Title:
Pre-molded window, door and floor frame incorporated into a building wall construction
Kind Code:
A1


Abstract:
A plurality of composite building components for use with an erectable wall associated with a building enclosure and for establishing an environmentally resistant barrier proximate a floor supporting bond and/or a window/doorway defining enclosure. Each of the components further includes an elongated body having a specified cross-sectional dimension which is constructed of a composite including a plasticized material with additional binder element. The elongated bodies are secured in end-to-end connecting fashion, both upon the perimeter-defining foundation as well as at locations corresponding to a window or doorway defined within the erectable wall. A plurality of floor joists are supported in spaced apart and extending fashion between spaced apart and parallel extending components comprising the perimeter-defining foundation. The foundation defining components further include a brick ledge support.



Inventors:
Hubbard, Richard L. (Pinckney, MI, US)
Application Number:
11/111516
Publication Date:
11/09/2006
Filing Date:
04/21/2005
Primary Class:
International Classes:
E04C2/38
View Patent Images:
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Primary Examiner:
KWIECINSKI, RYAN D
Attorney, Agent or Firm:
DINSMORE & SHOHL LLP (900 Wilshire Drive Suite 300, TROY, MI, 48084, US)
Claims:
I claim:

1. A composite building component for use with an erectable wall associated with a building enclosure, the enclosure further including a perimeter-defining foundation, said component further comprising: an elongated body having a specified cross-sectional dimension, said body being constructed of a composite including at least a plasticized material; and a plurality of said elongated bodies being secured in end-to-end connecting fashion upon the perimeter defining foundation, prior to assembly of additional building components associated with the erectable wall, and in order to provide an environmentally resistant barrier proximate the foundation.

2. The composite building component as described in claim 1, further comprising a plurality of floor joists supported in spaced apart and extending fashion between spaced apart and parallel extending components.

3. The composite building component as described in claim 1, said elongated body having a specified shape and size and further comprising a combined composite of plasticized resin and sawdust.

4. The composite building component as described in claim 1, said elongated body having a specified shape and size and further comprising a fiberglass composition.

5. The composite building component as described in claim 1, said elongated body having a specified shape and size and further comprising an axially extending and internal reinforcing insert.

6. The composite building component as described in claim 5, said reinforcing insert being constructed of a material including at least one of a metal, wood, and nylon.

7. The composite building component as described in claim 1, said body having a specified shape and size and exhibiting an “L” shaped cross-sectional dimension.

8. The composite building component as described in claim 1, said body having a specified shape and size and exhibiting a “T” shaped cross-sectional dimension.

9. The composite building component as described in claim 1, said body having a specified shape and size and exhibiting an inverted “U” shape in construction.

10. The composite building component as described in claim 1, further comprising an elongated brick ledge attachment disposed between the foundation and the interconnecting composite bodies.

11. The composite building component as described in claim 1, further comprising a plurality of interconnected bodies, each exhibiting an outwardly facing and recessed channel, a panel edge seating within each of said panels and being secured in place.

12. A plurality of composite building components for use with an erectable wall associated with a building enclosure, said components each further comprising: an elongated body having a specified cross-sectional dimension, said bodies being constructed of a composite including at least a plasticized material; and a plurality of said elongated bodies being secured in an end-to-end and perimeter-defining fashion, in association with the erectable wall, in order to provide an environmentally resistant barrier.

13. The composite building component as described in claim 12, each of said elongated and perimeter-defining bodies further comprising an “L” shaped cross-sectional dimension.

14. The composite building component as described in claim 12, said elongated and perimeter-defining bodies having a specified shape and size and corresponding in arrangement and placement to at least one of a window and doorway.

15. The composite building component as described in claim 12, said bodies each having a specified shape and size and further comprising a combined composite of plasticized resin and sawdust.

16. The composite building component as described in claim 12, said elongated bodies having a specified shape and size and further comprising a fiberglass composition.

17. The composite building component as described in claim 12, said elongated bodies each having a specified shape and size and further comprising an axially extending and internal reinforcing insert.

18. The composite building component as described in claim 17, said reinforcing insert being constructed of a material including at least one of a metal, wood, and nylon.

19. A plurality of composite building components for use with an erectable wall associated with a building enclosure and for establishing a floor supporting bond, the enclosure further including a perimeter-defining and concrete foundation, said components each further comprising: an elongated body having a specified cross-sectional dimension, said body being constructed of a composite including at least a plasticized material, said elongated bodies being secured in end-to-end connecting fashion upon the perimeter-defining foundation; and a plurality of floor joists supported in spaced apart and extending fashion between spaced apart and parallel extending components comprising said perimeter-defining foundation, said components establishing an environmentally resistant barrier proximate the foundation.

