Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
WO93/1427X ~1?, ~ ~ 8 0 PCT/US93/00271
IMPR~V~D BUILDING STRUCTURE ~ MET~OD OF USE
f
Fi~ld of the Invention
The present invention relates generally to residential
and commercial building structures and methods of forming
the same, and more particularly to integrated wall, floor
and ceiling structure formed of dimensionally stabile, pre-
manufactured structural elements which are rapidly
assembled in a manner resulting in 2 monolithic building
structure.
Backaround of ~he_Invention
As is well known in the construction industry,
builder~ of both residential and commercial building
structures often face numerous difficulties during the
construction process when utilizing forest products due to
the~ lack o~ dimensional stability inherent with such
products~ In this ~respect~, builders and craftsmen
typ~ically::labo~ wit~the wood in an attempt to shape and
it~ t~e wooden::components~. However, often times the wood
25: :members twi~t,: warp,~:split or :crack during and subsequent
to~completion of~ the~uilding project, thus impairing ~he
: qua:li~y~and appearance~of the building stru ture.
: In reIation~ ~o: consumer products; modern material
fabrication ~:~nd a sembly techni~ues have permitted
3~0 ~ man~acturers to hold close tolerances and have allowed for
the~development~:of~mass production methods which have made
possi~le ~or~:consumers to enjoy a wide variety of
:pxoducts ::at a~ordable prices. However, such mass
production methods~have not successfully found their way
~ ,
~::: : :
WOg3/1427g PCT/US93/0027~
2 1 27 8 8 D
--2
into the construction industry on any significant scale.
In this respect, billions of dollars have been spent by the
construction industry in an attempt t~ adopt mass
production methods to produce housing at more affordable
prices. However, such efforts have generally fallen short
due to the previously described dimensiona~~~nstability of
the wooden components typically utilized in construction,
as well as the requiremPnt of utilizing skilled labor to
build the structures.
In recent years, some advancements have been
introduced to wood construction through the use of
reconstituting wood based products with enhanced strength
and dimensional stability. O~her ~dvancements in
construction techniques have included the gradual
conversion to steel, aluminum, plastic and o~her more
stable building materials. Additionally, a number of
attempt~ have been made to develop building wall structures
which integrate framing and wall panels to ~orm a composite
wall. Certain ones of these prior ~rt wall structures
comprise an assembly of wall panels or wall bricks having
hollow passaqes which form a serles of interlocking
vertical and hori~ontal passages in the assembly. These
passages are filled with concrete, with or without rebar~
to form ~tructural framing, integral with the wall panel or
2~ bric~s. Other types of prior art structures comprise
;~ reinforced~composite wall panels that are interlocked to
: ~ ~ form a wall stru~ture~. A third type of prior art structure
comprises an a~sembly of foam p~astic forms khat function
'as permanent concrete forms after the concrete has been
poured between the forms.
Though many of the aforementioned prior art building
materials and systems present improvements over the more
traditional prior art materials and buildiny sy~tems, these
material5~and ~uilding systems possess cer~ain inherent
deficiencies which detract from their overall uti.lity~ In
.
WO93/14278 2 ~ 2 ~ ~ ~ a PCT/US93/00271
:
this respect, the aforementioned prior art wall structures,
although reputed as being easy to assemble, often require
su~stantial planning and piecemeal methods for forming
windows and doors. Additionally, these prior art wall
structures typically require a substantial amount of
concrete which, though being widely availa~l~rin some form,
i5 not always of su~ficient structural, load bearing
capability. Additionally, the aforementioned materials ~nd
building methods are often deficient with regard to
critical factors such as cost, material availability,
capital requirements for manufacturiny and transporta~ion,
technical skills both in the factory and field and ease of
construction.
The present invention specifically addresses these and
other deficiencies in the prior art by providing an
integrated wall, floor and ceiling structures that amploy
no concrete and is fabricated from a minimum number of
dimensionally stable, standardized framing elements and
standard panels to form a resultant monolithic structure.
In this respect, the present invention may be assembled
with a minimum ~f kools and d~es not require employment of
skilled labor, such as carp~nters, brick layers and
concrete pourers.
Summar~ of the Invention
In accordan~e with a preferred embodiment of the
~ present inventio~, there is provided an improved building
:~ : sys~m including dimensionally ~table, wall~ ~loor and
ceiling struc~ures. Tn ~h~preferred embodiment, the wall
~30 struc~ure comprise~ an ~longate ~rack having a generally U-
: shaped c onfiguration and defining~a bottom wall adapted to
rest on and b :secured to the building foundation and
opposing side walls extend~ng upwardly from the bottom
wall. The bottom~wall of the track includes a plurality of
~pre-formed, lin~arIy aligned bottom wall apertures at
WO93/1427$ : PCT/US93~00~71
~127~8~
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pxedetermined locations along the length thereof fsr
receiving fasteners to secure the track to the foundation.
Dimensionally stabile, pre-apertured vertical posts are
secured to the track at predetermined locations along the
length thereof via flanges extending perpendicularly upward
~rom the bottom wall of the track. T~-~cil`itate the
attachment of the posts to the track, each of the flanges
include a plurality of pre-formed flange apertures which
are precisely located so as to be in registry with pre~
formed lower post apertures disposed in the hottom ends of
the posts to receive fasteners such as self-tapping screws.
Advantageously, the bottom ends of the posts include
recesses disposed therein to receive the top portions of
the fasteners us d to secure the track to the foundation.
By positioning the posts directly over the fasteners used
to secure the track to the foundation, the track and post
are in effect directly secured to the foundation thereby
significantly enhancing the seismic stability of the
resultant wall structure. In this respect, during seismic
activity the weight of the building is resisted by the
inter~ction o~ the foundation to the wall structure wherein
the holding power at the lever arms of the posts is
maximized.
In the pr~ferred embodiment, the track is fabricated
from either sheet metal or from an extruded, rigid polymer
material. Where the track is fabricat~d from a rigid
polyme~, the battom wall thereof may further include a
; plurality of longitudi~ally extending projections formed on
the und~rside thereof for forming a moisture tight seal and
thermal barrier against the fsundation when the track is
: : secured thereto. Where the track i~ fabricated from sheet
metal, a layer of polymer sealing material may be placed
:between the botto~ wall of the track and the foundation to
~acilitate a similar moisture tight, thermal barrier.
3S Additionally, the opposing sidewalls of the ~rack is
WO93/14278 2 ~ 2 7 ~ ~ ~ P~T/U~93/002~1
preferably provided with pairs of V-shaped notches disposed
along ~he upper edges thereof for placing a drilling jig in
vertical registry with the bottom wall ~pertures to aid in
the attachment of the track to the foundation.
Secured to the top ends of the posts is an elongate
lower header beam preferably formed 0i- plural beam
segments. Attached to ~he top of the lower header is an
elongate upper header beam or top plate having a wi~th
preferably exceeding the width of the lower header. In the
preferred embodiment, the top ends of each of the posts are
attached to the lower header via a pair of header brackets.
Each of the header brackets includes a vertical flange
portion having a pair of pre-formed vertical ~lange
apertures disposed therein which are oriented so as to be
in registry with pre-formed upper post apertures disposed
in the top end of the postO The header brackets are
interfaced to the top end of the post such that the
vertical flange apertures of each header bracket of the
pair and thP upper post apertures are coaxially aligned.
The~e coaxially aligned apertures are adapted to receive
fasteners to secure the header ~rackets to the top end of
the post. Each of the header bracket~ further includes a
: horizontal flange portion having a pair of pre--formed
horizontal ~lange apertur~s ~isposed therein which are
oriented so as to be in registry with pre-formed lower
: : header apertures. The coaxially aligned horizontal flange
~ ~ ~apertures and lower header apertu~es are adapted to receive
: ~asteners~to secure the lower header to the pair of header
1~ brackets. The upper flange portions of the headex brackets
: 30 of~the pair and th~ lower header further include ap~rtures
in registry with each other and with a pair of pre-formed
upper header apertures to receive fasteners to secure the
upper header to the lower header.
