Note: Descriptions are shown in the official language in which they were submitted.
~8457~
RAPID ASSEMBLY BUILDING SYSTEM
FIELD OF T~E INVENTION
This invention is directed to a novel building
system which utilizes prefabricated components to enable
a completed building to be erected Erom the components
in a very short time.
BACKGROUND OF THE INVENTION
Techniques used to construct buildings in
western civilization, particularly residential homes,
are highly labour intensive and hence expensive. In
some cases, the labour cost can be 50 to 60 percent of
the total building cost. The cost of a finished build-
ing would be reduced substantially if the labour cost
could be reduced.
One approach to reducing labour cost is to
prefabricate at least some of the building components at
a factory under assembly-line conditions. This approach
includes constructing interior-exterior wall panels and
roof panels as units, which can then be assembled with
minimum labour input at the site upon which the building
is to be erected.
A number of building prefabricated and quasi-
prefabricated construction systems are disclosed in theprior art. The applicant is aware of the following
references which disclose constructions or systems which
are more or less relevant to this invention.
4571
United States
Patent Number Issue Date Inventor
3,145,504 August 24/64 J.B. Dunnington
3,236,014 February 22/66 N. Edgar
3,665,664 May 30/72 C.C. Watson
3,712,004 January 23/73 Y.H. Loebsack
3,783,563 January 8/74 C.M. Moore
4,147,004 April 3/79 S.W. Day et al.
4,163,349 August 7/79 G.W. Smith
4,435,928 March 13/84 E. Hulling
4,443,988 April 24/84 W.H Coutu, Sr.
U.S. Patent No. 3,145,504, Dunnington, at
column 2, lines 29 through 32, mentions a panel con-
structed of rigid polyurethane with plywood facings.
U.S. Patent No. 3,665,664, Watson, also teaches building
panels constructed of plywood outer faces with a suit-
able foamable material such as polyurethane admitted
between the facings (see column 3, lines 32 to 35).
U.S. Patent ~o. 4,174,004, Day, discloses a
building sandwich panel construction comprising "plywood
skins or facings" with expanded foam insulation (see
column 1, lines 43 to 65). Day's panels include top and
bottom plates, 12 and 14, which are positioned between
the top and bottom edes of the skins or facings 18 and
20 to provide a cohesive unit.
U.S Patent No. 3,712,004, Loebsack, at column
2, lines 49 to 62, discloses specifically a building
panel of standard size, measuring four feet in width by
eight feet in length, constructed of plywood outer
facings and a rigid foamed plastic interior. Such foam
interior could include rigid polyurethane foam because
this type of rigid foam was a well-known rigid foamed
plastic at the time. Loebsack teaches the use of a
spline member 11 at each joint with the spline member 11
4571
being positioned between the face members 6 and 7 of
each of the adjacent panels and engageable with the core
members 8 of each of the adjacent panels to be secured
together (see column 3, lines 15 to 23).
In Loebsack, the entire building is con-
structed of sandwich panels which cooperate in unison to
form a structural unit. The sy.stem involves erecting
the walls using a studless building panel construction,
the panels being constructed of high quality exterior
grade plywood with a rigid foam plastic core. The
building construction utilizes laminated floor, wall and
ceiling panels. The building can be constructed either
as a single story unit or as a multiple story unit,
lS without the use of studs and joists. The building can
be constructed to include a sloping roof (see column 5,
lines 43 to 54). The floor panels, wall panels and
ceiling panels are constructed to have standard four
foot widths and eight foot lengths as disclosed at
column 2, lines 43 to 47.
U.S. Patent No. 3,236,014, Edgar, discloses a
basic building construction which is constructed of
panels which may form the floor, walls and roof of the
building. Each panel has an integral joint component
which permits adjacent wall panels to be connected
together. The system is essentially studless and joist-
less. The building employs a sloped roof, the crown
being supported by a ridge beam member 57. Trusses are
also used in supporting the roof. The panels can be
constructed of various materials, including plywood
facings, and synthetic resin foam core (see column 5,
lines 5 to 9). The panels are connected together by
corresponding female and male joints as illustrated in
specific detail in Figure 13.
