US3783563A

US3783563A - Prefabricated building components

Info

Publication number: US3783563A
Application number: US00160037A
Authority: US
Inventors: C Moore
Original assignee: MOOREX IND Inc
Current assignee: MOOREX IND Inc
Priority date: 1971-07-06
Filing date: 1971-07-06
Publication date: 1974-01-08
Anticipated expiration: 1991-01-08
Also published as: FR2250634A1; FR2250634B1; DE2352779A1

Abstract

Prefabricated building construction using panel and connector modules formed of molded plastic material reinforced with glass fibers. The connector modules are elongated beam-like members having longitudinally extending open channels adapted to receive complementary ribs on the edges of generally flat panel modules. The connector modules permit the assembling of panels in any desired angular relationship and are provided with interior passageways constituting conduits for electrical wiring, heating, water and waste facilities.

Description

O Unlted States Patent 1191 Moore Jan. 8, 1974 PREFABRICATED BUILDING 2,756,464 7/1956 Clements.... 52/620 x COMPONENTS 2,142,305 1/1939 Davis 52/582 X 3,299,595 l/1967 Munk 52/580 X Inventor: C y Maurice Moore, Richmond, 3,583,123 6/1971 Holmgtfill 52/618 x Va. 3,529,389 9/1970 Wilkins 52/618 X [73] Assignee: Moorex Industries Inc., Richmond, 3,203,145 8/1965 Raynes 52/22 x 6, Simon X [211 App! NOJ 160,037 FOREIGN PATENTS OR APPLICATIONS 1,466,467 1/1967 France.... 52/281 579,926 4/1958 ltaly 52/282 [52] US. Cl. 52/11, 52/20, 52/79,

5 /90, 52/2 /309, 2/586, Primary Examiner-Frank L. Abbott 5 /589, 52/615 Assistant ExaminerCarl D. Friedman [51] Int. Cl. E041) l/14, E046 1/10 Attorney-Bacon & Thomas I [58] Field of Search 52/270, 271, 275,

52/284, 569, 576, 589, 615, 309, 613, 588, [57] ABSTRACT Prefabricated building construction using panel and 263 connector module's formed of molded plastic material reinforced with glass fibers. The connector modules [56] References C'ted are elongated beam-like members having longitudi- UNITED STATES PATENTS nally extending open channels adapted to receive 3,564,801 2/1971 Huerta 52/580 Complementary ribs the edges of generally flat 3,368,473 2/ 1968 Sohda et a1. 52/618 X panel modules. The connector modules permit the as- ,385,l /1968 Kortz 52/282 X sembling of panels in any desired angular relationship 2,950,786 8/1960 Markle 52/263 x and are'pmvided with interior passageways con tin 315461841 12/1970 52/615 X ing conduits for electrical wiring, heating, water and Sohns X a te facilitie 3,152,568 10/1964 Mayer 52/582 3,608,260 9/1971 Eckel et a1 52/284 13 Claims, 19 Drawing Figures Pmmmm 81w 3.783.563

SHEET 1 OF 4 /N VE N 70/? CLYDE M. MOORE 14 TTUPNE Y5 PAIENTEDJAN SHEET 3 (IF 4 I 1 r I 1 III //vvENTO/? 6y CLYDE M. MOORE ATTORNEYS PATENTED SHEET u [If 4 INVENTOR CLYDE M MO0A E EV ATTORNEYS 1 PREFABRICATEI) BUILDING COMPONENTS BACKGROUND OF THE INVENTION SUMMARY OF THE INVENTION The present invention comprises, generally, modular components for forming building structures of different designs and comprises a plurality of similar hollow panel members of reinforced plastic material configured to mate with similar panel members in edge-toedge relation to form large surfaces, such as floors, or the like. The invention also includes elongated connector members for connecting panels or assemblies of panels together in angular relationship whereby essentially the same form of panels may be employed to form roofs, ceilings, side walls, floors and the like, including interior partitions while providing considerable leeway and flexibility in designing the shape, size and content of a structure, such as a home commercial building or the like.

