Note: Descriptions are shown in the official language in which they were submitted.
BACKGROUND OF THE INVENTION
This invention relates to the production line
fabrication of housing components such as walls, roofs, and
floors, and, in more specific respects, to the fabrication
of walls, having pre-embedded elements, and the like from
polymers and foamed materials.
In the production of housing, more efficient pro-
duction techniques have replaced to some extent the age-old
method of construction at -the site from individual boards,
stones, and other parts. However, modern plastic materials
and other polymers and similar materials are not widely used
:~ as building materials, and the fabrication of walls, floors,
roofs, and similar elements from such materials is not
satisfactori~y efficient under
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prlor techniques ancl rc~ult~ in deficiencie.q in the products.
E'oamed plastic internal stlucturcs, such as of polyurethane
foam, are } ccognized as deYirable to provide cxcellcnt tllermal in~ula-
tion and satisfactory strength to the element at moderate cost, A major
defect, however, has been experienced in that the st~ength of the final
product is deficient at the bond between the foamed interior and the
outer layer or "skin". In at least one technique which attempts to over-
come this weakness, the foamed matcrial is made more dense near the
outer layer. Also, in the prior products foam frequentl~r does not fill
the entire interiorl resulting in defects caused by the voids.
Although basic techniques to mas~ produce structural members
are known and used, such as spraying a hardenable skin material within
the mold surface, the cost of production is realtively high. The mold
section must be held together by special equipment and, similarly,
internal members such as electrical boxes and conduit, must be held
in the mold cavities by special equipment.
Partition members such as walls, floors, and the like have been
pre-assembled at a separate production facility or factory with pipes
and other intexnal items pre-implanted. Construction of housing at the
site is by joilling the partition members together and connecting the pipes
and other elements of adjoining members as required. Prior to this in-
vention such pre-manufactured partition members have been in various
forms9 but none comprised a foamed polymeric interior or core.
Foamed polymeric internal structures, ~uch as of polyurethane
foam, are recognized a~ desirable to provide excellent thermal insulation
and satisfactory strength to the element at moderate cost. Difficulties
have been experienced in the prior art with producing such a member
having adequate strength. Hereinafter it iB disclo~ed how to form a
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very ~atisfactory member wlth thin external outer layer~ and a foam
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înternal core WhiCIl carl be produced at low co~t and with good other
economic factors. An assernbly line production of a product in accord-
ance with this invention i9 also de~cribed in which certain inserts~
internal elements, and similar items are attached to ~he outer layer or
held by brace~ or guides ~vhich are embeddecl in l:he foam. The internal
items are positioned at pre-determined locations as a part of the pro-
duction process.
Another embodiment is comprised of polymeric inner and outer
layers filled with a foamed, synthetic polymer. Internal elements such
as water pipes and electrical conduits are embedded within the foam during
assembly line production of the walls prior to shipment to installation sites.
Known prior art constructions used electrical conduits requiring
junction boxes at joints between connecting walls and were faced with
difficult alignment problems. Also difficulties were experienced in bend-
ing the conduits and pulling wires through them.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a structural member for
housing using foamed material within an external layer and having adequate
8trength at satisfactory cost,
It is, similarly, an object of this invention to provide production
efficiencies in the fabrication of structural members for housing having
foamed internal material and an external poly~ner layer.
It iB another, similar object of this invention to provide structural
members for housing fabricated at reduced cost having pre-installed
elements such;a6 electrical boxes and electrical condult,
- `, It i9 a more general object of this invention to provide improved
as~embly line techniques for the production of structural members, such
as walls, floors, roof~, and the like~
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It i3, si~ilarly, a general objcct of this invention to provide an
improved factory system for constructiol~ of structural members for
housing.
It is a more specific object of this invention to provide a.n assembly
line construction process for the fabrication of walls, roofs, floor~, and
the like having a polymeric exterior layer and a foamed interior with
housing members built into the structure.
It is a still further object of this invention to provide for uniformity
in location of embedded internal members from wall section to wall section
such that internal members similarly positioned in adjacently mounted wall
members are in mating arrangement.
It is a further object of this invention to hold certain internal
members in position by the use of the outer layer of hardenable polyester
formed over such element and the element is placed in contact with the
mold.
It is an object of this invention to provide an economical structure
and method requiring minimum on-site labor for installing wiring.
It is a further object of this invention to provide an improved elec-
trical wiring assembly adapted to be embedded within structural walls having
an interior of foarned, synthetic polymer.
It is a further object to provide an improved assembly of the type
described in the preceding paragraph which is particularly well-adapted to
be interconnected directly with other similar assemblies in walls joined
in line with or perpendicular to each other without junction boxes.
It i8 another object to provide raceways in the improved assembly
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which are characterized by positive alignment within the walk in which they
are ~:mbedded.
