U.S. patent number 3,918,233 [Application Number 05/439,059] was granted by the patent office on 1975-11-11 for construction system.
Invention is credited to Harold Graves Simpson.
United States Patent |
3,918,233 |
Simpson |
November 11, 1975 |
**Please see images for:
( Certificate of Correction ) ** |
Construction system
Abstract
A construction system is disclosed utilizing a prefabricated
plank which can be assembled in contiguous, aligned relationship
with other similar planks to form a construction section. The
individual planks are of varying geometric shapes and are of a
composite construction having a structural core with a flexible
membrane covering. The core may be formed from foamed plastic,
concrete or the like and the membrane a flexible plastic or light
gauge metal. The membrane covering includes an edge flap portion
adapted to overlie the marginal edge of the next adjacent plank to
provide a continuous weatherproof seal between planks. The flaps
are sealable by flexible fasteners carried on the membrane flap and
marginal portion in the form of interlocking rib and groove
elements. The groove and ribs may take various shapes such as a
barb and socket and may also include provision for a marginal
expansion joint to facilitate assembly of the membrane covering and
eliminate expansion and contraction problems caused by temperature
changes. In the corner area between adjacent planks, a compressive
fastener seals between the converging edge seals to effect a
weatherproof exterior. Another form of the edge seal is heat and
pressure bended to weatherproof the system. The interlocking
flexible structure is also adaptable to seal overlapping corrugated
metal building panels. The individual planks can be assembled to
form a roof, wall or any construction section. The present
invention also discloses the construction of a geodesic dome using
the planks of the present invention.
Inventors: |
Simpson; Harold Graves
(Oklahoma City, OK) |
Family
ID: |
26990171 |
Appl.
No.: |
05/439,059 |
Filed: |
February 4, 1974 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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336364 |
Feb 27, 1973 |
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Current U.S.
Class: |
52/745.07;
52/536; 52/81.3; 52/DIG.4 |
Current CPC
Class: |
E04D
3/363 (20130101); E04D 3/352 (20130101); E04D
3/38 (20130101); E04D 3/3601 (20130101); E04B
7/105 (20130101); E04D 3/358 (20130101); Y10S
52/04 (20130101) |
Current International
Class: |
E04B
7/10 (20060101); E04D 3/00 (20060101); E04D
3/363 (20060101); E04D 3/35 (20060101); E04D
3/38 (20060101); E04D 3/36 (20060101); E04D
13/04 (20060101); E04B 007/10 (); E04G
021/14 () |
Field of
Search: |
;52/81,747,592,512,288,540,543,549,544,545,546
;403/202,217,176,171,172 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Murtagh; John E.
Attorney, Agent or Firm: Hubbard, Thurman, Turner &
Tucker
Parent Case Text
This is a division of application Ser. No. 336,364, filed Feb. 27,
1973.
Claims
We claim:
1. The method of constructing a waterproof structure
comprising:
erecting a supporting substructure having a plurality of support
points arranged in a geometric pattern,
arranging a plurality of prefabricated, substantially rigid panels
in contiguous edge-to-edge relationship, each panel having edges
disposed adjacent at least three of the support points, each panel
having a waterproof surface, at least a portion of the panels
including a waterproof flexible flap extending from the waterproof
surface such that at least one flap is provided for each adjacent
pair of panel edges, the flaps extending along the respective edges
of the panels between and terminating at the support points,
sealing the flexible flaps to the waterproof surface of the
acjacent panels to form a continuous waterproof surface except for
openings at the support points, and
fastening the panels to the support points of the substructure
through the openings and sealing the openings at the support point
to provide a continuous waterproof structure.
2. The method of claim 1 wherein
the panels are fastened to the support points by positioning a cap
disposed above the waterproof surface, and overlying the openings
so as to cover the openings and extend over the adjacent panels,
and passing a fastener through the cap and through the opening and
engaging the fastener with the substructure at the support point to
clamp the panels between the cap and the substructure, and
the openings are sealed by a mastic between the cap and the
fastener and the surface of the panels which is flowed to form the
seal as the cap is pulled toward the substructure by the
fastener.
3. The method of claim 1 wherein the flexible flaps are sealed by
mechanically engaging tongue and groove fasteners on the adjacent
edges of the panels.
4. A method of constructing a geodestic dome or the like
comprising:
erecting a supporting substructure of a plurality of strut members
forming support points defining regular polygonal sections;
arranging a plurality of prefabricated panels each conforming to
the polygonal sections, each panel including one part of a
mechanically sealable tongue and groove fastener along each edge of
the panel, the fastener parts terminating near the ends of the
respective edges of the panels, at least one fastener part on each
adjacent pair of edges being on a flexible flap sized to bridge the
space between the adjacent panels, each panel having a waterproof
surface between the fastener parts;
mechanically engaging the fastener parts along adjacent edges of
the panels to form a continuous waterproof surface except for
openings at the corners of the adjacent panels; and
fastening the panels to the substructure without penetrating the
waterproof surface and sealing the openings at the corners to form
a complete waterproof surface.