In general, the panel members are provided at their edges with channels and/or ribs of special design adapted to mate with complementary structures on elongated connector members to join the panels in any desired angular or coplanar relationship.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an isometric view, partly in section and partly in broken line, illustrating a representative building capable of assembly from the components of the present invention;

FIGS. 2 through 14 are fragmentary enlarged sectional views taken on lines 2-2 14-14, respectively, of FIG. 1;

, FIG. 15 is an exploded isometric view showing the manner in which certain components interfit;

FIG. 16 is an isometric view showing an assembly of panel members in edge-to-edge relation;

FIG. 17 is a plan view of a representative panel component of the present invention;

FIG. 18 is an end elevational view, on an enlarged scale, of the panel member of FIG. 17; and

FIG. 19 is a top plan view of an assembly of panel members joined in the manner illustrated in FIG. 16.

DESCRIPTION OF THE PREFERRED EMBODIMENTS ways, conduits or ducts within building components, as

will be. more fully described later..'

Referring now to FIG. 2, numeral 10 designates a portion of a vertical panel structure defining at least a portion of an, outer wall of the building. An elongated connector member 12, preferably of glass reinforced plastic material is provided with a surface 14 mating with the outer surface of panel 10 and shown as being secured thereto by screws 16 or the like. The connector member 12 is provided with a channel 18 into which a flowable sealing andlor cementious material 20 is injected to effect a weather seal and to assist in holding the parts assembled. The connector member 12 is configured to define an upwardly and outwardly facing channel 22. The channel 22 can be said to constitute one side of the connector member facing in a downwardly and outwardly direction. A panel member designated generally at 24 is provided with a hollow rib structure 26 generally complementary to thechannel 22 and seated therein to direct the panel member 24 generally downwardly and outwardly. As is apparent from FIG. 1, this panel member 24 defines a lean-to type roof for a portion of the building 2.

Throughout the description numeral 24 is used to designate each of the'panels referred to in each Figure whether they be vertical or horizontal or employed as floor, roof, side wall or interior partition, since they are all essentially the same construction. Referring now more particulary to FIGS. 15 and 16, each panel member 24 contemplated by this invention comprises a unitary molded structure of preferably glass reinforced plastic material configured to define a first panel 28 of planar configuration and a second panel 30, also'of planar configuration parallel to and spaced from the panel 28. The panel 30 has integrally formed thereon depending hollow reinforcing ribs 32 and the edges of the panel 30 are integrally joined to the first panel 28. Preferably, at least two edges of the panel member 24 are configured so that the integral juncture between first and

second panels

28 and 30 are integrally joined by means defining the depending hollow rib 26, previously referred to. The remaining edges of each panel member are integrally joined by means defining an upwardly facing channel 34, similar to the channel 22 already referred to.

A cover panel 36 of the same reinforced plastic material is secured to the crests of the reinforcing ribs 32 and defines the face of each panel member 34 opposite first panel 28. The cover panels 36 may be secured to the ribs 32 by screws, cement, or the like. As shown, those edges of cover panels. 36 adjacent the hollow ribs 26 are turned upwardly as at 38 (FIG. 15') and integrally joined to the edge of the second panel 30, as shown at 40. The other edges of the cover panel 36 are secured to the lower crests of the channel portions 34, as bestshown in FIG. 16. Thus, the first and

second panels

28 and 30, and the cover panels 36 define unitary panel structures of substantial thickness and great rigidity, capable of constituting vertical bearing walls or horizontal floor-ceiling structures.

As is also apparent from FIGS. 2 to 14 and 16, the interior spaces between

panels

28 and 30 and the interiors of the hollow ribs 32 are filled with a substantially rigid material 42, preferably comprising a rigid foamed plastic material of light weight, which serves to prevent deflection of first panel 28 relative to second panel 30, particularly when the panels are assembled to form a floor surface. Also, the spaces between the exteriors of the ribs 32 and between second panels 30 and cover panels 36 is filled with similar material to add rigidity and strength to the panels. In addition, the foamed plastic material constitutes efficient sound and heat insulation. It is to be understood that all of the panel members contemplated by the present invention are of a type of construction described above and the relative positions of the channels and ribs at the edges thereof may be varied in accordance with the requirements of the environment in which those panels are to be used. For example, opposed edges of a panel member may be provided with the hollow ribs 26 and the end edges thereof may be provided with the channel formations 34, or vice versa. Likewise, some channels may be provided with hollow ribs on all edges and others with channels 34 on all or selected edges. It is to be further understood that, throughout the structure, when a rib on one component is seated within the channel of another component, the rib structure is preferably provided with means to hold the outer surface of-the rib 26 in spaced relation to the inner surface of the channel in which it is seated. As shown in FIG. 4, conduit means 44 are provided with an outer pressure-fitting 46 and communicating with the space between a rib 26 and the channel in which it is seated, so that sealing or cementious bonding material may be injected through the fitting 46 to flow along and fill the described spaces, thus serving to seal the joint between adjacent components and to also provide a securement bond therebetween. While not shown in the drawings, it is contemplated that upon placing a rib in a channel, the mated components will be secured together by screws, bolts or the like, with sufficient pressure to resist and prevent separation thereof when fluent sealing material is injected into the joint under pressure, in the manner described.