In accordance with thi~ invention an assembly line is provided
through which n-old frames are moved more or les~ continuous1y. Two
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rnold halve~ are po~itioned initially with thcir bottoms hori~ontal, or any
anglc of incline such that thc hardcnal~le material doeY not flow to any
significant degree, and full diameter in~erts such a~ windows and door~
are rested in place, Certain inserts which are less l:han a full diameter
are placed in a predetermined position against the side of the mold, In
the best embodiment, the- predetermined position is against the bottom side
of the mold such that inserts in adjacently positioned wall members will '~
be in mating relationship. The molds are then sprayed or otherwise coated
with a thin layer of a hardenable material, which prefera~ly also contains
a fire resistant fill~r such as hydrate of alumina. Enclosed internal ele-
ments such as electrical boxes and water pipes are subsequently rested
on the horizontal surfaces of the mold halves. A second thin layer of
hardenable material is applied on the internal elements, this layer pre-
ferably containing glass fiber as filler. Soon ~hereafter tbe mating mold
halves are brought to an inclined position, after the second layer has hard- ¦
ened sufficiently to hold the internal elements in an inclined position. The
~nold halves contain complementary parts of a hinge at one side, which are
connected together, and the molds are then rotated together and latched into
place to form an internal, mold cavity. The mold is first preheated, and,
with the rnold in the vertical position, a foamable rnaterial i8 introduced
into the cavity. The preheating brings the bo~daxy t~r~?era~e of the 1 "
mold cavity towar~ that generate~ internally during the exothermic, foaming
reaction. The mold halves are moved and ~upported by roller~ as the
foaming continue~.
In addition to the significance of the combined E~y6tem a~ a whole~
which progresse~ th~ molds from horizontal to vertical, at least three
elements have individual significans:c and are believed to be ~ubstanffally
novel ;ndiYidually, These are: tha coatiI~g of in~ide elements while re~ting
on the rclatively horizontal mold surface~ to hold them in position during
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th~ relativ~ly vcrtical opcral;ion, tlle hinginK to~cther of thc mold
elements after they havc been coated and otherwise used while separated,
and the pre-heating of the molds prior to the exothermic foaming operation.
In accordance with this invention a wall member, floor member, or
other hous;ng partition is provided in which the internal core is a foamed,
synthetic polym~r, preferably polyurethane. Internal elements, such as
water pipes, electrical conduits, ancl other electrical elements are ern-
bedded in the foam polymer, as are members which extend acros~ the
full diameter, such as door and window frames. The space relationship
of such before-mentioned internal elernents are controlled by their proper
positioning in the molcl prior to covering the mold surface and the internal
member positioned partly in contact with the mold surface and wholly
within the mold, with the polymeric outer coating. Upon the partial curing
of the polymeric outer coating, the mold halves are brought together and
the inner cavity is filled with a synthetic polymer, preferably polyurethane.
The outer surfaces preferably are a layer of polymer, which facilitates
; joining of partition members by abuting thern and applying a hardenable
substance used as an adhesive. In some uses it has been found satisfactory
that some internal items such as junction bo~es are embedded in the outer
polymer layer to some extent and are held by the polymer during the
foarning of the synthetic polymer to fill the mold cavity. Eleme~lts which
exteIld across the entire member are contacted by braces which extend from
the sides of the inserts into the foam. The positions of the internal items
are standardized for direct access and economic use. The large, outer
surfaces of the partitlons may be thin layers of hardened synthetic polyrners,
which, a~ is known in the art, may be textured 1:o give a desired appearance
~uch a~ stucco, building block~ and the lilce, For ~ome purpoqes, the outer
layers of the partitions may~be preferably plywood on one side. Qne s-lch
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u~e for a plywood surfacc is the floor surface. The plywood givc5 thc
floor a greater capacity for handlin~ loads and a greater resistance to
deformation.
The improved electrical assembly for use in wiring a building is
provided for use in housing (or commercial, industrial building) walls
and partitions of the type having an interior of a foa1ned, synthetic
polymer material.
The preferred forrn of the asse~bly includes a raceway having an
extruded three-sided shell of generally G-shaped cross-section and a
fourth side comprising an elongated generally rectangular cover. The
cover has a slotted l~wer edge which receives an upwardly extending lip
along the lower edge of the shell and is secured to the upper edge of the
shell by screws received through holes in the plate and secured into a
slot forming the forward upper edge of the shell. A decorative snap-on
cover is received over the raceway cover.
Axially aligned raceways are secured to each other by means of
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a flat bonding strip overlapping adjacent ends of the raceway and secured
to each raceway. An alternative means for securing a pair of axially
aligned raceways to each other comprises forwardly extending L-shaped
members on the rear side of the shell forrning a s10t together with a flat
rectangular strip received in the slots of the raceways and secured to
each by dimpling the L-shaped n~embers.
The raceway in a first wall perpendicular to a second wall inter-
mediate the end of the ~econd wall is jo~ned to the raceway in the second
wall by a bonding wire secured within the adjacent V-shaped slots at the
upper edges of the shells of the raceways. Optionally, the upwardly ex-
tending lip of the raceway overlapped by the other race~ay is removed to
prevent damage to wiring within the raceways,
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Whcn the ~nd of a firf3t wall i8 secured at ri~ ht ~ngle~ to the
~nd Or a se~ond wall, thc openin~ in the raceway of the wall which is
overlapped by the other i~ closed by means of a matching rectangular
plate and pair of plates secured ko the rectangular plate and to the inside
surface of respective shell rear walls.
