US3562978A

US3562978A - Building construction

Info

Publication number: US3562978A
Application number: US781671A
Authority: US
Inventors: Ewgeni Ali-Oglu
Original assignee: COMPONOFORM Inc
Current assignee: COMPONOFORM Inc
Priority date: 1965-02-16
Filing date: 1968-10-10
Publication date: 1971-02-16
Anticipated expiration: 1988-02-16
Also published as: GB1150871A

Abstract

A BUILDING CONSTRUCTION COMPRISING MODULAR CROSS ARM COLUMNS, FLOOR SLABS, BUILDING SLABS AND RELATED STRUCTURES IS PROVIDED. THE WALL PANELS WHICH MAY BE USED AS INTERIOR WALL PANELS HAVE AT LEAST ONE SIDE EDGE CARRYING AN ELONGATED FASTENING MEANS FOR INTERLOCKING WITH AN EDGE OF AN ADJACENT WALL PANEL AND FOR PREVENTING MOVEMENT OF SUCH INTERLOCKED PANELS DIRECTLY AWAY FROM EACH OTHER WHILE PERMITTING SLIDING OF SAID PANELS ALONG A LINE FIXED WITH RESPECT TO EACH OTHER AND SUBSTANTIALLY PARALLEL TO THE ONE SIDE EDGE. THE FASTENING MEANS COMPRISES HOOK MEANS FOR POSITIVELY PREVENTING MOVEMENT OF TWO INTERLOCKED PANELS DIRECTLY AWAY FROM EACH OTHER WITHOUT FIRST DESTROYING THE HOOK MEANS.

Description

Feb. 16, 1971 E. ALI-OGLU BUILDING CONSTRUCTION 7 Sheets-Sheet 1 Original Filed Feb. 15. 1966 INVENTOR BY A E. ALI-OGLU 3,562,978

BUILDING CONSTRUCTION 7 Sheets-Sheet 2 FIG. 6

Feb. 16, 1971 Original Filed Feb. 15. 1966 INVEN R FIG. 70

Feb. 16, 1971 E. ALI-OGLJJ BUILDING CONSTRUCTION 7 SheetsSheet 3 Original Filed Feb. 15. 1.966

FIG. I70

FIG. 79

FIG. Tb

l o" H. Il d-ca INVENTOR Que BY 9* m 2 ATTOR Feb. 16, 1971 ALI-OGLU 3,562,978

BUILDING CONSTRUCTION Original Filed Feb. 15. 1966 7 Sheets-Sheet 4.

7| FIG. ll

INVENTOR BY l" Feb. 16, 1971 E. ALI-OGLU BUILDING CONSTRUCTION 7 Sheets-Sheet 5 Original Filed Feb. 15. 1966 FIG. 7f

FIG. 7k

Al/l/l/A k. Panza FIG. 7d

Feb. 16, 1971 E. ALI-OGLU BUILDING CONSTRUCTION i i I i iti o Illll-l illll ll llilfillllllllli .Ilir! lllllllllllllllllllllllllll llm lfi.

7 SheetsSheet 6 FIG. 24

INVENTOR ATTORNEY FIG. 23

ltllll Original Filed Feb. 15'. 1966 Feb. 16, 1971 E. ALI-OGLU 3,562,978

BUILDING CONSTRUCTION Original Filed F91). 15. 1966 7 Sheets-Sheet 7 I I i INVENTOR ATTORNEY United States Patent US. Cl. 52122 12 Claims ABSTRACT OF THE DISCLOSURE A building construction comprising modular cross arm columns, floor slabs, building slabs and related structures is provided. The wall panels which may be used as interior wall panels have at least one side edge carrying an elongated fastening means for interlocking with an edge of an adjacent wall panel and for preventing movement of such interlocked panels directly away from each other while permitting sliding of said panels along a line fixed with respect to each other and substantially parallel to the one side edge. The fastening means comprises hook means for positively preventing movement of two interlocked panels directly away from each other without first destroying the hook means.

This application is a continuation in part of US. patent application Ser. No. 527,450 filed Feb. 15, 1966 and now abandoned.

The present invention relates to building construction and more particularly to modular building structures and prefabricated components for use in forming such structures. The invention is useful to permit building of a great variety of structures with a minimum amount of module components and can be used for homes, schools, oflices and other structures.

Prefabricated constructions are well known in the building industry but are often limited in usage due to cost, difiiculty of assembly, lack of versatility or other reasons.

An important object of this invention is to provide a modular building construction which provides for great rigidity and strength with a small number of module units which can be rapidly and economically assembled to form a variety of structures.

Another important object of this invention is to provide a plurality of relatively inexpensive components for use in the building construction in accordance with the preceding object.

Still another object of this invention is to provide a means and method for reducing the Weight of cast or molded components of a prefabricated or other cement type construction which means and method are inexpenv sive and simple to use.

Another object of this invention is to provide a means and method in accordance with the preceding object utilizing paper products which are compacted for storage and shipment and rapidly expandable for use.

According to the invention, a modular building construction comprises a building skeleton made up of a plurality of concrete columns with each column carrying integral radiating arms in cross formation. Ends of the arms of one column are rigidly joined to the ends of the arms of at least one other column to form a rigid modular building frame. A plurality of concrete floor/ceiling slabs rest on the radiating arms. Preferably adjacent cross arms are rigidly joined together through intermediate tie beams. The building frame or skeleton is covered with concrete exterior wall slabs in module form or with lightweight interlocking modular panels and the interior of the building frame can be divided into suitable rooms or compartments by the use of module wall panels carrying interconnecting or locking means at their edges.