:~ Disposed between each pair of adjacent posts is a pre-
fabricated wall section. In the preferred embodiment, each
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of the wall sections in fabricated from polystyrene foam
material and includes a vertical tongue formed along a
first vertical edge, a vertical 510t formed within a second
vertical edge, a lower edge having a pair of parallel
grooves foxmed therein for receiving the opposing sidewalls
of the track, and an upper edge having a~h~rizontal slot
formed therein for receiving the lower header~ Each of the
wall sections is disposed between a pair of adjacent pQsts
such thak the vertical tongue abuts one of the posts of the
post pair with the ~ertical slot receiving and
encapsulating the other post of the post pair and the
~ertical tongue of an adjoining wall section. The vertical
tongues and ~ertical slots of ea~h of the wall sections
further include one or more vertical grooves formed therein
for receiving a foam adhesive to form an expanded foam seal
between the vertical tongue and the cne post of the post
pair and the verti~al slot and the other post of the post
pair. Additionally, the horizontal slot and lower edge
in~lude horizontal grooves formed therein for receiving a
foam adhesive ~o ~orm an expanded foam seal between the
horiæontal slo~ and a lower header beam segment and the
: lower edge and track. ~d~antageously, the expanded foam
adhesive seals interface the posts, track, beam segments
and wall sQction~ ~o each other in a manner forming a
monolithic s~ructure. In this respect, the interface
between ~he posts~track, beam segments and wall sections
- ~ produces a synergistic effect by utilizing the aompressive,
:: ~en~ile and shear~force properties of the posts, track,
!beam egments and the wall sections thus forming the
; 30 monalithic wall tructure.
The floor structure of the present invention
.
` preferably cnmprises a plurality of elongate floor joists
~:~ which are attached to the ~oundation and extend in parallel
relationO Each of the floor joists is preferably
: : 35 configured as an I-~eam and comprises upper and lower
::
W093/14278 2 1 2 7 ~ ~ O PCT/US93/~0271
elongate flanges having a strand board web extending
perpendicularly therebetween. Disposed between each pair
of adjacent joists is a pre-fabricated, polystyrene foam
floor section. Each of the floor sections includes first
and second horizontal edge portions which are disposed
between and abutted against the we~s of ~ floor joist
pair. The first and second horizontal edge portions of
each floor section further include a plurality of
longitudinally extending channels formed therein for
receiving a foam adhesive to form an expanded foam seal
between the edge portions and the pair of joists.
The monolithic ceiling structure of the present
invention preferably comprises a plurality of elongate
ceiling trusts which are attached to the header beam and
extend in parallel relation. Like the floor joists, each
of the ceiling tru~ts preferably has a I-beam configuration
and comprises upper and lowzr elongate flanges having a
strand board web extending perpendicularly therebetween.
Disposed between each pair of ~djacent ceiling trusts is a
: ~ 20 pre-f~bricated, p~lystyrene foam ceiling section which
include~ first and second angled edge portions. Each
~eiling ~ection is disposed between a pair of adjacent
cei~ing trusts in a manner wh~rein ~he angled edge portions
: thereof are ab~tted against and adhesively secured to the
webs of each of the~ceiling trusts of the ceiling trust
pair~ `
The prese~t inYention further comprises a method of
; fo~ming a monolithic wall structure from a prefabricated
: ipost andjbeam frame and `interlocking foam wall sections.
The method comprises ~he steps of securing an elongate
track ~o a horizontal foundation and subse~uently ~ecuring
:~ the bottom end o~ an ~longate, vertical post to ~he track
at a predetermined location thereon via a first pre-
: fabricated registration means. A pre-fabricated wall
3~ section is then disposed upon the track in a manner wherein
: :
WO93/14278 PCT/US93/00271
~ ~738 -8-
the pair of parallel groove~ formed within a lower edge
thereof receive a portion of the track and a vertical
tongue formed along a first vertical edge of the wall
section abuts the post. A second post is then secured to
the track in a manner wherein a vertical slot formed wi.thin
a second verkical edge of the wall sect~nr receives and
encapsulates the second post. The vertical slot further
encapsulates the vertical tongue of a second adjoining ~all
section which is abutted against the second post.
Thereafter, at least one elongate, horizontal header beam
is received into aligned, horizontal slots formed in the
upper edges of the wall sections and secured to the top
ends of the posts via a second pre-fabricated registration
means.
The preferred method of forming the monolithic wall
~tructure ~urther comprises the step of injecting a foam
adhesive into vertical grooves formed in the vertical
tongue and vertical slot of each wall section and the
horizontal grooves formed in the horizontal slot and lower
edge of each wall section to form an expanded foam seal
between thQ vertical tongue and one post of the post pair,
the vertical slot and the other post of the post pair, the
horizontal ~lot and a lower beam segment and the lower edge
and the track. As previously specified, in the preferxed
method a fir~t vextical post i~ plumbed with all other
pos~s being subsequen~ly plumbed due to the dimensional
stability o~ the first and second registration mean~ of the
:track and header beam. Additionally, in the preferred
method the wall struct~re is adapted to be assembled
utilizing solely ~crew fasteners and the expansive
adhe~ive.
The preferred method further omprises the step of
enplacing of plumbing ~anifold and electrical ~ystem into
one or more of the wall sections without cutting through
: ~ ~5 the posts and/or header beam. The plumbing manifold and
: :
':
W0~3/1427~ 7 8 8 a PCT/US93/00271
_g_
electrical system are preferably installed following
assembly of the monolithic wall structure. As will be
recognized, such installation may comprise the further step
of using a foam chase in relation to particular plumbing
5 applications.
A~ter the monolithic wall struoe~rre has been
fabricated, a lAyer of finishing material may be applied to
the inner and/or outer surf~ces thereof. The finishing
material is typically selected from the group of drywalll
plywood, and fiberboard and may be affixed to the inner or
outer surfaces of the wall structure via the attachment to
the header beam or via an adh2sive. Additionally, a layer
of netting material may be applied to the outer surfaces of
the wall structure with a layer of stucco being
lS subsequently applied to the layer of netting material. ~s
previously specified, each of the posts is provided with a
plurality of linearly aligned apertures disposed alsng the
length thereof. ~dvantageously, these apertures may be
used to inter~ace pairs of window brackets to the posts for
~0 purposes of attaching a sill member an~ ja~ member between
pairs of adjac~nt posts. As will be recogniz~d, ~he sill
and ~am members are used for purposes of constructing
windows or doors. In those in tances when a window or door
is constructed~, the wall sections of the wall structure
must be cut to acco~modate the same~
The present inven ion further comprises methods of
forming floor and~Geiling:structures. The formation o the
floor structure c~mprises the steps of attaching an
elonga~ej floor joist to the foundation and subsequently
: 30~ abu~ing a first horizon~al~edge portion of a floor section
: th~rea~ainst~ A second floor joist is then attached ~o the
~foundation in ~ manner wherein the second joist is abutted
:against the second horizonta1 edge portion of the floor
ection. Thereafter, a foam adhesive is injected into the
longi~udinal chann~Is formed in the first and second
:
WO93/14278 PCT/US93/00~7l
~1~7~gO
--10--
horizontal edge portions of each floor section to form an
expanded foam seal between the horizontal edge portions and
each floor joist of the floor joist pair. The method of
fabricating the floor structure further comprises the step
of applying a layer of finishing material such a plywood
over the tops of the floor joists. ~ ~
The method of forming the monolithic ceiling structure
comprises the steps of attaching a ceiling trust to ~the
header beam and subsequently adhesively securing a first
angled edge portion of a ceiling section thereto. A second
ceiling trust is then attached to the header beam in a
manner wherein the second trust is abutted against and
adhesively secured to the second angled edge portion of the
ceiling sec~ion. Thereafter, a layer of sheathing is
applied to the tops of the ceiling trusts with a layer of
roofing material subse~uently being applied to the
shea~hing.
