BUILDING ROOF STRUCTURE AND METHOD
United States Patent 3722171
A building roof structure including adhered together panels defining a finished interior ceiling for space within the building and trusses structurally supporting a roof covering for the building is assembled by arranging the panels in horizontal array, superposing an arrangement of trusses above the panels, adhering the panels and trusses together into a unitary roof and ceiling structure and then superposing the unitary roof and ceiling structure on side walls for the building.
US Patent References:
Building and building construction
Lafferty - November 1940 - 2222037
Roof structure for use with prefabricated houses
Hansen - July 1952 - 2604060
Method for raising a stiff horizontal frame
Wiggins - August 1966 - 3268999
Method for forming roof structure
Lang - February 1967 - 3302362
Building and building construction
Lafferty - November 1940 - 2222037
Roof structure for use with prefabricated houses
Hansen - July 1952 - 2604060
Method for raising a stiff horizontal frame
Wiggins - August 1966 - 3268999
Method for forming roof structure
Lang - February 1967 - 3302362
Application Number:
05/186836
Publication Date:
03/27/1973
Filing Date:
10/06/1971
View Patent Images:
Export Citation:
Assignee:
Modular Wall Systems, Inc. (Charlotte, NC)
Primary Class:
Other Classes:
52/220.100, 52/745.060, 52/90.100, 264/46.400, 52/309.500, 264/263
International Classes:
E04B7/02; E04B7/02; E04B1/00; E04G21/00
Field of Search:
52/90-92,309,745
Primary Examiner:
Sutherland, Henry C.
Claims:
That which is claimed is
1. A method of assembling a building structure comprising the steps of arranging a plurality of ceiling panels in horizontal planar array and in such outline and dimensions as to span an interior area of the building structure, arranging a plurality of prefabricated trusses in superposition on the panels, applying foam material to the upper surface of the panels and adhering the panels and trusses together into a unitary roof and ceiling structure, and then superposing the unitary roof and ceiling structure on the side walls of a building structure.
2. A method according to claim 1 wherein the steps of applying foam material and adhering the panels and trusses together are preceded by a step of installing utility service in the superposed trusses and panels.
3. A method according to claim 1 wherein the step of superposing the unitary roof and ceiling structure on the side walls comprises lifting the unitary structure from an assembly location and transporting the unitary structure to a remote building construction location.
4. A sub-assembly for use in a building structure and comprising:
5. A building structure according to claim 4 further comprising utility service means penetrating at least portions of said truss means for distributing service through said building structure and further wherein said foam means is adhered to said utility service means for securing the same in said unitary roof and ceiling structure.
6. A building structure according to claim 4 wherein said truss means comprise a plurality of fabricated trusses each having an elongate lower member engaging said upper surface of said ceiling panel means and encased by said foam means.
7. A building structure according to claim 4 wherein said ceiling panel means comprises a plurality of ceiling panels arranged in a predetermined horizontal planar array.
1. A method of assembling a building structure comprising the steps of arranging a plurality of ceiling panels in horizontal planar array and in such outline and dimensions as to span an interior area of the building structure, arranging a plurality of prefabricated trusses in superposition on the panels, applying foam material to the upper surface of the panels and adhering the panels and trusses together into a unitary roof and ceiling structure, and then superposing the unitary roof and ceiling structure on the side walls of a building structure.
2. A method according to claim 1 wherein the steps of applying foam material and adhering the panels and trusses together are preceded by a step of installing utility service in the superposed trusses and panels.
3. A method according to claim 1 wherein the step of superposing the unitary roof and ceiling structure on the side walls comprises lifting the unitary structure from an assembly location and transporting the unitary structure to a remote building construction location.
4. A sub-assembly for use in a building structure and comprising:
5. A building structure according to claim 4 further comprising utility service means penetrating at least portions of said truss means for distributing service through said building structure and further wherein said foam means is adhered to said utility service means for securing the same in said unitary roof and ceiling structure.
6. A building structure according to claim 4 wherein said truss means comprise a plurality of fabricated trusses each having an elongate lower member engaging said upper surface of said ceiling panel means and encased by said foam means.
7. A building structure according to claim 4 wherein said ceiling panel means comprises a plurality of ceiling panels arranged in a predetermined horizontal planar array.
