
slender elongated metal elements. The lattice elements are arranged
to define a pair of substantially parallel spaced major lattice
surfaces, and side and end lattice edge surfaces. A plurality of
strut members traverse the interior of the lattice and interconnect
the major surfaces to define a plurality of passages within the
lattice. The passages are open at at least one end thereof to one
of the lattice edge surfaces. Thermal insulating filler material is
disposed within the lattice and extends from side to side and from
end to end of the lattice. The filler material includes a plurality
of insulative elements positioned in the passages through the
passage open ends to be disposed wholly within the lattice. A
bonding agent is used to secure the insulative elements in position
within the lattice, and the bonding preferably is a layer of foam
material applied over the insulative elements within the lattice to
foam at least partially in situ and to bond to the insulative
elements and to the metal elements of the lattice, particularly the
lattice strut members.
Inventors: |
Weismann; Victor P. (South
Pasadena, CA) |
Family
ID: |
26898099 |
Appl.
No.: |
05/365,538 |
Filed: |
May 31, 1973 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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202879 |
Nov 29, 1971 |
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Current U.S.
Class: |
52/309.5;
52/309.12; 52/577; 52/410; 52/600 |
Current CPC
Class: |
E04C
2/205 (20130101); B21F 27/128 (20130101) |
Current International
Class: |
B21F
27/00 (20060101); B21F 27/12 (20060101); E04C
2/10 (20060101); E04C 2/20 (20060101); E04c
002/26 () |
Field of
Search: |
;52/650,309,409,410,382,576,577,582,405 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
Architectural Record, July 1960, pp. 224..
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Primary Examiner: Murtagh; John E.
Attorney, Agent or Firm: Christie, Parker & Hale
Parent Case Text
This is a continuation of application Ser. No. 202,879, filed Nov.
29, 1971, now abandoned.
Claims
What is claimed is:
1. A prefabricated modular building panel as an article of
manufacture comprising a three-dimensional lattice fabricated of a
plurality of slender elongated metal elements arranged to define a
pair of substantially parallel spaced major lattice surfaces, side
and end lattice edge surfaces, and a plurality of strut members
traversing the interior of the lattice and interconnecting the
major surfaces thereof to define a plurality of passages within the
lattice open at at least one end thereof to one of the edge
surfaces, and thermal insulating filler material disposed within
the lattice to extend from side to side and from end to end of the
lattice, the filler material being held in position within the
lattice by the elements defining the lattice, the filler material
being comprised of a plurality of insulative elements positioned in
the passages through the open ends of the passages to be disposed
wholly within the lattice and sized relative to the passages to
make substantial positioning contact with the lattice elements
defining the respective passages whereby the insulative elements
are held in predetermined positions within the lattice by the
lattice itself, and a bonding agent disposed between the insulative
elements and the adjacent lattice elements for immovably fixing the
insulative elements in said predetermined positions within the
lattice, wherein the bonding agent is comprised of a layer of
cellular foamed material foamed at least in part and at least
partially hard set within the lattice.
2. A panel according to claim 1 wherein the bonding agent comprises
polyurethane foam material.
3. A prefabricated modular building panel as an article of
manufacture comprising a three-dimensional lattice fabricated of a
plurality of slender elongated metal elements arranged to define a
pair of substantially parallel spaced major lattice surfaces, side
and end lattice edge surfaces, and a plurality of strut members
traversing the interior of the lattice and interconnecting the
major surfaces thereof to define a plurality of passages within the
lattice open at at least one end thereof to one of the edge
surfaces, and thermal insulating filler material disposed within
the lattice to extend from side to side and from end to end of the
lattice, the filler material being held in position within the
lattice by the elements defining the lattice, the filler material
being comprised of a plurality of insulative elements defined by a
rigid cellular foam material positioned in the passages through the
open ends of the passages to be disposed wholly within the lattice,
and a bonding agent disposed between the insulative elements and
the adjacent lattice elements for fixing the insulative elements in
position within the lattice.