5. The method of claim 4 wherein the panels are fastened to the
substructure by bolt means passed through a cap member and then
through the corner openings, the cap member extending over the
corners of the panels to connect the panels to the substructure and
over the ends of the engaged fastener parts of all of the panels
forming the corner openings, the cap member containing a flowable
sealing means which is flowed around the bolt member and around the
ends of the fastener parts to form the completed waterproof
surface.
Description
This invention relates to a building construction system and more
particularly relates to a prefabricated building plank structure
adapted for assembly with similar planks to form a roof, wall or
other construction section.
The construction of roofs and exterior walls by conventional
methods is a laborious process usually requiring onsite fabrication
and erection of a suitable support structure. Insulation,
weatherproofing and exterior sheeting, are applied in place and
decorative coverings, if desired, are applied to complete the
construction section. Typical of this method of construction are
built-up roofing systems which have been employed for many years.
With this method of construction, a horizontal roof deck is
supported on underlying structural beams. The roof deck is covered
by a weatherproof membrane, usually comprising alternate layers of
felt and bitumen applied as a field operation, to prevent
penetration of moisture into the building interior. Once the
membrane is applied to the desired thickness, gravel, rock or
similar aggregate material, is spread upon the roof to provide
protection against weathering. To reduce heat transfer across the
roof deck, insulation is often applied to the underside of the roof
at the interior of the building. A wallboard or plasterboard, or
other similiar finishihg material secured at the interior side of
the roof, completes the roof structure.
There are many difficulties with building systems of the general
type described above. Since this type of construction requires
extensive field fabrication, there is little formity of quality
from one building to another. Construction as described above is
expensive and time consuming, requiring a great deal of skilled
labor. Sealing and weatherizing the structure is a particular
problem.
The disadvantages of such a system are particularly apparent in
roofing systems. A built-up roof section as described above is
subject to deterioration due to a number of reasons including
expansion and contraction from severe temperature changes, moisture
trapped below the water membrane, and improper construction
techniques. The exterior application of hot tar as a sealant to the
roof involves safety and environmental hazards, and for these
reasons has become less widely practiced.
In an attempt to overcome the problems inherent in conventional
construction methods, it has been suggested to utilize panels which
are prefabricated at the factory and are secured together at the
job site. The building industry has made limited use of factory
prefabricated units which are field assembled. For example,
pre-engineered metal panels are commonly used in the construction
of certain structures. The corrugated metal panels being lapped and
secured by metal fasteners to one another and to a supporting
structure. Lapping joints are usually additionally sealed by
application of a sealant or mastic.
Roof panels of the prefabricated type generally include some type
of insulation such as polystyrene or urethane foam sandwiched
between wallboard or asbestos sheeting. A problem arises in sealing
these type panels from the weather and water once the panels are
arranged in a construction assembly. Often sealing is accomplished
by placing a membrane similar to that used in built-up roofing over
the roof panels. Obviously such fabrication procedures require
considerable field labor and do not entirely avoid the shortcomings
of conventional construction systems.
Co-pending patent application entitled ROOF CONSTRUCTION SYSTEM,
Ser. No. 336,370, filed concurrently herewith, discloses a
prefabricated plank ideally suited for roof construction which
utilizes a corrugated metal panel as a structural component. An
exterior, weather resistant sheet material is preadhered to the
plank exterior. The sheet material is formed with a flap along one
or several edges which is adapted to overlie a marginal portion of
an adjacent plank. A seal is effected by vulcanization or by virtue
of interlocking fastener members carried on the plank and the
marginal portion of the next adjacent plank. At the common juncture
of several planks a condition exists where several flaps overlie
one another. A fastener structure seals the layers together at this
juncture which may be reinforced by vulcanization of the overlying
members or by inclusion of an appropriate sealant. This novel roof
plank represents a substantial improvement over prior art
construction methods and prior art roof fabrication. The roof plank
disclosed in the co-pending application is a convenient,
structurally sound method which when installed provides a
weathertight seal at the exterior surface.