Preferably, the columns, cross arms, tie beams, fioor/ ceiling slabs and outer wall slabs are formed of concrete. The floor/ceiling slabs and wall slabs are preferably provided with hollow spaces to reduce weight while maintaining cross sectional area and strength over long spans. The hollow spaces are preferably provided by the use of inexpensive cores positioned in molds when the slabs or other concrete members are formed. Preferably the cores are constructed to allow flat shipment and compact storage yet provide for expansion into rigid forms of substantial size.

It is a feature of the invention that the skeleton construction of the columns, cross arms and tie beams used provides rigidity and acts as a means for mounting wall panels and other components of varying types without the need for said wall panels and other components providing strength or rigidity to the overall building construction.

These and other features, objects and advantages of the present invention will be better understood from the following specification when read in conjunction with the accompanying drawings in which:

FIG. 1 is an exploded view of a preferred embodiment of a building construction in accordance with the present invention;

FIGS. 2, 2a and 2b are top views of module floor slabs thereof;

FIG. 3 is a cross sectional view taken through line 33 of FIG. 1;

FIG. 4 is a cross sectional view taken through line 44 of FIG. 1;

FIG. 5 is a cross sectional view taken through line 5-5 of FIG. 1 showing a completed joint between two side edges of two fioor slabs resting on a cross arm tie beam joint;

FIG. 6 is a cross sectional view taken through line 66 of FIG. 1 showing a completed joint;

FIG. 6a is a top view of the joint shown in FIG. 6;

FIG. 7 is a cross sectional view taken through a completed joint between two axially extending columns and cross arm members taken along line 7-7 of FIG. 1;

FIG. 7a is a top plan view of the joint shown in FIG. 7 taken along line 7a7a thereof;

FIGS. 7b, 7c, 7d, 7e and 7] are cross sectional views taken on a vertical plane through the center of aligned columns in alternate joint constructions of this invention;

FIGS. 7g, 7h, 7i, 7 and 7k are cross sectional views through lines 7g7g of FIG. 7b, 7h7h of FIG. 7c, 7i-7i of FIG. 7d, 7j-7j of FIG. 7e and 7k7k of FIG. 7 respectively;

FIG. 8 is a top plan view of a column and cross arm component of this invention;

FIG. 8a is a side view thereof;

FIG. 9 is a top plan view of a preferred embodiment of a tie beam component;

FIG. 9a is a side view thereof;

FIG. 10 is a side view of an exterior wall slab of this invention;

FIG. 11 is a top plan view thereof;

FIGS. 11a, 11b, and are top plan views of alternate sizes for module exterior wall slabs as illustrated in FIGS. 10 and 11;

FIG. 12 is a top plan view of an alternate embodiment oi the exterior wall slabs of this invention;

FIG. 13 is an exploded view of a connector useful in the preferred embodiment of this invention;

FIG. 14 is a side view of a joint between components of this invention;

FIG. is a top plan view of still another joint construction in accordance with this invention;

FIG. 16 is an enlarged plan view of the element shown in FIG. 12 positioned with respect to a column member of this invention;

FIGS. 17. 17a, 17b, 17c and 17d illustrate diagrammatically various size internal wall panels useful in the building construction of this invention;

FIG. 18 is an exploded perspective view of two adjacent interior wall panels of this invention and a connector element;

FIG. 19 is a cross sectional view on a vertical plane through another joint construction of this invention;

FIG. 20 is a cross sectional view on a horizontal plane through a joint between four interior wall panels in accordance with this invention;

FIG. 21 is a cross sectional view on a vertical plane through an interior wall panel of this invention joined to a ceiling;

FIG. 22 is a cross sectional view on a vertical plane through an interior wall panel of this invention joined to a floor;

FIG. 23 is a cross sectional view on a horizontal plane through a door frame joint construction in accordance with the present invention;

FIG. 24 is an end view of a gasket strip of this invention;

FIGS. 25, 25a, 25b and 26 are cross sectional views taken on horizontal planes through alternate joint constructions of the type shown in FIG. 18;

FIG. 27 is a fragmentary perspective view of a core element in accordance with this invention;

FIG. 28 is a plan view of a blank for the coring element shown in FIG. 27;

FIG. 29 is a fragmentary perspective view of an alternate embodiment of the coring element of this invention;

FIG. 30 is a plan view of a blank thereof; and

FIGS. 31 and 32 are perspective views of alternate embodiments of coring elements in accordance with this invention.

With reference now to the drawings and more particularly FIG. 1, a building construction 10 in exploded form is shown made up of column components 11, tie beams 30, floor/

ceiling slabs

12, 13 and 14 and exterior wall slabs 15. All of these components are prefabricated preferably of cement or other cementious type material commonly used in the building industry. By selecting predetermined module size components, a variety of structures can be built with a minimum number of diverse size components. In the preferred embodiment, the components are dimensioned on a four foot square module unit although other preselected sizes can be used.

The building skeleton is made up of groups or modules preferably comprising four column components 11 vertically arranged to form a first level upon which can be placed additional column components to provide a second or any practical number of additional layers or floors in a building construction. Similarly additional modules can be formed on a single level by adding additional columns 11. wall slabs l5 and floor/ceiling slabs if desired. Each column 11 has a vertical portion 16 carrying at its upper end integral

cross arms

17, 18, 19 and 20 preferably of equal size. The arms 17-20 lie substantially in a plane perpendicular to the axis of column portion 16. The end of each cross arm is formed with a recess 21 defined by

vertical walls

22 and 23 connected at their bottoms by a horizontal wall 24.