Description:
Conventional procedures for constructing a building include the steps of erecting side walls, constructing a roof structure above the side walls and thereafter finishing the interior of the building structure by applying ceiling and wall finishing panels or the like. Such conventional practice in the erection of roof structures has been adhered to even with progress in the prefabrication of building side wall structures and with the development of prefabricated trusses for roof structures. As a result, economically significant time and labor have heretofore been expended in ceiling finish work even where the best developed current state of knowledge is applied in erecting a building structure. Similarly, installation of thermal insulation materials such as loose fill or batts has heretofore been an expensive time consuming task to be undertaken only after application of ceiling finish panels has been completed.
It is an object of the present invention to facilitate a reduction in the time and expense required to achieve a finished ceiling in a building structure. In accomplishing this object of the present invention, the conventional practice of erecting a roofing structure over building side walls, enclosing the building and thereafter applying a ceiling finish is obviated by a novel and advantageous method by which interior ceiling finish work following erection of a building structure is eliminated. In particular, trusses are preassembled with ceiling finish panels prior to superposition of the roof structure on the building side walls.
A further object of the present invention is to assemble a building structure in which a unitary roof and ceiling structure economically provide enhanced thermal insulation qualities as compared with conventional building structures. In accomplishing this object of the present invention, reliance is placed upon a thermally insulating material for adhering together a plurality of ceiling panels which provide the finished interior ceiling and a plurality of trusses which provide the structural components of the building roof system.
Some of the objects and advantages of the invention having been stated, others will appear as the description proceeds, when taken in connection with the accompanying drawings, in which
FIG. 1 is an exploded perspective view of a building structure in accordance with this invention;
FIG. 2 is an elevation view, partially in section, illustrating adhered together ceiling panels and trusses at one step in the method in accordance with this invention;
FIG. 3 is a perspective view somewhat similar to FIG. 1 illustrating the superposition of a unitary roof and ceiling structure in accordance with this invention on building side walls during the assembly of a building structure;
FIG. 4 is a plan view, partially in section, through the structure of FIG. 2, taken generally along the line 4--4 in that figure;
FIG. 5 is an elevation view, partially in section, through a portion of a building structure assembled in accordance with the present invention;
FIG. 6 is a reduced elevation view of a side wall panel as used in a building structure in accordance with this invention; and
FIG. 7 is a perspective view of a unitary roof and ceiling structure in accordance with this invention.
In the detailed description which follows, reference will be had to the accompanying drawings which illustrate a representative embodiment of this invention. At the outset, however, it is to be understood that the drawings and the detailed description with reference to the drawings are set forth as illustrative of and not as limiting upon this invention, as it is contemplated that persons skilled in the construction trades will be able to apply the teaching of this invention broadly to assemblies other than that specifically described hereinafter.
In the illustrated embodiment of this invention, a residential building structure generally indicated at 10 is assembled by positioning a plurality of pre-cast concrete wall panels 11, 12, 14, 15, 16 and 18 about the periphery of a cast concrete foundation slab 19. While such use of a cast concrete foundation slab 19 and pre-cast wall panels is particularly advantageous for residential building structures intended to have a low initial cost, the present invention contemplates that the foundation and building side wall structures, as well as building interior walls, may be constructed, erected, or assembled in accordance with any known practice considered desirable by the builder assembling the building structure.
In accordance with important features of the present invention, a finished interior ceiling and a roof system for the building structure 10 are provided by a unitary roof and ceiling structure generally indicated at 20. In accordance with the present invention, the unitary roof and ceiling structure 20 comprises a plurality of trusses 21, which may be of a prefabricated timber construction as presently known and used. Adhered to the plurality of trusses 21 are a plurality of ceiling panels 22 which together define the finished interior ceiling of the building structure 10. The ceiling panels 22 and trusses 21 preferably are adhered together into the unitary roof and ceiling structure by a body of foam material 24 which additionally provides thermal insulation and fire-proofing for the building structure 10. Desirably, the foam material 24 is a urethane foam spray applied as will be described hereinafter.
In assembling a building structure in accordance with the method of this invention, a suitable horizontal surface is provided, preferably as by casting a slab 19' to serve as a foundation for an adjacent building structure. Thereafter, a plurality of ceiling panels 22 are arranged on the horizontal surface in horizontal array, with the interior finish surface of the panels facing downwardly (FIG. 2). A plurality of trusses 21 are then superposed on the plurality of panels and are arranged in upright position thereabove. The plurality of trusses are spaced apart one from another at such distance as may be required by applicable building codes.
Following superposition of the plurality of trusses on the plurality of ceiling panels, utility services may be installed in the unitary roof and ceiling structure. By way of example only, such a utility service may include an air circulation duct 25 (FIGS. 2, 4 and 7) for distribution of heated or cooled air within the finished building structure 10. The assembled components are then adhered together into a unitary structure by the spray application of urethane foam material 24.
