US3800489A

US3800489A - Modular wall construction

Info

Publication number: US3800489A
Application number: US00214539A
Authority: US
Inventors: G Boice
Original assignee: Structural Systems Inc
Current assignee: Structural Systems Inc
Priority date: 1972-01-03
Filing date: 1972-01-03
Publication date: 1974-04-02
Anticipated expiration: 1991-04-02

Abstract

A wall structure comprising opposed panels supported on spaced apart vertical and horizontal channels mounted on support elements having differently configurated structures. The space between the opposed panels can remain open or be filled with a permanent building material. A variety of wall base constructions are provided, together with detachable frame assemblies for mounting doors and windows in the wall structure.

Description

United States Patent Boice Apr. 2, 1974 [54] MODULAR WALL CONSTRUCTION 3,475,870 11/1969 Birum 52/498 x [75] Inventor: G. Newton Bo ce, McKeesport Pa- 3,487,60l 1/1970 James 52/498 X Assigneer Structural y Primary Examiner-Price c. Faw, Jr.

MCKBCSPOTL Attorney, Agent, or Firm-Christel & Bean [22] Filed: Jan. 3, 1972 21 Appl. No.: 214,539 [571 ABSTRACT A wall structure comprising opposed panels supported [52] U S CI 52/208 52/498 on spaced apart vertical and horizontal channels [51] E66) 1/04 mounted on support elements having differently con- [58] Fieid 4 214 498 figurated structures. The space between the opposed panels can remain open or be filled with a permanent [56] References Cited building material. A variety of wall base constructions are provided, together with detachable frame assem- UNITED STATES PATENTS blies for mounting doors and windows in the .wall 2,945,269 7/1960 Domen 52/498 X tructure 2,983,001 5/l961 Gulda'geL. 52/208 3,090,085 5/1963 Brown 52/498 X 6 Claims, 79 Drawing Figures ATENTEDAPR 21974 sum over 17 PATENTEBAPR 21974 sum '06 or17 PATENIEDAPR 2:914

saw um 17 /IIII' FIG. 25

FIG. 27

PAIENTEDAPR em I 1800.489 sw ne or17 PATENTEHAPR 2 I974 saw 10 or 17 PAIENTEDAPR 2 m4 SHEET '12UF17 FIG. 52

PAIENTEBAPR 2mm 3,800,489

' saw 150F17 BACKGROUND OF THE INVENTION This invention relates generally to the construction art and, more particularly, to certain new and useful prefabricated, modular building constructions.

There presently exists a need for an inexpensive and practical form of construction for residential housing, industrial, commercial and institutional buildings which can be mass produced and prefabricated off the job site and readily installed at the construction site by unskilled labor with maximum efficiency. In an effort to satisfy this need, various prefabricated modular building constructions have been proposed to provide structures which can be readily installed and which are demountable and movable to shift walls, partitions and the like to other positions. While these prior known prefabricated constructions partially satisfy this need, they possess certain disadvantages. Some of these constructions include structural elements and components which span the entire width between walls to interfere with the placement of conduits, piping and the like. Sometimes, these known constructions do not provide adequate sound and heat control and are not capable of withstanding abnormally elevated temperatures, such as accompany a tire. Moreover, their versatility is often limited so that the various components constituting the prefabricated construction can not be readily interchanged or combined to form a variety of arrangements.

SUMMARY OF THE INVENTION A primary object of the present invention is to obviate the above disadvantages by providing an improved modular wall construction, which can be quickly erected at the construction site by unskilled labor and which results in a strong and rigid construction, which is attractive in appearance, extremely versatile, relatively low in costs, and which possesses desirable sound and heat control qualities.

Another object of this invention is to provide a detachable, double wall panel construction defining a substantially uninterrupted space therein which can be left undisturbed for the placement of conduits and the like therein, or which can be filled with concrete or other building material in which case the detachable double wall panel construction serves as a pouring form which can either be removed when the building material has set to leave a permanent wall core remaining or which can remain intact to form with such core a composite permanent wall structure.