~45~71
~ .S. Patent No. 4,163,849, Smith, in Figure 4,
demonstrates a groove in a foamed core of a foam sand-
wich panel. U.S. Patent No. 4,443,988, Coutu, in the
background art portion of the disclosure, in column 1,
states at lines 35 to 48 that a system of interlocking
two panels together with splines which run lengthwise of
the abutting edges of two adjacent panels, fitting
within grooves routed or milled out of the insulating
material, half of one spline being accommodated in one
panel and the other half of the spline being accommo-
dated with a mating groove in the adjacent panel, is
known. Coutu points out a number of disadvantages with
such a system and advocates his own design involving a
two-spline system.
SUMMARY OF THE INVENTION
This invention is directed to a novel poly-
urethane foam-plywood or chipboard sandwich panel,
including the building which is constructed from such
panels, and in particular, a novel technique of forming
a very strong building sandwich panel by cutting a
chipboard or plywood-polyurethane foam sandwich panel
into long strips and using such strips as structural
reinforcing spacer-beams in wall and roof panel systems.
Other suitable materials such as gypsum wallboard,
siding, wood, plastic sheet, and the like, can be
utilized as one or both of the exterior skins of the
strips on the overall panel. The strips are rotated 90
degrees relative to the main chipboard or plywood
exterior surfaces of the wall or roof panel so that the
exterior skins of the strips per se are oriented perpen-
dicular to the exterior skins forming the wall or roof
panel. The strips are spaced at parallel intervals
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throughout the interior of the wall or roof panels and
are adhesively knitted to the exterior skins of the
panels by foaming polyurethane foam into the spaces
between the strips and the chipboard or plywood exterior
skins. This construction greatly increases the strength
of the panels forming the wall or roof panels and enable
free spans of up to 32 feet to be obtained.
The invention is directed to a panel for use
in constructing a building comprising: (a) a first
exterior skin means; (b) a second exterior skin means;
(c) at least one spacer means positioned between the
first and second exterior skin means, said spacer means
comprising a pair of skin means having a plastic foam
insulation means therebetween, the pair of skin means
being oriented perpendicular to and extending between
the first and second exterior skin means; and (d)
plastic foam insulation means located between the first
and second exterior skin means and the spacer means.
In the panel~ at least two spacer means may be
located between the first and second exterior skin means
and the pair of spacer means extending substantially the
length of the first and second exterior skin means. The
pair of spacer means may be located at each side of the
first and second exterior skin means. Longitudinal
extending notches may be formed in the exterior facing
surfaces of the pair of spacer means located at each
side of the first and second exterior skin means. At
least one further spacer means may be located between
the pair of outside spacer means.
The spacer means may comprise two planar wood
sections which enclose on two sides a rigid plastic
insulation foam which is foamed in place before the
lX84571
spacer means is installed between the first and second
exterior skin meansO A spacer beam means may be located
between the first and second exterior skin means at each
end of the panel. The end spacer beam means may include
therein a port for enabling insulation foam to be foamed
in place in the spaces formed between the first and
second exterior skin means and the longitudinally
extending spacer means.
In the panel, the foam may be foamed in place
rigid polyurethane. The panel may include an interme-
diate laterally extending spacer means between the
respective end spacer beam means.