It is to be noted that the spray application of foam material 24 extends across the entire upper surface area of the ceiling panels 22 and extends over the lower members 21a of each of the trusses 21. Thus, large areas of contact of the foam material with the ceiling panels are obtained while transfer of loading forces to the trusses also results. Finally, as is known from the properties of urethane foam materials, substantially enhanced thermal insulation and fire proofing qualities are obtained.
Following the adhering together of the plurality of trusses 21 and the plurality of ceiling panels 22, together with any utility services which may be incorporated in the structure at that time, a roofing cover may be applied to the unitary roof and ceiling structure if desired. Such a roofing cover may adopt conventional practices through the use of plywood sheathing 26 and shingles applied thereto, if desired, as the present invention contemplates that any satisfactory covering for the roof structure may be employed.
Either before or after a covering for the roofing structure 20 is applied, the structure is raised from the slab 19' on which it was assembled and is superposed on building side walls to complete assembly of the building structure. Such raising and superposition of the ceiling structure may be accomplished by a crane or similar equipment, inasmuch as the unitary nature of the roof and ceiling structure 20 will accommodate the loads and force distributions which occur. Further, while it is contemplated that the unitary roof and ceiling structure 20 would be raised from one slab 19' to be superposed on building side walls 11, 12, 14, 15, 16, 18 which have been erected on an adjacent slab 19, it is understood that the unitary roof and ceiling structure 20 may be held in the raised position for such time as may be required to position prefabricated building side walls on the slab which earlier supported the unitary structure 20, if lifting equipment such as a crane may be made available for such periods of time.
Particularly in application of the method of this invention to the assembly of a low cost residential building structure, it may be advantageous to provide in the unitary roof and ceiling structure 20 and in the side wall panels, such as the panel 18 (FIG. 6), electrical wiring which will cooperate in facilitating completion of utility services to the building structure 10. That is, it is contemplated that wiring harnesses having necessary conductors and junction boxes may be installed in the unitary roof and ceiling structure 20 and in wall panels such as the panel 18 prior to superposition of the unitary structure 20 on the building side walls. Where such a practice is followed, interconnection of the previously installed wiring is relatively simple and quick and full utility service to the building structure 10 may be promptly completed.
In the drawings and specification, there has been set forth a preferred embodiment of the invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation.
It is an object of the present invention to facilitate a reduction in the time and expense required to achieve a finished ceiling in a building structure. In accomplishing this object of the present invention, the conventional practice of erecting a roofing structure over building side walls, enclosing the building and thereafter applying a ceiling finish is obviated by a novel and advantageous method by which interior ceiling finish work following erection of a building structure is eliminated. In particular, trusses are preassembled with ceiling finish panels prior to superposition of the roof structure on the building side walls.
A further object of the present invention is to assemble a building structure in which a unitary roof and ceiling structure economically provide enhanced thermal insulation qualities as compared with conventional building structures. In accomplishing this object of the present invention, reliance is placed upon a thermally insulating material for adhering together a plurality of ceiling panels which provide the finished interior ceiling and a plurality of trusses which provide the structural components of the building roof system.
Some of the objects and advantages of the invention having been stated, others will appear as the description proceeds, when taken in connection with the accompanying drawings, in which
FIG. 1 is an exploded perspective view of a building structure in accordance with this invention;
FIG. 2 is an elevation view, partially in section, illustrating adhered together ceiling panels and trusses at one step in the method in accordance with this invention;
FIG. 3 is a perspective view somewhat similar to FIG. 1 illustrating the superposition of a unitary roof and ceiling structure in accordance with this invention on building side walls during the assembly of a building structure;
FIG. 4 is a plan view, partially in section, through the structure of FIG. 2, taken generally along the line 4--4 in that figure;
FIG. 5 is an elevation view, partially in section, through a portion of a building structure assembled in accordance with the present invention;
FIG. 6 is a reduced elevation view of a side wall panel as used in a building structure in accordance with this invention; and
FIG. 7 is a perspective view of a unitary roof and ceiling structure in accordance with this invention.
In the detailed description which follows, reference will be had to the accompanying drawings which illustrate a representative embodiment of this invention. At the outset, however, it is to be understood that the drawings and the detailed description with reference to the drawings are set forth as illustrative of and not as limiting upon this invention, as it is contemplated that persons skilled in the construction trades will be able to apply the teaching of this invention broadly to assemblies other than that specifically described hereinafter.