Referring now to FIG. 3, numeral 48 designates a foundation member comprising an elongated member formed by extrusion or the like, constituting a connector of the present invention. The foundation member 48 is of hollow construction and is provided with a base 50 adapted to rest on a suitable supporting surface. The top edge of the member 48 is configured to define a horizontally facing channel 22 which may be substantially identical in all respects to the channel 22 shown in FIG. 2. Throughout this description reference will be made to the channel 22 on various different forms of connector members, and it is to be understood that all of these channel structures are similar. The member 48 is further provided with integral means 51 defining a further upwardly facing channel 22 adapted to receive a panel or assembly of panels 24 to define a floor structure for the building. Also, the horizontally facing channel 22 referred to receives the rib structure 26 of an upstanding panel 24 constituting a vertical wall of the building 2. As shown in FIG. 3, and other figures of the drawings, the upstanding or load-bearing walls defined by panels 24 are of greater thickness and mechanical strength than the horizontally extending panels or assembly of panels. However, this relationship is not a critical part of applicants invention.

FIG. 4, as can be seen from FIG. 1, is a horizontal sectional view through an exterior corner of the building. The connector member 52 is elongated vertically and is shown as of generally square outline and provided with channels 22, on two adjacent sides, to receive upstanding wall panels 24 in the manner already described. It is to be noted that the wall panels 24 extend in directions at right angles to each other, are of similar construction and may be employed for internal partitions where an exposed corner is desired and the same connector members 52 may be employed, where desired, to extend in a horizontal direction.

FIG. 6 illustrates a connector member 54 for use in those regions of the building defining the eaves thereof. The connector member 54 is preferably of hollow construction, as illustrated, to reduce the weight thereof while providing the desired mechanical strength and is formed to define an outwardly facing channel 22 receiving a wall panel 24 and an upwardly facing channel 22 to receive a horizontal panel 24 defining an attic floor-ceiling member. The upper portion of the connector 54 is formed to define the outwardly and downwardly projecting surface 56 terminating at its lower edge in a formation 58 defining an upwardly and outwardly facing channel 22. A roof panel 24 mates with the channel 22 in the manner shown and defines a portion of a roof of the building 2. The integral formation 58 further includes an upwardly open channel formation 60 integral therewith and defining an eavestrough or gutter for the building. While not shown in the drawings, it is contemplated that certain of the upstanding corner connectors 52 (FIG. 4) may be formed with integral downspouts adapted to be connected to the channel formations 60 to conduct rain water or other drainage downwardly along the building. The interior passageway 62, shown in FIG. 4, may be employed for such purpose.

As shown in FIG. 5, the roof panel 24 or a panel of an assembly thereof, defining the roof of the building, is provided with a hollow rib 26 mating with and seated in a channel 22 in an elongated ridge member or connector 64. The ridge connector 64 is formed with two of the channels 22, one on each side thereof, and defining those sides of the connector which face downwardly and outwardly therefrom whereby further panels or panel assemblies 24 maybe connected thereto to define another side of the roof referred to.

FIG. 7 shows a connector 66 provided with top and bottom channels 22 each facing in an outwardly direction and adapted to receive ribs 26 on upstanding wall panels 24 extending upwardly and downwardly therefrom in coplanar relation. Thus, the horizontally extending connector 66 defines a portion of an outer wall of the building. It is obvious, however, that the connector 66 may also be employed for internal partition construction. The connector 66 is further formed with an integral formation 68 on its inner side, defining an upwardly facing channel 22 for receiving and mating with a rib 26 on a horizontally extending panel member 24.

