Low energy building

• US 4,435,928 A
• Filed: 03/30/1981
• Issued: 03/13/1984
• Est. Priority Date: 03/30/1981
• Status: Expired due to Fees

• Current Assignee: Edward E. Huling III
• Original Assignee: Edward E. Huling III
• Inventors: Huling, Edward E. III
• Primary Examiner(s): RIDGILL JR, JAMES
• Application Number:
  US06/249,149
• Time in Patent Office: 1,079 Days
• Field of Search: 52/90-94, 52/665, 52/666, 52/474, 52/292, 52/293, 52/299, 52/586, 52/509, 52/512, 52/483, 52/127.1, 52/309.4
• US Class Current: 52/91.1
• CPC Class Codes: E04B 1/26 the supporting parts consisting of wood
• CPC Class Codes: E04B 1/49 with self-penetrating parts, e.g. claw dowels

Abstract

A prefabricated, low-energy building adapted to be erected on a usual foundation wall, has a prefabricated modular post and beam frame of heavy wooden timbers fastened together with hardware concealed from within the building. The timbers are relatively short and light in weight permitting the construction to be completed on the site one floor level at a time and allowing the frame to be extensible in length, width and height to form buildings of diverse exterior shape and size. The side walls, end walls and roof of the building are completed by a prefabricated modular panel system including frameless sandwich type panels which are secured to the outside of the framework and envelop the latter from the roof ridge to and below the top of the foundation wall. The panel system also includes means for sealing against infiltration and conduction heat losses through the walls and roof and also between abutting panels. Improvements in the modular frame and panel systems are disclosed which greatly simplify the erection and utility of the building.

Claims

1. A low energy building having one or more stories adapted to be erected one story at a time on an existing foundation from prefabricated components comprising:

a modular post and beam framing system including;

short, integral beams of at least two modules length having vertical rectangular joist notches cut therein at modular increments along their length,

floor joists having their ends seated in said notches,

a plurality of boards laid on top of said beams and said joists forming a floor at each story of the building,

posts upstanding from said floors at suitable spacing and height to provide modular openings for the side and end walls of the building

roof rafters supported at one of their ends on said beams and meeting at another of their ends at the roof ridge,

a plurality of prefabricated laminated panels secured to said framing system and covering said openings;

said panels having a central core member of insulating material, an outer layer of siding material connected to one side of said core by a layer of adhesive, and an inner layer of finish material connected to the other side of said core by a layer of adhesive.

2. The framing system in accordance with claim 1 wherein sheet metal spiked plates are secured to the tops of said short, integral beams and joists overlying their abutting areas.

3. A building according to claim 1 wherein rectangular plates are nailed to adjacent panels through the predrilled holes provided at each corner of said plates and said panels are spiked to the outside surface of said framing system by spikes extending through a central hole in said plates and between the edges of adjacent panels.

4. The low energy building according to claim 1 wherein means are provided to disguise the longitudinal exposed joint between two adjacent inner layers of finish material on said laminated panels comprising:

said inner layer having a plurality of wood boards oriented to extend the full length of said laminated panels, wherein the joints between said boards appear visually identical to the tightly abutting joint between two adjacent panels.

5. A laminated panel system wherein said panels are applied to the side and end walls of a building and to the roof rafters and present a continuous insulating envelope which extends from the roof ridge to and below the top of the foundation comprising:

an insulation-to-insulation joint where the vertical wall panels meet the sloping roof panels,

an insulation-to-insulation joint where the end wall panels meet the side wall panels, and

an insulation-to-insulation joint where the roof panels from one side of the roof meet the roof panels from the other side of the roof.

6. A panel system according to claim 5 having a prefabricated ledger assembly including a layer of finished wood laminated to the outside of an insulating board of substantial thickness, a thin sheet of material laminated to the inside of said insulating board, said ledger assembly being fixed to the first floor assembly and of sufficient width to extend below the joint between the beams and joist of said first floor assembly and the top of the foundation wall of the building, said ledger assembly consisting of sections of convenient length joined together at their abutting ends and extended continuously about the entire building and providing a level base on which to support the first floor panels during erection and forming a permanent and attractive part of the finished building.

7. The panel system according to claim 5 wherein first floor wall panels extend below the surface of the first floor, thereby insulating the area at the joint between the wall framing and the floor.

8. A low energy panel system adapted to be erected on an existing foundation from prefabricated components wherein a means is provided to position the continuous insulation layer of said panel system in closely abutting relation to the frame of a window and in which one or more panels are adapted to have a rectangular opening cut therein to receive a prefabricated window assembly comprising:

window jambs in closely abutting relation to foam insulation around the entire perimeter of said rectangular opening from the innermost edge of said foam insulation to the outermost edge,

an exterior casing overlying said panels and secured to said outside layer of said panel about the window opening therein,

an inner casing secured to said jambs and to said inside layer of said panel.

9. The panel system in accordance with claim 8 wherein a layer of foam sealant is provided between the window jambs and the insulating core material of the adjacent panel.

10. The panel system in accordance with claim 8 wherein a prefabricated door assembly is installed in said rectangular opening.

11. On a low energy modular panel system a means of filling the insulation void created by the intersection of standard side wall and roof panels, comprising:

a special laminated eave panel to nest with the first roof panel to provide continuity of insulation between wall and roof.

12. The panel system in accordance with claim 11 wherein said special eave panel is derived from a standard modular panel and whereby the remaining piece of said standard modular panel complements the angle of said special derived eave panel to form the first row of roof panels.

13. On a low energy panel system a means of filling the insulation void created by the intersection of standard side wall and end wall panels, comprising:

a special laminated corner panel to nest with the side wall and end wall panels to provide continuity of insulation between wall and roof panels.

14. On a low energy panel system a means of filling the insulation void created by the intersection of standard end wall and roof panels, comprising:

a special laminated rake panel to nest with the top row of end wall panels and the roof panels to provide continuity of insulation between wall and roof.

15. A modular floor and ceiling assembly for a post and beam building comprising:

short integral beams placed end-to-end having vertical joist notches therein at modular increments along their length,

short joists having their ends seated in the notches in said beams,

sheet metal spiked plates fastened to the tops of said beams and joists at their areas of abutment, and

finished material fastened to the tops of said beams and joists overlying said plates and presenting finished surfaces for floor and ceiling.

16. The modular floor assembly in accordance with claim 15 wherein means are provided to support a partial roof weight load comprising:

a carrying beam floor joist of greater cross-section than said typical floor joists, and having both ends milled to precisely fill said vertical rectangular joist notches.

17. A prefabricated laminated panel adapted for use in modular construction, comprising:

an outside layer of exterior siding material,

a thick core of insulating material,

an inside layer of finish material,

layers of adhesive material between said core and said inside and outside layers, and

means of insuring that said inside layer of finish material of adjacent panels engage in closely abutting relation said means comprising a tolerance rout about the margin of said exterior siding material which extends through said material and a short distance into the adjacent core material.