Title:
BUILDING MEMBER
Document Type and Number:
United States Patent 3861100
Abstract:
A monobloc box building member for use in horizontal structural components of buildings. The box is of rectangular section, formed with a bottom and sidewalls of low height relative to their width.
Inventors:
Application Number:
05/320002
Publication Date:
01/21/1975
Filing Date:
01/02/1973
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Export Citation:
Primary Class:
Other Classes:
52/793.100
International Classes:
E04B5/08; E04C1/24
Field of Search:
52/227,474,585,586,629,606,582,619,615,613,618,262,614,309,663
US Patent References:
| 1917603 | Display panel | July 1933 | Schultz | |
| 2742115 | Insulated construction panel | April 1956 | Strong | |
| 2971295 | Prestressed concrete units and structures | February 1961 | Reynolds | |
| 3073476 | Packaging panel | January 1963 | Heacock | |
| 3082489 | Building panels for and coupling joints therebetween in prefabricated buildings | March 1963 | Douglas | |
| 3367076 | Wall panel construction | February 1968 | O'Brian | |
| 3386221 | Lightweight panel | June 1968 | Giovannucci | |
| 3614915 | October 1971 | Perry | ||
| 3706168 | PREFABRICATED BUILDINGS | December 1972 | Pilish | |
| 3757481 | MONOLITHIC STRUCTURAL MEMBER AND SYSTEMS THEREFOR | September 1973 | Skinner | |
| 3783563 | PREFABRICATED BUILDING COMPONENTS | January 1974 | Moore |
Primary Examiner:
Abbott, Frank L.
Assistant Examiner:
Friedman, Carl D.
Attorney, Agent or Firm:
Darby & Darby
Claims:
We claim
1. A building component formed by a plurality of adjacent monobloc members, each of said monobloc members comprising a bottom wall of generally rectangular shape, a sidewall integrally formed with and extending downwardly from and continuously along the length of each edge of said bottom wall below said bottom wall and defining an open central area between the sidewalls, the height of each said sidewall being less than that of the length or width of said bottom wall, a bore formed in each of said sidewalls and totally surrounded thereby, each of said bores extending longitudinally of its respective sidewall for the entire length thereof, the bores of two transverse sidewalls of a member which intersect being spaced apart one above the other, tie means in said bores extending the length and width of the component and aligning the corresponding sidewalls of adjacent members which extend in the same direction, and means engaging said tie means for holding said plurality of members under compression with the sidewalls thereof in juxtaposed relationship to form a two dimensional array, the sidewalls of juxtaposed members extending in the same direction forming a beam.
2. A component as in claim 1 wherein a said monobloc member is formed by a sandwich of two liquid impermeable and strong outer skins connected by an insulating cellular central core.
3. A component as in claim 1 wherein said tie means for said monobloc members are incorporated into the sidewalls, each said tie means having the length of a respective sidewall and terminating in means for connecting to the tie means of a juxtaposed monobloc member.
4. A component as in claim 1 wherein the sidewalls of the monobloc members are provided with voids.
5. A component as in claim 1 wherein the bottom wall of the monobloc members is dome shaped.
6. A component as in claim 1 wherein the outer faces of the sidewalls of the monobloc member have at least one groove for holding weatherproofing means.
7. A component as in claim 1 wherein the edges of the sidewalls of the monobloc members are formed with grooves for receiving partitions.
8. A building component as in claim 1 further comprising vertically extending means engaging said component for holding the same in a raised position.
9. A building component as in claim 8 wherein said vertically extending means comprise panels, said panels being of a predetermined height and a width corresponding to an integral multiple of the number of said monobloc members forming said building component and having walls at the upper and lower ends thereof connected by an insulating portion, and means including at least one of said tie means for connecting at least one of said walls to said building component.
10. A building component as in claim 1 wherein said means engaging said tie means are connected at the outer sidewalls of the component and extend generally transverse to a respective tie means and bridging and engaging the adjacent sidewalls of two of said monobloc members.