FIG. 8 shows a modified form of foundation member .70 provided with illustrated channels 22 for. receiving corresponding ribs of panel members 24 similar to those described with reference to FIG. 3. The foundation member 70, however, is not adapted to rest directly on a support surface but is provided with an integral formation defining bearing surfaces 72 adapted to be embedded in a concrete footing member 74. Obviously, the site must be prepared and the footing members 74 poured with the foundation connector member in place before assembly of the building commences. This same order of assembly is necessary for the form shown in FIG. 9, which illustrates a further configuration of foundation member 76 having the bearing surfaces 72 integrally formed thereon. FIG. shows an assembly wherein a floor panel 24 supports an upstanding panel assembly 24, with the floor panel 24 resting on a suitable support 78. As shown in FIG. 1, the section of FIG. 10 is taken along the baseboard of an interior partition and illustrates duct members 80, likewise preferably formed of the reinforced plastic material referred to, which duct members 80 define longitudinally extending passages 82 extending along the base of partition panels 24. At suitable locations the duct members 80 are provided with opening 84 communicating with the interior of the room in which duct members are located. A building constructed as suggested in FIG. 1 will include in its interior partitions and exterior walls vertically and/or horizontally extending hollow connector members, past which the duct members extend. In the regions where the duct members 80 are adjacent the connectors referred to, suitable openings are provided to establish communication between the passageways '82 and passageways in the connecting members, to bedescribed, whereby heated air, cooled air, or the like may be distributed throughout the building.

FIG. 1 1 likewise illustrates duct members 86 adapted to be placed between partition panels 24 and ceiling panels 24 to provide passageways 88 for distribution of, for example, refrigerated air, for cooling the building when it is desired to have the air issue into the respective rooms near the ceilings thereof.

FIG. 12 illustrates connector member 90 having channel formations 22 on opposite sides thereof whereby to connect adjacent panels 24 in coplanar relationship. Obviously, such connectors may be employed extending horizontally in a floor-ceiling assembly, or may extend vertically within an interior partition or an exterior wall. As shown, the connector 90 as provided with the longitudinal passageway 92 therein, which may define a conduit for conducting cool or heated air to the passageways 82 of FIG. 10 or 88 of FIG. 11. In like manner, the passageway 92 may be so connected to associated passageways in the building to constitute waste drainage channels, in which case suitable connection to a sewage system is contemplated at the-lowermost end of a passageway 92. As also suggested in FIG. 12, the connector 90 may be provided with adjacent passageways 94 constituting conduits for hot and cold water or the like. Wherever desired, openings 96 may be formed to provide access to the conduits 94 for connection to the water-using appliances in the building.

In FIG. 13, the connector 98 may be substantially the same as the connector 90 of FIG. 12 but in this form, the connector is shown as having a large passageway 100 therein, preferably serving as a main distribution duct for cooling or heating the building. Also shown is a further passageway 102 which may be employed to provide vacuum outlets in each room of the building whereby a central vacuum system may be installed to provide vacuum for cleaning purposes in all of the rooms of the building.

FIG. 14 shows a further contemplated connector 104 which is also similar to the

connectors

90 and 98, but in which a passageway 106 therein is provided with means 108, such as a filler material 110 and a surface member 112. The connector of FIG. 14 will be employed in an assembly ofpanels 24 defining a horizontal floor or floor-ceiling portion of the structure. The

passageway 106 constitutes a waste conducting conduit and the tiller material and surface member 112 are arranged therein to provide slope along the channel 106 for flow of fluid waste materials therealong. The discharge end of the passageway 106 will obviously be in communication with a vertical passageway in an up.- standing connector member, as previously referred to with reference to FIG. 12.

It is to be remembered that when the connector and panel structures described herein are employed to construct a building, such as that illustrated in FIG. 1, some of the connectors will extend vertically and others will extend horizontally. Obviously, the building can be planned so that horizontally extending connectors of the type shown in FIGS. 12-14 will extend to and terminate at vertically extending connectors or other horizontally extending connectors, extending at right angles thereto and it will be obvious to those skilled in the art how the various passageways in the adjacent connectors may be interconnected for the desired communication 'therebetween.