The invention is also directed to a joint
assembly which joins together two adjacent sandwich
panels comprising: (a) a first sandwich panel having
disposed along one side thereof a pair of spaced apart
longitudinally extending strips oriented vertically
relative to the exterior skins of the sandwich panel,
with rigid plastic foam insulation disposed in the space
between the two longitudinally extending strips, the
exterior edge facing longitudinally extending strip
having formed therein a longitudinally extending
groove; (b) a second sandwich panel having disposed
along one edge thereof a pair of spaced apart longitu-
dinally extending strips oriented vertically relative to
the exterior skins of ~he sandwich panel, with rigid
plastic foam insulation disposed in the space between
the two longitudinally extending strips, the exterior
edge facing longitudinally extending strip having formed
therein a longitudinally extending groove; (c) the
first and second sandwich panels being disposed so that
the two longitudinally extending grooves face one
another, a longitudinally extending strip being posi-
~84571
tioned in the space formed by the two facing notches;
and; ~d) means securing the two adjacent facing panels
to the longitudinally extending strip positioned in the
two adjacent grooves of the adjacent panels.
The securing means may be nails which are
driven from the exterior of the adjacent facing panels
into the elongated strip positioned in the adjacent
grooves of the adjacent panels. The sealing means may
be located between the facing edges of the two adjacent
panels.
The invention is also directed to a corner
connection for two adjacent sandwich panels comprising:
(a) a first sandwich panel comprising two exterior
skins, with an intermediate rigid plastic insulation
foam therebetween, the edge of the side of the panel
having disposed between the two skins at right angles a
pair of longitudinally extending strips extending
substantially the length of the sandwich panel, a rigid
plastic foam insulation foam located between the two
longitudinally extending strips, and one exterior skin
of the sandwich panel extending beyond the location of
the two longitudinally extending strips; (b) a second
sandwich panel comprising two exterior skins, with an
intermediate rigid plastic insulation Eoam therebetween,
the edge of a side of the panel having disposed between
the two skins at right angles a pair of longitudinally
extending strips extending substantially the length of
the sandwich panel~ a rigid plastic foam insulation foam
located between the two longitudinally extending strips,
and an interior facing skin being cut back to expose the
two longitudinally extending strips; (c) an angled
strip placed over the corner formed by the two adjacent
sandwich panels and extending substantially the length
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of the corner formed by the two adjacent sandwich
panels; and (d) means fastening the angled strip to the
two adjacent panel means and securing the two panel
means together in a corner configuration.
The securing means may be nails which are
driven from the exterior to the interior of the adjacent
facing panels. Sealing means may be located between the
facing sides of the two adjacent panels.
The invention is also directed to a building
constructed from at least one of the above-described
panels.
DRAWINGS
In the drawings, which illustrate specific
embodiments of the invention, but which are not to be
interpreted as limiting the scope or spirit of the
invention in any way~
Figure 1 illustrates a top section view of a
wall panel assembly;
Figure 2 illustrates a side view of a wall
panel assembly
Figure 3 illustrates a top section view of a
roof panel assembly;
Figure 4 illustrates a side view of a roof
panel assembly;
5'~L
Figure 5 illustrates a side section view of a
wall panel to roof panel connection;
Figure 6 illustrates a side section view of a
wall panel to floor connection;
Figure 7 illustrates a side section view of a
roof panel to roof panel connection;
Figure 8 illustrates a side section view of a
wall panel to wall panel corner connection;
Figure 9 illustrates a roof panel to roof
panel crown connection;
Figure 10 illustrates a wall panel to wall
panel connection;
Figures 11, 12, 13, 14, 15 and 16 illustrate
perspective views of a building being erected utilizing
the novel components and techniques of the invention;
Figure 17 illustrates an exploded view of the
various components of the building system invention;
and
Figure 18 illustrates a perspective view of a
residential home constructed according to the building
system invention.
DETAILED DESCRIPTION OF SPECIFIC
EMBODIMENTS OF THE INVENTION
The applicant has invented a novel prefabri-
4571
cated modular building, utilizing stressed skin polyure-
thane sandwich panels on a four foot module. The panels
are used to form wall sections, free spanning floor
units and free spanning roof panels. To date, two
experimental homes have been designed and constructed
utilizing this system and have been fully accepted by
the building inspection and engineering departments of
their respective municipalities. These departments have
examined the experimental homes to ensure conformance
with the National Building Code of Canada, the
Provincial Building Code and the Municipal Building Code
and Bylaws.