As best shown in FIGS. 1, 8 and 8a, reinforcing rods 25 extend longitudinally through the vertical column portion 16 of each column component preferably adjacent each of the four corners and outwardly of the upper end. Extension rods 25a are welded or otherwise joined to the lower ends of each rod 25 and extend downwardly of the lower end of each portion 16. Similarly, reinforcing rods 26 extend adjacent the four corners of each lll of the cross arms past the end walls 27 of the recesses and freely into the recesses 21. The reinforcing

rods

25 and 26 are known in precast concrete construction and conventional weight rods can be used and positioned in the columns and tie beams during fabrication using conventional procedures. In some cases the rods can be re placed with wire elements or other common reinforcing means for concrete construction. Preferably transversely extending wire elements 41 are provided at spaced intervals embedded in the cross arms. tie beams and column portions 15 surrounding the

rods

25 and 26 and act as additional reinforcements as is shown in the art.

In the preferred embodiment tie beams 30 best shown in FIGS. 1, 9 and 9a are used extending between ends of longitudinally aligned arms. The tie beams preferably have cross sections equal to the cross section of the arms of the column components 11 and are similarly fitted with recesses 21' identical with recesses 21.

Rigid joints are formed between tie beam ends and arm ends as shown in FIGS. 6 and 6a. The ends are butted as shown in FIG. 6 with the

recesses

21 and 21 facing each other to form a basically rectangular hollow recess. Preferably the ends of rods 26 at the upper portion of both the arms and tie beams are inclined downwardly at an angle and then freely outwardly parallel with the lower rods 26 of arms 19 and tie beams 30. Similar rods 26 of the tie beams butt the rods 26 of the arms and a collar 31 is crimped over each of the free butting rod ends to form rigid joints thercbetween. After the collars 31 are criinped the hollow recesses formed by recesses 21 and 21' are then filled with a grouting material of any conventional nature which may be for example conventional hydraulic cement. Thus. a strong. rigid joint can be formed between the ends of the arms and the tie beams as in the building skeleton construction shown in FIG. 1 in exploded form.

In FIG. 6 an alternate joint construction is shown wherein extension rods 26a are welded to each of the top rods 26 of the tie beam and arm at portions embedded in the concrete. The extension rods are butted and joined by a crimped collar 31. This construction gives maximized strength against both compression and tension at the joints.

In some cases, the arms of the column components can be extended and the need for tie beams eliminated by butting arms of adjacent column components against each other and forming joints of the type shown in FIGS. 6 and 611. While it is preferred to use crimped connections. it will be obvious to those skilled in the art that various joint arrangements can be made between the reinforcing rods of the components of this invention. In some cases. the reinforcing rods can extend beyond the recesses or can comprise hook members for interlocking with adjacent ends of similarly designed components. Of course the number of reinforcing rods employed in each tie beam. arm. or column section can vary as desired depending upon the load to be placed on the structure and its ultimate desired strength in the module construction.

The floor/ceiling slabs of the present invention are preferably formed with hollow chambers 35 as best shown in FIGS. 2. 2a. 2b. 3 and 4. Preferably four chambers 35 extend longitudinally through the slabs and permit maintaining a desired thickness of concrete while reducing weight and thereby greatly increasing strength at least against forces applied to the top and bottom of the slabs. The hollow chambers can be of various sizes and dimensions depending on the type of core elements used to form the chambers during molding of the floor/ceiling slabs.

Preferably the slabs each have reinforcing rods 36 of the type previously described extending both longitudinally and transversely. Preferably the side edges of the slabs each have a facing vertical wall 37 and a rebated portion formed with reversely angled longitudinally extending surfaces 40. The ends of the slabs are preferably each formed with a vertical wall 39 and an angled inwardly extending surface 38.

The corners of the basic three

slabs

12, 13 and 14 are designed differently depending on the position in which they are to lie on the building skeleton. Thus. slab 12 has square corners and is adapted to lie in the middle of a bay as shown in FIG. 1 with its ends resting on opposed tie beams or arms. Slab 13 carries two corner portions 13a reinforced with metallic supports 43 which are adapted to lie between the bottom of one column and the top of another in the position shown in FIG. I. Slab 14 has slightly elongated ends with reinforced corners such as 43 adapted to overlie cantilever sections of the cross arms as suggested in FIG. 1 with portions 43 positioned between the top of one column and the bottom of another.

In the module building construction, the ceiling/floor slabs are laid on top of the arms and tie beams as suggested in FIG. 1. Slabs 12 are substantially rectangular and are preferably middle slabs positioned with their ends resting on parallel arms and tie beams and with their sides adjacent corresponding slabs. Slabs such as 13 are placed on the outside edge of a bay with two slabs 13 each overlying half of a tie beam as best shown in FIG. 5. The floor/ceiling slabs can overlie each bay formed in the building skeleton or, since the skeleton is rigid by itself, in some embodiments the top of at least some bays can be left opened. Reinforcing rods 36 of the slabs extend outwardly of their ends and can be interlocked with adjacent slabs if desired although this is not necessary.

FIG. illustrates positioning of two slabs 13 in side by side relationship over a tie beam 30. Rebated side edges can be locked together by filling the recess thcrebetween with conventional grouting as previously described. In the joint shown in FIG. 5 the transverse reinforcing member 41 has an upwardly extending portion lying between the side edges acting to further anchor grouting (not shown) which completes the joint.