B~ief Descri~tion of the Drawin~s
These as well as other features of ~he present
invention will become more apparent upon reference to the
drawings wherein:
Figure ~1 is~a perspective view of a resid~ntial
dwelling:aons~ructed~ utilizing the building structures of
the present invention,
Figure~::2~ a cross-sectional view of the floor
structure ta~en:along line 2-2 o~ Figure 1;
Figure~3~is~a ~utaway fragmentary view of the flosr
structurç ~f the pre ent invsntion;
~ Figure 4 is~:an elevational view of the floor structure
~ : of:the present invention;
-~ Figure~ 5: is a cutaway fragmen~ary view illustrating
the components~comprising the floor and wall structures of
the~present invention;
WO93tl427B 21 ~ 7 ~ 8 ~ PCT/US93/00271
Figure 6 is an exploded view of the components
comprising the wall structure of the present invention;
Figure 7 is a partial perspective view of the track
used in constructing the wall structure;
Figure 8 is a partial persp~ctive vlew illustrating
the manner in which the posts of the wa~ structure are
secured to the track and header brackets of the wall
structure;
Fig~re 9 is a cross-sectional view taken along line 9-
9 of Figure 5;
Figure gA is a cross--sectional view illustrating the
engagement of the wall structure to the foundation;
Figure 10 is a cross-sectional view taken along line
lO-10 of Figure 5;
Figure 11 is a cross-sectional view ta~en along line
11-11 of Figure 5;
Figures 12A, 12B, and 12C are perspective views
illustrating the method o~ constructing th~ wall structure
of ~he present invention;
: Figure 13 is :a perspective view illustrating the
manner in which plumbing and electrical conduits are formed
in the wall sections of the wall structur~;
Figure 14 is a partial perspecti~e view of a po~t of
the wall~structure~ lustrating the~manner in which jam and
25~ sill:members are~:engaged:thereto for forming a window;
Fig~re~ 15~is a partial perspective view of a wall
secti:on illus~rating the manner ~in~:which an electrical
system~ s emplaced into the:wall section after conduits are
~ ormed therein in the mahner shown in Figure 13;
:~ 30 : Figure ~6 ~is a cutaway~perspective view illustrating
the manner~in~which~layers of finishing materials may be
: : appl~iéd:to~the inner or outer~wall surfaces o~ the wall
~; : stru~ture; :~
~ : :
:~
WO g3/1~27~ . ; PCr/USg3/00271
2~27~0
-12-
Figure 17 is a cutaway perspective view iliustrating
khe manner in which layers of finishing materials may be
applied to the outer wall surfaces of the wall structure;
Figure 18 is a cross-sectional view illustrating the
ceiling structure of the present invention;
Figure 19 is a cross-sectional view~of thè ceiling
structure taken along line 19-19 of Figure 18;
Figures 20 and 21 are perspective views illustrating
a track constructed in accordance with a second embodiment
of the present invention; and
Figure 22 is a partial perspective view illustrating
the manner in which a wall section of wall structure is
engaged to the ~rack illustrated in Figures 20 and 21.
15Detailed_Desc~i~tion of the Preferred Embodiment
Referring now to the drawings wherein the showings are
:~ ~ for purposes of illustrating a preferred embodiment of the
present invention only, and not for purposes of limiting
the same, Fi~ure l illustrates a residential structure lO
constructed utilizing thc improved wall, floor and ceiling
~: ~ building structures~of the present:invention. Although the
present inventian as will hereinafter be described has
speci~ic: utility~ :residential structures, it will be
recognized that thé varlou~ buil~lng~s~ructures and methods
2~5 ~ of~fabricating~the~ ame may a~ditio~ally be uti~.ized in
conjunction;wi~h~;~commercial building structures as well.
Additionally,~th~ough~the wall, floor and ceiling structures
: of~ the:~present~;invention: will be: described as being
;lu~iliz~ed~to~fabricate the residential structur. 10 having
the~design depi~ted~,: it will be recognized that such
compon~nts~are~o ~sufficient architectural flexibility so
: as: to::~be usable~ in conjunction with residential or
comme}cial structures having a wide variety of different
deslgn con~igurations.
WO93/14278 ~ 12 ~ ~ 8 0 PCT/VS93/00271
-13-
The wall, floor and ceiling structures of the present
invention are fabricated from dimensionally stable
components which allow the structures, and hence the
residential structure l0 to be assembled by unskilled labor
with a minimal amount of difficulty. Additionally, each of
the components utilized to fabricate the ~ll, floor and
ceiling structures are pre-fabricated off-site using high
tolerance mass production techniques. The present building
structures and building technique are adapted to fabricate
the residential structure l0 from the foundation to the
roof by pro~iding the necessary wall, floor and ceiling
structural elements. In the following paragraphs, the
wall, flo~r and ceiling structures of the present invention
and methods of fabricatinq the same will be separately
described.
LOOR STRUCTU~E
Referring now to Figures l 5, ~he floor structure 12
comprises a plurality of floor joists 14 which are attached
to a foundation structure 16 in a manner wherein the floor
joists 14 extend in spaced, ~arallel relation. Each o the
floor joists l4 preferably has an I~beam configuration and
comprises an~elongate Upp8~ flange 18 and an elongate lower
f1ange 20 having a generally planer strand board web 22
extending perpendicularly therebetween. The upper flange
18~ lower flange 20 a~d web 22 are preferably fabricated
~rom:gang laminated LV~ (laminated ~eneer lumber) material
though other materials may be utilized as an alternati~e.
Advantageously, each of the floor joists 14 is given an I-
eam Gonfiguration for s-^ength as well as for greater
ver~ical and lateral load resi tance.
The foundation structure 16 to which the joists 14 are
:~ connec ed compri~es a concrete foundation which is
~35 fabricated in accordance with con~entional foundation
W~93/1~27~ P~T/US93/00271
~:~27~30
-14-
construction techniques. To facilitate the attachment of
the floor joists 14 to the foundation structure 16, a notch
16 is preferably formed in the inner, upper edge of the
foundation structure having a generally rectangular
configuration. Disposed within the notch 24 is a
foundation bracket 26 having a configurat ~ complementary
to the notch 24. Th~ foundation bracket 26 is sized such
that when placed in the notch 24, the upper end thereof
extends slightly beyond the top surface of the foundation
s~ructure 16 to a height substantially flush with the top
surface of a mud sill 28 attached to the top surface of the
foundation structure 16. Though not shown, the foundation
bracke~ 26 i.s rigidly attached to the inner edge of the mud
sill 28 via a sill bolt. The use of the mud sill 28, in
addition to serving as a support structure for the
foundation bracket 26, will be discussed in greater detail
below. In attaching the floor ~oists 14 to the foundation
structure 16, the floor joists 14 are secured to the
foundation bracket 26 in a manner wherein one end of ~he
lower flange 20 resides upon the lower, horizontal edge 27
of the foundation~bracket 26, with the outermost ends of
both the upper flange l8 and lower flange 20 being abutted
against the ver~i~al portion of the foundation br~cket 26.
As seen in Fi~ur~ 2, when the floor joists 14 are securely
: 25 inter~aced to the f~u~dation bracket 26, the top surface of
the upper flange 18 is substan ially flush with both the
~:: t~p end of t~e ~oundation bracket 26 and top surface of the
mud siIl 28. Advantageously, the foundation bracket 26
allows th~ ~loor joists I4 and hence the floor structure 12
to be suspended within the interior of the building
structure and ~foundation, thus providing increased seismic
: stabi~ity by preventing the floor structure 12 from rol7ing
~ off the foundation during an earthquake. A~ also seen in
: Figure 2, additional support may be provided to each of the
:
WO93/14~78 2 1 ~ 7 ~ ~ O PCT/US93/00271
, ....
-15-
floor joists 14 via one or more secondary concrete support
walls 30 of the foundation of the residential structure 10.
Disposed between each pair of adjacent joists 14 is a
pre-fabricated floor section 32. In the preferred
embodiment, each of the floor sections 32 ls fabricated
from polystyrene foam and de~ines firs~ and second
horizontal edge portions. Each of the floor sections 32 is
disposed between an ad~acent pair of floor joists 14 in a
manner wherein the first and second horizontal edge
portions thereof are each received into a recess defined by
portions of the top surface of the lower flange 20, bottom
surface of the upper flange 18 and one planer face of he
we~ 22 of one:of the floor joists 14 of the pair.
As best see~ in Figures 3 and 4, formed in the first
and second horizontal edye portions of ea~h of the floor
sections 32 are a plurality of longitudin~lly extending
channels 34. ~ Preferably, each of the horizontal edge
portions of the fl~or section 32 include four channels
formed therein~ When the horizontal edge portions of the
2~0 floor section 32:~are disposed between a pair of adjacent
floor:~joists~14, ~one:channel 34 is disposed adjacent the
~:corner de~ined~by~the upper flange 18 and web 22, a second
: ~~ channel:is :disposed::adjacent the corner defined by the
wer flange~2g~and~:web 22~, with the;remaining two channels
25 : 34~bein~:disposed~adjaaént the central portion of the web
22.~ In~:~the~preferred~embodimsnt~, each o~ the channels 34
are~;adapted~to~ eceive a~quantity of~an adhesive such as a
foam~material~:for~;purposes~:of:forming e~panded foam seals
36 between the first and~second horizontal edge portions of
:30 ~th~:floor sec~ion 32 and the floor joists 14 of the pair.
Though~the f~loor sect~ion~32 is preferably ~butted against
ea~h~ of the~floor~joists 1~4 of the pair when inserted
therebetw~en, the~ expanded foam seals 36 are operable to
secure~the floor sections to the floor joists and thereby
;: 3~5 inG~easé the compriessive~ strength of ieach foam floor
WO93~1427~ PCT/USg3/00271
2~ 27.~80
-16-
section 3~ so as to enhance the shear resistance of the
floor structure 12. Additionally, the foam seals 36 aid in
sealing against the infiltration of moisture, air or
harmful radon gas into the residential structure 10 via the
floor structure 12 as well as reduce heat transfer across
the floor structure.
In assembling the floor structure 12, a first floor
joist 14 is attached to the foundation structure 16 via.the
foundation bracket 26 in the manner previously described.
Thereafter, one of the horizontal edge portions of a floor
section 32 is inserted into the recess defined by the lower
flange 20, upp~r flange 18 and strand board web 22 and is
secured to the first floor joist 14 via the injection of
foam adhesively into the channels 34 of the horizontal edge
portion to create ~he foam seals 36. A second floor joist
14 is then attached to the foundation structure 16 such
that a recess defined thereby captures the horizontal edge
portion of the first floor section 32 not captured in the
recess defined by the first floor joist 14. Thereafter,
; : 20 foam adhesiv~ material is injected into the channels 34 of
thP second, captured horizontal edge portion to firmly
secure the floor section 32 between the adjacent pair of
floor joi ts 14. Retaining floor joists 14 and floor
~sections 32 are ;subsequently assembled in an analogous
~: : 25 matPrial throughout:the structureO
After the assembly of the floor joists 14 and floor
sections 32, a layer: of f:inishing material such as a
plywood~ sheet :~38 is secured to the top surfaces of the
:
upper $1ange~ 18. As best seen in Figure 4, when the
:30 plywood ~heet 38 is~attached to the upper flanges 18 of the
: floor joists 14, a space 40 is defined between the plywood
: shee~ 38 and the top surfaces of the floor sections 32.
Advantageously/ the space 40 provides dead-space insulation
which, in c~njunckion with the poly~tyrene floor sections
~ 35 32 and foam seals 36, greatly enhances the overall thermal
: ~ .
WO93~1427g 2 ~ ~ l g 8 ~ PCT/US93/0027l
-17
efficiency of the ~loor structure 12. Additionally, the
space 40 serves as electrical/plumbing service conduit as
will be described in more detail below.
Though the floor structure 12 has been described for
use in conjunction with a plywood sheet 38 serving as the
layer of finishing material, it will be reoognized that the
design of the floor structure 12 may be modified to
accommodate a concrete slab floor as would be used in a
commercial building structure. Advantageously, the floor
structure 12 of the present invention is designed so as to
possess significant seismic stability when seismic forces
are applied to the res~dential structure 10. Additionally,
since the floor structure 12 does not incorporate cement or
any other hy~rophilic material, continual watering as would
occur from automatic sprinklers around the base of the
residential structure 10 is not easily absorbed into ~he
floor structure 12 and thus not transported to the wood
componénts there~f. As such, problems associated with
mildew, dry rot, fungus and ground settling which are
typically en~ountered with conventional floor structures
are~ eIiminated by ~the design and material~ used in
coniunction with the floor structure 12. As such, the
floor s~ructure 12 is particularly adapted to be less
susceptible to risk of damage when seismic forces are
applied thereto. ~
WkLL S~RUCTU~ -
.
Referring now to Figures 5 11, the present invention
: ~: 30 further comprises a dimensionally stable, monolithlc wall
structure 42 which, like the 1Oor structure 12, i5
. specifica~lly adapte~ to resist shear and to be seismically
: stable. As seen in Figure 6, the wall structure 42 is
: ~ formed generally~of an elongate track 44, plural posts 56,
~ :35 a lower header 98, upper header or top plate 1009 and
: :
:~ ~
WO93/14278 PCT/US93~00271
~ 27 ~ ~ 0 -18-
plural wall sections 126 which are assembled upon the
floor. The po5ts 56, and headers 98, 100 are preferably
fabricated from dimensionally stabile L~L material or
kubular metal and are pre-fabricated off-site. The track
44 is preferably formed having a generally U-shaped
configuration definin~ a bottom wall 46 a~ pposing side
walls 48 which extend upwardly from the bottom wall 46. As
seen in Figure 9, the track 44, and more particularly the
bottom wall 46 thereof, is adapted to rest on the plywood
sheet 38 or other ~inishing material of the floor structure
12 and is secured to the underlying mud sill 28 via a
plurality of faskeners 50 such as self-tapping screws. The
fasteners 50 extend through t~e bottom wall 46 via a
plurality of pre-formed, linearly align~d bottom wall
apertures 51 disposed therein at predetermined locations
along the length of the track 44. Dis~osed within the
upper edges of the opposing sidewalls 48 of ~he track 44
~ are pairs of V-shaped notches 53 which are used for placing
: a drilling jig or ~imilar structure in vertical registry
: : 20 with a respective~ bottom wall: aperture 51. As will be
recognized, in~hose instances where the wa~l structure 42
is~not: constructed about the outer periphery of the
residentlal:s~ructure 10, ~he fasteners 5Q may extend
: : through the pl~wood~shee~ 38 into a support structure other
25: than the~ mud~sill~;28, cuch as the upper flange 18 of a
loor~:joist ~14. ~rth r, as seen~in Figure 9AJ the track
44 ;may a~lso~be~ anchored directly~to a portion of the
foundation~of~ the~residential structur,e 10 such as the
,Q~ncrete s~upport wall 30 via an anchor bolt 52 which
30~ ~ex~ends from the support:wall 30, through the plywood sheet
38~:and~:track ~44~ with ~the track 44 being ~ecured to the
bo~lt:~:52;via a nut;~54.
The wall structure 42 further:comprises a plurality of
e~ongate, vertical posts 56 of :predetermined lengths, the
~bottom~ends of~which are secured at predetermined locations
WO93/14278 PCT/US93/00271
7 ~
--19~
along the length of the track 44. In the preferred
embodiment, the bottom ends of the posts ~6 are secured to
the track 44 via a plurality of flanges 58 which extend
perpendicularly upward from the bottom wall ~6 of the track
44. Each of the flanges 58 preferably include four pre-
formed apertures 60 disposed therein in a ~e~eral~ly square
configuration which are oriented so as to be in registry
with pre-formed lower post aperture~ 62 disposed in ~he
bot~om ends of the posts 56. As seen in Figure 9, the
posts 56 are secured to the flanges 58 by abutting the
bottom ends thereof against the flanges 58 in manner
wherein the apertures 60 and 62 are coaxially aligned.
- Thereafter, fasteners 64 such as self-tapping screws are
inserted into the lower post apertures 62 and through the
posts 56 so as to eng~ge the flanges 58 via the aper~ures
60, thus securing the pos~s 56 to the flanges 58. Though
as shown in Figure 8, four fast~ners 64 are utilized to
secure each of the posts 56 to a respective ~lange S8, it
will be recognized that greater or les~er numbers of
fasteners 64 may:~be UtilizedA
Referring now to~Figures 20-22, disclosed is a track
66- constructed in accordance with a second embodiment of
the present invention. Track 66, like track 44, also has
a generally U-shaped con~iguration and defines a bottom
25~ wall~ 68 ~havi~g~ opposing sidewalls 70 extending
perpendicularly~ upward there~rom. To facilitate the
at~aGhment;~o~ the~track: 66 ~ta the support structure
underlying t~e~ pl ~ ood shee~ 38,~disposed in the bottcm
, wall 68~are a ~plurality'of pre-formed, linearly aligned
30 ~ bottom:wall apertures 72.~ As an alternative to the flanges
58::inaluded~with~the track 44, the bottsm ends of the posts
56 are secured to :the track 66 via a plurality of track
brackets 74 wh`ich :are attachable to the bottom wall 68 of
the~ track 66. Each~ of the track brackets 74 has a
~gPnerally L-shaped~configuration and defines a lower flange
~ ::
WO93/14278 PCT/US93/00271
2l2~a
-20-
portion 76 having a pre-formed lower aperture 78 extending
therethrough, and a pair of registry tabs 80 formed on the
bottom surface thereof. In the preferred embodiment, the
registry tabs ~0 are adapted to be receivable into a pair
of locator apertures 82 disposed adjacent each of the
bottom wall apertures 72. When the regi~t~y tàbs 80 are
received intv a respective pair of locator apertures 82,
the lower aperture 78 disposed in the lower flange portion
76 is coaxially aligned with the respective bottom wall
aperture 72. Thereafter, both the track ~racket 74 and
track 66 are simultaneously secured to the underlying
support structure via fasteners 84 such a self-tapping
screws which are received through the coaxially aligned
lower aperture 78 and bottom wall aperture 72. Similar to
the track 44, the track 66 includes pairs of V shaped
no~ches 86 disposed along the top edges of the opposing
sidewalls 70 for placing a drilling jig in ~ertical
registry with the coaxially aligned lower aperture 7~ and
bottom wall aperture 72.
~: ~ 20 To facilitate their attachment to the bottom ends of
the~:posts 56, each of the track ~rackets 74 further
încludes an upper- flange portion 88 which extends
perpendicularly upward from the bo~tom wall 68 wh n the
lower flange~portion 76 is secured thereto. The upper
~lange ~portion 88 includes four pre ~ormed upper flange
apertures 90: disposed therein in a generally square
configuration~ The upper flange apertures 90 are oriented
so as to be~in~:registry with the pre-formed lower post
apertures 62 disposed in;the bottom ends of the posts 56.
30: In this respect,~ the posts 56 are secured to the track
brackets 74 b~abutting the bottom ends thereof against the
upper flange portions 88. l'herea~ter, fasteners 92 such as
sel~-tapping~screws are inserted into the lower post
apertures 62~and through the pos~s 56 so as to engage the
~`: :
: ~;
WV93/14278 2 ~ ~ r7 3 ~ ^a PCT/US93/OQ271
-21-
upper flange portions 88 of the track brackets i4 via ~he
upper flange apertures 90.
In the second embodiment, the track 66 is a moisture
track which is fabricated from an extruded polymer. Formed
on the bottom surface of the bottom wall 68 and on each of
the opposed edges of the bottom wall 68 ar~ Iongitudinally
extending projections 9~ which are utilized to form a
moi~ture-tight seal and thermal barrier against the plywood
sheet 38 or other layer of finishing material when the
track 66 is rigidly secured to the underlying support
structure. Though the track 44 which is preferably
fabricated from sheet metal is not provided with such
projections, it will be recognized that prior to securing
the track 44 to the underlying support structure, a
separa~e polymer plate or similar structure may be inserted
between the bottom wall 46 and top surface of the plywood
sheet 3~ so as to form a moisture-tight, thermal barrier as
do the projections 94 of the extruded polymer track 66.
Advanta~eously, the moisture and ~hermal barrier
facilitated by the projectionC 94, or polymer plate used in
c~njunction wi~h the track ~4, is not violated over a
prolonged duration of time~ Though the track 66 is
~a~ricated from a polymer, the track brackets 74 attached
: there~o are preferably fabricated from metal, though other
material~ may be:utilized as an alt rnative.
As :seen in Figur~s 9 and 9AI in the preferred
embodiment, the top ends oiE selected ones of the f asteners
50, 52 whic~ are utilized ~o secure the track 44 to the mud
I~;ill 28,1 suppo~t wall 30, floor joist 14 or other
30 underlying support structure are disposed directly under
:: the po~ts 56 . In the preferred embodiment , each of the
: posts 56 of the wall structure 42 includes a fastener 50,
5~: directly underneath the bottom end thereof. To
:: acco~modate the top ends of the fasteners 50, 52 he bottom
end of each post 56 is provided with a recess or
: ~:
W093/14278 PCT/~S93/0~271
2 ~ a
-22-
counterbore 96. Advantageously, by placing the fasteners
50, 52 into the underlying support structure directly under
the posts 56, the seismic stability of the wall structure
42 is significantly increased. In this respect, during
seismic activity the weight of the residentlal structure 10
is resisted by ~he interaction of the fo~ation and the
wall structure 42 since the holding power is maximized at
the levex arms of the posts 56~ Though each of the posts
56 preferably includes a fastener 50,52 located underneath
~0 the bottom end thereof, the fasteners may only be included
under selected ones of the posts 56.
Referring now to Figures 6l 8, and 11, in constructing
the wall structure 42, attached to the top ends of the
posts ~6 is a lower header beam 98 and an upper header beam
or top plate 100. In the preferred embodiment, the lowar
header beam 98 is formed in segments 99 extending in
abutted end to-end orientation, each spanning ~etwsen and
being secured to the top ends of adj~cent posts 56 via a
pair of header brack~ts 102. Each of the headex brackets
102 has a generally L-shap~d configuration and includes a
~ertical flange portion 104 having a pair of pre formedl
linearly aligned~ vertieal flange apertures 106 disposed
therein. The vertical flange apertur s 106 are oriented so
as to be~in registry wi~h a pair of~ pre-formed uppex post
apertures disposed in the top end of each post 56. Two
header brackets 102 are ~ttached: to the top end of each
post~56 ~by~abutting~ the vertical flange portions ~Q4 of
each bracket 102 ag~inst the top end~such that th~ vertical
f~ange: qpertures~106 disposed in each of the vertical
:30~ flange~portions-1~4 are coaxially aligned with the upper
: post apertures~ of the post 56~ Ther~after, a pair of
; : fasteners 108~such as self-tapping screws are inserted into
the: v~rtical flange apertures 106 of one of the header
~; brackets 102 and inserted through the upper post apertures
~;
:
' ~ .
W093/14278 2 ~ PC~/US93/O~t71
-23-
so as to engage the other header bracket 102 via the
vertical flange apertures 106 thereof.
To facilitate the attachment of a seyment 99 ~f the
lower header beam 98 to a pair of header brackets 102 on
adjacent posts 56, each of the header brackets 102 of the
header bracket pair further includes a~hQrizontal flange
portion 110. Disposed in each horizontal flange portion
110 is a pair of horizontal flange apertures 112 which are
oriented so as to be in registry with a corresponding pai~
~0 of pre-formed lower header apertures 114 disposed within
the segment 99. When the pair of header brackets lV2 are
secured to a respective pair of posts 56, the horizontal
flange portions 110 thereof and the uppermost ends o~ the
posts 56 define a pair of planer surfaces against which the
bottom surface o~ the segment g9 is rest d~ When the
segment 99 i5 abutted against the horizontal flange
portions 110 of the header brackets 102, fasteners 116 such
as self-tapping screws are inserted into both pairs of the
lower header apertures 114 of the seg~ent 99 and through
.~ 20 ~he segmènt 99 so as to engage the headex brack~ts 102 via
both pairs of horizontal flange ~pertures 112 thus securing
the segment 9~ to ~he header brackets 102.
After the ~egments 99 have been secured to the top
ends of the posts 56 via the header bra kets 102 thus
for~ing the lvwex header b~am 98, the upper header beam or
top plate 100 is disposed upon the top ~urface of the lower
header beam 9~8~ and: likewise secured to the horizontal
flange portions llO of the header brackets 102. In this
: re~p~ct, the ho~izontaL flange portion 110 of each header
`~ 30! bracket 102, in addition to including the pair of
horizontal flange apertures 112, further includes an
aperture 118~. When the brackets 102 are attached to the
~: :posts~ 56, the apertures 118 of the horizontal flange
: portions 110 are oriented so as to be in registry with pre-
formed upper header apertures 120 disposed in ~he upper
:: :
:: :
.
WO93/14278 PCT/US93/~0271
2~c 27~80
-24-
header beam lOo. Each segment 99, in addition to including
the pairs of low~r header apertures 114, also includes
aper~ures 122 which are in registry with the apertures 118
of the pair of header brackets 102 when the segment 99 is
attached thereto. In attaching the upper header beam 100
to the header brackets 102, inserted into~e upper header
apertures 120 are fasteners 124 such as self-tapping screws
which extend through the upper header beam 100 and .the
apertures 122 of the segments 99 of the lower header beam
98 so as to engage the horizontal flange portions 110 of
the header brackets 102 via the apertures 118. As best
seen in Figure 11, the top ends of the lower header
apertures 114 are preferably counter sunk so that the head
portions of the fasteners 116 do not interfere with the
upper head2r beam 100 when such is attached to the lower
: header beam 98. In the preferred embodiment, the header
brackets 102 are fabricated from metal, though other
materials may be utilized as an alterna~ive.
Disposed betw~en each pair of adjacent posts 56 is a
pre-fabricated wall sections 126. In the preferred
embodiment, each of~;the wall:sec~ions 126 is pre-fabricated
of~ site ~rom~nominal 6 inch thick polystyrene foam and has
~ a generally rectangular configuration defining a vertical
: tongue 128 fo~med along first vertical edge and a vertical
sIot 13:0 formed~ within a second ~ertical edge. As best
: seen in Figures~6 and 22, each~of the wall sectlons 126
~urther includes à ~lower ~edge havin~ a pair sf parallel
roo~es~132:~formed therein for recei~ing the opposing
idewalls 48, 70 of the tracks 44, 66 as will be explained
balow. Ea h~wal~l section 126 further includes an upper
:edge having a~:horizontal slot 134 formed therein for
receiving the lower header beam 98. In the preferred
embodiment, each wall section 126 is disposed between a
: pair of adjacent posts 56 such that the vertical tongue 12~
abuts~ one the posts 56 of the post pair and the vertical
WO 93/1427~ 7 ~ ~ ~ P~/US93/00271
--25--
slot 13 0 receives and encapsulates the other post 56 of the
post pair and the vertical tongue 128 of an adjoining wall
section 126.
As best seen in Figure 10, formed within the vertical
5 tongue 128 and vertical slot 130 of each wall section 126
is a vertical groove 136. Additionally, f~rn~ed wi~hin the
lower edge and horizontal slvk 134 of each wall section 126
is a horizontal groove 137. When a wall section 126.is
disposed between an adi~2n~ pair of posts 56 and
interfaced to an adjoi~ir~g wall section 126 in the
aforementioned manner, a liquid foam adhesive is injected
into the vertical grooves 136 to form expanded foam seals
138 between the wall sestion 126 and each of the posts 5~
of the post pair. The liquid foam adhesive is also
injected into the horizontal grooves 137 to form expanded
foam seals 13~ between the wall section 126 and the track
44, ~6 and lower header beam 98 as will be explained below~
Advantageously, the c:reation of the foam seals 138, 139
transforms the wall struc:ture 42 into a monolithic
20 structure and add~ to the overall strength of the wall
. structure 42 by enhancing the fundamental shear strength
thereof.
To assemble the wall structure 42, the entire track
44, is i~itial~y laid down upon the floor for the entire
25 wall s~ructure 42 oiE the residerltial structure 10 to en~llre
roper location. ~Thereafter, the V-shaped notc:he~ ~3, 86
are utilized to register the fasteners 50, 52 within a
r~spective bottom wall aperture 51, 72. In the preferred
embodiment, the V-shaped notches 53, 86 are disps:~sed at
30 seven irlc:h centers or at se~ren inc:h multiples, i.e. center-
to-center distances of f ourteen inches, twenty eight
inches, etc. A~ such, the track 44, 66 allows for the
exact:and precise positioning and tying in of the track 4~,
66 and hence the wall structure 42 to the foundation of the
~5 residential struoture 10.
WOg3/14278 PCT/~93/00~71
~ 2~8~a
-26-
Referring now to Figures 12A, 12B, and 12C, after the
track 44, 66 is secured to the underlying support structure
in the desired configuration for the residential structure
10, the bottom end of a first post 56 is secured to the
track 44, 66 via a flange 58 or track bracket 74 in the
aforementioned manner. After a first post~ 56 has been
secured to the track 44, 66, a first wall section 126 is
lowered upon the ~rack 44, 66 such that the opposing
sidewalls 4~, 70 of the track 44, 66 are received into the
parallel grooves 132 Pormed in ~he lower edge of the wall
section 126. Importantly, the wall section 126 is oriented
such that the vertical slot 132 faces the first attached
post 56. Thereafter, the wall section 126 is slid toward
the first post 56 such that the post 56 is received into
the vertical slot 130 and firmly abutted against the
innermost surface 140 ~hereof. When the post 56 is
received into the vertical slot, the horizontal flange
portion llG of one of header brackets 102 of the pair
~lr ady secured to the top end of the first post 56 wilI be
received into the horizontal slot 134 and abutted against
the lowermost surface 142 thereof.