Another object of the present invention is to provide the foregoing double wall panel construction with a plurality of novel components having a structural configuration whereby they can be used in pairs in a nested relation or combined with each other to support the double wall panel construction in any orientation as perimeter or partition walls.

Still another object of this invention is to provide the foregoing wall construction with various detachable frame assemblies for mounting doors, windows and the like therein.

A further object of the present invention is to provide the foregoing double wall panel construction with supporting base structures in a variety of forms to enable erection of the former in any desired arrangement.

The foregoing and other objects, advantages and characterizing features of this invention will become clearly apparent from the ensuing detailed description of illustrative embodiments thereof, taken together with the accompanying drawings wherein like reference numerals denote like parts throughout the various views.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary, perspective view of a modular, double wall structure, constructed in accordance with the present invention;

FIG. 2 is a perspective view of a pair of spaced channel members of this invention;

FIG. 2A is a perspective view of a spacer plug adapted to be interposed between the channel members of FIG. 2;

FIG. 3 is a front elevational view, on a reduced scale, showing the channel members of this invention arranged in a rectangular pattern;

FIG. 4 is a top plan view of a base channel member used with this invention;

FIG. 4A is a vertical sectional'view, illustrating one form of a floor edge member incorporated in this invention;

FIG. 5 is a fragmentary, perspective view illustrating basic structural elements in an assembled relation for supporting the channel members in a spaced relation;

FIG. 6 is avertical sectional view, on an enlarged scale, showing the structural elements of FIG. 5 in combination with the base channel members of FIG. 4, to gether with various plug elements;

FIG. 6A is a view similar to FIG. 6 showing the assembly of the latter secured together by an anchor element;

FIG. 7 is a horizontal sectional view, on an enlarged scale, taken about on line 7-7 of FIG. 5, illustrating connector clips for joining the channel members together;

FIG. 8 is a fragmentary, vertical sectional view, showing base clips used in conjunction with this invention;

FIG. 9 is a perspective view ofa foundation shoe element of this invention;

FIGS. 10 and 11 are perspective views of inner and outer corner foundation shoe elements used in this invention; I

FIG. 12 is a perspective view of a combination of differently configured foundation shoe elements arranged to form a T intersection;

FIG. 13 is a perspective view of a structural bridging plate incorporated in this invention;

FIGS. 14 and 15 are perspective views of inner and outer corner structural angles used in this invention;

FIGS. 16 and 17 are perspective views of inner and outer structural runner angles used in this invention;

FIG. 18 is a fragmentary, sectional perspective view, on an enlarged scale, taken about on line 18-48 of FIG. 4;

FIGS. 19 and 20 are fragmentary, perspective views, illustrating various stages of the formation of one form of spacer used in conjunction with this invention;

FIG. 21 is a fragmentary, longitudinal sectional view of one form of a spacer assembly of this invention;

FIG. 22 is an exploded view of a fastening assembly of this invention;

FIG. 23 is a longitudinal sectional view, partly in elevation, showing the fastening assembly of this invention securing various structural elements together;

FIG. 24 is a fragmentary, perspective view illustrating a cross brace member assembled with one of the corner structural angles of this invention;

FIG. 25 is a horizontal sectional view illustrating some basic components of this invention for supporting the channel members in a spaced relation;

FIG. 26 is a fragmentary, cross sectional view, partly in elevation, illustrating a tool implement of this invention used for detaching interlocked structural members;

FIG. 27 is a fragmentary, sectional view illustrating a portion of a finished double wall construction incorporating the spaced wall panel members of this invention;

FIG. 28 is a fragmentary, sectional view illustrating a modified wall panel member especially adapted for use as a form in the pouring of a pliant building material;