The present invention relates to a building construction plank
which is prefabricated and adapted for field assembly into a
construction section as a roof, wall or similar unit. The present
invention provides a composite plank having a core which may be
conventional laminated foam, cellular honeycomb or concrete as well
as other construction materials such as polymerizable oil in water
emulsions. An exterior sheeting or membrane of weatherproof
material such as a plastic or light gauge metal is secured to the
outer surface of the plank. The membrane is formed with a flap
along one or several edges which is adapted to overlie a marginal
portion of adjacent panel. The membrane flap is adapted to
sealingly engage the marginal portion of the next adjacent plank.
At the common juncture of several planks where several flaps
overlie one another, a mechanical fastener seals the exterior
membrane surface against leakage. The panels may assume any variety
of geometric shape such as rectangular, triangular or polygon. The
novel combination of the plank structure carrying the sealable
membrane flap along with mechanical compressive seal at the
juncture of several planks, serves to form a continuous exterior
surface which is substantially weatherproof and resistive to
moisture. In the preferred form of the invention, the flap and
marginal membrane portions are sealable by virtue of male and
female interlocking fasteners carried on the respective membrane
portions. The interlocking fastener structure may take various
forms and may include an expandable section to accommodate field
assembly. In another alternate form of the invention, the flap is
sealed by bonding.
A further aspect of the present invention provides for the
construction of a geodesic dome using complementary construction
sections having a core formed of a suitable insulative and
structural material. An exterior membrane carries the interlocking
fasteners described above. The exterior surface of the dome is
conveniently field sealable by engaging the interlocking fastener
portions at the time of erection and installation of the dome panel
sections.
The plank of the present invention is a highly efficient structural
member which can be manufactured with a minimum of labor and a
maximum of quality control resulting in an economical product with
few field maintenance problems. The plank is highly versatile and
can be fabricated with varying characteristics to meet different
requirements of strength, weight, thickness, size, shape and
thermal conductivity. Field installation can be accomplished by
semi-skilled labor using mechanical fasteners and bonding agents.
The plank can be altered in the field to meet special requirements
by normal drilling, sawing, screwing and cutting operations. The
core can be fabricated from a wide selection of conventionally
available construction materials.
The above and additional objects and advantages of the present
invention will become more apparent by reference to the following
specification, claims and appended drawings in which:
FIG. 1 is a perspective view showing a number of the planks of the
present invention assembled to form a typical construction
section;
FIG. 2 is an enlarged perspective view of a single plank;
FIG. 3 is an enlarged partial detail view in perspective showing
the relationship of the overlapping membrane members at a four
corner junction;
FIG. 4 is an enlarged fragmentary plan view of a corner joint at
the junction of the adjacent panels showing a sealing member in
place;
FIG. 5 is a sectional view taken along lines 5--5 of FIG. 4;
FIG. 6 is an enlarged sectional view taken along lines 6--6 of FIG.
1 showing the interlocking fastener members;
FIG. 7 illustrates an alternate form of the edge seal;
FIG. 8 is a cross-sectional view of another embodiment of the
interlocking fastener;
FIG. 9 is a cross-sectional view showing an alternate embodiment of
the interlocking membrane fastening member;
FIG. 10 shows the use of the interlocking fastener members as
applied to conventional metal building panels;
FIG. 11 is a perspective view showing a construction section formed
of a member of construction planks of a polygonal shape and having
a cellular plastic core structure;
FIG. 12 is a plan view showing the construction of a roof section
using concrete panels carrying the membrane covering; and
FIGS. 13 through 15 illustrate the system of construction for a
geodesic dome using the plank members of the present invention.
Referring now to the drawings, FIG. 1 shows a construction assembly
generally designated by the numeral 10 supported on an underlying
series of parallel beams or rafters 11. For purposes of
illustration the construction assembly 10 is shown in a horizontal
position supported on members 11 as representative of a typical
roof structure. However, it should be noted that the assembly could
as well be an exterior building wall with the members 11 being
vertical studs or beams.
The construction assembly 10 includes a plurality of individual
planks generally designated by the numeral 15. The appended
letters, a, b and c are used here and throughout the specification
to denote separate components or elements of similar construction.
In FIGS. 1 and 2, plank 15 is shown as being rectangular having
opposite side edges 31 and 32 and opposite end edges 33 and 34. A
number of similar planks 15 are contiguously aligned in a
side-by-side and end-to-end arrangement to form assembly 10 with
the individual planks abutting at common corner junctures 16.
Planks 15 are covered with outer membrane sheet 20 of a weather
resistant flexible material preadhered to the exterior surface
providing a pair of adjacent edge portions or flaps 18 and 19 which
extend beyond the corresponding plank edges and are adapted to
overlap the marginal portion of the next adjacent plank. At the
corner junction 16 of several planks, multiple layers of membrane
overlay one another and are sealed by corner sealing structure 21.
The edge seal and corner seal arrangement will be explained in
detail with reference to subsequent drawing figures.