As shown in many of the figures, after assembly of the panel and connector components in the manner described, interior surfacing may be provided, such as the floor surfacing 114 shown in FIG. 13 or the ceiling sur-.

face 116 shown in FIG. 12. Likewise, interior walls or ceilings may be provided with suitable surfacing as shown at 118 in FIG. 3 and at 120 in FIG. 2.

Referring now to FIG. 15, the panels and connector members shown therein in exploded relation may be considered representative of the panel and connector assembly illustrated particularly in FIG. 7, but applicable to all panel-connector assemblies showing the connector and panels being shown somewhat incomplete to facilitate illustration.

As already described, the panels 24 are provided with the hollow integral reinforcing ribs 32 and as shown herein two such ribs extend across each panel member at right angles to each other and they extend to and are formed, at their ends, integral with the respective channel formations 34 and rib formations 26. As shown in FIG. 15, the connector 122 defines an upwardly facing channel 22 having an outer wall 124. That outer wall is provided with notches 126 positioned to receive and embrace the ends of ribs 320i the panel 24 mating therewith and to receive the ends of either ribs 26 or channels 34 at the perpendicular edges of panel 24 mating with the channel 22 referred to. This permits assembly of a plurality of adjacent panels 24 with a single connector 122 wherein the latter is of a length to extend along and receive the edges of a plurality of panels 24. In like manner, the wall members 128 defining horizontally facing channels 22 of connector member 122 are provided with notches 130 to receive corresponding ribs 32 and/or ribs 26 or channels 34 of the vertically extending panels24 mated therewith.

FIG. 16 illustrates the manner in which a plurality of panels 24 may be joined togetherto define an extensive coplanar assembly of panels'24, as schematically illustrated in FIG. 19. It is desirable that transverse or end edges of panels 24 mated together not be in coextensive or aligned relation to corresponding joints between adjacent rows of panels. FIG. 19 illustrates how the transverse joints between panels are preferably staggered. To permit assembly of the panels in the manner contemplated each of the channel formations 34' extending along the side edges of the panels are provided with a notch 132 in position to receive the end of a channel formation 34 of a transverse joint intersecting therewith at right angles. It is believed the manner of assembling the panels in this relationship will be obvious. As shown in FIG. 19, a channel structure 34 extends the full length of a panel 24 having its side edge interconnected by a transverse joint and the notch 132 therein accommodates a transverse channel 34 whereby both the longitudinal and transverse channels may receive the rib formations 22 on a panel such as the panel shown at A in FIG. 19.

Obviously, those panels employed to form the exterior walls and/or roof may be provided with suitable exterior decoration, texture, configuration, or the like. While not shown herein, it will be obvious to those skilled in the art that certain panels or connectors will be constructed to define window and/or door openings or framing therefor.

While a limited number of embodiments of the invention are shown and described herein, it is to be understood that the same are merely illustrative of the principles involved and that the scope of the invention is limited only by the appended claims.

I claim:

1. In a prefabricated building structure:

a rigid panel member of reinforced plastic material formed to define a generally fiat first panel forming one face of said panel member;

a second panel adjacent but spaced from and opposed to said first panel in parallel relation thereto;

said second panel being formed to define reinforcing ribs extending thereacross spaced inwardly of its edges and extending away from said first panel;

integral means directly joining the peripheral edges of said panels, said integral means, on at least two edges of said panel member, being formed to define peripheral ribs extending away from said first panel and having side faces converging in a direction away from said first panel; and

rigid filler material filling the space between said first and second panels.

2. A panel member as defined in claim 1 wherein said filler material comprises a substantially rigid foamed plastic.

3. A panel member as defined in claim 1 wherein the integral means at the other edges of said panel member are configured to define open channels, substantially complementary in shape to said ribs facing said one face of said panel member outwardly of the periphery of said one panel.

4. A panel member as defined in claim 1 including a cover panel of sheet material defining the other face of said panel member, said cover panel abutting and being secured to the crests of said reinforcing ribs with its edge portions, adjacent said peripheral ribs, extending to said second panel in spaced relation to said peripheral ribs, other edges of said cover panel being secured to said integral means.

5. A panel member as defined in claim 1 wherein the spaces venclosed between said reinforcing ribs, said cover panel and said second panel being filled with a filler material of substantially rigid foamed plastic.