FIG. 29 is a framentary, horizontal sectional view, on an enlarged scale, taken about on line 29-29 of FIG. 1, showing a corner construction in accord with this invention;

FIG. 30 is a cross sectional view of a corner trim element used in this invention;

FIG. 31 is a cross sectional view of an inner corner filler block used in conjunction with this invention;

FIG. 32 is a cross sectional view of a backing strip incorporated in this invention;

FIG. 33 is a vertical sectional view, on an enlarged scale, taken about on line 33-33 of FIG. 1, showing one form of a wall base construction of this invention;

FIG. 34 is a cross sectional view of one form ofa filler block employed in the wall base construction of FIG. 33, shown assembled with a modified form of base clip;

FIG. 35 is a view similar to FIG. 33, showing spaced panel members supported on the wall base construction thereof;

FIG. 36 is a cross sectional view of one form of a base edging member utilized in the wall base construction of FIG. 35;

FIG. 37 is a cross sectional view of another form of a base edging member optionally used in the wall base construction of FIG. 35;

FIG. 37A is a cross sectional view of still another form of a base edging member incorporating electrical connection means therein;

FIG. 38 is a cross sectional view, partly exploded, of another form of wall base construction;

FIG. 39 is a view similar to FIG. 38 showing the various components in an assembled relation;

FIG. 40 is a fragmentary, vertical sectional view, of still another form of a wall base construction of this invention;

FIG. 41 is a cross sectional view of a modified base clip used in conjunction with the wall base construction of FIG. 40;

FIG. 42 is a cross sectional view of another form of filler block of this invention;

FIG. 43 is a cross sectional view of another form of filler block of this invention;

FIG. 44 is a view similar to FIG. 40, showing a completed wall base construction;

FIG. 45 is a cross sectional view of an element employed in the wall base construction of FIG. 44;

FIG. 46 is a cross sectional view of a carpet retaining element used in conjunction with the element of FIG. 45;

FIG. 47 is a cross sectional view of a floor edging member used with the wall base construction of FIG. 44;

FIG. 48 is a vertical sectional view, illustrating still another form of a wall base construction of this invention;

FIG. 49 is a cross sectional view of a modified base clip used in conjunction with the wall base construction of FIG. 48;

FIG. 50 is a vertical sectional view, taken about on line 50-50 of FIG. 1, showing one form of a threshold assembly;

FIG. 51 is a vertical sectional view ofa wall base construction, showing another form of wall base construction;

FIG. 52 is a vertical sectional view illustrating a modified form of wall base construction and threshold assembly;

FIG. 53 is a partially cut away and sectional perspective view of the double wall construction of this invention, showing a threshold component prior to assembly with the former;

FIG. 54 is a fragmentary, horizontal sectional view of a door assembly used in this invention;

FIG. 55 is a partially cut away and fragmentary, sectional perspective view of a door frame assembly component, showing a portion of the door assembly secured thereto;

FIG. 56 is a horizontal sectional view, on an enlarged scale, taken about on line 56-56 of FIG. 1;

FIG. 57 is a cross sectional view, of a locking member, used in conjunction with the door frame assembly of this invention;

FIG. 58 is a partially cut away and fragmentary, sectional perspective view of a header assembly forming a part of the door frame assembly;

FIG. 59 is a fragmentary, vertical sectional view, on an enlarged scale, taken about on line 59-59 of FIG.