Access to switch boxes and receptacles is provided by vertic~l
thin wall tubing and connectors received through holes drilled in the
upper wall of the raceway and secured thereto.
After the partitions are assembled on site, ~he raceways are
connected to each other. Power distribution wires are then inserted into
the raceways. Additional wires are inserted in the conduits to connect
the switches and outlets to the power distribution wires. Covers are
secured to the raceways, switch boxes and outlet boxes. The power
dist-ribution wires can then be connected to a source of power.
More particularly there is provided, a method of fab- ;
ricating structural members having opposed major surfaces
and formed of a rigid polyurethane foamed core and a :
skin of a cured, hardened unsaturated polyester completely :
encasing said core as a continuous layer, which method
comprises: placing mold sections in a generally horizontal
position, providing a coating on all inner surfaces of
the mold of a hardenable unsaturated polyester resin .
and fiberglass for foFming the skin of the structural
me~ber at least partially curing said polyester; and then :
introducing into the mold materials which react exothermically
within the mold to form a rigid polyurethane foam filling said
- mold and bonded with the coating on the mold, said mold
~ including a first mold part and a second mold part, each of
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said mold parts having a respective major surface, the coating :::
being furnishea on all inner surfaces of each of the mold parts ~
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while the majo.r surface of each mold part is positionea
substantially horizontally, and, after the coating is so
furnished, the first mold part is connected with the second
mold part to form a mold cavity and then raised to a generally
vertical position such that an opening is positioned on the top
of the m~ld sections ~1. having the coating positioned on the
total boundary of the mold cavity; and wh~rein ~ first insert
is positioned within the mold prior to introduction of the
polyurethane materials and said coating comprises two separate
layers applied by a first coating step which forms a first
layer of a hardenable unsaturated polyester resin and a second
coating step which forms a second layer of a hardenable
-unsaturated polyester resin in admixtur~ with fiberglass, and
wherein the insert is positioned after the formation of the ..
first layer of the coating and before formation of the second :
layer of the coating. -- -
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; BRIEF DESCRIPTION OF THE DRAWINGS ~ :
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- Figures 1, 2 and 3 in combination show different part~ of a single
plant production line layout. The left side of Figure 2 is the area at which ;
~he right side of E'igure 1 terminates, and t~le left side of Figure 3 is the
area at which the right side of Figure 2 terminates. ~
Figure 4 shc~ws a mold half in the horizontal po~ition on the con- ;
veyor and a spray apparatus which applies the outer layer of material.
Figure 5 illustrates the hinges joining of the mold halves.
E'igure 6 illustrates a wall partition in accordance wi~h this inven-
tion having pre-embedded pipes for both hot and c:old water extending 1`
acros~ the wall.
Figure 7 illu6trate~ a wall partition in acc~rdance with thi~ inven-
tion havin~ electrical conduit extendln~ across the wall and a ~witch ~ox
and an s~utlet bo~c located in contact with the s~uter layer.
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Figure 8 illustrates a wall partition in accordance
with this invention having a door opening provided by an in-
sert and having pre-e~bedded electrical conduit.
Figure 9 illustrates a wall partition in accordance
with this invention having a raceway for electrical wires
located across the floor-adjoining side, the open side of the
raceway being flush with the outer layer.
Figure 10 is a cross sectional end view of a pre-
ferred form of the raceway;
Figures lla and llb are each a front elevation view
of a pair of axially aligned raceways with alternative means
for bonding the raceways to each other;
Figure 12 is a perspective view of a pair of race-
ways perpendicular to a third raceway together with a clos-
ure plate and metal strips for closing the end of the third
raceway and means for securing the raceways to each other;
Figure 13 is a perspective view of the means for
-~ receiving and for connecting wires from electrical switches
and outlets to wires within the raceway; and
Figure 14 is a perspective view of a pair of typical : .
wall members having the improved raceways embedded therein.
:. DESCRIPTION OF THE PREFERRED EMBODIMENT
In the preferred production system, high quality
structural members such as walls, roofs, and floors are pro~
duced efficiently in a factory having a foam interior and
good strength characteristics, and with functional elements ~:
built in. These improved features and characteristics are :
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.~ achieved with an actual financial saving in production costs :
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. over comparable prior systems. .:
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'~ C prcfe~I~red ~yHtem is ~ continuous one, but prod~lction can
logically be thought l:o begin with the application of wax or other con-
ventional release agent to the bottom of t:he mold halves 1. A thin
coating of the release agent is ~prayed on the surface of l:he mold parts 1
from the spray applicator 3.
In the final product the layers of one of the mold halves 1 will be
the exterior surface of the wall or thc like produced and the layer of the
other mold half 1 will be the interior surface. As i9 known in the art,
the surfaces of the molds 1 are te~tured to give the desired appearahce.
The interior surface will be formed to simulate a desired interior material
such as wood or stucco or other conventional interiors. The exterior may
simulate building block, board and bat, or other conventional exteriors.
The mold halves 1 are guided by overhead rails 5, to which they
are attached. As the lower ends of molds 1 encounter conve~ror bed 7,
y ~r~ ~uided by bed ~ and ~3y the arop in height of raii ~ to a position
at which the bottom surfaces of the molds 1 are relatively horizontal.
The term horizontal is used hereinafter in the specification and claims
~I to mean any convenient position such that the sprayed ~ c~oatings do not
flow but remain substantially as spray on. The term vertical is used
hereinafter in the specification and claims to mean any convenient posi-
tion such that the foaming of the material introduced into the mold is not
impeded by the angle of inclination.
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When the molds 1 arc horizontal and priol to the location at which
l;hey enter the flrst Foating stations 9, selected internal elements 11
`~ are manually placed in the molds 1.
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A preferred example o such an insert 11 which is placed directly
against the mold surface is a raceway for electrical conduit. Such a
raceway i8 shown In F`igure 9 located across the flow-adjoining side of
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the wall, t]l~ open ~idc of thc racc~vay l>cing flush wil:h the outcr laycr.
Switch boxe~ 66 and outlet boxes 64 are also placed flush again~t the
surface of the mold. The conduit 62 i~ held away from the surface of
the mold by its connections to the raceway 82, switch box 66 and outlet
box 64.~
During production, the inser~s 11 are rested in the mold halves
l. The inserts 11 are stacked conveniently on a stand 15 located between
the two conveyors. Certain of the inserts 11 such as the raceway shown
with reference to Figure 9, does not necessarlly extend across the
entire diameter of the mold.
The mold sections 1 are continuously moved at about 8 feet per
minute. They enter spray stations 9, and in spray stations 9 the surface
is coated with a hardenable polyester sprayed from a nozzle 17 (Figure 4)
reciprocating fram side to side, pe~ dicular to the direction of travel. I~e
polyester is filled with a large proportion of hydrate of alumina or another
comparable filler and the polyester resin itself, when hardened, is
preferably a particularly fire retardant kind (a preferred resin has a B I
rating classification of 26 to 75). The material is applied evenlv over the
inserts 11, and in a quantity so that it will harden to thickness of 1/32
inch with any tolerance variation being toward an increase in thickness.
The materials and spray techniques at stations 9 are basically j
well known and cornmercially emploved. Of course, hardenable materials ¦¦
may function by different mechanisms, such as by reaction at unsaturated
sites or by condensation reactions. One known hardenable material
suitable for use with this invention comprises a liquid polyester material
having double bond sites which react during the hardening phase. Such
specific chemical factors forrn no part of the novelty of thi~ invenffon,
and any satisfactory hardenable material may be employed.
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1~7~367 : ACI 1~3
The 1nolds witll int( rnal elcment~ 11 then Inove into spray
sta~ions 19. ~t sta.tions 19, tllc matcrial applicd is a mixture of 20~o
by weight choppecl glass fiber to 80% hardcnable polyester resin. The
material and technique of application is otllerwise substantially iden~ical
to that of spray stations 9. Such application of a second, under laycr
comprising a n~ixture of glass f;bers and res;n is essentially conven-
tional. The material is applied over all areas, including the internal
elements 11. Applicatiotl is in amounts which harden to a thickness of
1/32 inch with any tolerance variation being toward greater thickness
I~nrnediately past spray stations 19 the applied layers are
promptly traversed by rollers, as is conventional, to remove air bubbles
and other discontinuities from the glass fiber and resin layer. Excess
- material is trimmed from the side of the molds shortly past stations 19
after the material has hardened.
The applied polyester mater;als harden rapidly. As the molds
1 move continuously beyond spray stations 19~ overhead rails 5 progress
upward and the conveyor beds 7 guide the sides of the molds 1 so that
the bottoms are moved to a vertical position. At that time the coated layers
have hardened substantially, thus holding the inserts 11 in place after the
bottom surfaces of molds 1 are moved frorn the horizontal.
Overhead rails 5 take up a horlzontal position at a high level so
that the bottoms of molds 1 hang vertlcal. The molds 1 are then brought
together manually to form the completed mold. As indicated in Figure 5,
each mold 1 eontains one of two parts 25a and 25b of a hinge mechanism
25, which mechanism may simply comprise external sockets adapted to
be 1nterleaved, through which a pin is then rnanually inserted. The two
molds are joined to form the hinge 25, pivotcd together on hinge 25, and
held together on the ~ide away from the hinge 25 by a latch 27 or the like,
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all wl~ile still susp~ncl~c1 fro-n tl1e rails 5. l~n intornal molcl cavity
is l:hus forrned ~vit:h the hardened laycrs on thc boundary of the c:avity.
Th~ combined n~old~ 1 then ~n~:er th~ e1Ongated curing oven 29.
Oven 29 simply applies a 150 F 170E~ environmcnt~to the molds 1. The
elevated telnperature prol~ol:es fulther curing of the applied hardenable
layers. The sarne operation brings the parts in which the core will be
created by foa1~ing to an elevated temperature, which has been found in
accordance with this invention to produce very significant advantages.