Referring to FIGS. 2 through 6 which illustrate the details of
construction of plank 15, the individual plank is formed having a
core 25 of a suitable material having good compressive, insulative,
flexible and shear strength characteristics. For example, core 25
could be urethane foam or a polystyrene. The upper surface of core
member 25 is covered by sheathing member 27 and the lower or
interior side of core member 25 is covered by sheathing member 28.
Sheathing members 27 and 28 are typically a plastic or wood
material suitably bonded or laminated to the opposite sides of core
25 which serve to give additional strength to the structure. Upper
sheathing 27 also serves to provide a relatively hard, smooth
underlay or surface beneath flexible membrane 20. Sheathing 28 may
be provided with an appropriate decorative treatment when exposed
within the building interior.
Upper sheathing 27 is covered with membrane sheet 20 in the form of
a weather resistant material to protect and seal the roof system
10. Membrane sheet 20 is substantially coextensive with the upper
surface of the plank along edges 31 and 33. Along adjacent edges 32
and 34, portions 19 and 18, respectively, extend laterally beyond
the corresponding panel edge. Generally rectangular cutouts 44 to
47 are provided in the membrane at the corners of the plank.
Membrane 20 is preferably a natural or synthetic rubber or plastic
bonded or adhesively joined to the surface of upper sheathing
member 27. Membrane 20, for example, may be of a material known
under the tradename "Hypalon" manufactured by the DuPont Chemical
Company. Other material such as a flexible, light gauge aluminium
or galvanized sheeting may be used as a material for the
membrane.
The closure assembly, shown engaged in FIG. 6 and typical of the
closure along either the longitudinal edges 31, 32 or transverse
edges 33, 34, is generally designated by the numeral 38. Closure
member 38 includes parallel longitudinal groove members 39
extending the upper surface of membrane 20 immediately adjacent
plank edge 31 and transverse grooves 40 extending in membrane 20
parallel to edge 33. The underside of membrane flap portions 18 and
19 are respectively provided with a corresponding number of
downwardly projecting rib sections 41 and 42 adapted to coact and
engage parallel groove members 39 and 40 when the panels are
assembled. The ribs and grooves of closure 38 are adapted to
interlock when force is applied, for example, to member 41 forcing
the ribs into the grooves 40. The coacting sections are thus
capable of being interlocked in zipper fashion to form a tight
mechanical seal. As seen in FIG. 6, a loose flap of material 44 may
extend along the membrane inward of grooves 39 and 40. Flap 44 is
of sufficient width to overlap the seam of engagement of the rib
and groove members. The purpose of the flap is to serve as a "kick"
flap to prevent mechanical separation of the fastener components
due to traffic across the membrane surface.
Various configurations of the ribs and grooves are suitable for the
fastener arrangement. Generally the configuration includes a
lateral projection such as lip 43 on ribs 41. The preferred
configuration of this general type of fastener is shown and
described in U.S. Pat. No. 3,373,464.
Closure 38 can easily be engaged by workmen as the panels are
assembled to form a weatherproof and waterproof seal. In some
instances an adhesive or vulcanizing agent can be applied between
the coacting grooves and ribs at the time of securing the overlying
membranes together to further ensure against penetration of
moisture and seal the interior plank structure.
A special overlapping condition exists at the juncture of three or
more panels as for example, at corner 16 which is sealed by a
special corner structure seal 21. FIG. 3 illustrates the
overlapping condition in better detail having a typical corner
between planks 15a, 15b, 15c and 15d. A transverse edge seal is
formed between adjacent planks 15a and 15d by the closure member
formed by the ribs 41d on the underside of flap 18d engaging
grooves 40a between the panels. Similarly flap 19b overlies and
interlocks with grooves 39a of panel 15a to form a longitudinally
extending edge seal between the adjacent edges of panels 15aand
15b. A laterally extending seal is formed between adjacent panels
15c and 15b by the interlocking relationship of the ribs on the
underside of flap 18c interlocking with the grooves at the edge of
panel 15b. Flap 19c overlies the marginal edge portion of panel 15a
forming a longitudinally extending seal between panels 15c and 15d
which are arranged in side-by-side relationship. Thus it will be
observed that longitudinally and transversely tight edge seals are
provided extending from the corner junction of the four abutting
panels. Note that the outermost rib and groove members of the
closure assemblies 38 cooperate at a location immediately inward of
the edge of the flaps 18 and 19. With a full line seal formed along
the marginal edges of the respective closure carrying flaps,
moisture is prevented from entering under the flap in following a
path beneath the flap either transversely or longitudinally to the
rectangular opening 48 formed by the cutouts 44-47 at the corner of
the membranes.