11. A building component as in claim 1 wherein the open central area of each said monobloc member faces upwardly and further comprising at least one flat member mounted on top of the bottom edges of the sidewalls of the monobloc members.
12. A building component as in claim 1 wherein the open central area of each said monobloc member faces downwardly and further comprising at least one flat member mounted on top of the bottom walls of said monoblock members.
1. A building component formed by a plurality of adjacent monobloc members, each of said monobloc members comprising a bottom wall of generally rectangular shape, a sidewall integrally formed with and extending downwardly from and continuously along the length of each edge of said bottom wall below said bottom wall and defining an open central area between the sidewalls, the height of each said sidewall being less than that of the length or width of said bottom wall, a bore formed in each of said sidewalls and totally surrounded thereby, each of said bores extending longitudinally of its respective sidewall for the entire length thereof, the bores of two transverse sidewalls of a member which intersect being spaced apart one above the other, tie means in said bores extending the length and width of the component and aligning the corresponding sidewalls of adjacent members which extend in the same direction, and means engaging said tie means for holding said plurality of members under compression with the sidewalls thereof in juxtaposed relationship to form a two dimensional array, the sidewalls of juxtaposed members extending in the same direction forming a beam.
2. A component as in claim 1 wherein a said monobloc member is formed by a sandwich of two liquid impermeable and strong outer skins connected by an insulating cellular central core.
3. A component as in claim 1 wherein said tie means for said monobloc members are incorporated into the sidewalls, each said tie means having the length of a respective sidewall and terminating in means for connecting to the tie means of a juxtaposed monobloc member.
4. A component as in claim 1 wherein the sidewalls of the monobloc members are provided with voids.
5. A component as in claim 1 wherein the bottom wall of the monobloc members is dome shaped.
6. A component as in claim 1 wherein the outer faces of the sidewalls of the monobloc member have at least one groove for holding weatherproofing means.
7. A component as in claim 1 wherein the edges of the sidewalls of the monobloc members are formed with grooves for receiving partitions.
8. A building component as in claim 1 further comprising vertically extending means engaging said component for holding the same in a raised position.
9. A building component as in claim 8 wherein said vertically extending means comprise panels, said panels being of a predetermined height and a width corresponding to an integral multiple of the number of said monobloc members forming said building component and having walls at the upper and lower ends thereof connected by an insulating portion, and means including at least one of said tie means for connecting at least one of said walls to said building component.
10. A building component as in claim 1 wherein said means engaging said tie means are connected at the outer sidewalls of the component and extend generally transverse to a respective tie means and bridging and engaging the adjacent sidewalls of two of said monobloc members.
11. A building component as in claim 1 wherein the open central area of each said monobloc member faces upwardly and further comprising at least one flat member mounted on top of the bottom edges of the sidewalls of the monobloc members.
12. A building component as in claim 1 wherein the open central area of each said monobloc member faces downwardly and further comprising at least one flat member mounted on top of the bottom walls of said monoblock members.
Description:
This invention relates to an improved building member for use in construction of horizontal structural components of buildings.
The cost price of a building constructed of shop-manufactured members is related on the one hand to the price of the members and on the other to the costs of shipment, erection and site work (adaptation work and non-industrialized portions).
Certain solutions, in order to reduce the costs of erection and the work on site, enable shop manufacture of complete cells including door-frames, pipework, etc. The offset to this is high cost of shipment.
If on the contrary one tries to reduce the shipment one ends up generally with a large number of parts and complicated and costly erection.
The present invention aims at resolving this problem by an industrialized system of construction which enables an optimum balance to be achieved between the various costs mentioned above whilst affording great latitude in planning the buildings which result from it.
In the French Pat. No. 71,20428 filed on 7.6.71, the applicants have described a prefabricated construction comprising a structure forming a framework and platform, consisting of a square-meshed lattice made of timber sections erected and assembled by means of metal ties.