The molds 1 leave the curing oven 19 and immediately reach the
foam material introduction scation 31. The preferred material used is
a con~entional ~aterial which reacts exothermically while in the molds
to produce a foamed polyure'chane. The reactive materials are intro-
duced into the mold cavity in a liquid form through two or more open
ports left in the 'cop, as is basically conventional. Injection is preferably
by a machine controlled froth or pour method o~ a pre-measured amount
for the particular r~old. The operator need only note the mold type and
push a button to dispense the proper amount. ~Injection is at not more
than 50 pounds per minute per port to prevent splashing. )
Since the molds 1 are vertical, the material drops between the
coated sides. As the automatic foaming reaction proceeds, the foamed
product rises to the top and a small part may expand out through the
open ports through which the foamable material was introduced, which
is subsequently trimmed away~
The polyurethane foaming operation and product is conventional.
Commercial materials are employed. The foarn rises freely to form a
foam solid of final weight densi'cy of 2. 0 to 2. 5 pounds per square foot.
The reaction is ~elf init1atir1g and susl:ailing, and exothermic, Tempera-
tures within the rnolds ri~e to about 300 E~. The reaction is fully com-
.
pleted in about 25 minute~, while internal pres~ure ri~e~ to 15 pouncls
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per sq~l~rc inch in 5 to 8 mi nutes and drops to ~ero within 25 minutes.
Durin~ tlle ~ime o~ e reaction, tlle n~olds 1 move bet~een t~ro,
long facing ro~vs of closely spaced, vert;cal rollers 33. The rollers 33
provide support to the bottoms of the ~nolds 1 against the internal pressures
produced by the foaming reaction ~nd also provide a conveying device
through which the Inolds 1 are progressed while the continuous production
proceeds. Such a roller configuration, used ~imilarly, is known in the
art. The rollers 33 are driven directly~,vhile the overhead rails 5 are
passive. The rnolds 1 filled with the foaming material are held in the
conveyor rollers 33 thirty to thirty-five rninutes to assure l.hat complete curing
has occurred while the molds 1 are supported.
The preheating of the molds I in oven 29 produces rignificant ad-
~rantages over the prior art. The internal, foarned product serves ~s a
~tructural support for the completed member. Studies incident to the
making of this invention have established that the polyurethane foam as it
I ~` forms on the coated surfaces at ambient temperatures drags, sticks, rolls,
and peels. The resulting bond between the foam and the coating is weak.
When &e temperature is raised in accordance with this invention, the
foam appears to form in its final position on the layers bounding the mold
cavity and the final bond is strong. This is highly significant since the
strength of the bond between the core and the outer layer has been a basic
problem in the prior art.
When the molds leave the vertical rollers 33, the mold halves 1
are separated. The fiDished product ir grasped by a suction cup or the
like of a conveyor 35, and moved aside to a storage area. The mold halves
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1 are normally conveyed directly through another cycle as described.
;, The wall~ and other members are manufactured directly in sizes
desired fbr complete housing units. In prar ticc, walls would generally be
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coIlstructed in dilnensions fro~n 11 fcet long ancl 2 to 4 inch(~s thick
to the san~e thicIcness at Z0 feet in length. To reduce the lerlgth pro~
duc~d, the sarne molds 1 may be used in conjunction~with appropriate
- dividers 11 positioned at an end so as to shorten the effective length
of the n:~olds 1.
VlThere internal elements, such as elcctrical junction bo~es. are
to be accessible from the outside, the outer skin to thern is simply
trin~med away with a knife. In the case of the raceway shown in Figure 6,
the raceway is automatically exposed since it was originally pl~ced
against the mold surface before the first layer of hardenable polyester
is applied.
A typical member 51, a wall member, having water pipe pre-
embedded i8 illustrated in Figure 6. The outer layer of the wall 51 is a
hardened polyester about 1/16 inch thick. More specificalIys the extreme
outer layer is a polyester filled with a large proportion of hydrate of
alumina or a comparable filler~ the polyester resin itself being of a
flre retardant kind having a B rating classification of 26 to 75. The layer
is l/32 inch thick with any tolerance variation being toward and increase
in thickness. Intimately bonded to the extreme outer layer is a layer of
20% by weight chopped glass fiber and 80% hardenable polyester resin.
That layer is also l/32 inch thick with any tolerance variation being
toward greater thickness.
The outer layer of polyester in the preferred embodiments
illustrated extends around the entire partition such a~ wall Sl. A searr
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line~ 52 appears in the preferred embodiments which results from two
halves being joined during the assembly process. In a preferred
a~9embly proce6s two molds, each carrying the partially hardened
polyester outer layer for onc h21f of the fini~3hecI partition, each including
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all of one of the two large surfaces, are held together with the
items to be embedded positioned in the mold cavity formed.
The completed mold is positioned so that the large sides are
vertical. ~Iaterial which reacts ~o form a foam polymer is
inserted into the cavity and the foaming reaction occur~.
The outer layers are bound to the final item by the internal
foam and also possibly somewhat by the intermingling of
material where it touches during the final hardening.
The mold cavity is elevated in temperatuxe at the time of the
foaming reaction, which results in improved ~trength and other
physical chaxacteri~tics.