20. The composite building component as described in claim 19, said elongated components each exhibiting a specified shape and size and further comprising a brick ledge support location in addition to a floor joint support location.

21. The composite building component as described in claim 19, each of said bodies having a specified shape and size and further comprising at least one of an “L” shaped, “T” shaped and “U” shaped cross-sectional dimension.

Description:

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to molded construction members and, more particularly, discloses a composite building component in the form of a pre-molded and elongated bond member for use in structural wall applications associated with window, door and brick ledge supports of an enclosure. The structural bond member of the present invention further incorporates various modified “L” and “T” cross-sectional shaped structures which are manufactured from a plastic/sawdust composite or heavy-duty fiberglass construction in order to provide the combined features of water and termite infestation resistance.

2. Description of the Prior Art

The prior art is well documented with examples of floor and wall construction systems. The objective in each instance is to simplify the time and effort necessary to construct a building enclosure, as well as to incorporate improved materials and techniques which reflect in the quality and durability of the structure so erected.

U.S. Pat. No. 4,389,831, issued to Baumann, teaches a simplified construction system in which a box-like building is constructed one room at a time and by which concrete slabs are used for building the walls, floor and ceiling. These are poured in a horizontal position, and are stacked vertically with bond-breaking layers between them to allow separation.

A plastic sheet is applied as a bond-breaking layer to the upper surface of the foundation and, after the foundation and stub wall are partially cured, a ceiling slab is poured with wedge-shaped edges clearing stub walls by approximately one inch. Tiltable wall slabs are then poured on top of the ceiling slab, each connected by hinges to its own stub wall. An accelerated lightweight and low-slump concrete is normally used, which makes possible a rapid, nearly continuous pouring sequence.

U.S. Pat. No. 3,867,802, issued to Murphy, teaches a floor support assembly for building structures which includes a beam having a ledge, a floor joist and a locking clip for connecting the joist to the beam. An elongated bottom wall portion of the joist terminates at an end, and a pair of the walls project along the length of the bottom wall and at an angle thereto so as to form a member having a generally V-shaped cross section. Each of opposing side walls include a ledge extending therealong, the ledges being coplanar and adapted to be received within respective grooves in a floor panel to support the panel therealong. The joist is supported at its end by the ledge of the beam and is connected to the beam by the clip. Of note, the beam includes a flange portion for connection to a similar beam to form a hollow beam section which not only serves as a support for associated floor joists, but also serves as a heating and/or cooling duct.

U.S. Pat. No. 5,473,849, issued to Jones, Jr., teaches a building wall and method of constructing the same and which provides hollow cored walls, beams, girders, joists and the like, these typically being constructed of a manufactured and exterior-grade fiberglass reinforced cement board, and within which is poured a flowable fibrous, foam-cement mix. In relevant part, the fiber-foam cement core supplies structural strength, insulating properties and monolithic bonding of all components. An inner, cement board creates the interior side of the wall and an outer cement board is used as a permanent form creating one side of the building wall.

U.S. Pat. No. 6,550,215, issued to Pulte et al., teaches a casting tool for forming precast concrete walls. A base is disposed generally in a horizontal plane and has an upper surface. A pair of opposing sidewalls are disposed proximate the upper surface. Each of the sidewalls has a first position in which the sidewall is located substantially in a vertical plane.

First and second opposing bulkheads are disposed proximate the upper surface, each having a respective first position in which the bulkhead is located substantially in a vertical plane. The bulkheads are further arranged to abut the pair of opposing sidewalls so that the inner surfaces of the sidewalls, the bulkheads, and the upper surface of the base define a form for receiving concrete to make the precast concrete wall section. The first bulkhead is configured for movement so as to vary a first dimension of the form, and thus the dimension of the concrete wall section.

Finally, U.S. Pat. No. 4,454,695, issued to Person, teaches a composite floor system including a plurality of joists, each having a top and a bottom chord and a web in the space between the chords. The top chord includes a pair of angle bars, each having a vertical leg of differing heights and a horizontal leg. The top of the web extends between the vertical legs of the chord to a point between or level with the top of the larger vertical leg of the angle bars. Decking is supported by the horizontal legs of the top chord of adjacent joists and a concrete slab poured on the decking and between the vertical legs of the top chord to provide bonding between the concrete slab, top chord and web.

SUMMARY OF THE PRESENT INVENTION

The present invention relates generally to molded construction members and, more particularly, discloses a pre-molded and elongated composite building component, or bond, for use in structural wall applications associated with window, door and brick ledge supports of an enclosure. The structural bond member of the present invention further incorporates various modified “L” and “T” cross-sectional shaped structures which are manufactured from a plastic/sawdust composite or heavy-duty fiberglass construction.