The present invention aims at improvements in this construction enabling the production and erection of it to be considerably simplified.
The basic member of the construction in accordance with the invention is a monobloc box of square section, formed of a bottom and sidewalls of low height relative to their length, the said sidewalls including longitudinal housings for the passage of ties.
The construction in accordance with the invention is characterized in that at least certain of the horizontal structures (floors, ceilings, roofing) are obtained by juxtaposition of the said boxes in a rectangular array like a chessboard and assembling them by horizontal ties passing through the beams formed by the juxtaposition of the sidewalls of the boxes.
The construction in accordance with the invention is effected in accordance with the method described in the aforesaid French Pat. No. 71,20428, that is to say, that a horizontal structure of the kind is assembled on the ground and then raised to a height and propped up, the bearer members (partitions, walls, stanchions) being put in place afterwards.
The advantage of these members and their assembly is in achieving simultaneously the supporting structure, sealing, insulation, vapour barrier, and ceiling and in enabling simple connection onto the exterior walls and interior partitions.
For greater clarity the description of the invention will be pursued by reference to the attached drawings, in which:
FIGS. 1 and 2 display in plan and in section a box member in accordance with the invention;
FIG. 3 is a partial perspective view of an assembled horizontal structure;
FIGS. 4 and 5 illustrate in section how sealing is effected between boxes;
FIGS. 6, 7 and 8 illustrate production of floor structures and surfaces;
FIG. 9 illustrates a variant embodiment of the box;
FIGS. 10 and 11 illustrate two variants relative to tension ties; and
FIG. 12 shows in vertical section an embodiment of a wall panel in accordance with the invention.
Referring to FIGS. 1, 2 and 3, it is seen that the member in accordance with the invention is a square-section box 1 consisting of sandwich material, that is to say, formed of two strong outer skins connected by a cellular central core. It is formed of a bottom and sidewalls 2, and is monobloc, that is to say, produced by bonding and its strength is that of a double-walled shell. This inherent strength enables it to constitute the basic member of a supporting of self-supporting structure. It is weathertight and its cellular core makes it insulating. Its dimensions will be, for example, of the order of 90 cm a side by 30 cm height of the sidewalls; in the variant as FIGS. 1 and 2, lengthwise apertures 3 are provided in the sidewalls 2 for passing through ties 4.
The construction in accordance with the invention comprises at least one horizontal surface obtained by juxtaposition of the boxes 1 like a chessboard FIG. 3) and assembly of them by ties 4 terminating at, for example, endplates 5. The former pass through the horizontal beams formed by the juxtaposition of the sidewalls 2 and ensure their resistance to bending. The whole forms a three-dimensional supporting structure.
Surfaces so produced may constitute both the floor, the ceiling and the roofing of a building. For roofing it is in fact sufficient to see to the weather-tightness at the joints between the boxes as shown in FIGS. 4 and 5, the latter being in themselves weather-tight.
According to FIG. 4, one or a number of channels or grooves 6 are provided in the sidewall of the box in which sealing strands will be placed at the time of erection. An upper channel 7 is advantageously provided in which a strand is formed or placed after erection (for example, a strand of neoprene laid by a pump).
In FIG. 5 the sidewalls of the boxes 1 are provided at 8 with grooves for their weathertight assembly by adhesive. The channel 7 will with advantage be retained.
For the production of roofing it is preferable to give the bottoms of the boxes a domed shape to facilitate water flow.
A horizontal surface is thus obtained which forms straight away a roofing and ceiling of boxes without any complementary work.
In particular the invention completely obviates the necessity of covering the ceiling structure with insulation, weatherproofing and a load of grit, which obviates a significant constraint of the known construction systems.