In the wall member 51 a hot water line 53 and a cold
water line 55 extend across the length of the wall 51. They
are spaced somewhat from one another and are positioned
approximately centrally across the diameter of the wa~l 51.
In a typical memher 51 the wall would be about two inches
thick and the lines 53 and 55 would be about one ~nch from both
the front and back surfaces. The line~ have extensions 53a
and 55a which ~xtend out for connection to a facility requiring
: 20 plumbing, such as a vanity.
The polyurethane may be a commercial material,
preferably foamed to form a foam solid of final weigh~ density
of 2.0 to 2.5 pounds per foot of volume. In a preferred
process the mold cav1ty is pre-heated to 150~F-170F.
~he ~oaming operation is self sustaining and exothermic, and a
strong bond results between the foam core pxoduced and the
outer, polyester layer.
~ Embedded water llnes are pre-tested ~or leak~ before
: use in a partition member. Walls with waste line are ~ade
- 30 thick enough to contai~ 3 or 4 i~h line~.
- Figure 7 illu~trate~ ano~her wall member 60 which
is identical in many re~pects to that of Figure 6~ ~he wall
60 of Figure 7 ~ontains
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~7~3~7 A C I F 3
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electrical concluit ~2 connectcd to all el{~ct:rical outlel; box 64 ancl
an elcctrical switch box 6h. The condu;t 62 is a small pipe, which
may be metal or plastic depending on structural rcquirements and
-building codes and other factors. The conduit 62 terminates in the
boxes 64 and 66 50 that wires may be exlended through the condui1: 62
and enter the boxes 64 and 66
The boxes 64 and 66 are embedded in the outer layer of the
member 60. Specifically, in a preferred process, a mold is first
coated with the outermost la~ers, as described in connection with Figure
6, comprising alumina or equivalent filler and material hardenable to a
polyester. When 1;hat has hardened somewhat, iunction boxes 64 and 66
are rested in the pre-established positions for them. Then the layer of
glass fiber filler and a material hardenable to a polyester is applied
over the boxes and allowed to harden.
The conduit 62 is held by the boxes 64 and 66, spaced somewhat
internally of the polyester outer layers. After the partition member is
formed, the part of the outer layer outside of the boxes 64 and 66 is
cut away around the boxes 64 and 66 to leave an opening to them. The
` ifoam polyurethane which fills the internal area supports all of the elements
62, 64 and 66 in the final partition member 60.
The conduit 62 includes a set screw connector 68 on one end l;o
facilitate connection with the conduit of an adjoining wall member. Braces
or guide elernents, not shown, may be employed for maintaining a pre-
determined position for the end~ of the conduits as they exit tbe member 51.
Figure 8 illustrates a different wall member 70 which is ~lso -
identical in many respects to that o Figure 6. The wall 70 of Figure 8
contains a doo- opening 72 provided by a door frame in~ert 74 positioncd
acro~s the diameter of the wall 70.
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The door framl: 7~1 pIovides a porla.l Ihrou~ll the wall 70. Framc
7~ may he of esc.,entially convent;onal form and of material to provide the
appearance desirecl, such as wood or an imitation wood. In contact with
internal po;nts of frame 7a, and extending out into the foam interior from
the frame 74 are several braces or guides 76. These resist movement
of the frame 74 by e~ternal forces
Construction such as that of the door is basically similar for
other elements which extencl completely across the partition, particularly
for windows. In the preferred pI~ocess for construction by assembly line,
the frame insert 74 is rested in the mold before any of the material which
forms the ou-ter polyester layer is applied. The braces or guides 76 are
then wedged firmly between the frame 74 and the sides of the mold. The
internal foam forms around the braces 76.
Both Figures 8 and 9 illustrate variations in electrical element
positioning and the use of a lower raceway to insert wires. The elec-
trical boxes 64 and 66 and the conduit 62 are mounted as described in
connection with E'igure 7. In Figure 8 the conduit 62 is positioned in
a path around the door 72. An exterior light outlet box 78 is located at
the top, right-hand corner of the door 72.
Adjoining the floor on the sides of the door 72 in Figure 8 and
acro.ss the entire bottom of the wall 80 in Figure 9 is a raceway or open
face channel member 82, which is embedded in the wall partition where
it meets the floor. In Figure 8 one member 82a and another member 82b
i8 positioned on each side of the door. The raceway is conveniently ex-
posed on one major surface of the wall B0 and on the bottom surface of
the wall 80.
The raceway members 82 are elongated elements, preferably of
a material such as aluminurn, with square or rectangular cross section.
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~n opcn sidc, which ~il] ull;;lnatc!ly l~e closed by an inscrt or ~pecial
mokling, is flu~h with (:he outer side s~f tlle wall partition 70 or 80.
The raceway metnber 82 can accommodate large amount~ of electrical
wire, which can be c~asily in~3talled Oll location through the open front.
Finally, with regard to all members in accordance with this
invention, the embedded items having an independent function are
normally installed at predetermined locations defined by the locations
desired for efficient production of housing by assembly of the partition
memb~rs. Electrical outlets and the like arc accordingly installed in
final position. Items which are to be connected, such as conduit and
pipe, are located where they will come together with a minimum of
adjustment or additional steps.