In a first application, the elongated components are arranged in an end-to-end connection fashion upon a perimeter-defining foundation associated with the building structure. Typically, the bond components are constructed, such as within a press application, of a composite material including a plasticized resin mixed with a sawdust and binder. Alternatively, the components may be constructed with fiberglass or other suitable material which exhibits the necessary properties of strength, durability, and environmental insulation.

The elongated components exhibit any desired cross-sectional configuration, among those including an “L” shaped, “T” shaped or “U” shaped design. A reinforcing insert may be embedded in axially extending fashion within the elongated component, such as during its press or formation stage, and may include a metal, wood, heavy-duty nylon or other suitable material which provides the necessary degree of reinforcement to the component. The insert may also be configured to replicate the overall “L”, “T” or “U” shaped cross section of the material in order to maximize the overall rigidity of the component along its axial direction.

In one preferred application, the elongated components are assembled in end-to-end engagement upon the building foundation, this being accomplished either by integrally forming the components with the foundation or, alternatively, by securing the same with glue, fasteners and the like. The foundation “bond” layer thus created exhibits desired waterproof and infestation-resistant properties, and may also be configured along its cross-sectional extending dimension to provide both an inner support ledge for a plurality of inner extending floor joists, as well as an outer supporting and brick ledge.

A further variant of the present design contemplates the provision of end-to-end engaging components assembled at varied locations along an erected building wall and corresponding to a window or doorway opening. In such a variant, a plurality of “L” shaped members are typically employed and which, upon being assembled together, define a structure which can be incorporated into such as an assembled brick and frame construction or poured wall construction.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to the attached drawings, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout the several views, and in which:

FIG. 1 is a first perspective illustration of an elongated “L” bond set upon a building foundation and according to a first preferred embodiment of the present invention;

FIG. 2 is an end cutaway of an “L” bond, such as referenced in FIG. 1, and further illustrating the features of an internal reinforcing insert incorporated within the “L” bond according to the present invention;

FIG. 3 is an end cutaway of a modified “T” bond according to a further preferred embodiment of the present invention;

FIG. 4 is a perspective illustration of a pre-molded window or door frame for incorporation into the building wall construction and according to the present invention;

FIG. 5 is a cutaway illustration taken alone line 5-5 of FIG. 4 and showing the cross-sectional configuration of one of the bond elements of FIG. 4;

FIG. 6A is a cutaway illustration of an “L” shaped bond element according to a preferred variant of the present invention;

FIG. 6B is a cutaway illustration of a “T” shaped bond element according to a further preferred variant of the present invention;

FIGS. 6C-6E are cutaway illustrations of further modified “L” shaped bond elements according to the present invention;

FIG. 6F is a cutaway illustration of a bond cap according to the present invention;

FIG. 6G is a cutaway illustration of an exterior bond in use with the bond cap of FIG. 6F;

FIG. 7 is a perspective illustration of a modified bond and brick ledge support associated with a foundation support and according to the present invention; and

FIG. 8 is a cutaway illustration of a door and window framing member utilized in combination with the bond according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIG. 1, a composite building component is illustrated at 10 according to a first preferred embodiment of the present invention. The component 10 is secured in extending fashion upon a concrete foundation 12 and it is contemplated that the component may either be integrally formed with the foundation or, alternatively, can be separately attached to the foundation through the use of heavy-duty adhesives, fasteners, or the like.

In a first application, a plurality of the elongated components 10 are assembled in end-to-end fashion about the perimeter defining foundation 10 and in order to define a lowermost bond layer associated with the foundation. As discussed, the advantage of such a bond layer is that it provides a degree of waterproofing, as well as termite and other infestation resistance, not found in other prior art applications and, most notably, in conventional wood bond constructions.

The elongated component 10 exhibits a substantially “L” shape with a first foundation supporting ledge 14 and an interconnected and upwardly extending ledge 16. In the application of FIG. 1, a plurality of floor joists, illustrated in phantom at 18 and 20, extend in spaced-apart fashion between corresponding spaced apart and typically parallel components (only one of which is shown at 10 in FIG. 1) and such that the ends of the joists are supported upon the components. As is known in the art, such joist spacing can include indicia markings 22 and 24 which correspond with conventional 16″ on center or 24″ on center applications in order to facilitate quickly aligning and assembling the floor joists 18 and 20 in extending fashion between the opposing elongated bond components 10.