After the first post 56:has been received into the
vertic~l 510t 130, a second post 56 is secu~ed to the track
~4~ 66~in ~ manner wherein the second posk 56 is firmly
,
a~u~ted against the outermost sur~ac~ of the vertical
tongue~128. ~dvantageously, the flang~ 58 or track bracket
7~ ~ which the bo~tom end sf the second post 56 is secured
: is specifically oriented such ~hat the second post 56 will
abut thelvertical tongue 12B in the aforementioned manner
when ~ecured there~o. After the second pos~ 56 is secured
to the track 44, 66, the wall ~ection 126 will be firmly
disposed, i.e. compressed between the pair of adjacent
posts 56. Thereafter, liquid foam is injected into the
~: vertical grooves 136 to fo~m the foam seals 138 between the
~: 35 wall section 126 and pair of posts 56. The liquid fo~m is
W0~3~14278 2 ~ ~ 7 ~ ~ O PCT/US93/00271
"'~1
, -27-
also injected into the horizontal groove 137 in the lower
edge to form the foam s~al 139 between the wall section 1~6
and the track 44, 66. A second wall section 126 is then
placed upon the track 44, 66 in the same manner previously
described and oriented such that the vertical slot 130
thereof faces the vertical tongue 128~ ~of the first
installed wall section 126 and second installed post 560
The second wall section 126 in then slid toward the first
wall section 1~6 to a position whereat both the second post
56 and vertical tongue 128 of the first ~all section 126
are received into the vertical slot 130 thereof.
Thereafter, a third post 56 is affixed to the track 44, 66
so as :to abut ;the vertical tongue 128 of the second
installed wall section 126 in the same manner previously
described. Liquid foam adhesive is then injected into the
vertical grooves 13:6 of t~e second wall section 126 and
, horizontal groove 1~7, in the lower edge to form the foa~.
seals, 138, 139~ between the second;wall se~tion 126 and
those~posts 56~between which it is orien~ed and the second
~wall~ se~.ion ~126~and :th~ track 44, 66. As will be
recognizcJd~,~third~and~subsequent:wall sections 126 used to
the~orm:the~wall structure 42 are added in the sa~i manner
previ~usly:~described.~ :~
After a~;~wall~section 12~ ha~ ~een orianted between a
,pair~ of~posts 56,,~a~segment 99 of the lower header beam 98
is;~disposed~ into~ the horlzonta~slot 134 of the wall
se~tion~12~6~ an~secur~d~o~the~;horizontal fla~ge portions
llO~ of~a~pair~of~:~the header~bra ~ ets:102~in the manner
pre~iou~ly described. ~ The liquid foam i~ then injected
30~ into ~he~horizontal~groove~:137~of :the horizontal slot 134
to~orm~ he foam~sea~ 139~between the ho~izontal slot 134
and~ the ~:segment,~99. ~:~After the~desired ~u ~ er of wall
secti~ons;:lZ6~have:been assembled~ in the wall structure 42
and~the lower~header beam 98-formed by the receipt of the
35~ ~segments~ 99~ into~ the horizontal slots 134 in the
WO93/14278 PCT/US93/00271
2~27~0
-28-
aforementi~ned manner, the upper header 100 is placed upon
the lower header 98 and likewise secured to the horizontal
flange portions 110 of the header brackets 102 in the
aforementioned manner. As best seen in Figure 11, the
width of the upper header beam is substantlally identical
to the overall width of the wall sections~Z6.
As will be recognized from the aforementioned
construction process, when the wall structure 42. .is
erected, khe foam wall sections 126 are entrapped, i~e.
encapsulated, by the posts 56, lower he~der beam 98 and
upper header beam 100, thus becoming an integral part of
the wall structure 42. Advantageously, the wall sections
42 and upper header beam 100 provide uniform surfaGes to
which may be applied final wall finishes. Importantly, the
extension of the foam wall sections 126 outward from both
sides of the post 56 and the interlock of the wall sections
126 facilitated by the overlap of the vertical tongues 128
and vertical slots 130, provides ~he foam wall sections 126
with compressive strength to resist shear, which is
increased by the expanded foam seals 138, 13g. In thi~
respect, by entrapping the foam wall sections 126 between
the track 44, 66, posts 56 and upper and lower header beams
g8 ~ 100 r the shear ~trength capability of ~he foam wall
:sections 126 are maximized due to the p~ysical interaction
: 25 of the c:omponents.~Additiona~ly, the aforementioned manner
of construction; eliminates slop and prevents moisture
:
~deterioratIon.
A~ previo~sly~specified, the wall sections 126 and
upper header beam l00 provide uniform surfaces to which may
: 30 ~ be~applied final wall finishes. In this respect, dry wall
:may be applied to the interior wall surfaces of the wall
~: ~ : sections 126 by securing the top edge thereof to the inner
:~ : edge 143 of the upper header beam 100 or by applying the
:`; drywall to ~he inner wall surfa~es of the wall sections 126
~ 35~ via an adhesiveO Additionally, as seen in Figure 17, a
::
W093/14278 2 ~ 2 7 ~ 8 0 PCT/US93/00271
-29-
wall finish such as a sheet of plywood 144 may be applied
to the outer wall surfaces of the wall sections 126 by
securing the upper edge thereof to the outer edge 146 of
the upper header beam 100 via fasteners such as nails 1~
and/or ~y utilizing an adhesive 150 applied to the outer
wall surfaces of the wall sectîons 126. A~er the plywood
sheet 144 has been secured to the outer wall surfaces of
the wall sections 126, materials such as aluminum or wood
siding 152 may be applied to the plywood sheet 144. As ~n
alternative to the plywood sheet 144, other materials such
as steel, vinyl, etc. may be applied to the inner and/or
outer wall surfaces of the wall sections 126.
Additionally, as seen in Figure 16, a layer of netting 15~
may be applied to khe inner and/or outer wall surfaces of
the wall sec~ions 126 via securing the ~ame to the upper
header beam 100 or utilizing an adh~sive, the netting 154
serving as a support material for a polymer based marble
filled, stucco-appearing coating 156 for ornamental
fini~hes. ~mportantly, irrespective of the particular
finishi~g material applied to the inner a~d/or outer wall
: : surfaces of the wall sections 126, the foam core of the
wall structure;;42 :facilitated by the wall sections 126
maximi:zes the ~hermal, acoustioal and insulation qualities
of the wall ~structure 42 and provides the necessary
moisture barrier, ~resulting in~ a rigid, flat, smooth,
squa~e a~d~plu~b~tructure.
Referring now~to Figures 13 and 15, subsequent to the
::se¢u~ing o~the~wall sections 126 be ween the posts 56 and
upper and lower ~eader beams 9B, 100, ona or more of the
wall sect~ions~l26~may be provided with conduits ~58 for
: imp~acing a plumbing anifold or electrical ~ystem into the
wall sections 126.: Typically, the conduits 158 are formed
via the~u~ zation of ~ tool such as a hot knife 160,
though~other forming methods may be utilized~ Through the
;35 use of ~he hot knife 160, oth r recesses may be formed
:: :
:~ :
:
~093~14278 PCT/US93/00271
~12 7 8 8 ~3
-30-
within the wall sections 126 to accommodate components such
as electrical outlet boxes 162. Advantageously, the one
and one~half inch foam overlay of the wall sections 126
facilitated by the vertical slots 130 allows for the
emplacement of the plumbing and electrical systems into the
wall ~ections 126 only and eliminates th~- need to cut
through the posts 56 and/or upper and lower header beams
98, 100. In relation to parkicular plumbing applications,
a foam chase may be utilized. Additionally, as seen in
Figure 15, after the plumbing or electrical system
~omponents have been inserted into the conduits 158, taping
materials 164 may be utilized to cover the conduits 158 so
as to provide uniform inner or outer wall surfaces for the
wall sections 126 so that finishing materials may be
applied thereto.