4. A panel according to claim 3 wherein the foam material is a
synthetic non-cementitious foam material.
5. A panel according to claim 4 wherein the foam material is
polystyrene foam.
6. A prefabricated modular building panel as an article of
manufacture comprising a three-dimensional lattice fabricated of a
plurality of slender elongated metal elements arranged to define a
pair of substantially parallel spaced major lattice surfaces, side
and end lattice edge surfaces, and a plurality of strut members
traversing the interior of the lattice and interconnecting the
major surfaces thereof to define a plurality of passages within the
lattice open at at least one end thereof to one of the edge
surfaces, and thermal insulating filler material disposed within
the lattice to extend from side to side and from end to end of the
lattice, the filler material being held in position within the
lattice by the elements defining the lattice, the filler material
being comprised of a plurality of insulative elements positioned in
the passages through the open ends of the passages to be disposed
wholly within the lattice and sized relative to the passages to
make substantial positioning contact with the lattice elements
defining the respective passages whereby the insulative elements
are held in predetermined positions within the lattice by the
lattice itself, and a bonding agent disposed between the insulative
elements and the adjacent lattice elements for immovably fixing the
insulative elements in said predetermined positions within the
lattice, the bonding agent being comprised of a latex base
material.
Description
FIELD OF THE INVENTION
The invention pertains to improvements in modular building panels.
More particularly, it pertains to building panels having a
three-dimensional wire lattice within which is disposed a composite
insulative core comprised of insulative elements inserted into the
interior of the lattice and a bonding agent securing the inserted
elements in fixed position within the lattice.
BACKGROUND OF THE INVENTION
Review of the Prior Art
My prior U.S. Pat. Nos. 3,305,991 and 3,555,131 describe a
reinforced modular foam building panel and methods for fabricating
such a panel, respectively. The panel is a composite of a welded
three-dimensional wire lattice and of an insulative core defined by
a quantity of cellular foamed material foamed and hard-set in the
lattice to bond to the strut members which traverse the interior of
the lattice. The strut members interconnect and reinforce the wire
elements defining the two spaced major surfaces of the lattice.
Panels in accord with the disclosures of these patents have been
approved for use by the International Conference of Building
Officials, Pasadena, Calif. Report No. 2440, as structural or
non-structural roof and wall panels for commercial and residential
construction. These panels are characterized by their light weight,
good thermal, moisture and acoustic insulative properties, their
adaptability to efficient erection procedures, their compatibility
with conventional construction techniques, and their strength. The
strength of these prior panels is obtained in part from the
intimate bonding relation between the foamed-in-situ core of the
panels to the strut members of the wire lattice.
For many applications, however, it has been found that panels
fabricated according to U.S. Pat. No. 3,305,991, for example, so
far exceed the requirements of the application that they may not be
a practical alternative to other more conventional construction
materials. For example, in warm or tropical areas where a structure
need not be designed to withstand snow loads or the like, these
prior panels are stronger and more insulative than is necessary.
Also, in some instances, notably in the case of foreign markets and
special usages, suitable insulation materials and elements may
exist which are equally well or better suited to the particular
application than the foam materials contemplated by my prior
patents and which may be more attractive economically. In view of
these factors, a need exists for modular building panels which have
the general advantages of my prior panels, such advantages deriving
in large part from the wire lattice, but which incorporate
insulative cores different from those encountered in panels
fabricated pursuant to my prior patents. Satisfaction of this need
will enhance the utility and usage of my prior panels and will make
possible the use of improved construction techniques in many
geographic and functional areas where the prior panels cannot or
are not being used to best advantage.
SUMMARY OF THE INVENTION
This invention fills the need described above by providing
improvements in reinforced welded-wire lattice modular building
panels. The present panels possess all of the advantages found in
my prior panels due to the presence of the lattice therein. The
present panels, however, incorporate insulative core elements and
materials which may differ from those of my prior panels to adapt
the present panels to particular applications or to take advantage
of particular economic and supply situations. The present panels
are light, strong, simple to use in construction, efficient and
economical.