In accordance with the invention a ceiling-roof is assembled from boxes on the ground, the assembly being constructed over an erection jig which enables the ceiling to be adjusted for flatness, after which the ceiling-roof is then hoisted to its final height and propped up. Erection of partitions is carried out next and the props are withdrawn. Grooves 9 are provided in the free edges of the boxes 1 for the purpose of putting the partitions 10 in place (FIGS. 1 and 5). At these points the arrangements described in the French Pat. No. 71,20428 may be adopted.
If it is a question of flooring, the boxes 1 will be arranged inverted, that is to say, with the bottom downwards as shown in FIG. 6, and covered with slabs 11. The boxes 1 in FIG. 6 have in their sidewalls 2, openings or voids 12 which may be of various shapes and enable ductwork to be passed through.
In the case of intermediate floors, the arrangement of FIG. 6 can be employed, the lower face of the boxes forming the ceiling, or that of FIGS. 7 or 8. In the case of FIG. 7 the slabs 11 rest on parts 13 placed on the joints between the boxes and forming bearer-joists. In the case of FIG. 8 a box has been provided of which the upper face is flat. In this case the slabs 11 can be replaced by a surface layer 14 resistant to wear, applied during manufacture of the boxes 1.
The boxes 1 will preferably consist of sandwich material, that is to say, formed of two thin impermeable skins 15 of high mechanical strength braced by a core of insulating cellular material 16.
The skin walls can be of metal or reinforced synthetic resins and the inner core of rigid plastics foam obtained by casting or injection. The whole can be produced in a single operation by the injection into a mould of a plastics material, the outer epidermis of which is compact and strong, the inner bulk being cellular.
Incorporation of rigid, for example, tubular reinforcement into the body of the box may likewise be provided.
As a variant, the box may likewise be composed of wood particles or fibre, or other material, bonded by resin in a press. In this case it will be as well to provide an impermeable surface layer 18 over the whole or part of the box, at least at the upper part, and possibly an insulating layer 19 as a ceiling (FIG. 9).
As shown in FIGS. 1 and 3, assembly is performed by means of metal ties. In the example of FIGS. 1 and 3 ties pass through longitudinal apertures in the sidewalls 2. In the example of FIG. 10 the ties 4 pass between two adjacent boxes and are housed in grooves 3 provided for this purpose. In these cases the ties must have a length in the one direction of the length of the building, and in the other of its width.
In accordance with FIG. 11, there can be provided during manufacture the incorporation into the body of the sidewalls 2 of the boxes, of a metal or plastics rod the length of the sidewall, having at its ends means for connection with like rods of other boxes, such, for example, as a threaded ferrule 20 at one end and a shoulder 21 at the other end retaining the head of a hollow-headed bolt 22 (the rods 4 being tubular).
In this case, each box is fabricated to include rod members which, by connection to adjoining members, form assembly ties.
As indicated above, the method of building in accordance with the invention consists in preparing on the ground horizontal surfaces, placing them at height on temporary props and erecting the partitions and outer walls which will be bearer members. The partitions may, for example, be produced of bonded materials and provided with doorframes. The outer walls may be panels of storey height and of width identical with or a multiple or sub-multiple of that of the boxes. Preferably they will be composed in the same way as the latter, that is to say, of sidewalls 23 joined together by a partition forming a bottom or a lid, or placed centrally as shown in FIG. 12. They may be mounted directly onto the ties 4 of the horizontal structures by means of bolts or the equivalent 24.
From the foregoing it will be understood that a building of the kind may have a particularly low cost price whilst having qualites of comfort and high sound or thermal insulation. In manufacture it will be possible to give exposed faces their final appearance, which eliminates any painting.
The cost price of a building constructed of shop-manufactured members is related on the one hand to the price of the members and on the other to the costs of shipment, erection and site work (adaptation work and non-industrialized portions).
Certain solutions, in order to reduce the costs of erection and the work on site, enable shop manufacture of complete cells including door-frames, pipework, etc. The offset to this is high cost of shipment.