The prefabricated panels can be assembled in a
variety of configurations conforming with conventional
home designs and layouts. The panels have considerable
strength, both as compression load bearing members and
as free spanning floor and roof units. Overall stabil-
ity of the building is provided by novel secure connec-
tions between the panels. Stability against wind andearthquake is provided by the configuration of interior
crosswalls. The structural designs disclosed herein are
sufficient to cover all aspects of normal building
design within the terms of the National Building Code of
canada-
Essentially, the applicant's overall building
system is based on a novel sandwich panel construction
formed of facing exterior skins of gypsum wallboard,
plywood, or other suitable materials with a core of
foamed-in-place rigid polyurethane foam, with spacer
beams, which together provide a panel having excep-
tional strength, stiffness and built-in insulation
qualities.
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~457~L
Referring to the drawings, Figure 1 illus-
trates a top section view of a basic wall panel assem-
bly. The wall panel 2 is constructed of an interior
skin 4, which is typically gypsum wall board, and an
exterior skin 6, which is typically aspenite (a wafer
board formed of aspen chips and a phenolic resin~,
plywood, or the like. Four spacer beams 8 are distri-
buted throughout the width of the wall panel 2. The
spacer beams 8 are also shown in parallel orientation in
Figure 2, which illustrates a side view of the wall
panel assembly 2. Typically, the wall panel 2 is con-
structed so that it measures eight feet in length and
four feet in width. This matches standard North
American construction industry standards, and thereby
enables the panels to be combined with and utilized in a
standard building system environment.
The construction of the spacer beam 8 is novel
and in combination with the interior and exterior skins
4 and 6, provides exceptional strength to the overall
wall panel assembly 2. The spacer beams 8 are con-
structed by first forming a large sandwich panel of two
skins 8 and 9~which have disposed between them foamed in
plac~ rigid foam insulation 12. Typically, the insula-
tion 12 can be rigid foamed in place polyurethane whichhas good insulating qualities and adheres well to the
exterior skins 8 and 9. Once the overall sandwich panel
is formed, it is cut into elongated strips to form a
number of spacer beams 8. One novel aspect of the
applicant's system is that two or more of these spacer
beams 8 are rotated 90 degrees relative to the interior
skin 4 and the exterior skin 6 of the basic panel 2. As
shown in Figures 1 and 2, there are four spacer beams 8
with eight skins 8 and 9 positioned perpendicular to and
having foamed insulation 12 extending between each pair
~8~S7~3L
of exterior skins 4 and 6. The spaces which remain
between the four spacer beams 8 and the skins 4 and 6
are filled with foamed~in-place rigid foam 10 such as
rigid polyurethane foam. The foamed-in-place foam 10
knits strongly to the skins 8 and 9 which comprise the
exteriors of the spacer beams 8 and the exterior skins 4
and 6. It has been found that this unique construction
of wall panel has exceptional strength per unit weight,
compared to conventional wall panel constructions.
As can be seen in Figure 1, the wall panel 2
has respective notches 14 formed along the longitudi-
nally extending sides of the panel 2. These notches 14
are utilized in one wall panel 2 to the corresponding
~5 longitudinal side of another wall panel 2 in side to
side relationship as will be discussed in further detail
below in association with Figures 7 and 10.
Figure 2 illustrates in side view the con-
struction of the wall panel assembly 2, including the
four spacer beams 8, which are positioned parallel to
one another and extend substantially the length of the
wall panel 2. At the top of the wall panel, there is
located an upper end beam 16, which extends laterally
across the top of the wall panel 2 and fits between the
top ends of the interior skin 4 and the exterior skin 6.