The sealing of the construction assembly 10 is completed by sealing
around the opening 48 at the juncture of the panels. The corner
seal is shown in FIGS. 4 and 5 and is generally designated by the
numeral 21. The exterior side of the corner joint 21 is defined by
a generally convex compression member 52 having an annular lip
portion 54. A fastener 53 extends through member 52 and into flat
bearing plate 50 and subjacent plank 15a. Neoprene washer 51 seals
between the fastener 53 and member 52. Bearing plate 50 is located
at the panel corner 46 and may be located above or below sheathing
27 and, as shown, may be of sufficient size to overlap the adjacent
planks. Preferably plate 50 is formed as an integral part of the
plank at the factory to minimize field assembly operations.
Tightening of the mechanical fastener 53 will draw member 52 down,
compressing the lapping membrane sections together. Annular lip 54
of the member 52 completely encompasses cutout area 48 so that a
continuous seal exists between adjacent longitudinal and transverse
edge seals. The area of bearing plate 50 and the area encompassed
by compression member 52 should be large enough to also provide for
any misalignment which might occur in assembly of the plank
sections. To further ensure the integrity of the seal formed by
member 52 a suitable mastic or sealant may be placed around lip 54.
Thus an efficient, easy to install watertight and weaterproof seal
is formed across the upper surface of the planks. The cooperable
closure members 38 define a highly effective watertight seal at the
very outer edge of the respective flap portions 18 and 19 carried
on the planks 15. This prevents any water from entering beneath the
flap portions and following a path along either the longitudinal or
transverse plank edges to cutout area 48. Seal 21 including member
52 serves to completely enclose and seal cutout area 48 and
prevents entrance of moisture and serves as a bridge between
adjacent edge seals.
Member 52, fastener 53 and plate 50 are preferably of a heat
conductive metal. Once the joint is assembled, heat may be applied
to member 52. Heat will be transferred via fastener 53 to the
underside of the joint and as edge 54 and plate 50 are heated, the
compressed membrane layers will become heated and bond to one
another and to members 52 and 50. The additional optional step of
heat bonding further ensures the integrity of the seal.
If edge closure 38 were constructed so that the effective line of
seal between abutting panels were substantially inward of the outer
marginal edge of the overlying flap portion, it would be necessary
to provide a barrier to moisture or water between the closure
members at the edge of cutout 48 beneath annular lip 54. For
example, if the edge seal were defective between the outer grooves
and the ribs 39a and 42b on the underside of flap 19b, water could
enter beneath flap 19b and flow longitudinally into cutout 48. It
will be observed that member 52 serves primarily only to seal at
the exterior surface of the membrane between the edge seals and,
unless extreme compression were applied, would not ensure the
effectiveness of the seal transversely across flap 19b. For this
reason it is important to ensure a seal at the outer edges of flaps
18 and 19. Addition of mastic or other sealants in the closure
members 38 may be desirable. Thus the combination of the edge seal
at closure 38 between adjacent panels and the corner seal 21 must
be effective to seal the entire exterior surface of the membrane by
sealing marginally along the flaps 18 and 19 of the closure and
also transfer the seal between adjacent closures. Alternately, the
surface can be sealed inwardly of the margin of the flaps if an
effective barrier is provided transversely across the adjacent
closures 38 around the exterior surface of opening 48 directly
beneath the lip 54 of the member 52.
FIG. 7 shows an alternate form of the flap portions and of the
membrane. In this structure the plank 15 and membrane 20 generally
are formed as shown in FIG. 2. However, in this structure the plank
flap and marginal sections 60 and 61 are formed without the groove
and rib closure and are adapted to be sealed to the adjacent panel
marginal membrane portion by vulcanization or other bonding
methods. The material of the membrane is preferably a natural or
synthetic rubber or a thermosetting resin which characteristically
is adaptable to vulcanization or upon application of heat fuses or
joins. The planks are assembled with the flaps 60 overlying the
marginal portion 61 of the adjacent panel membrane. The membranes
are sealed together by application of heat and/or heat and pressure
along flaps 60 and 61 with a heating unit 58 which is shown as a
flat iron having an appropriate temperature control. Following the
application of heat a pressure member 59, shown as a weighted
roller, serves to compress the cooperating membrane members
together to ensure a good seal. The temperature applied at the
flaps should be sufficient to at least partially melt the upper
membrane flaps so that the underlying layers are heated and bonded
to the flaps. It will be noted that in this way a good seal is
provided between adjacent planks so that water cannot enter under
the flap and follow a path either directly to the crevice between
the adjacent panels or follow a path along the seal and enter the
cutout area 48 at the corner area. The vulcanizable seal is
cooperable with the corner seal 21 which provides a complete seal
in the exterior surface of the panels. Bonding can also be
effectuated by application of electric, magnetic, sonic or heat
waves, to cause molecular bonding.