FIG. 60 is a vertical sectional view, illustrating portions of the door frame assembly in a solid wall construction;

FIG. 61 is a vertical sectional view, partly in side elevation, showing the header and side frame of the door frame assembly just prior to assembly;

FIG. 62 is a horizontal sectional view taken about on line 62-62 of FIG. 60;

FIG. 63 is a view similar to FIG. 61, showing the threshold and side frame of the door frame assembly just prior to assembly;

FIG. 64 is a fragmentary, perspective view of the double wall construction of this invention, illustrating a cut out section for the placement of a window therein;

FIG. 65 is an expanded view of a window frame assembly including a window unit therefor constructed in accordance with this invention;

FIG. 66 is a fragmentary, perspective sectional view, on an enlarged scale, taken about on lines 66-66 of FIG. 1;

Claims

1. Means for supporting a glazing assembly in a wall construction comprising: a wall structure provided with a rectangular opening therethrough defined by vertical and horizontal edges; a window frame assembly comprising a plurality of separably mounted channel shaped members arranged and interfitted vertically and horizontally to form an assembled frame for said opening; each of said members comprising a web overlying one of said edges and spaced, parallel outer legs extending in a direction generally normal to said web in overlapping relation with portions of the exposed surfaces of said wall structure; said web having a longitudinal recess substantially centrally thereof for supporting a glazing assembly; said recess defining a longitudinal abutment shoulder against which one side of said glazing assembly is positioned; said web having a longitudinal groove adjacent said recess and a separable locking member concealing a portion of said channel member and having a projection snap fitted into said groove and engagable against the other side of said glazing assembly for securing said glazing assembly in place.

2. Means for supporting a glazing assembly in a wall construction comprising: a wall structure provided with a rectangular opening therethrough defined by vertical and horizontal edges; a window frame assembly comprising a plurality of channel shaped members arranged vertically and horizontally to form a frame for said opening; each of said members comprising a web overlying one of said edges and spaced, parallel outer legs extending in a direction generally normal to said web in overlapping relation with portions of the exposed surfaces of said wall structure; said web having a longitudinal recess for supporting a glazing assembly and a longitudinal groove adjacent said recess; and a separable locking member having a projection snap fitted into said groove for securing said glazing assembly in place; said wall construction comprising a pair of spaced panel members and said channel shaped member including an intermediate leg in substantial parallelism with said outer legs and extending between said opposed panel members.

3. Means for supporting a glazing assembly in a wall construction comprising: a wall structure provided with a rectangular opening therethrough defined by vertical and horizontal edges; a window frame assembly comprising a plurality of channel shaped members arranged vertically and horizontally to form a frame for said opening; each of said members comprising a web overlying one of said edges and spaced, parallel outer legs extending in a direction generally normal to said web in overlapping relation with portions of the exposed surfaces of said wall structure; said web having a longitudinal recess for supporting a glazing assembly and a longitudinal groove adjacent said recess; and a separable locking member having a projection snap fitted into said groove for securing said glazing assembly in place; said locking member being provided with right angularly related legs; one of said legs overlying one of said channel member outer legs and the other locking member leg overlying a portion of said web and terminating in said projection.

4. Supporting means as defined in claim 3 wherein said one locking member leg is provided with an inturned flange for snap-fitted engagement behind the edge of said one channel member outer leg.

5. Supporting means as defined in claim 3 wherein the opposite ends of said one locking member leg project axially beyond said other right angularly related leg thereof and are provided with inturned segments engagable against the edges of said one channel member legs of said vertically extening channel shaped members.

6. Means for supporting a glazing assembly in a wall construction comprising: a wall structure provided with a rectangular opening therethrough defined by vertical and horizontal edges; a window frame assembly comprising a plurality of channel shaped members arranged vertically and horizontally to form a frame for said opening; each of said members comprising a web overlying one of said edges and spaced, parallel outer legs extending in a direction generally normal to said web in overlapping relation with portions of the exposed surfaces of said wall structure; a glazing asssembly; said web having a longitudinal recess for supporting said glazing assembly and a longitudinal groove adjacent said recess; a separable locking member having a projection snap fitted into said groove for securing said glazing assembly in place; said glazing assembly comprising a rectangularly shaped primary frame having a recessed offset portion for supporting a glazing panel for defining an abutment bearing shoulder ofr one side of said glazing panel; and a secondary rectangularly shaped frame secured to said offset portion and bearing against the other side of said glazing panel to secure the latter in place.