Likewise, at the bottom edge of the panel 2, there is
positioned a laterally extending lower end beam 18 which
fits between the bottom ends of the interior skin 4 and
exterior skin 6. The upper end beam 16 and the lower
end beam 18 are each drilled at three locations corres-
ponding respectively with the three spaces 15 that are
formed between the four parallel vertically extending
end beams 8 so as to form foam access ports 20 for each
internal space 15. These ports 20 permit the entry of a
- 12 -
34571
conventional polyurethane froth wand (not shown) and
thereby enables the spaces 15 between the interior skin
4 and the exterior skin 6 to be filled with foamed-in-
place rigid foam 10. These ports 20 not only permit the
insertion of a polyurethane froth wand in the ports 20,
but they also enable yases to esca~e from the spaces 15
so that undue internal pressures are not built up within
the panel 2~ Such pressures might bulge or distort the
overall construction of the wall panel 2, thereby
rendering it unsuitable for construction purposes.
Figures 3 and 4 illustrate in top section view
and side elevation view respectively a typical construc-
tion of a roof panel assembly 22. The roof panel 22 is
formed in a manner similar to the wall panel 2 (Figures
1 and 2), except that different dimensions are typical.
For instance, the length of the roof panel 22 may be
much longer than the typical eight foot length of the
wall panel. This is to accommodate the longer spans
which are typical of roof constructions. Referring to
~igure 3, the roof panel 22 is constructed of a first
skin 24 and a second skin 26, which typically has a foam
core 28 poured-in-place between the three spaces 29 (see
Figure 4) formed by the four spacer beams 30. As in the
wall panel construction 2, the spacer beams 30 are
formed to have two external skins, with a foam insula-
tion therebetween. As with the wall panel 2, the
elongated spacer beams 30 are rotated 90 relative to
the first skin 24 and second skin 26, so that the pair
of skins of the beams are perpendicular to and extend
substantially the length of the first skin 24 and the
second skin 26. Similar to the wall panel 2, the
longitudinal sides of the roof panel 22 have formed
therein respective end notches 32. Also, as is the case
with the wall panel 2, the roof panel 22 has at each end
71
thereof a first laterally extending end beam 34 and
second end beam 36. These respective beams 34 and 36
have foam ports 38 formed therein to permit the inser-
tion of a urethane froth wand into the interior of the
wall panel 22. This permits the three spaces 29 between
the four spacer beams 30 to be filled with foamed-in-
place rigid foam, typically rigid polyurethane foam.
Optionally, but usually in long roof panel construc-
tions, a lateral spacer beam 40 can be positioned and
foamed-in-place across the mid section of the wall panel
22. This lateral spacer beam 40 assists in minimizing
twist which may occur in the wall panel 22 during
construction.
Figure 5 illustrates a side section view of a
wall panel 2 connected to a roof panel 22. The connec-
tion detail is uniquely simple, but provides solid
strength which meets the most rigorous of building code
standards. The roof panel 22 can be formed with an
overhang 42 which extends beyond the connection. The
wall panel 2 to roof panel 22 connection is typically
formed by laying a long cantilever strip 46 along the
top edge of the wall panel 2 (end beam 16). This
cantilever strip 46 has a triangular cross-section which
corresponds with the angle that the roof panel 22
assumes relative to the wall panel 2. Once the roof
panel 22 has been laid over the cantilever strip 46, a
long nail 48 is driven at an angle through the end beam
34 (or end beam 36, as the case may be) into end beam 16
of the wall panel 2. Typically, four long nails are
driven per width of roof panel 2. Then, a metal angle
44 is secured to the interior angle of the wall panel
roof panel connection by means of a series of nails 50.
The horizontal nails 50 penetrate into the cantilever
strip 46, while the vertically extending nails pene-
3457~
trate through the interior face of the skin 24 of the
wall panel 22. This combination provides a solid strong
wall panel to roof panel connection.