FIG. 8 shows still another embodiment of the edge seal between
adjacent panels. In this embodiment, generally designated by the
numeral 64, the closure member 38 again comprises interlocking rib
and groove members carried on membrane flaps and marginal edges 65
and 66 of adjacent panels. Membrane flap 65 is bonded to the upper
surface of the plank leaving a loose selvage 67 adjacent the panel
edge. In the area of selvage 67 the membrane is formed into an
expansion joint 68 having a plurality of ribbed accordion-like
members 69 or similar configurations that allow for expansion and
contraction. When the panels are assembled and the membrane edge
seal secured, misalignment at the time of installation can easily
be accommodated at expansion joint 68. Expansion joint 68 is in
tension and the membrane will remain taut across the upper surfaces
of the adjacent planks.
FIG. 9 shows still another embodiment or form of the edge seal
between the adjacent planks. The embodiment of FIG. 9 is generally
designated by the numeral 71 and includes interlocking male and
female members 72 and 73 which are engageable and which each
respectively are secured to a membrane edge. Male member 72 is
showh associated with membrane edge 83 and female member 73 is
shown associated with membrane 82. The embodiment of the fastener
shown is preferably formed of a light gauge metal and adaptable for
use with either a plastic or light gauge metal membrane. Female or
socket member 73 is formed having one edge reversely bent to form a
longitudinally extending channel 74 which is adapted to accept the
terminal edge of the associated membrane 82. Socket 73 is formed
with an opening defined by inwardly turned ribs 75. Male member 72
is formed having a longitudinally extending channel 79 adapted to
receive the terminal edge of associated membrane 83. An
intermediate stringer portion 78 carries an enlargement 80 which is
preferably in the form of a barb engageable within socket 73.
Preferably socket 73 contains a quantity of factory appplied mastic
or sealant.
When the individual planks are fabricated, one or more edges 82 of
the membrane are provided with the socket or female member 73 with
the terminal edge of the membrane compressed within channel 74.
Similarly the opposite cooperating edges 82 of the membrane are
secured to the fastener element member 72 at its channel 79, the
channel being suitably crimped about the terminal edge of the
membrane. When several panels are placed in contiguous, aligned
relationship the exterior membrane covering is sealed by inserting
barb member 80 within socket 73, socket ribs 75 being resiliently
separable to accommodate the barb. Mastic within the socket further
ensures a tight seal and prevents leakage across the seal. Both
members 72 and 73 are adapted to be easily extruded by conventional
metal working machines. The material of the fastener elements 72
and 73 is preferably an extruded aluminum or similar metal. The
corner seal described above is adaptable for use with the edge seal
71. Members 72 and 73 are appropriately crushed or crimped at the
corner by a hammer blow and by mechanical compression of the corner
joint members.
FIG. 10 shows still another aspect of the present invention. In the
embodiment of FIG. 10 generally designated by the numeral 86,
construction panels 90 and 91 are shown as conventional metal
panels having overlapping corrugations 92 and 93 respectively. The
interior of corrugation 92 carries male fastener portion 98 and the
exterior surface of corrugation 93 carries cooperable female
locking member 105 which together are engageable to form a
weatherproof seal at the interface between panel sections 92 and
93. Fastener members 98 and 105 extend longitudinally and are
adhesively bonded or otherwise affixed to the edge of the panel at
the factory during the fabrication process.
Male closure member 98 is formed or extruded having longitudinally
extending rib members 101 and 102 each having a barbed outer end
projecting downwardly from opposite edges of fastener member 98.
Generally rectangular rib member 104 projects downwardly
intermediate barbed members 101 and 102.
Coacting closure member 105 is formed having longitudinally
extending marginal grooves 106 and 107 spaced to receive rib
members 102 and 101. The opening into grooves 106 and 107 is
defined by overhanging ridge members 108 and 109 respectively. The
openings between ridge members 108 and 109 are beveled or tapered
at 113 and 114 to guide the insertion and engagement of rib members
102 and 101 into grooves 108 and 107 respectively. A longitudinal
channel 110 extends intermediate the grooves 106 and 107.
Preferably channel 110 contains a quantity of sealant or mastic. It
will be seen that when fastener member 98 is aligned with fastener
member 105 and pressure is applied to compress the cooperable
members together, the barbed ends of ribs 101 and 102 will deform
the overhanging ridge members 109 and 108 to permit the ribs to
gain entry into the marginal grooves. Intermediate rib member 104
extends into channel 105 and the mastic contained in this channel.