If on the contrary one tries to reduce the shipment one ends up generally with a large number of parts and complicated and costly erection.
The present invention aims at resolving this problem by an industrialized system of construction which enables an optimum balance to be achieved between the various costs mentioned above whilst affording great latitude in planning the buildings which result from it.
In the French Pat. No. 71,20428 filed on 7.6.71, the applicants have described a prefabricated construction comprising a structure forming a framework and platform, consisting of a square-meshed lattice made of timber sections erected and assembled by means of metal ties.
The present invention aims at improvements in this construction enabling the production and erection of it to be considerably simplified.
The basic member of the construction in accordance with the invention is a monobloc box of square section, formed of a bottom and sidewalls of low height relative to their length, the said sidewalls including longitudinal housings for the passage of ties.
The construction in accordance with the invention is characterized in that at least certain of the horizontal structures (floors, ceilings, roofing) are obtained by juxtaposition of the said boxes in a rectangular array like a chessboard and assembling them by horizontal ties passing through the beams formed by the juxtaposition of the sidewalls of the boxes.
The construction in accordance with the invention is effected in accordance with the method described in the aforesaid French Pat. No. 71,20428, that is to say, that a horizontal structure of the kind is assembled on the ground and then raised to a height and propped up, the bearer members (partitions, walls, stanchions) being put in place afterwards.
The advantage of these members and their assembly is in achieving simultaneously the supporting structure, sealing, insulation, vapour barrier, and ceiling and in enabling simple connection onto the exterior walls and interior partitions.
For greater clarity the description of the invention will be pursued by reference to the attached drawings, in which:
FIGS. 1 and 2 display in plan and in section a box member in accordance with the invention;
FIG. 3 is a partial perspective view of an assembled horizontal structure;
FIGS. 4 and 5 illustrate in section how sealing is effected between boxes;
FIGS. 6, 7 and 8 illustrate production of floor structures and surfaces;
FIG. 9 illustrates a variant embodiment of the box;
FIGS. 10 and 11 illustrate two variants relative to tension ties; and
FIG. 12 shows in vertical section an embodiment of a wall panel in accordance with the invention.
Referring to FIGS. 1, 2 and 3, it is seen that the member in accordance with the invention is a square-section box 1 consisting of sandwich material, that is to say, formed of two strong outer skins connected by a cellular central core. It is formed of a bottom and sidewalls 2, and is monobloc, that is to say, produced by bonding and its strength is that of a double-walled shell. This inherent strength enables it to constitute the basic member of a supporting of self-supporting structure. It is weathertight and its cellular core makes it insulating. Its dimensions will be, for example, of the order of 90 cm a side by 30 cm height of the sidewalls; in the variant as FIGS. 1 and 2, lengthwise apertures 3 are provided in the sidewalls 2 for passing through ties 4.
The construction in accordance with the invention comprises at least one horizontal surface obtained by juxtaposition of the boxes 1 like a chessboard FIG. 3) and assembly of them by ties 4 terminating at, for example, endplates 5. The former pass through the horizontal beams formed by the juxtaposition of the sidewalls 2 and ensure their resistance to bending. The whole forms a three-dimensional supporting structure.
Surfaces so produced may constitute both the floor, the ceiling and the roofing of a building. For roofing it is in fact sufficient to see to the weather-tightness at the joints between the boxes as shown in FIGS. 4 and 5, the latter being in themselves weather-tight.
According to FIG. 4, one or a number of channels or grooves 6 are provided in the sidewall of the box in which sealing strands will be placed at the time of erection. An upper channel 7 is advantageously provided in which a strand is formed or placed after erection (for example, a strand of neoprene laid by a pump).
In FIG. 5 the sidewalls of the boxes 1 are provided at 8 with grooves for their weathertight assembly by adhesive. The channel 7 will with advantage be retained.
For the production of roofing it is preferable to give the bottoms of the boxes a domed shape to facilitate water flow.