The components 10 are typically constructed of a composite material in order to exhibit the desired properties of strength and environmental insulation. Typically, the bond components are constructed, such as within a press operation utilizing a given forming temperature, as a composite of a plasticized resin mixed with a sawdust and binder. Alternatively, the components may be constructed with fiberglass or other suitable material such that the finished product exhibits the necessary properties of strength, durability, and environmental insulation.

Referring further to FIG. 2, a modification 26 of the elongated and “L” shaped component is shown and which includes a substantially resinous material 28, within 5 which is encapsulated an interior reinforcing member 30. The reinforcing insert may be embedded in axially extending fashion within the elongated component, such as during its press or formation stage, and may include a metal, wood, heavy-duty nylon or other suitable material which provides the necessary degree of reinforcement to the elongate extending component 26. The insert may also be configured to replicate the overall “L” shaped component 26, such as by exhibiting a likewise “L” shape in cross section, and in order to maximize the overall rigidity of the component along its axial direction. As will be further discussed, a reinforcing insert may also be provided in either a “T” shape or “U” shape configuration in order to provide a likewise degree of axial rigidity to a corresponding cross-sectionally configured elongated component.

Referring now to FIG. 3, a further application of an elongated bond component is illustrated at 32, again supported upon a building foundation 12, and which is provided in a generally inverted “T” shaped construction. The elongated component 32, as illustrated by its cross-sectional cutaway, is constructed of a composite of a resinous material and sawdust, and such as which is formed in a press with the selective application of heat and/or a binder element.

As with the “L” shaped embodiment of FIG. 1, the inverted “T” bond component 32 of FIG. 3 may exhibit an inwardly facing floor joist ledge, see floor joists 34 and 36. Arranged on an opposite facing ledge surface is a brick ledge support such as which may support a plurality of stacked bricks 38.

Referring now to FIGS. 4 and 5, a perspective illustration is shown at 40 of a pre-molded window or door frame for incorporation into the building wall construction. A plurality of elongated components 42, 44, 46 and 48 are assembled in end-to-end fashion (such as again mechanically or through the use of adhesives) and such that they define an overall doorway or window frame. The variant illustrated defines a plurality of “L” shaped members and which, upon being assembled together, define a structure which can be incorporated into such as an assembled brick and frame construction or poured wall construction (not shown). As previously described, the interlocking elongate components 42, 44, 46 and 48 for constructing a doorway/walkway are typically composed of a material similar to that associated with the floor bond components of FIGS. 1-3 and include a composite of a resinous/ sawdust/binder or fiberglass material.

FIG. 6A illustrates at 50 a cutaway perspective illustration of an “L” shaped bond element, similar to that illustrated in FIG. 2, and including a reinforcing insert 52 according to a preferred variant of the present invention. FIG. 6B is a further succeeding cutaway illustration of a “T” shaped bond element 54 according to a further preferred variant of the present invention, and which likewise incorporates a likewise “T” shaped reinforcing component 56.

Referring further to FIGS. 6C-6E, successive cutaway illustrations of further modified “L” shaped bond elements are shown at 58, 60 and 62, respectively, according to the present invention. In each instance, the configuration of the interconnecting ledges is modified, such as for differing floor and wall applications.

FIG. 6F illustrates at 64 a perspective cutaway of a “U” shaped bond cap according to the present invention. The cap 64 may be assembled separately upon a concrete foundation or may be used with an exterior bond as further referenced at 66 in FIG. 6G. The exterior bond 66 includes a modified “U” shaped cross-sectional configuration exhibiting an upper and rectangular shaped projection 68 upon which may be seated the cap 64.

As is further shown in FIG. 7, a modified foundation 70 is positioned intermediate an outer ground location 72 and an inner insulative layer 74. The foundation 70 includes an upper square projection 76 which is designed to matingly engage within an opposing recess defined in axial fashion along a bottom-facing surface of the exterior bond 66. A brick ledge support 80 (typically constructed of a metal or other suitable material) is configured to be secured upon the concrete foundation 70 and includes an internally recessed projection 82, which matingly engages over the cap engaging projection 76 in order to secure the brick ledge 80 in place.

Finally, and referencing FIG. 8, a cross-sectional cutaway is shown of a window or door framing member 84 which exhibits a modified rectangular shaped extrusion which includes a side-recessed and extending channel 86 exhibiting inwardly recessed side walls and interconnected end wall. The member 84 can be sectioned to any desired length and interconnected in end-to-end fashion to construct a door or window opening. In practice, an associated edge of an OSB board or the like (see at 88) can be inserted into the outwardly facing and extending notched recessed channels 86 and nailed in place to establish a wall support surface. The member 84 can be utilized in combination with the bond structure described herein.

Having described my invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains, without deviating from the scope of the appended claims.