Once fastener member 98 is fully inserted in member 105, the
overhanging ridges 108 and 109 assume an unstressed condition and
engage the rear portion of the barb or hook members on ribs 101 and
102 to prevent reopening or separation of the fastener elements.
The mastic or sealant further serves to prevent leakage of moisture
laterally across the seal formed by the seal elements.
FIG. 11 shows another embodiment of the present invention in which
a construction assembly generally designated by the numeral 112 is
comprised of a cooperating number of individual planks 115. In this
embodiment the individual planks 115 have a hexagonal geometric
shape rather than rectangular as shown in previous figures.
Inidividual planks 115 are formed having a core material 116 which
is shown as a sandwich panel having exterior and interior sheeting
members 118 and 119 disposed against the opposite surfaces of core
member 116. Core member 116 is shown as a honeycomb cellular
plastic structure having a geometric configuration to yield good
rigidity of flexural strength. Typical of a cellular core material
of this nature is the cellular plastic honeycomb material
manufactured by the Norfield Corporation of Danbury, Conn. Exterior
sheathing and interior sheathing 118 and 119 are of a suitable
plastic or light gauge metal which is adhesively bonded or
laminated to the opposite surfaces of core 116 to provide a
relatively hard, smooth surface which is necessary to provide the
underlayment for the membrane covering 120. Membrane 120 is
preadhered to the exterior surface of exterior sheeting 118 and
carries flap portions 123 which extend beyond the edge portion of
the core at three adjacent sides of the panel. The underside of
flap portions 123 carries a flexible fastener rib member, not
shown, which is cooperable with marginal groove portions 128 of
adjacent planks. When the planks are arranged to aligned,
contiguous relationship, as shown, flaps 123 overlie the marginal
portion 128 of the next adjacent plank and may be sealingly engaged
to the adjacent plank. The form of fastener may also be similar to
those shown in FIG. 7 to FIG. 9.
If it is desired the planks can be fabricated to permit passage of
light. Plank 130 is geometrically cooperable with planks 115 and is
fabricated having a core 131 of transparent or translucent
material. The membrane 132 is bonded or preadhered to the periphery
of the exterior surface of the plank leaving a cutout 133 in the
panel to permit entry of natural light to the building
interior.
At the juncture or intersection of several planks an overlap
condition exists which may be sealed by the corner seal 121 similar
to seal 21 as shown in FIG. 4. It will be noted that the corner
seal 121 is adaptable to use with the various geometric shapes and
is usable at an intersection of three or more planks 115.
FIG. 12 shows still another form of plank section identified by the
numeral 135 assembled to form a roof structure. Plank sections 136
are parallelograms having a shape to achieve more unusual
architectural requirements. The individual concrete planks 135 have
precast cores 137 and carry a membrane 138 preadhered or bonded to
the exterior surface of the plank. Planks 135 are fitted together
at the job site and the exterior sealed by the membrane carries a
form of the flexible edge seal of the type described above. The
corner seal 141, similar to seal 21, is adapted for use with this
geometrical configured plank. Thus it will be seen that the plank
can be almost any geometric shape and material and be usable with
the integral membrane seal and edge and corner sealing
structure.
FIGS. 13 through 16 show the construction system of the present
invention as applied to the construction of a geodesic dome again
illustrating the versatility of the system of the present
construction system. The geodesic dome generally indicated by the
numeral 150 has a supporting structure including a peripherally
extending base ring or tension member 151. Base ring 151 serves as
a connector for tubular structural members 155. Tubular structural
members 155 are arranged to form a frame comprised of a series of
annular tiers of triangular structural components 153 extending to
the apex 154. Triangular structural sections 153 commonly intersect
at connector hub members 160 with six tubular members 155 radially
projecting from hub 160. Hub 160 is shown in detail in FIG. 15.
Connector hub 160 is provided with six radially extending slots 163
which are adapted to receive the flattened ends 156 of tubular
elements 165. When the tubular frame members 155 are fitted into
the slots 165 of hub 160, washers 168 and 169 are secured in place
at opposite sides of the hub to secure the frame membes to the hub.
Cooperating teeth in the slots 165 hub maintain the rigidity of the
frame. Washers 168 and 169 are held in place by fastener 170 which
is adapted to be received within a concentric bore in hub 160. The
head of fastener 170 defines internal threaded bore 175.
Once the frame of the geodesic dome is constructed as described
above, the roof cover is ready to be put in place. Conventional
geodesic domes generally utilize a roof structure comprising a
series of roof structure support angles secured to the frame hubs.