A horizontal surface is thus obtained which forms straight away a roofing and ceiling of boxes without any complementary work.
In particular the invention completely obviates the necessity of covering the ceiling structure with insulation, weatherproofing and a load of grit, which obviates a significant constraint of the known construction systems.
In accordance with the invention a ceiling-roof is assembled from boxes on the ground, the assembly being constructed over an erection jig which enables the ceiling to be adjusted for flatness, after which the ceiling-roof is then hoisted to its final height and propped up. Erection of partitions is carried out next and the props are withdrawn. Grooves 9 are provided in the free edges of the boxes 1 for the purpose of putting the partitions 10 in place (FIGS. 1 and 5). At these points the arrangements described in the French Pat. No. 71,20428 may be adopted.
If it is a question of flooring, the boxes 1 will be arranged inverted, that is to say, with the bottom downwards as shown in FIG. 6, and covered with slabs 11. The boxes 1 in FIG. 6 have in their sidewalls 2, openings or voids 12 which may be of various shapes and enable ductwork to be passed through.
In the case of intermediate floors, the arrangement of FIG. 6 can be employed, the lower face of the boxes forming the ceiling, or that of FIGS. 7 or 8. In the case of FIG. 7 the slabs 11 rest on parts 13 placed on the joints between the boxes and forming bearer-joists. In the case of FIG. 8 a box has been provided of which the upper face is flat. In this case the slabs 11 can be replaced by a surface layer 14 resistant to wear, applied during manufacture of the boxes 1.
The boxes 1 will preferably consist of sandwich material, that is to say, formed of two thin impermeable skins 15 of high mechanical strength braced by a core of insulating cellular material 16.
The skin walls can be of metal or reinforced synthetic resins and the inner core of rigid plastics foam obtained by casting or injection. The whole can be produced in a single operation by the injection into a mould of a plastics material, the outer epidermis of which is compact and strong, the inner bulk being cellular.
Incorporation of rigid, for example, tubular reinforcement into the body of the box may likewise be provided.
As a variant, the box may likewise be composed of wood particles or fibre, or other material, bonded by resin in a press. In this case it will be as well to provide an impermeable surface layer 18 over the whole or part of the box, at least at the upper part, and possibly an insulating layer 19 as a ceiling (FIG. 9).
As shown in FIGS. 1 and 3, assembly is performed by means of metal ties. In the example of FIGS. 1 and 3 ties pass through longitudinal apertures in the sidewalls 2. In the example of FIG. 10 the ties 4 pass between two adjacent boxes and are housed in grooves 3 provided for this purpose. In these cases the ties must have a length in the one direction of the length of the building, and in the other of its width.
In accordance with FIG. 11, there can be provided during manufacture the incorporation into the body of the sidewalls 2 of the boxes, of a metal or plastics rod the length of the sidewall, having at its ends means for connection with like rods of other boxes, such, for example, as a threaded ferrule 20 at one end and a shoulder 21 at the other end retaining the head of a hollow-headed bolt 22 (the rods 4 being tubular).
In this case, each box is fabricated to include rod members which, by connection to adjoining members, form assembly ties.
As indicated above, the method of building in accordance with the invention consists in preparing on the ground horizontal surfaces, placing them at height on temporary props and erecting the partitions and outer walls which will be bearer members. The partitions may, for example, be produced of bonded materials and provided with doorframes. The outer walls may be panels of storey height and of width identical with or a multiple or sub-multiple of that of the boxes. Preferably they will be composed in the same way as the latter, that is to say, of sidewalls 23 joined together by a partition forming a bottom or a lid, or placed centrally as shown in FIG. 12. They may be mounted directly onto the ties 4 of the horizontal structures by means of bolts or the equivalent 24.
From the foregoing it will be understood that a building of the kind may have a particularly low cost price whilst having qualites of comfort and high sound or thermal insulation. In manufacture it will be possible to give exposed faces their final appearance, which eliminates any painting.