Generally speaking, this invention provides a prefabricated modular
building panel which includes, as a principal component, a
three-dimensional lattice fabricated of a plurality of slender
elongated metal elements. These elements are arranged to define a
pair of substantially parallel spaced major lattice surfaces, and
side and end lattice edge surfaces. The metal elements include a
plurality of strut members which traverse the interior of the
lattice and interconnect the lattice major surfaces. The strut
members and the other elements of the lattice are arranged to
define a plurality of passages within the lattice which open at at
least one end thereof to the lattice edge surfaces. Thermal
insulation filler material is disposed within the lattice and
extends substantially from side to side and from end to end of the
lattice. The filler material includes a plurality of insulative
elements which are positioned in the lattice passages through the
open ends of the passages to be disposed wholly within the lattice.
A bonding agent interconnects the insulative elements to the
adjacent lattice elements, notably the strut members, to secure the
insulative elements in position in the lattice.
DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features of this invention are more
fully set forth in the following description of certain presently
preferred embodiments of the invention, which description is
presented with reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view of a portion of a panel according to
this invention;
FIG. 2 is a cross-section view taken along line 2--2 in FIG. 1;
FIG. 3 is a cross-section view taken along line 3--3 in FIG. 2;
FIG. 4 is a view similar to that of FIG. 2 but of another
panel;
FIG. 5 is a transverse cross-section view of another panel; and
FIG. 6 is a transverse cross-section view of another panel.
DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
As shown in FIG. 1, the principal components of a building panel 10
are a lattice 11 and a core 12 of insulative filler material
disposed within the lattice. The lattice is defined by a plurality
of elongate, slender rod-like metal elements. Conveniently, the
lattice may be made of elements defined by wire having a size of
from 8 to 16 gage, inclusive, and preferably the elements of the
lattice are defined by 14 gage wire. Preferably, the same size wire
is used throughout lattice 11, but it is within the scope of this
invention that the wires used to define one group of elements of
the lattice may be of a different size, within the preferred range
mentioned above, from the elements defining the remainder or
different groups of elements within the lattice.
The lattice includes a plurality of spaced parallel upper
longitudinal elements 13 which are conveniently referred to as
upper truss runners. A corresponding plurality of spaced parallel
lower longitudinal elements 14 define lower truss runners. The
upper truss runners 13 are interconnected by a plurality of spaced
parallel transverse members 15, and the lower truss runners 14 are
interconnected by a corresponding plurality of transverse members
16. The upper truss runners and their corresponding transverse
members define an upper major surface of panel 10. Similarly, the
lower truss runners and their transverse members define a lower
major surface of the lattice. These major surfaces are spaced apart
in substantially parallel relationship to each other by a plurality
of strut members 17 which traverse the interior of the lattice and
interconnect the lattice major surfaces.
As shown most clearly in FIG. 1, it is preferred that the upper and
lower truss runners be disposed in pairs in which one upper truss
runner 13 and one lower truss runner 14 are disposed in parallel
spaced alignment with each other. Strut members 17 preferably are
interconnected between the upper and lower truss runners in each
aligned pair thereof rather than being interconnected between
transverse members 15 and 16. Accordingly, a plurality of parallel
passages 18 are defined within the interior of lattice 11 between
the lattice major surfaces and between adjacent pairs of truss
runners as interconnected by the strut members. Each passage 18 is
open at at least one end to one of the lattice edge surfaces.
Preferably the passages extend along the length of the lattice and
open at their opposite ends to the end surfaces of the lattice.
In a presently preferred lattice, truss elements 13, 14, 15 and 16
are spaced apart from each other on 2 inch centers within their
respective groups. Also, it is preferred that the aligned upper and
lower truss runners be spaced apart on 2 inch centers. Accordingly,
lattice 11 is organized on a 2 inch cubicle module and conveniently
is fabricated in 4 foot widths and in lengths of from 8 to 14 feet,
the length varying within this range in 2 inch increments. It will
be appreciated, however, that different spacing of the elements of
lattice 11 may be used as desired and that the lattice may be
fabricated with different nominal width or length, all without
departing from the scope of this invention.