Appropriate trusses extend across the roof support angles from the
base to the apex of the dome. A covering of material such as form
board is placed over the roofs support angles and the trusses. Wire
reinforcing then covers the form board and a lightweight insulating
concrete is applied over the entire surface of the dome. When the
concrete is set up an exterior weathering membrane of a plastic or
rubber material is applied over the surface of the concrete.
With the construction of the present invention, the roof is applied
over the frame structure as a series of interlocking prefabricated
planks. The necessity for extensive substructure reinforcing is
eliminated as is a requirement for application of concrete and
separate application of a weathering membrane. The individual roof
plank sections 179 and 180 each comprise a core 181 of a suitable
lightweight construction material such as a urethane, cellular
plastic material, or lightweight concrete. The planks are
configured to correspond to the triangular shape 153 defined by the
tubular members 155 and having a slight exterior curvature. Core
181 is covered with a membrane 184 such as the flexible plastic or
light gauge metal described above. To accommodate fastening of the
adjacent membrane members, the planks are constructed with groove
members 185 extending along the marginal edge at three sides of the
planks. Cooperating panel 179 is formed having flap members 188
projecting beyond the edges of the plank. The underside of flaps
188 each carry a flexible fastener component adapted to be received
in interlocking relationship with grooves 185 carried on adjacent
planks 180. The rib and groove arrangement would typically be
similar to the zipper arrangement described in FIG. 6. It will be
seen that when the planks are arranged in contiguous, aligned
arrangement as shown in FIG. 14, the flaps 188 carried on planks
179 will overlie and engage the grooves 185 carried on the adjacent
planks 180. Thus a complete weathering membrane seal is effected at
the joint between adjacent planks.
At the intersection of multiple planks a corner structure 210 seals
this area. The edges of the individual planks at the area of the
hub are supported on washer 169 and hub 160. Washer 169 is of
sufficient size to bridge and support the corner. A sealing plate
211 is placed over the upper surfaces of panels and secured tightly
to member 170 by fastener 215 received within bore 175. Fastener
215 serves to compress plate 211 tightly against the lapping
membrane sections forming a watertight seal at this point. Mastic
or sealant may be provided around the periphery of plate 211 to
further ensure the integrity of the seal at this location. Washer
216 seals around fastener 215.
Thus it will be seen that the construction of the geodesic dome can
rapidly proceed with the workmen simply placing the individual
planks in place. Sealing is accomplished by engaging the edge
membrane seals and placing the corner seals at the appropriate
locations.
The construction system of the present invention provides a system
which permits a variety of prefabricated structures to be quickly
erected in a wide range of weather conditions. Ambient temperature
is not critical as with application of materials such as bitumen.
Because of the modular nature of the system, the planks can be
placed and erected quickly to enclose a building in a minimum of
time allowing crews to complete the interior work in a protected
environment.
The plank, because of its unique structural design, provides a
smooth, hard surface which is very resistant to exterior damage. As
a roof member the plank is particularly advantageous as the hard,
smooth surface directly under the weather resistant membrane
provides support for the membrane and is resistant to exterior
damage from foot traffic, weather and vibration. The plank of the
present invention is particularly adaptable for use with a wide
variety of accessories. The plank can be cut, sawed or bored to
accept various fittings and accessories such as windows,
ventilators, or conduits for electrical or mechanical
accessories.
Other advantages to the construction system of the present
invention reside in its light weight. Less supporting foundation
for the structure is required because the weight of the planks is
substantially less than the equivalent structure of concrete or
block. The pre-finished exterior and interior permits fast
installation and eliminates the need for additional work. The
components of the plank, all being of a non-flammable or
fire-resistant material, result in a structure with a good U-factor
with corresponding reductions in building and insurance costs.
The basic plank structure is particularly good as a structural
member because it incorporates features which give it both good
longitudinal and lateral and diaphragm strength. Factory assembly
of the plank allows minimum labor cost and provides maximum quality
control resulting in a more uniform economical product with reduced
field maintenance problems. The plank is highly versatile and
allows substantial various construction to meet various end needs
such as strength, weight, thickness, fire characteristics and
thermal conductivity. The plank is the fabricated or wide variety
of geometric shapes such as rectangular square or triangular, to
accommodate almost any architectural requirement.
It will be obvious to those skilled in the art to make
modifications and changes to the plank of the present invention.
For example, it will be obvious to substitute other structural
elements for the interior panel or core member. Similarly, various
forms of insulation and interior and exterior panels can be used.
The membrane may be of the wide variety of natural or synthetic
materials to provide the desired weatherproof exterior and
flexibility required for incorporating integral fastener members.
To the extent these changes and modifications do not depart from
the spirit and scope of the present invention, they are intended to
be encompassed therein.
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