6. In a building structure:

a substantially rigid elongated member of reinforced plastic material having'side faces facing in different angularly related lateral directions;

at least two of said side faces having longitudinally extending integral flange means defining therewith longitudinally extending V-shaped channels outwardly of said faces and opening in a direction generally parallel thereto and laterally of the length of said elongated member;

a pair of generally flat hollow panel members of reinforced plastic material, each having peripheral edge faces, at least one edge face of each panel member having a rib integral therewith extending along and spaced therefrom, said ribs being generally complementary to said channels and extending into respective channels whereby said panels and elongated member define a portion of a building structure, said ribs extending generally perpendicular to the planes of said panel members whereby the planes of said panel members extend generally perpendicular to said side faces of said elongated member; and

means securing said panels and elongated member together.

7. A building structure as defined in claim 6 wherein said elongated member comprises a horizontally extending member, said two side faces thereof being respectively on the top and one side thereof, said panel members being respectively, an upstanding wall panel and a horizontally extending panel.

8. A building structure as defined in claim 7 wherein said elongated member comprises a foundation element and is provided with integral bearing means for engaging a support.

9. A building structure as defined in claim 6 wherein a third side face of said elongated member is provided with an elongated channel, as described, and a third panel member engages said third elongated channel and extends outwardly of said member.

10. A building structure as defined in claim 6 wherein said two side faces of said elongated member face in directions at right angles to each other, said panel members thereby being in right angled relation. 4

1 l. A building structure as defined in claim 6 wherein said elongated member extends horizontally and said two faces are respectively on the bottom and one side thereof with said panels extending, respectively, downwardly and horizontally therefrom;

said elongated member having further integral channel-defining means thereon arranged to engage a roof panel member, similar to said pair of panel members, to extend at an upwardly inclined angle over said horizontally extending panel member whereby said portion of a building structure comprises a roof and cave portion thereof.

12. A building structure as defined in claim 11 wherein said elongated member is further provided with an integral channel formation defining an eaves trough.

13. A building construction as defined in claim 6 wherein said elongated member extends generally horizontally and said two side faces are on generally opposite sides thereof and arranged to engage said panel members extending angularly downwardly and outwardly therefrom, said elongated member defining a roof ridge and said panels comprising roof panels.

Claims

1. In a prefabricated building structure: a rigid panel member of reinforced plastic material formed to define a generally flat first panel forming one face of said panel member; a second panel adjacent but spaced from and opposed to said first panel in parallel relation thereto; said second panel being formed to define reinforcing ribs extending thereacross spaced inwardly of its edges and extending away from said firSt panel; integral means directly joining the peripheral edges of said panels, said integral means, on at least two edges of said panel member, being formed to define peripheral ribs extending away from said first panel and having side faces converging in a direction away from said first panel; and rigid filler material filling the space between said first and second panels.

5. A panel member as defined in claim 1 wherein the spaces enclosed between said reinforcing ribs, said cover panel and said second panel being filled with a filler material of substantially rigid foamed plastic.

6. In a building structure: a substantially rigid elongated member of reinforced plastic material having side faces facing in different angularly related lateral directions; at least two of said side faces having longitudinally extending integral flange means defining therewith longitudinally extending V-shaped channels outwardly of said faces and opening in a direction generally parallel thereto and laterally of the length of said elongated member; a pair of generally flat hollow panel members of reinforced plastic material, each having peripheral edge faces, at least one edge face of each panel member having a rib integral therewith extending along and spaced therefrom, said ribs being generally complementary to said channels and extending into respective channels whereby said panels and elongated member define a portion of a building structure, said ribs extending generally perpendicular to the planes of said panel members whereby the planes of said panel members extend generally perpendicular to said side faces of said elongated member; and means securing said panels and elongated member together.

10. A building structure as defined in claim 6 wherein said two side faces of said elongated member face in directions at right angles to each other, said panel members thereby being in right angled relation.

11. A building structure as defined in claim 6 wherein said elongated member extends horizontally and said two faces are respectively on the bottom and one side thereof with said panels extending, respectively, downwardly and horizontally therefrom; said elongated member having further integral channel-defining means thereon arranged to engage a roof panel member, similar to said pair of panel members, to extend at an upwardly inclined angle over said horizontally extending panel member whereby said portion of a building structure comprises a roof and eave portion thereof.