Each upper truss runner 13, its corresponding lower truss runner
14, and the strut members 17 which interconnect them define a truss
section 20 within lattice 11. Because of the above-mentioned 2 inch
spacing between adjacent ones of truss runners 13 and 14,
respectively, it is apparent that the truss sections are spaced
apart from each other in parallel relationship on 2 inch centers
across the width of lattice 11. Each passage 18 longitudinally
through lattice 11 is defined between an adjacent pair of truss
sections 20.
FIGS. 2 and 4 illustrate, respectively, two different styles of
truss sections which may be used to advantage in the lattice for a
panel according to this invention. Truss section 20, shown in FIG.
2, is characterized in that strut members 17, located within the
ends of the truss section, are disposed in alternate converging and
diverging relationship to each other along the length of the truss
section. That is, one strut member may slope at about a 45.degree.
angle from left to right proceeding upwardly from lower truss
runner 14 to upper truss runner 13, and the next strut member to
the right may slope from left to right proceeding downwardly from
upper truss runner 13 to lower truss runner 14, and so on
throughout the length of the truss section. At each end of truss
section, however, an end strut member 22 is provided and is
disposed perpendicular to the adjacent truss runners. In lattice
11, or in any other lattice according to this invention, it is
preferred that the various elements defining the lattice be
interconnected via resistance welding, although other
interconnection techniques may be used if desired. Where the truss
sections in the lattice have the configuration shown in FIG. 2, in
which strut members 17 are alternately inclined to each other, it
is preferred that the converging ends of strut members 17 be
interconnected to the truss runners on opposite sides of and spaced
from alternate ones of the transverse members associated with that
truss runner. That is, if an adjacent pair of strut members 17
converge toward each other at the upper truss runner 13, then the
upper ends of these strut members are interconnected to the upper
truss member in somewhat spaced relationship from and on opposite
sides of one of upper transverse members 15; it is preferred that a
lower transverse member 16 be disposed directly below this upper
transverse member. Proceeding along the length of the truss
section, however, the next upper transverse member 15 lies between
the diverging ends of a pair of strut members which have their
lower ends interconnected to lower truss runner 14 close to and on
opposite sides of the next lower transverse member 16.
FIG. 4 illustrates another truss section 23 for use in a lattice
for a panel according to this invention. As to truss section 23,
however, the strut members are identifed as 17' to distinguish them
from the alternately converging and diverging strut members of
truss section 20. Strut members 17' are all disposed parallel to
each other perpendicular to upper and lower truss runners 13 and 14
in each truss section 23. It is preferred that, if lattice elements
13, 14, 15 and 16, respectively, are spaced apart upon 2 inch
centers within their corresponding groups, then strut members 17'
are spaced apart on 1 inch centers along the length of each truss
section 23. As a practical matter, the configuration of truss
section 20 is preferred over the configuration of truss section 23
since truss section 20 requires the use of a smaller amount of
lattice wire stock than does truss section 23 to define a lattice
of comparable strength. That is, to define lattices of equivalent
structural properties, about 40 percent more lattice wire stock
must be used to define strut members 17' of truss section 23 than
is required to define strut members 17 of lattice section 20.
Regardless of whether truss sections 20, 23, or some other truss
section configuration is used in the definition of a lattice for a
panel according to this invention, it is preferred that the truss
sections be defined as subassemblies of the lattice, which
subassemblies are then interconnected by transverse members 15 and
16, for example, to define the completed lattice.
In the manufacture of panel 10, for example, it is preferred that
insulative core 12 be installed within the lattice after the
lattice has been fabricated. The core of a panel according to this
invention is composed of a plurality of discrete insulative
elements which are inserted into the lattice one to each passage 18
through the open ends of the passages. A suitable bonding agent is
then applied to the inserted insulative elements to connect the
inserted insulative elements to the lattice structure, thereby to
secure the insulative elements in the desired relationship to one
another within the lattice.