In the illustrated embodiment of this invention, a residential building structure generally indicated at 10 is assembled by positioning a plurality of pre-cast concrete wall panels 11, 12, 14, 15, 16 and 18 about the periphery of a cast concrete foundation slab 19. While such use of a cast concrete foundation slab 19 and pre-cast wall panels is particularly advantageous for residential building structures intended to have a low initial cost, the present invention contemplates that the foundation and building side wall structures, as well as building interior walls, may be constructed, erected, or assembled in accordance with any known practice considered desirable by the builder assembling the building structure.
In accordance with important features of the present invention, a finished interior ceiling and a roof system for the building structure 10 are provided by a unitary roof and ceiling structure generally indicated at 20. In accordance with the present invention, the unitary roof and ceiling structure 20 comprises a plurality of trusses 21, which may be of a prefabricated timber construction as presently known and used. Adhered to the plurality of trusses 21 are a plurality of ceiling panels 22 which together define the finished interior ceiling of the building structure 10. The ceiling panels 22 and trusses 21 preferably are adhered together into the unitary roof and ceiling structure by a body of foam material 24 which additionally provides thermal insulation and fire-proofing for the building structure 10. Desirably, the foam material 24 is a urethane foam spray applied as will be described hereinafter.
In assembling a building structure in accordance with the method of this invention, a suitable horizontal surface is provided, preferably as by casting a slab 19' to serve as a foundation for an adjacent building structure. Thereafter, a plurality of ceiling panels 22 are arranged on the horizontal surface in horizontal array, with the interior finish surface of the panels facing downwardly (FIG. 2). A plurality of trusses 21 are then superposed on the plurality of panels and are arranged in upright position thereabove. The plurality of trusses are spaced apart one from another at such distance as may be required by applicable building codes.
Following superposition of the plurality of trusses on the plurality of ceiling panels, utility services may be installed in the unitary roof and ceiling structure. By way of example only, such a utility service may include an air circulation duct 25 (FIGS. 2, 4 and 7) for distribution of heated or cooled air within the finished building structure 10. The assembled components are then adhered together into a unitary structure by the spray application of urethane foam material 24.
It is to be noted that the spray application of foam material 24 extends across the entire upper surface area of the ceiling panels 22 and extends over the lower members 21a of each of the trusses 21. Thus, large areas of contact of the foam material with the ceiling panels are obtained while transfer of loading forces to the trusses also results. Finally, as is known from the properties of urethane foam materials, substantially enhanced thermal insulation and fire proofing qualities are obtained.
Following the adhering together of the plurality of trusses 21 and the plurality of ceiling panels 22, together with any utility services which may be incorporated in the structure at that time, a roofing cover may be applied to the unitary roof and ceiling structure if desired. Such a roofing cover may adopt conventional practices through the use of plywood sheathing 26 and shingles applied thereto, if desired, as the present invention contemplates that any satisfactory covering for the roof structure may be employed.
Either before or after a covering for the roofing structure 20 is applied, the structure is raised from the slab 19' on which it was assembled and is superposed on building side walls to complete assembly of the building structure. Such raising and superposition of the ceiling structure may be accomplished by a crane or similar equipment, inasmuch as the unitary nature of the roof and ceiling structure 20 will accommodate the loads and force distributions which occur. Further, while it is contemplated that the unitary roof and ceiling structure 20 would be raised from one slab 19' to be superposed on building side walls 11, 12, 14, 15, 16, 18 which have been erected on an adjacent slab 19, it is understood that the unitary roof and ceiling structure 20 may be held in the raised position for such time as may be required to position prefabricated building side walls on the slab which earlier supported the unitary structure 20, if lifting equipment such as a crane may be made available for such periods of time.
Particularly in application of the method of this invention to the assembly of a low cost residential building structure, it may be advantageous to provide in the unitary roof and ceiling structure 20 and in the side wall panels, such as the panel 18 (FIG. 6), electrical wiring which will cooperate in facilitating completion of utility services to the building structure 10. That is, it is contemplated that wiring harnesses having necessary conductors and junction boxes may be installed in the unitary roof and ceiling structure 20 and in wall panels such as the panel 18 prior to superposition of the unitary structure 20 on the building side walls. Where such a practice is followed, interconnection of the previously installed wiring is relatively simple and quick and full utility service to the building structure 10 may be promptly completed.
In the drawings and specification, there has been set forth a preferred embodiment of the invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation.