Building structure and method of use

• US 5,353,560 A
• Filed: 06/12/1992
• Issued: 10/11/1994
• Est. Priority Date: 06/12/1992
• Status: Expired due to Fees

• Current Assignee: Heydon International Incorporated
• Original Assignee: Heydon Building Systems International, Limited
• Inventors: Heydon, John J.
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): CANFIELD, ROBERT
• Application Number:
  US07/897,909
• Time in Patent Office: 851 Days
• Field of Search: 52/290, 52/243.1, 52/243, 52/241, 52/239, 52/238.1, 52/763, 52/779, 52/778, 52/79.9, 52/79.12, 52/264, 52/270, 52/271, 52/272, 52/281, 52/284 , 52/474, 52/475, 52/593, 52/595, 52/592.1
• US Class Current: 52/281
• CPC Class Codes: B26D 3/006 specially adapted for cutting blocs of plastic material
• CPC Class Codes: B26D 3/06 Grooving involving removal of material from the surface of the work
• CPC Class Codes: B26F 3/08 with heated members
• CPC Class Codes: E04B 1/0007 Base structures; Cellars
• CPC Class Codes: E04B 1/76 specifically with respect to heat only heat insulation in general F16L59/00
• CPC Class Codes: E04B 1/7654 comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings
• CPC Class Codes: E04B 2/707 obturation by means of panels
• CPC Class Codes: E04B 2001/2415 Brackets, gussets, joining plates
• CPC Class Codes: E04B 2001/2451 Connections between closed section profiles
• CPC Class Codes: E04B 2001/2454 Connections between open and closed section profiles
• CPC Class Codes: E04B 2001/2481 Details of wall panels
• CPC Class Codes: E04B 2001/249 Structures with a sloping roof
• CPC Class Codes: E04B 2001/2496 Shear bracing therefor
• CPC Class Codes: E04B 7/22 the slabs having insulating properties, e.g. laminated with layers of insulating material
• CPC Class Codes: E04C 2003/026 Braces
• CPC Class Codes: E04H 3/02 Hotels; Motels; Coffee-houses; Restaurants; Shops; Department stores

Abstract

An improved building structure and method of use comprising separately fabricated floor, wall and ceiling structures capable of withstanding shear and seismic forces. The floor and ceiling structures of the present invention generally comprise I-beams having foam panels extending therebetween. The wall structure comprises an elongate track rigidly secured to the foundation structure of the building having a plurality of posts secured thereto. Disposed between the posts are a plurality of interlocking foam wall sections which encapsulate the posts of the wall structure. Attached to the top surfaces of the posts are header beams which serve as a support structure for the ceiling structure.

Claims

1. An improved building system including a dimensionally stable, monolithic wall structure, said wall structure comprising:

an elongate, generally U-shaped track defining a bottom wall which is extended along and attached to a horizontal foundation means and opposing side walls extending upwardly from said bottom wall, said bottom wall including a plurality of preformed, linearly aligned bottom wall apertures disposed therein at predetermined locations along the track;

a plurality of elongate, vertical posts of predetermined lengths having top ends and bottom ends, said bottom ends being attached to said track at said predetermined locations along the length thereof and including recesses disposed therein to receive portions of fasteners;

at least one elongate, horizontal header beam attached to the top ends of said posts; and

a plurality of pre-fabricated wall sections, each of said wall sections being disposed between a pair of adjacent posts and including first and second vertical edges which each abut a respective post of the post pair;

said posts and said wall sections being fabricated from materials having selected compressive, tensile and shear force properties so that when interacted with each other by the abutment of said first and second vertical edges of the wall sections against the posts, a monolithic wall structure is formed.

2. The device of claim 1 wherein said track further comprises a plurality of flanges extending perpendicularly upward from said bottom wall, each of said flanges including a plurality of pre-formed flange apertures disposed therein which are oriented so as to be in registry with pre-formed lower post apertures disposed in the bottom ends of each of said posts to receive fasteners to secure said posts to said track.

3. The device of claim 2 wherein said track is fabricated from sheet metal.

4. The device of claim 1 wherein each of said posts include a plurality of linearly aligned apertures disposed along the length thereof for interfacing said posts to pairs of window brackets.

5. The device of claim 1 wherein said posts and said at least one header beam are fabricated from wood.

6. An improved building system including a dimensionally stable, monolithic wall structure, said wall structure comprising:

an elongate, generally U-shaped track defining a bottom wall which is extended along and attached to a horizontal foundation means and opposing side walls extending upwardly from said bottom wall, said bottom wall including a plurality of pre-formed, linearly aligned bottom wall apertures disposed therein at predetermined locations along the track;

a plurality of elongate, vertical posts of predetermined lengths having top ends and bottom ends, said bottom ends being attached to said track at said predetermined locations along the length thereof;

a lower header attached to the top ends of said posts;

an upper header attached to said lower header; and

a plurality of pre-fabricated wall sections, each of said wall sections defining;

a first vertical edge having a vertical tongue formed therealong;

a second vertical edge having a vertical slot formed therewithin which defines an interior surface;

a lower edge having a pair of parallel grooves formed therein for receiving the opposing side walls of said track; and

an upper edge having a horizontal slot formed therein for receiving a portion of said lower header;

each of said wall sections being disposed between a pair of adjacent posts such that the vertical tongue thereof abuts one of the posts of the pair and the interior surface of the vertical slot thereof abuts the other post of the post pair which, together with the vertical tongue of a previously installed adjoining wall section, is received into and encapsulated by the vertical slot;

said posts and said wall section being fabricated from materials having compressive, tensile and shear force properties so that when interacted with each other by the abutment of the vertical tongues and the interior surfaces of the vertical slots of the wall sections against the posts, a monolithic wall structure is formed.

7. The device of claim 6 wherein each of saig posts is attached to said lower header via a pair of header brackets, each of said header brackets comprising;

a vertical flange portion including a pair of pre-formed vertical flange apertures disposed therein which are oriented so as to be in registry with pre-formed upper post apertures disposed in the top ends of each of said posts, said vertical flange apertures of the header bracket pair and said upper post apertures being adapted to receive fasteners to secure said header bracket pair to the top end of said post; and

a horizontal flange portion including a pair of pre-formed horizontal flange apertures disposed therein which are oriented so as to be in registry with pre-formed lower header apertures to receive fasteners to secure said header bracket pair to said lower header.

8. The device of claim 7 wherein each horizontal flange portion of said pair of header brackets and said lower header further include apertures in registry with each other and with a pair of pre-formed upper header apertures to receive fasteners to secure said upper header to said lower header.

9. The device of claim 6 wherein each of said wall sections is fabricated from polystyrene foam.

10. The device of claim 9 wherein the vertical tongues and vertical slots of each of said wall sections include a vertical groove formed therein for receiving foam to form an expanded foam seal between the vertical tongue and one post of the post pair and the vertical slot and the other post of the post pair to form a monolithic wall structure.

11. An improved building system including a dimensionally stable, monolithic wall structure, said wall structure comprising:

an elongate track which is extended along and attached to a horizontal foundation means;

a plurality of elongate, vertical posts of predetermined lengths having top and bottom ends, said bottom ends being attached to said track at predetermined locations along the length thereof;

at least one, horizontal header beam attached to the top ends of said posts; and

a plurality of pre-fabricated wall sections, each of said wall sections defining;

a first vertical edge having a vertical tongue formed therealong; and

a second vertical edge having a vertical slot formed therewithin which defines an interior surface;

each of said wall sections being disposed between a pair of adjacent posts such that the vertical tongue thereof abuts one of the posts of the pair and the interior surface of the vertical slot thereof abuts the other post of the post pair which, together with the vertical tongue of a previously installed adjoining wall section, is received into and encapsulated by the vertical slot;

said posts and said wall sections being fabricated from materials having selected compressive, tensile and shear force properties so that when interacted with each other by the abutment of the vertical tongues and the interior surfaces of the vertical slots of the wall sections against the posts, a monolithic wall structure is formed.

12. The device of claim 11 wherein the vertical tongue and interior surface of the vertical slot of each of said wall sections includes a vertical groove formed therein for receiving foam to form an expanded foam seal between the vertical tongue and one post of the post pair and the interior surface of the vertical slot and the other post of the post pair to form a monolithic wall structure.

13. The device of claim 12 wherein each of said wall sections is fabricated from polystyrene foam.

14. The device of claim 11 wherein said track has a generally U-shaped configuration defining a bottom wall which is extended along and attached to said foundation means and opposing side walls extending upwardly from said bottom wall, and said wall section further defines a lower edge having a pair of parallel grooves formed therein for receiving the opposing side walls of said track.

15. The device of claim 14 wherein each of said wall sections further defines an upper edge having a horizontal slot formed therein for receiving at least a portion of said header beam.

16. The device of claim 14 wherein said bottom wall of said track includes a plurality of pre-formed linearly aligned bottom wall apertures disposed therein.

17. The device of claim 16 wherein the opposing side walls of said track include pairs of V-shaped notches disposed therein for placing a drilling jig in vertical registry with said bottom wall apertures.

18. The device of claim 11 wherein the bottom ends of said posts include recesses disposed therein.

19. The device of claim 11 wherein said at least one horizontal header beam comprises a lower header attached to the top ends of said posts and an upper header attached to said lower header.