In most applications, the recess formed by the setback or rebated edges of the ceiling/floor slabs are filled with grouting material which is sufficient to smooth the surface on which top flooring may be laid and to lock the elements together due to the bending of the reinforcing rod ends as illustrated at 42 and the reverse angle of surfaces 40.

The preferred joint between an upper column component 11 and an underlying axially aligned column component 11 is best illustrated in FIGS. 7 and 7a. The lower portion of the upper column portion 16 is formed with extension reinforcing rods a welded or otherwise secured parallel to the ends of rods 25 which are cut off at the bottom edge 44 of each portion 16. Thus, extensions 25a are parallel to reinforcing rods 25 and extend outwardly of the bottom 44 so as to lie parallel to and adjacent upwardly extending rods 25. The upper portions of the rods 25 coming from the upper portion of a column are crimped together with their corresponding extension rods 250 by a collar such as 31 as previously described. As shown in FIG. 7 this joint provides for a butting face of each rod 25 of the upper column portion axially aligned with a butting face of a rod 25 of the lower portion 44. The abutting faces act to bear some of the load while a rigid joint is formed by the extension portions 25a. In some cases collars 31 can be eliminated and the rods 25 welded to extensions 25a. The extension portions 25a are preferably molded in the columns when they are cast or prefabricated. Part of the load of the upper column 11 is borne by the metallic corners 43 of the floor slabs as best shown in FIGS. 7a and 7. The collars 31 can be welded to corners 43 as shown in FIG. 70 although this is optional. Preferably metal angle irons 47 are cast in the bottoms and tops of the columns as best shown in FIG. 7 to provide load bearing edges and prevent chipping during erection of the skeleton. Thus. corners 43 extend between the bottom 44 and the top portion 45 of each of the columns. Due to the spacing of the column portion 44 from portion 45 by the floor slabs a recess 46 is formed in the joint between the column components. Since there is a recessed edge to each floor slab as illustrated in FIGS. 4 and 70,

a crimping tool can be passed into the cavity 46 to form or crimp the collars 31. Similarly grouting or suitable Waterproofing and gasketing material can be positioned in the cavity 46 after completion of the crimping operation to reinforce the joint construction.

In the alternate embodiments of the joints between the bottom 44 of one column component 11 and the top 45 of a second column component 11, extension rods 2541 are eliminated. In the joint shown in FIGS. 7!] and 7g the top of the column 11 is provided with a metallic facing plate a preferably welded or secured to top ends of reinforcing rods 25. Two crossed U-shaped connecting rods are embedded in the column and have threaded ends 1510: extending upwardly through holes provided in the facing plate 150a. Preferably plate 150a carries four outwardly extending tabs 152a through which ends 1510 extend. A second facing plate 153a preferably identical to plate 150a is welded to lower portions of rods 25 at bottom 44. The plates 153a and 150a are butted in joining two column components 11 in vertical alignment and nuts 154a applied and tightened to form a joint. This joint as Well as the joint illustrated in FIG. 7, will support the upper column component without the need for bracing during construction or until the cross arms of the upper column are joined to supporting components. In this joint the recess 46 is eliminated.

In the embodiment of FIGS. 70 and 77:, identical fiat metallic plates 180 are welded to rods 25 in the positions shown. Pairs of rods 25 of each column component pass through a plate 180 and form two upwardly extending inverted parallel U-shaped extensions 181 and corresponding parallel downwardly extending U-shaped extensions 182. Extensions 181 are offset from the axes of rods 25 as shown in FIG. 7h. Upon positioning of the column components one above another extensions 181 and 182 are parallel and define a passageway 183 in which a locking wedge is positioned to lock the components together. After wedge locking, conventional grouting is placed in recess 46 to complete the joint.

In the embodiment of FIGS. 7d and 71', rods 25 extend upwardly and downwardly from the top and bottom of each column and have enlarged ends 155 with butting faces. A split collar 156 is crimped about facing ends 155 at each of the four connections in the joint to form a rigid joint which supports the upper column. Grouting as previously described is preferably used to fill recess 46 and complete the joint.

In the embodiment of FIGS. 7e and 7 the top of column component 11 has a fiat plate 160 welded to ends of rods 25 with four outwardly extending tabs 161 positioned preferably 90 degrees apart. Ends 162 of each tab are turned over preferably at an acute angle and their top edges 163 define a first periphery greater than the periphery of column portion 16. The bottom of column component 11 has a second plate 164 welded to rods 25 and substantially identical to plate 160 but having its acute angled tabs 165 bent over at 166 with edges defining a second periphery smaller than said first periphery. In the joint,

plates

160 and 164 butt each other and four wedges 167 are forced between each set of bent over

tabs

162, 166 to form a rigid joint with the elimination of recess 46 and the need for grouting. Of course any spaces at the joint can be filled with grouting if desired.

The wedge locking effect of the joint shown in FIGS. 7e and 7 can also be achieved with modification of

plates

160, 164 as by the use of circular plates having overturned edges.

In the embodiment of FIGS. 7 and 7k, recess 46 is maintained as described with relation to FIGS. 7 and 7a. Rods 25 are cut flush with top 45 and two identical steel brackets 170 are embedded in cross formation in the top portion of column component 11. Brackets 170 are generally U-shaped in front view as shown in FIG. 7 and have integral inverted U-shaped freely extending portions 171 at either end. Preferably rods 25 of column portion 16 extend downwardly to butt ends of rods of top of an underlying column component 11. The bottom of the column portion 16 carries two identical crossed, embedded, generally Vshaped steel brackets 173 having inverted U-shaped ends 174 extending downwardly.

Ends

174 and 171 interlock as best shown in FIG. 7k to support the upper column component 11. Portion 171 can be bent over and interlocked with portions 174 after positioning of the columns as shown in FIG. 7f. Preferably in this construction grouting is used to fill recess 46 and complete the joint. The upper column component 11 should be braced or supported in position until the grouting has hardened to complete the joint.

Turning now to the exterior wall slabs or panels, a typical wall panel is shown at 15 in FIG. 11, comprising a concrete layer 51 with an interior thin concrete layer 52 sandwiching a foam or other insulating layer 53 therebetween. Preferably the concrete layer 51 is provided with hollow spaces or cores in the same manner as the floor slabs previously described. Reinforcing rods 54 or other conventional concrete reinforcing means are preferably embedded in the layer 51. The side plan view shown in FIG. 10 illustrates a module unit 15 which may for example have a width of four feet and a height of ten feet corresponding to a complete module panel reaching from ceiling to floor. Heights of seven feet and three feet may also be provided for door and sill heights respectively. These three heights of the panels are sufhcient to provide for all exterior wall surfaces. FIGS. Ila, 11b and 110 show top views of varying size and configuration panels useful in outer wall construction.

FIG. 12 illustrates joining of two module panels such as 15 having angled corners, to form a corner joint better illustrated in FIG. 16. The joint 60 has a gasket member 61 extending throughout the length of the joint in corresponding channels provided on facing 45 degree angled surfaces of the panel edges. The gasket 61 as best seen in FIG. 24 preferably comprises an elongated hollow cavity 62 and a resilient neoprene or other long-life rubber body portion 63. Preferably at least two surfaces carry adhesive means 64 which can be any of the well-known rubber cements covered by a conventional protective tear strip. This particular gasket permits compression of the gasket causing a tight seal in addition to adhesive sealing which reinforces the seal and provides a waterproof joint having long life. Other gasket means can be used in place of gasket 61.

FIG. 15 indicates still another joint between two wall panels 15 employing a gasket 61 as above described.

Preferably all four edges of the wall panels 15 have embedded wing connection means which rigidly join the panels to each other or to other components of the building construction. The connection means 70 comprises a pair of internally threaded tubes 71 having integral wing extensions wardly on each side thereof. A facing plate 73 is provided having

apertures

75 and 76 aligned with the threaded apertures of the tubes 71. Tubes 71 are preferably embedded at the edges of the concrete wall panels as best shown in F168. ll and 14 as is the facing plate 73. Pin connectors 77 are provided having a threaded end 78 and a non-threaded plug end 78a. Other connectors comprise flat headed screws 79, Thus. when adjacent or stacked wall panels are to be connected, tubes 71 present in each panel are aligned and connecting pins such as 77 as shown in FIG. 14 are used to form a joint. Where a flat floor 80 or other material is to lie directly over the joint the flat headed screw 79 is used as shown in FIG. 14. Preferably three connection means 70 are provided on each peripheral edge of each exterior wall panel.

The connection means 70 can also be used in the floor slabs. The connection means serve a dual function in that they are used to form joints and in addition are helpful in handling the panels or slabs. Thus, pins 77 can be positioned and used to attach lifting crane hooks to the 72 extending outwardly and downpanels to lift them into position in a stack or building construction.

As best shown in FIG. 14, the panels 15 preferably have a hooked inwardly extending top 81 defining a means for keying and locking the wall panels 15 with a floor/ ceiling slab. The bottom of each wall panel preferably has an angled wall 82 adapted to overlie the top angled wall 83 of an identical panel 15 permitting a planar surface to be presented on the outside of a building when wall panels 15 are stacked as in a first and second story construction fragmentarily shown in FIG. 14. The wall panels further interlock with the floor/ceiling slabs by the hooked portion 81 lying adjacent walls 40 as previously described. Various conventional moldings such as 84 can be employed in the module building construction as shown in FIG. 14.

While panels 15 have been referred to as exterior wall panels they can also function to provide room or partitioned sections in the interior of a building structure of this invention.

Turning now to FIGS. 17, 17a, 17b, 17c, 17d and 18, a lightweight interior sandwich panel construction is shown. The sandwich panel can be formed in module units as are the exterior wall panels 15 and preferably comprises plywood outer layers 91 with an intermediate sandwiched organic foam layer 92. The various layers can be varied as desired depending on the particular application of the panels. FIGS. l7l7d "illustrate various modular sizes including floor to floor heights, spandrel heights and under beam heights. The widths of the panels also vary as suggested in the drawings to provide for modular construction.

The interior sandwich panels 90 are preferably rectangular and carry fastening or joining and sealing means preferably on their vertical side edges and top edge. A mating joining and sealing means 101 is used on bottom edges of panels to be positioned vertically over similar panels. A slightly altered form of the joining and sealing means 135 (FIG. 22) is mounted on the bottom edge of the panels 90 positioned in contact with a floor. The joining and sealing means 100 is preferably an alu minum extrusion having a hacker plate 102 flush with the edge of the panel and seated thereon by longitudinally extending webs 104. The webs 104 can be locked to the panels during lamination of the sandwich layers to form a firm connection. Flange portions at the edges of the backer plate are angularly arranged slanting inwardly of the edges of the panel and outwardly of the backer plate as shown at 105 having a rabbeted recessed portion 106 for receiving a sealing gasket as will be described. A longitudinally extending channel 107 is formed by

walls

108 and 109 which have overturned inwardly extending lips or edge walls 110. The channel 107 is adapted to receive a barb such as 111 of a joining clip 112.