Figure 6 illustrates in side section view the
manner in which the base of a wall panel 2 is secured to
the floor 52 of a building. Again, the connection is
very simple, and easy to assemble, but is very strong
and effective. A metal angle 54 is first secured to the
floor 52, which is typically wood, by means of a series
of nails 56. Then, the base of the wall panel 2 is
fitted against the upwardly extending lip of the metal
angle 54. A series of nails 58 are then driven into the
lower end beam 18 of the wall panel 2 through the side
upwardly extending lip of metal angle 54. If reinforce-
ment is required in any way, another metal angle 54 can
be nailed in place at the interior base of the wall
panel 2 where it meets the floor 52.
Figure 7 illustrates in side-section view the
manner in which one roof panel 22 is secured in side-
to-side relationship with a second roof panel 22. A
long spline 60 is fitted into the adjacent meeting
notches 32 of the respective roof panels 22. Once the
adjoining roof panels 22 have been fitted over the
spline 60, a seal such as caulking compound 62 is laid
on one or both sides of the joint against one or both
sides of the spline 60. Then, the two adjoining roof
panels 22 are secured together by driving a series of
nails 64 from both sides of the wall panel 22 so that
they penetrate into the spline 60. This combination
provides a unique strong joint between wall panels 2 or
roof panels 22.
57~
Figure 8 illustrates in top section view the
manner in which a pair of wall panels 2 are secured
together to form a corner connection. It should be
noted that no separate corner post is required. One
wall panel 2 is formed so that it has an overhang 66
which extends essentially the thickness of a typical
wall panel. The interior skin 4 of the adjoining wall
panel 2 is cut away the thickness of a wall panel to
form a cut away corner 72. The combination of the cut
away corner 72 and overhang 66 in combination with
securing nails and beams 8 forms a secure joint which
is self supporting and load bearing and importantly does
not provide any space which extends directly from the
exterior to the interior of the corner connection.
Thus, no separate sealing is required, yet potentlal
drafts are eliminated. A long metal corner plate 68 is
nailed to the exterior corner of the adjoining wall
panels 2 and 2 by means of long nails 69 which extend
respectively from the side through the overhang 68 and
beam 8 and from the top (as seen in Figure 8) through
the coincident spacer beam 8 of the adjacent wall panel
2 with the corner 72.
Figure 9 illustrates in side section view the
manner in which one roof panel 22 is connected to
another roo panel 22 to form the crown of a roof. The
crown connection is cupported on a plurality of vertical
roof supports 74, which in turn support a horizontal
longitudinally extending support beam 76. The weight of
adjacent panels 22 is carried by the roof support 74-
support beam 76 combination by means of a cantilever
strip 84, which is positioned on the top of the support
beam 76. Adjoining triangular shaped wood cantilever
strips 86 are fitted into the angled space formed by the
adjoining wall panels 22. A metal roof cap 78 is then
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nailed to the top crown of the adjacent roof panels 22
by means of long nails ~0 which penetrate down into the
cantilever strip ~4. The wood cantilever strips 86 can
be the same as the cantilever strip 46 which is used in
forming the roof panel to wall panel connection dis-
cussed previously (Figure 5) to reduce costs.
Figure 10 illustrates in side-section view the
manner in which one wall panel 2 is connected to an
adjacent wall panel 2. It will be noted that there are
many similarities to the roof panel 22 to adjacent roof
panel 22 connection discussed previously (Figure 7). A
spline 92 fits in the grooves 14 which are formed in the
adjoining side of the adjacent wall panels 2. Caulking
go is laid against both sides of the spline 92 in the
spaces formed by the adjoining wall panels 2. Long
nails are then driven through the exterior skins of the
adjoining wall panels 2 so that they penetrate the
spline 92, but do not penetrate through the interior
skin 4. This construction provides a strong, well
insulated joint between adjacent wall panels 2.