Referring now to Figure 14, each post 56 is provided
with a plurality of pre-formed, linearly aligned apertures
166 which sre disposed along substantially the entire
le~gth of the post 56. In the preferred embodiment, the
~ 20 apertures 166 in each of the posts 56 are used for purposes
: of forming windows and doors between pairs of posts 56.
Particularly, windows are formed via the utilization of a
Il member 168 and a jam member 170, each of which are
interfaced to the~ posts 56 via pairs of window brackets
2S 172. The window~:bracke~s 172 each have a generally L
~ ~ :
shaped con~iguration and are secured to either the sill
member 168 or~:jam~member 170 via the receipt of fasteners
` :into~a~pair of~:~apertures di posed~in one of the two planarportions,thereof~ Therea'fter, the sill member 168 and jam
: : : 30 member I70, ~ach; having a pair of window brackets 172
attached thereto, are horizontalIy oriented between and
secured to a pair of posts 56. The attachment to the posts
56 is facilitated by the receipt of fasteners into pairs of
apertures disposed ~n the other planar portion of each of
:35 ~ the window bra kets 172 in~o corresponding, coaxially
WO93/14278 2 ~ 2 7 ~ 8 0 P~T/~S93/00~71
-31-
alig~ed pairs of apertures 166 disposed within the posts
56. Advantageously, due to the placement of the apertures
166 within the posts 56, the window may be constructed
ha~ing a multitude of different heights. Additionally, by
cutting out central portions of one or more lnterior posts
56, the windows may be constructed havin~-~y of a number
of desired widths~ As will be recognized, when a window is
formed within the wall structure 42, one or more wall
sections 126 must be cut so as to accommodate the window.
As pre~iously specified methods similar to those previously
discussed may be utilized to form doors within the wall
structure ~2.
ROOF STRUCTURE
1~
Referring now to Figures 18 and 19, the building
system of the present invention further co~prises a roof
structure 174 fo~med in substantially the same manner as
the floor structure 12.. In the preferred embodi~ent, the
~20 roo~ structure 174 comprises a plurality of ceiling trusts
: 176 which are attached between the upper he~der beam 100
and a central suppor~ beam 178 in spaced, parallel
relation. In:the preferred embodiment, each of the ceiling
trusts 176 has an~ I-beam con~iguration and includes an
upper flange~180 and a lower flange 182 having a strand
: ~ board web 184 extending perpendicularly therebetween. Like
:the floor joists~ he ceiling trusts 176 are fabricated
from gang laminated::LVL (laminated veneer lumber) and are
provided wi~h an I-beam configuration for strength and for
:30 greater:vertical an~ lateral load r~sistance.
: Disposed between each pair of adjacent ceiling trusts
176~is a pre fabricated ceiling section 186, which like ~he
~floor sections 32 and wall sections I26 is fabricated from
:~ ;;p~lystyrene foam. Each of the ceiling sections 186 further
~35 includes first ~nd;second angled ed~e portions which are
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WO93/14Z7~ PCT/US93/00271
21 2 78 ~ ~ -32-
abutted against the ceiling trusts 176 of the ceiling trust
pair when disposed therebetween. In the preferred
embodiment, the first and second angl~d edge portions of
each ceiling section 186 are glued in th~ recesses of the
ceiling tru~ts 17~ of the pair which are defined by
portions of the lower surface of ~he up~ flànge 180,
upper surface of the lower flange 182 and web 184. Thus,
each of the ceiling sections 186 is rigidly maintained.in
position between th~ adjacent pair of c~iling trusts 176.
In the preferred embodiment, the ceiling sections 186 are
fabricated from six inch thick foam. When inserted between
the pair of ceiling trusts 176, the upper plane of the
ceiling section 186 is flush with the bottom surface of the
upper flange 180 while the lower plane is flush with the
top surface o~ the lower flange 182.
In the preferred embodiment, the roof structure 174 is
constructed in a manner substantially identical to the
manner by which the floor structure 12 is constructed.
Initially, a first ceiling tru~t 176 is attached to the
upper header beam 100 and central support beam 178.
Thereafter, either the first or second angled edge portions
of a ceiling section 186 are secured within the recess
:~ defined by the upper and lswer flanges 180, 182 and web 18~
of the first ~ru~t 176 Yia an adhe~ive. A second ceiling
2~ trust 176 is then oriented so as to capture the angled edge
portion of the:ceiling s~c~ion ~86 not disposed within the
: recess of ~he:first ceiling trust 176. The second edge
portion then i~ adhesively affixed within the recess of the
second ceiling trust 17~ ~in the same manner previously
:~ ~ 30 descri~d. Subsequent ceiling sections 186 and ceiling
: ~: trusts 176 are a~ded to the roof structure 174 in ~he
.
aforementioned:manner.
~ : After the:ceiling trusts 176 and ceiling sections 186
: ha~e been assembled, a layer of sheathing 188 is then:
: 35 secured to the ceiling trusts 176/ and more particularly
.
w~ 93/1427~ ~ ~ 2 7 ~ ~ O PCT/US93/0027l
-33-
the upper flanges 180 thereof~ Thereafter, a layer of
roofing material 190 is applied to the layer of sheathing
188. As seen in Figure lg, when the sheathing 18B is
applied to the upper flanges 180, a space 192 is formed
S between the upper plane of the ceiling sectlons 186 and the
sheathing 188. As seen in Figure 18,~is space 192
created between the ceiling sections 186 and sheathing 188
forms an air pathway for ventilating and cooling the roof
surface when eave and ridge vents are installed.
~dvantageously, flat, shed and gabled roofs are easily
designed utilizing the roof structure 174 of the present
invention. As can be appreciated, ventilation of the roof
structure 174 facilitated by the air pathway carries off
heat and prevents heat buildup on the roof surface thus
extending khe life of the layer of roofing l90.
Additionally, the fresh air introduction and circulation
within th~ roof structure 174 is provided by a natural
chimn~y effect without electric fans and without
compromising the insulatio~.
20Due to the mann~r in which the floor structure 12,
. wall structure 42 and roof structure 174 of the present
; invention are pre~fabricated, all wall, flooring and roof
portions:of the residential structure 10 may be assembled
: utilizing only~screw fasteners and a drill. Additionally,
: 25 due to the dimens~ional stability associated with the pre-
apertured tràcks ~4, 66, posts 56 and beams 98, 100 as well
: ~ as the interlocking overlay of the wall panels 126, the
residential:structure 10 may be constructed with unskilled
labor in:la minimal amount of time and with a minimal amount
:~ : 30 of difficulty. In this respect, in fabricating the wall
structure 42, one post 56 may be first plumbed with all
: other posts~56~heing subsequently au~omatically plumbed due
: to khe dimensional sta~ility associated with the pre-
:~ fabricated registration means of the tracks 44, 66, i.e.
the flanges 58 and track brackets 74. Further; the manner
WO93/14Z78 PCT/VS93/00271
~12~881~
34-
of forming the floor, wall and ceiling strutures of the
present invention promotes increased resistance to shear
and enhanced seismic stability due to the formation of
monolithic structures which take advantage of the
compressive strength of the foam components thereof.
Further, those skilled in the art wil~ecognize that
the present invention takes a substantial departure from
the prior art by providing a pre-fabricated, pre-apertured
building system which is assembled by progressively working
solely from one side of the structural posts, with all
fasteners being inserted from one side of all posts. This
feature permits unskilled labor and is only a~hieved by the
high tolerance pre-fabrication of the structural building
elements.
Additional modifications and improvements of the
present invention may also be apparent to those skilled in
the art. Thus, the particular combination of parts
~escribed and illustrated herein is intsnded to represent
only one embodiment of the invention, and is not intended
2Q to serve as limitations of alternative devices within the
spirit and scope of the invention.
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