The joining clip 112 is preferably formed of four spring metal strips each having bent over flaps 113 at either end which extend longitudinally with the backs of the strips joined together at longitudinally extending lines 114 to form the barbs 111. The elongated bent over strips 113 are adapted to be deformed when pressed into the channel 107 and spring back to a locking position with the inturned walls as best shown in FIG. 20.

As shown in FIG. 20, four panels 90 are joined together at a corner by a single joining clip member 112. The barb construction provides for rigid interlocking while preventing passage of air from the outside through the joint construction due to the many bends that an air current must take if it is to flow from one side of any panel through the joint to another side of that panel or another panel.

As shown in FIG. 20, when a joint construction is formed. sealing gaskets 61 are positioned between the rabbeted portions 106 to further weatherize the joint and prevent passage of moisture or air. The barb joint con- 9 structions permit vertical adjustment of the panels with respect to each other after interlocking.

FIGS. 25, a, 25b and 26 illustrate various joint constructions possible using the extrusion and clip 112. In the corner section shown at 25!) a specially designed corner flashing post is used to cover the outer extremity of the corner and provide an attractive appearance. This flashing unit 120 has an inner portion designed with a channel such as 107 and a flat outer side. Similarly plates 121 can be formed with a channel 107 as previously described to cover interior sandwich panels aligned with the same plane or at a three-corner intersection as shown in FIG. 25a.

As shown in FIG. 18, the joining extrusion 101 is formed with a barb member 122 having bent over spring flaps 113 as previously described. Member 122 can be integrally formed with the extrusion 101 or can be attached as by welding of suitable folded strips of the type used in element 112. Edges of the backer plate 102 in this embodiment extend downwardly in the same plane as the faces of the panel 90 and are provided with rabbeted edges 123 to mate with

edges

105 and 106 of a member 100. A completed joint of this basic construction is shown in FIG. 21 where the extrusion is basically similar to 101. However, in the extrusion 130 shown in FIG. 21. extensions 104 are eliminated and screws are used to attach the extrusion 130 to a ceiling under which the top of a panel 90 may be connected.

FIG. 22 illustrates an elongated extrusion having a backer plate or base 131 lying adjacent the elongated bottom edge of a panel 90. The base 131 has downwardly extending side flanges 132 beneath which are positioned

wedges

133 and 134. Upwardly extending legs 136 lie on either side of the wall panel. A channel such as 107 is provided on either upwardly extending leg 136 and hooked over ends 139 form the top edges of the legs 136. The extrusion 135 is adapted to have a baseboard strip 140 clipped thereto by spring means as shown in FIG. 22. The baseboard strip 140 has a spring member 141 attached to an overturned hook portion 139 and a barb 111 as previously described to provide for positioning of the strip 140 to cover the joint between the panel and a conventional floor surfacing 142.

The

wedges

133 and 134 which underlie member 135 preferably are used in pairs with two or more pairs spaced on the floor under each panel 90. The specific number of pairs of wedges used can be varied. These wedges have angled faces 143 and 144 and are slipped under the wall panels 90 in the positions shown in FIG. 22. By pushing the wedges towards each other in the position shown in FIG. 22, they raise portions of the panel into proper alignment and locking engagement with a ceiling as the parallel grooved faces 143 and 144 catch with each other. Preferably each wedge has teeth 145 and 146 which are designed to permit sliding towards each other in the position shown and prevent reverse sliding in use. The leading face 146 of each tooth if extended meets the horizontal plane at angle A, the trailing face 147 of each tooth if extended meets the horizontal plane at angle B and the slope line C of each wedge block meets the horizontal plane at angle C. Angle A is always less than 20 degrees and can be less. Angle B can be equal to angle A and angle C is no greater than 10 degrees. Angles A and C are interrelated in that by increasing angle C angle A is increased relatively so long as face 147 is not parallel to the horizontal plane. Both angle C and the size of the teeth should be small.

FIG. 19 illustrates still another joint construction possible with the modified clip arrangements of this invention. An extrusion 150 is provided with members 104 as previously described for anchoring it to the bottom of a wall panel under which a standard wall panel 90 is to be mounted. Extrusion 150 is basically similar to extrusion 101 but has an upwardly extending leg 136 as in extrusion 13S. Leg 136 of this embodiment has predrilled holes 10 permitting attachment to panel 90 by conventional screws. The leg 136 can be integral with extrusion 150 or preferably separate as shown with a plurality of rivets 148 joining it along its length to the extrusion.

In FIG. 23 there is illustrated still another extrusion 151 which acts as a door frame member. Extrusion 151 can be provided with a barb such as 111, or as in the preferred embodiment with a plurality of holes along its length through which nails 152 are inserted. Extrusion 1S1 overlies and acts as 21 facing for the raw edge of a panel 90. An elongated door stop molding 153 is preferably attached to extrusion 151 by a plurality of screws 154 positioned along the length of the face of extrusion 151.

From the above description, it will be understood that there is provided module components for the formation of single or multiple bays in a building skeleton and wall construction on a single level or on a plurality of levels. The components described can be put together in various described configurations as desired. It is a feature of this invention that by preselecting the dimensions of the components, the number of components can be minimized to a small number of standard sizes. Thus, by using standard components. joints and sizes, one can plan a particular layout and immediately calculate the specific number of each of the components and their standard sizes necessary for construction of the layout. For example, a single structural bay can be made consisting of four column components 11, eight floor/ceiling panels and four tie beams 30. Using a 4 0" dimensional module the cross arms are 90 from end to end of aligned arms. Tie beams 30 are 8-00 long. Column components 11 are 9'-4 high. The cross sectional dimensions of the concrete cross arms, tie beams and column portions 16 are 1 0 x l-4. The floor/ceiling panels are 6 in depth, 4'0 wide and l6-5" long. With these components a standard bay 260" x 26'0 is made with a maximum enclosed space which can be 676 sq. ft. The total amount of concrete necessary for such a bay would be 5075 cu. ft. weighing about 73,680 pounds. Additional bays can be added by multiplying the number of components as desired.

While it is preferred to preform the components of this invention before delivery to a site where a building is to be constructed, the components can be formed on the construction site if desired.

Turning now to a description of core elements which are preferred for use in forming the hollow spaces in the concrete slabs in accordance with this invention, preferred embodiments of core elements are shown in FIGS. 27-32. It should be understood that these core elements are useful to form hollow spaces or passageways in many types of molded constructions. Other core elements can be used in the slabs of the present invention.

An important feature of the novel core elements of thi invention is the use of inexpensive, lightweight materials which can be shipped and stored flat and folded just prior to usage to an expanded form. The expanded form has an enclosed substantially hollow shape reinforced with a plurality of gusset members.

The word paper as used herein refers to lightweight stock sheet material which preferably has a paper base. Preferably the paper materials are impregnated or coated with waterproofing compounds in a known manner to prevent loss of strength when exposed to wet concrete during molding or casting. Suitable materials include kraft paper, cardboard, corrugated paper and the like. In the preferred embodiment, forty point chip board is used.

in the preferred embodiment of the core element shown in NO. 27, the element 210 is formed from a flat sheet of chip board 211 cut in the outline shown and having a series of prescored lines along which the sheet is to be folded in use. The sheet 211 can have substantial lengths depending upon the length of the hollow passageway desired in a concrete or other section to be cast. Normally the length will be at least four feet. Similarly the width of the sheet will be determined by the size of the hollow passageway desired. The sheet 11 can be shipped or stored in its flat form shown in FIG. 28.

The core element 210 is formed by folding along the prcscored lines indicated to form gusset members 212. 212. 213. 213'. 214, 214 outer sections 215, 215', corner ortions 216, 216', 217, 217' and semicircular portion 218. Preferably the end edges of section 212 and 212' carry a pressure-sensitive adhesive indicated at 223 and portions of walls 214 and 214' carry a similar adhesive 224 which acts to hold the expanded form 210 in position when folded as shown in FIG. 27. After folding of the gusset members into the form shown in FIG. 27. end flaps 219. 219' are folded over to close the front end with tabs 220. 220 and 221, 221', which also carry pressure-sensitive adhesive, folded over and sealed to close the float end. Similarly the rear end is closed by the corresponding 1'tt1' wardly extending flaps.

The doubled over corner sections 216, 216' strengthen the structure and permit support by conventional clips or wires in a mold cavity to position the core elements and permit concrete or other material to be poured therearound. After hardening of the poured material, the paper elements can remain in the concrete and due to their inexpensive construction do not add materially to the cost of the final products which may be floor/ceiling slab as previously described. In some cases where the passageways extend to the end of the cast sections, the paper material can be removed from the passageways after formation and hardening of the concrete.

FIG. 31 illustrates an alternate embodiment wherein a single flat sheet is folded into a generally rectangular form 230 with adhesive means 231 holding the ends of the sheet in a central portion thereof in place. Closing flaps similar to flaps 219. 219' can be used at ends of the form 230. The zig zag gusset members are adhesively secured by adhesive means 231.

In the alternate embodiment of the core element shown at 240 in FIGS. 29 and 30, a flat sheet 249 is cut. Flaps 246 are positioned on section 241 and have ends glued to the face of section 241 whereupon their free ends can be folded outwardly and transversely of a rectangular form to be folded with

panels

242, 241, 243 and 244 as shown in FlG. 29.

The sheet 249 is preferably prescored along the lines shown and folded into the position shown in FIG. 29 just prior to use. The folding of the hinges of transverse gusset portions 246 is preferably accomplished by means of a tie string 245 passing through holes provided at the free ends of the gusset portions. The tie string is knotted to provide for preselected spacing between the hinges when the rectangular outline is formed and the string pulled. As in the embodiment of FIG. 27. adhesive means can be used on the free end of panel 244 to lock the form in shape. End flaps 247 are employed along with adhesively connected tabs 248 to close ends of the core element 240. In some cases the form shown in FIG. 29 can be constructed and then folded flat prior to shipment.

In the embodiment shown in FIG. 32. two separate elongated

polygonal elements

250 and 260 are combined to form a single core element having an expanded form. Element 250 has the cross sectional form of a six-sided figure wh le element 260 has a rectangular cross sectional outline. Each of the

forms

250 and 260 can be expanded from flat sheets or tubular elements can be formed and compressed into their fiat form for shipment. Upon assembly of

elements

250 and 260 element 250 is slipped within element 260 after first applying adhesive at points 261. 262. 263, 264, 265 and 266. The adhesive can be precoated on the paper forms. When pressure-sensitive adhesives are used. conventional tear strips which can be discarded overlie the adhesive strips. Water or other solvent activated adhesives may also be employed in any of the embodiments of this invention. Suitable end flaps can be provided to close ends of the combined core elements shown in FIG. 32.

The scored lines between sections or panels of the geometric forms of the embodiments of FIGS. 27-32 can be conventional pressed lines or other weakened portions to facilitate folding. Alternatively, the fold lines may merely be printed on the sheet stock or eliminated if desired.

While specific embodiments of this invention have been shown and described. it should be understood that many modifications thereof are possible. For example, various ones of the elements can be substituted with other known structures. For example. the interior wall panels can be eliminated and other conventional interior wall panels used. in some cases wall panels 90 can be used as exterior panels to form the facing of a building. Similarly, the various elements described can be used by themselves in other constructions. The cross section of the column, cross arms and tie beams can be circular rather than square or rectangular as shown. The term cross formation" as used herein refers to the use of at least two arms on the column components 11 although four arms as in the embodiment of FIG. 1 is preferred. The various column joint constructions can be used to interconnect cross arms and ti: beams or other elongated components in end to end relationship.

What is claimed is:

1. A modular lightweight wall panel for use in a modular building construction, said panel comprising side edges,

said side edges each carrying elongated fastening means for interlocking said edges with adjacent modular wall panels and for preventing movement of such interlocked panels away front each other while permitting sliding of said panels along a line fixed with respect to each other,

said fastening means comprises an elongated backer plate mounted adjacent each edge substantially coextensive therewith,

said backer plate having flange portions tapering inwardly of sides of said panel and extending outwardly of said plate, and constructed and arranged to be received in facing engagement with corresponding flange portions of a second backer plate on a second identical wall panel,

an integral elongated channel defined by joining walls extending outwardly of said backer plate, and said joining walls carrying integral overturned edges facing each other.

2. A modular lightweight wall panel in accordance with claim 1 wherein said hacker plate flange portions are rabbeted to receive a gasket means.

3. A modular, lightweight wall panel in accordance with claim 1 wherein said fastening means is an integral extrusion and comprises,

elongated webs extending outwardly of said backer plate embedded in said panel to secure said backer plate to said panel.

4. A modular lightweight wall panel for use in a modular building construction. said panel comprising side edges.

said side edges each carrying elongated fastening means for interlocking said edges with adjacent modular wall panels and for preventing movement of such interlocked panels away from each other while permitting sliding of said panels along a line fixed with respect to each other,

an edge carrying an elongated backer plate coextensive therewith,

said backer plate having parallel side walls extending outwardly thereof and defining angled ends constructed and arranged to be received in facing engagement with a fastening means of an adjacent component,

and an elongated barb projecting from said backer 13 plate between said side walls for interlocking said backer plate with another wall panel.

5. A modular lightweight wall panel in accordance with claim 1, and further comprising an elongated connecting member,

said connecting member having a central support with at least two elongated outwardly extending spring barbs disposed at angles to each other, each constructed and arranged to enter and lock said channel of a wall panel with said connecting member.

6. A modular lightweight wall panel in accordance with claim wherein four equally dimensioned barbs are provided spaced 90 degrees apart about said central axis of said support.

7. A modular lightweight wall panel in accordance with claim 5 wherein said barbs are interlocked with the channels of four identical said wall panels with a gasket means lying betwen portions of said facing edges.

8. A modular lightweight wall panel in accordance with claim 12 and further comprising said panel having a top edge positioned adjacent a ceiling member, and a bottom edge,

wedge means underlying said bottom edge and urging said panel towards said ceiling member,

said wedge means comprising first and second wedge blocks each having a plurality of transversely extending teeth on inclined surfaces thereof,

said teeth each defining an inclined leading face defining a first angle with a horizontal plane and a reverse face defining a second angle with a horizontal plane, and a third angle defined by the slope of the inclined surface of each block meeting with the horizontal plane,

said first angle being no greater than about 20 degrees and said third angle being no greater than about degrees.

9. A modular lightweight wall panel for use in modu lar building construction, said panel having side edges and front and rear surfaces,

at least one side edge carrying an elongated fastening means for interlocking with an edge of an adjacent wall panel and for preventing movement of such interlocked panels directly away from each other while permitting sliding of said panels along a line fixed with respect to each other and substantially parallel to said one side edge,

said fastening means comprising hook means having a reversely bent hook portion for interlocking with a mating portion on an adjacent panel for substantially preventing movement of two interlocked panels directly away from each other without destruction of said hook means.

10. A modular lightweight wall panel in accordance with claim 12 wherein 14 said hook means comprises an elongated channel defined by joining walls extending outwardly of said backer plate,

said joining walls carrying overturned edges facing each other,

and said gasket means are mounted in said backer plate.

11. A modular lightweight wall panel in accordance with claim 12 wherein said hook means comprises,

an elongated central support with two elongated outwardly extending spring metal barbs disposed at an angle to each other.

12. A modular lightweight wall panel for use in modular building construction, said panel having side edges and planar front and rear surfaces,

said fastening means comprising hook means for substantially preventing movement of two interlocked panels directly away from each other without destruction of said hook means,

said fastening means further comprising a backer plate carrying said hook means and gasket means lying on either side of said hook means with said gasket means and hook means acting to provide a double seal against passage of fluids through joints between said interlocked panels.

References Cited UNITED STATES PATENTS 176,090 4/1876 Stewart 52-122 1,294,115 2/1919 Knight 52586X 1,723,306 8/1929 Sipe 52--396X 2,664,740 l/ 1954 Cochrane 52-583 2,947,040 8/1960 Schultz 52585X 3,203,149 8/1965 Soddy 52588X 3,296,759 l/l967 Paulecka 524()3X 3,310,917 3/1967 Simon 52624X 3,312,021 4/1967 Rolland 52l22 FOREIGN PATENTS 622,687 6/ 1967 Canada 52-583 FRANK L. ABBOTT, Primary Examiner P. C. PAW, JR., Assistant Examiner US. Cl. X.R.