Figures 11, 12, 13, 14, 15 and 16 illustrate
in sequential order the manner in which a typical
residential building is erected according to the inven-
tion. A horizontal concrete slab or a wood framing
floor used as a foundation is shown in Figure 11. In
Figure 12, the wall panels 2 are shown being erected in
adjacent orientation according to the system discussed
previously in associat,ion with Figures 6, 8 and 10.
Since all components are of standard industry dimen-
sions, standard window frames and door frames can be
readily included in the assembly.
S~l
Figure 13 illustrates the method whereby an
interior stud wall is formed of a series of upright
standing 2X4's (support beam 74 in Figure 9) and panels
to support a horizontal wood beam 76, which extends
along the crown the length of the building. Once the
wood beam 76 has been erected, a plurality of roof
panels 22 are laid in series adjoining the wall panels 2
and the crown 76 as shown in Figure 14. Latterly, as
illustrated in Figures 15 and 16, roofing such as
shingles or the like may be laid over the roof panels 22
and windows and doors can be fitted into the wall panel
window and door frames. An exterior finish such as
aluminum or vinyl siding can be clad over the wall
panels 2. Finally, as illustrated in Figure 16, stan-
dard partitions formed of wall board and additionalpanels or studwork are erected to form rooms in the
interior of the building.
Figure 17 illustrates in exploded view the
various components that can be joined together in order
to form a standard building.
Angle 54 is anchored to the periphery of the
foundation or floor 52. Wall panels 2 are then mounted
in series on angle 54 and nailed or screwed to it.
Splines 92 are placed in respective notches 14 and the
wall panels 2 are nailed or screwed together. Support
beams 3 are installed over all window and door openings.
A continuous cantilever strip 46 is installed on top of
the wall panels 2. Angles 68 are installed at all
corners.
Once the exterior walls have been erected, the
interior load bearing stud walls 74 (to support the roof
panels 22) are erected in accordance with accepted
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571
construction standards. The roof panels 22 can then be
laid on the wall-beam 76 stud wall and the exterior wall
panels 2. The roof panels 22 are nailed to stud wall 76
and wall panels 2 with 4-6" gaw nails per panel. The
metal cap 78 is nailed on to the crown of the roof
panels 22. Angles 44 are nailed to the inside corner
where wall 2 meets with the roof panels 22.
Figure 18 illustrates in perspective view the
type of residential building that can be constructed
according to the applicant's invention. It will be
noted that the building is extremely attractive and it
is difficult to distinguish it from conventional resi-
dential buildings that are constructed according to well
known labour intensive methods.
It can be recognized from the test results
discussed in tabulated form below that considerable
strength is developed through the use of this novel
combination of materials and thus an exceptionally
strong and stable building can be constructed.
EXAMPLE 1
Experimental Model
1. Desiqn
An experimental building was erected according
to the applicant's system in Vancouver, Canada upon an
integral slab type foundation. Overall lateral and
longitudinal stability for the building was provided by
crosswalls of either conventional frame construction or
utilizing panels according to the applicant's design.
-- 19 --
~4S7~
2. _oads
The experimental building was designed to
satisfy Part 4 of the Structural Design Section of the
National Building Code of Canada, 1985 Edition. In
particular, the system was designed to the requirements
of Section 4.1.1.3 which re~uires buildings to have
sufficient structural capacity and structural integrity
to resist safely and effectively all loads and effects
of loads and influences that may reasonably be expected
having regard to the expected service life of the
building. Load factors have been applied according to
the tables and notations supplied below.
3. Panel Specifications
(a) Wall Panels: Exterior skin, 4 ft. x 8 ft.
standard 7/16 inch thick waferboard, interior
skin, 4 ft. x 8 ft. standard gypsum board
sheet, 1/2 inch thick, to CSA A 82-27M 1977.
(b) Roof Panels: Upper and lower skin, 4 ft. wide
standard waferboard sheathing 7/16 inch thick,
to CAN.3-0188.2-M78.