In panel 10, core 12 is defined by a plurality of strips of
polystyrene foam 25, which are shown best in FIG. 3. Polystyrene is
prefoamed to define strips of the appropriate length, width and
thickness, or the strips 25 are cut from a board of polystyrene
foam to the desired size prior to insertion of the strips into
passages 18 of lattice 11. In panel 10, each strip 25 has a width
which approximates the spacing between the adjacent surfaces of the
strut members of the truss sections which bound opposite sides of
passages 18. Strips 25 have a thickness which is substantially less
than the spacing between the upper and lower major faces of lattice
11. For example, strips 25 may have a width just slightly less than
2 inches so that they may be inserted into passages 18, and have a
thickness on the order of about three-fourths inch. In panel 10,
the strips are inserted into passages 18 to be disposed within the
passages parallel to and substantially midway between the major
faces of the lattice. The inserted polystyrene foam strips are
maintained in this position while a suitable bonding agent 26 is
disposed, preferably by spraying, over at least one side of the
array of strips 25. The bonding agent hardens to secure the strips
in their predetermined positions within lattice 11. In panel 10,
the bonding agent preferably is a polyurethane foam which is
deposited over the upper surfaces of the array of inserted strips
25 to foam in situ and to cure to a hardened state, thereby to bond
the inserted insulative elements to the adjacent portions of
lattice 11. It is preferred that foam layer 26 be formed to a
thickness which is less than the spacing between the substantially
coplanar upper surfaces of insulative elements 25 and the upper
major surface of lattice 11.
FIG. 4 illustrates that the precise nature of the insulative core
for a panel according to this invention is not dependent upon the
use of a particular type of truss section in the lattice of the
panel. Accordingly, FIG. 4 illustrates a panel 27 in which the
lattice 28 thereof includes truss sections 23, but in which core 12
is identical to the core of panel 10, illustrated in FIGS. 1, 2 and
3.
FIG. 6 is a fragmentary transverse cross-sectional elevation view
of another panel 30 according to this invention. Panel 30 includes
a lattice 11, which may include truss sections 20 or 23, as
desired. Panel 30 has an insulative core 31 which is defined by
elongate pieces of rigid foam material 32, one of which is inserted
into each passage 18 provided within the lattice. Each inserted
insulative element 32 for panel 30 has a cross-sectional
configuration which corresponds closely to the cross-sectional
configuration of each passage 18 so as to substantially fill
passage 18. In the case of panel 30, a layer 33 of bonding agent is
deposited over the surfaces of elements 32 which are exposed to the
opposite major faces of the lattice. Bonding agent 33 may be
provided in the form of liquid latex or latex-base material applied
to the inserted insulative elements to cure and thereby produce the
desired bond of the insulative elements to the lattice elements,
notably the strut members of the lattice. Preferably, the core,
comprised of the inserted insulative elements and the bonding
agent, is disposed essentially wholly within the lattice of the
completed panel and does not significantly embed the lattice
elements defining the major and edge surfaces of the lattice.
Another panel 40 according to this invention is shown in FIG. 5 and
includes a lattice 11. Panel 40 has an insulative core 41 which is
composed of a plurality of hollow paper tubes 42, preferably
treated on their interior surfaces to be water impermeable, and a
quantity of polyurethane foam 43, for example, disposed over those
exterior surfaces of tubes 42 which lie adjacent the major surfaces
of the lattice. Preferably tubes 42 are of an elliptical shape and
are configured so that in the normal state of the tubes the major
diameter of the ellipse is slightly greater than the width of
lattice passages 18, and in which the minor diameter of the ellipse
is less than the distance between the spaced major surfaces of the
lattice. Tubes 42 may be held in position in their respective
lattice passages following insertion of the tubes into the lattice
by interferring mechanical engagement between the tubes and the
strut members of the lattice prior to application of the liquid
polyurethane foam material. The foam material is deposited over the
exterior surfaces of the tubes in such a condition that the foam
material foams in situ within the lattice and cures to a hardened
or semi-hardened state to embed the strut members and secure tubes
42 in position within the lattice.
The accompanying drawings illustrate that the cores for the panels
of this invention may be disposed wholly within the confines of the
lattice of the corresponding panel; this disposition of the
insulative core wholly within the panel lattice is the preferred
relationship of the core to the lattice. It is within the scope of
this invention, however, that the insulative core may, if desired,
extend outside the lattice and embed the lattice elements defining
one or both of the lattice major surfaces, but preferably not any
of the lattice edge surfaces. The manufacture of a panel in which
one or both of the lattice major surfaces is embedded by the
insulative core of the panel is particularly possible where the
bonding agent is a foam material which is susceptible of being
foamed and hardened in situ, i.e., within the panel lattice rather
than in a separate foaming chamber. For example, the manufacture of
a polystyrene foam requires that the constituents of the foam
material be foamed in a closed mold. Polyurethane foam, on the
other hand, may be foamed and set in an open mold at ambient
temperature and pressure conditions. Accordingly, where a foam
material is used as the bonding agent to secure the inserted
insulative elements of the core in position within the panel
lattice, the foam bonding agent must be of the type which may be
foamed in an open container.
In the preceding description, reference has been made to specific
materials for use as inserted insulative elements of the panel core
and also to specific materials which may be used as the bonding
agent in the core. As is apparent from the foregoing description,
the bonding agent itself may contribute to the insulative
properties of the core, as in the case where the bonding agent is
foamed in situ urethane foam, for example. Other foams which can be
used either solely or in combination with other foam materials to
define the inserted insulative elements of the core are phenolic
foam, expanded vinyl foam, cross-linked polyvinyl chloride foam,
low density polyethylene foam, cross-linked polyethylene foam, and
ureaformaldehyde foam. All of these foams are of the type which
require formation in a closed, or at least partially closed mold,
and therefore may be used to advantage in a panel according to this
invention only to define the inserted insulative elements.
Materials other than foams, such as balsa wood, may be used to
define the inserted insulative elements of the panel. Other bonding
agents which may be used to advantage in the fabrication of a panel
according to this invention include foamed plaster, asphalt or
asphalt-based materials, or suitable adhesives such as epoxy system
adhesives.
Urethane foams are preferred as the bonding agent to secure the
inserted insulative elements within the lattice of a panel
fabricated according to this invention. Also, rigid urethane foams
may be used to define the inserted insulative elements. Urethane
foams possess several important properties, notably good insulating
efficiency, light weight, strength, and adhesion in the in situ
situation. When a urethane foam is used as the bonding agent, it is
particularly desirable because it structurally bonds itself
securely to the inserted insulative elements and to the adjacent
members of the panel lattice. Polystyrene foams, on the other hand,
cannot be used to advantage as a bonding agent in a panel according
to this invention since polystyrene foams cannot be foamed in an
open container. Polystyrene foams are somewhat less expensive than
urethane foams and have thermal and acoustical insulating
properties which closely approach those of polyurethane foam.
If desired, a panel according to this invention may be formed with
an opening to conveniently receive a window or door assembly.
In erecting a structure, such as a dwelling, from panels provided
by this invention, extremely simple techniques may be used. The
panels are first aligned with each other with the edges abutting.
Since the lattice members of the panels are exposed at the edges of
the panels, or are just barely covered by the bonding agent used in
the fabrication of the panel, adjacent panels may be wired or
welded together by very simple and economical techniques. In such a
manner, the entire external and internal wall system of a building,
as well as the roof of the building, may be erected by one or two
men in an extremely short time.
The panels of this invention are characterized by their light
weight. Preferably the panels weigh no more than about 2 pounds per
cubic foot of panel. The exact weight per unit volume of the panel
would be dependent upon the gage of wire used in the fabrication of
the panel and the precise nature of the materials used to define
the panel core.
While this invention has been described above in conjunction with
specific panels and materials constituting the same, it is to be
understood that this has been by way of describing certain
presently preferred embodiments of the invention and is not
intended as a limitation of the scope of this invention.
* * * * *