The foam, polymeric interior when formed is a strong solid
which supports and holds in place all of the embedded items.
The raceway 110 of Figure 10 preferably comprises an extruded
aluminum section 111 and an aluminum cover plate 112. The section
.~ .
111 is generally C--shaped in cross section and can be generally
rectangular or square. The bottom 113 of section 111 h,as an upwardlsr
extending lip 114 at the free edge thereof. The top 115 of section 111 has
.~ . .
a forwardly extending slot portion 116 adapted to receive and engage the
threads of screws 117.
~, The lower edge of cover plate 112 has an upwardly extending
slot port1on 118 adapted to receive the lip 114. The lip 114 and slot ~ -
portion 118 are preferably rectangular for non-slipping engagement
when assembled on site. The upper part o~ cover plate 112 has holes
tllrough which screws 117 are received to secure plate 112 to the section
. 111.
An extension 119 is provided at the upper edge of cover 112 and
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~.~71.3f6~ A C I E' 3
h~8 a rourlde~l ecl~e for receivin~; a matillg curvcd end of a snap-o
decorativc cove1 plate 120. Thc inside edge 121 of the lower ex-
tremity lZZ of cover plate 112 is tapered to receive the lower curv~d
edge of the decorative cover plate 120.
Suitable dimensions of a comrx~ercial form of the raceway 110
are as follows: external height and width of section 11, 1. 5" and 1. 2$";
thickness of section 11, 1/8"; depth of slot 16 section, 7/16"; height of
lip 19, 1/8"; height and thickness of plate 112, 2" and 3/32".
As seen in Figure lla~ two a}~ially aligned raceways llOa and
l lOb are butted together by a flat, rectangular plate 125 and screws 126
and 127 received through holes in plate 125 and secured to the inside of
the rear walls 128a, lZ8b of raceways llOa, llOb.
Figure llb illustrates an alternative method of butting raceways
llOa and llOb to each other. In this embodiment, channels 130a, 130b
are Iormed on ~he rear waiis i~a, 1~b during extrusion of the sections
llla, lllb of the raceways llOa, llOb. A flat, rectangular plate 131 is
received in the adjacent ends of the channels 130a, 130b and is secured
by dimpling the overlapping channel forming members, e. g. by tapping
sharply with a nail and hammer on-site.
As seen in Figure 12, perpendicular raceways llOa, llOd have
their abuttinL~ ends preferably joined by means of a closure plate 132,
an L-shaped plate 133 and a flat, rectangular plate 134. The closure
plate 13Z has outer dimensions matching those of section llla to close
the opening at the end thereof. Plates 133, 134 are secured to the plate
132 and to the inside surface of the rear walls of sectionsllla, llld by
means of screws 135. Bonding wire 136 in slots 116a, 116d is also used
to join the raceways llOa, 110d.
Chànnel~ (not ~hown~, such as 130a, 130b (~igure llb) on closure
plate 132 and the raceway sections llla, 111d can be l1sed alternatively to
Pa~e 21
secure the closure plate 132 to the raceways llOa, llOd. The
section 114a of lip 114 is cu~ away to prevent damage to wiring.
When a raceway llOc, abuts the raceway llOa inter- -
mediate its ends, the sections llla, lllc are joined on-site by
a right-angle bonding wire 137 placed in slots 116a, 116c before
the cover plates 112a, 112b are secured in place~ The portiGn
- 114c of lip 114a is removed to prevent damage to wiring (not
shown) in the raceways.
. Figure 13 is an enlargement of the pre~erred means
: 10 for connecting thin wall conduit 140 to the top 115 of raceway
. 110. A hole is drilled in the top 115 and the lower portion
141a is forced (or screwed~ through the hole until a flange
portion 141c engages the upper portion ~41b of the connector
and is ~ecured by dimpling of the upper portion 141b at 141d.
As seen in Figure 14, the conduit sec~ions 140a 140d
connected to conventional ~witch boxe~ 143a, 143b and electrical
outlets 144a, 144b respectively. Raceways llOa and llOb are
. pre-embedded in a stxuctural wall 150. ~ raceway llOc is
: pre-embedded in a structural wall 151. ~he walls 150 and 151
are of the type whi~h are fabricated on an assembly line~
The walls in a preferred form have thin (e.g~ 1/16") fiberglass
skins filled with polyurethane foam. .:
Prior to fabrication of the wall 150, the electrical
switch b~x 143a and outlet 144a are attached to the raceways
llOa and llOb by conduits 140a and 140c. An external light
; outlet box 145 i~ connected to the ~witch box 143a and the
outlet box 144a by conduit sections 146a, 146b. The conduit
sections are secured to respe~tive boxe~ in any conventional ~;
manner, e.g. a threaaed condult end and mating female socket.