(c) Floor Panels: Similar to the roof panels.
All panelst walls, roofs and floors had 4 -
3.1/2 x 3.3/8 spacer beams inserted
longitudinally to increase strength
characteristics.
(d) Splines and Anqles: 1/2" plywood splines and
angle connectors, 20 gauge galvanized sheet
steel.
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(e~ Urethane Foam Properties:
Density, 2.0 lbs. per cu. ft. as produced by
Polymer Development Laboratories Inc. P.D.L.
210-2 Class 1 NFPA Class A;
Compressive strength, 30 lbs. per sq. in.;
Tensile strength, 30 lbs. per sq. in.;
Percentage closed cells, to 96%;
R factor per inch of thickness, 9.0, shear
strength 35 psi. Thermal Insulation as per
CGSB 51-GP-21M.
(f) Fire Hazard ~_alification:
ASTM E 84, equivalent to CTSB, JP21M 1978;
Flame spread 20; fuel contributed Q; smoked
developed 300; F Permeability rating 2 at 74
degrees F; STM 355.
4. Buildinq System Characteristics
(a) Assembly
The assembly of the panels into an erected
finished home did not require any large or
specialized equipment. The panels could be
handled manually and lifted into place by a
normal crew of carpenters and labourers.
(b) Connections
The connections of the various joints and
supporting edges of the panels, designed in
accordance with generally established theory,
utilized steel light gauge angles, wood screws
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57~
and spikes of conventional size. The calcu-
lations and results presented in Example 2 of
this application have been developed to
provide safe load capacities for the connec-
tions included in the system.
EXAMPLE 2
_aboratorY Testinq0
The prefabr~cated sandwich panels of the
applicant's system have been individually tested in
conformance with their respective technical requirements
through a comprehensive testing program, organized and5 implemented by Warnock Hersey Ltd.
J.A. Rogers & Associates Ltd., consulting
professional engineers, Vancouver, Canada, conducted a
detailed plant inspection at the time of manufacture of
the test samples. The samples were chosen at random and
clearly identified for shipment to Warnock Herseys'
Laboratory. There they were subjected to the respective
tests. J.A. Rogers representatives were present at the
Warnock Hersey Laboratory at the time of testing and
were familiar with and comfortable with the methods and
effectiveness of the testing.
EXAMPLE 2
Results of Structural Analysis0
Results which are presented below in tabulated
form used the configurations of connections depicted in
the drawings. All wood used in assumed to be Douglas
Fir and steel is assumed to have a yield strength of 40
ksi.
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~34~71
It is emphasized that resistances shown in the
Table below are "allowable" and not ultimate. If com-
bined loadings are to be anticipated, the following
equation should be used:
T/U Applied + S Applied < 1.0
T/U Allowable S Allowable -
Where: T - tension
S = shear
U = uplift
TABLE
Resistance
Construction TYpe Load Type Kq/m lb./ft.
Fiqure 5 Uplift - 276 185
Wall Panel to Shear
15 Roof panel (Horizontal) - 239 160
Fiqure 6 Uplift - 115 77
Wall Panel to Shear
Floor (Horizontal~ - 188 126
Fiqure 7 Tension - 160 107
Roof to Roof Shear
(Horizontal) - 160 107
Fiqure 8 Shear
Wall Panel to (Vertical) - 161 108
Wall Panel ~Corner) Shear
(Horizontal) - 270 181
Fiqure 9 Uplift - 206 138
Roof Panel to
Roof Panel (Crown)
Fiqure 10 Shear
Wall Panel to (Vertical) - 79 53
Wall Panel Tension - 79 53
As will be apparent to those skilled in the
art in the light of the foregoing disclosure, many
alterations and modifications are possible in the
practice of this invention without departing from the
spirit or scope thereof. Accordingly, the scope of the
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7~
invention is to be construed in accordance with the
su`~stance defined by the following claims.
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