~- 30 The interior skin o~ the wall lS0 i~ ~prayed on one
- of two m2ting mold halv~s ~not ~hown~ during assembly line
f~bri~ation. The electrical
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ass~lnbly, corIlprising the laceways llOa and llOb, tllc SWitCtl box 1~3~,
outlets 144a alld 145, and conduit sections 140a, 140c, 146a and 146b,
i8 sccured in position with tlle one mcld half. The other mold half
(not shown) with thc exterior skin ifi joined to the one mold half and the
inner cavity is filled Witll tlle synthetic polyureth2.ne and a foaming re-
action occurs. The hardened foarn supports the electrical assembly se-
curely in place. It will be appreciated that other internal members, e. g.
water, gas lines (not shown) are also formed and held in place within the
hardened foam core.
The electrical assembly including raceway llOc, switch box
143b, outlet 144b and conduit sections 140b and 140d are preferably pre-
assembled in wall 151 in a sirr~ilar manner.
The forward edges of the raceways llOa and llOb and the raceway
llOc are flush with the interior surfaces of walls 150 and 151. The
forward edges of the open sides of switch boxes 143a, 143b and outlets
144a, 144b are preferably flush with the interior surfaces of walls 150,
151. Decorative cover plates (not shown) are secured to the boxes 143a,
143b and outlets in overlaying relation and abut against the interior wall
surfaces. The outlet box 145 is preferably flush with the exterior sur-
face of the wall 150.
Standard 1. 25" deep switch boxes 143a, 143b and outlets 144a,
I44b and 145 are preferably used. The conduit sections are secured so
that they are 1/2" behind the interior wall surfaces, thereby preventing
~hadows in the wall.
I
To assemble the wiring in a buildin~, the wallfi such as 150 and
151 are all assembled on site. After the walls are in place and assembled,
the required power distribution cablos are laid in all of the raceway~ fiuch
a~ llOa and llOb. The required conn~sctions between abuttirlg raceways are
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iL0~71367 A C~ F3
m~d~ a~ OW~ il] Fil7111eS 11a ~InCl 1Z and t:hC~ reqllired C10S~Ire P1.1tCS
132 arc installed.
The wiring for each switch box 143 alld electric~l outlet 144 i9
dropped through the box or outlet and through its co~duit so that its
lower ends are exposed in the raceway below. The upper ends are con-
nected to the connector blocks such as 160 (Figure 13), and the lower en:ls
are connectecl to the appropriate wires 161 of the distribution cable by
splicing or ~y s~curin~ quick-attach connectors (not shown) on the wires.
The decorative cover plates are secured to the switch bo}{es and to the
outlel:s. Finally, the cover plates such as 112 are secured to the race-
way shells as shown in Figure 1 and the decorative covers 120 are
snapped on over the cover plates. After this the power distribution cable
can be connected to the power supply at the fuse or circuit breaker box
(not shown).
If any of the walls have internal conduit s~ch as 146, it is neces~
~ .
sary to pull the wiring from the switch box 143a and outlet 144a to the outlet
tS
' 14~.
.
Since the raceways 110 extend to the ends of the walls and their
alignment is assured, there is no need to cut conduits to desired lengths
or bend them to required shapes. No junction boxes at wall junctions are
required, nor does the previous requirement of splicing wires at junction
boxes exist. Consequsntly, the time consuming on-site labor is eliminated.
The embedded conduit sections 40 are all straight pieces of standard
length minimizing labor during the assembly-line fabrication. Alignment
problems are eliminated. The total length of conduit i9 substantially
reduced.; Design and pl~nning is mlnimized. Standard minimum size
electrical boxes are ùsed. -
Since switch boxe~ and outlets are at s~andard heights, pre-cut
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wirc harlle6~el willl quiclc-cltl~ch connectors can be utilized to the
fullest advantage.
Kitchen walls having built-in cabinets and the lilce do not require
the race~vays since the condu;l; is hidden and the wiring and outlets can
be pre-assembled at the factory.
Wiring repairs are easily made by merely removing the decorative
cover and cover plate from the raceway shell to gain access to the
power distribution cable.
Finally, with regard to all members in accordance with this
invention, the embedded items having an indepenclent function are
normally installed at predetermined locations defined by the locations
desired for efficient product;on of housing by assembly of the partition
members. Electrical outlets and the like are accordingly installed in
final position. Items which are to he connected, such as the raceway,
are located where they will come together with a minimum of adjust-
ment or additional steps.
The foam, polymeric interior when formed is a strong solid
which supports and holds in place all of the etnbedded iterns.
Because of the materials ùsed, the final structural member is
highly resistant to moisture, insects and other organisms, and fire.
It is strong and does not warp, and it exhibits very high thermal,
acoustic~ and electrical insulative values. Additionally, it is virtually
free of corrosion and need for maintenance.
The expense of fabrication of the structural member is quite
satisfactory when it is produced in accordance with this invention.
.~ .
Employment of the product for most building applications and uses
appcars to be practical in all respects, including econotnic factors and
technical requirements, and this invention is accordingly considered to
be a very~benefic~ial contribution to the housing industry
Pa~c 2:
31Fi~
Variations of the invention deseribed will be ap-
parent, and variations may well be developed which employ
more than ordinary skill in the art involved, but which
nevertheless employ one or more of the basie eontributions
and elements of the invention. Accordingly, patent protection
should not be essentially limited by the preferred aspeets
diselosed, but should be as provided by law, with particular
reference to the accompanying claims.
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