Fire rated modular building system

Static structures (e.g. – buildings) – Machine or implement

Patent

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Details

527381, E04C 330

Patent

active

059538805

DESCRIPTION:

BRIEF SUMMARY
FIELD OF THE INVENTION

This invention relates to modular building systems of the type disclosed in my Canadian Applications Serial No. 2,070,079 filed May 29, 1992 and Serial No. 2,097,226 filed May 28, 1993 and Serial No. 2,124,492 filed May 27, 1994, whereby houses or other building structures can be easily and quickly erected using prefabricated extruded thermoplastic interlocking structural components.
As disclosed in my earlier applications, I have provided elongated extruded thermoplastic components including hollow rectilinear wall and roof panels, box connectors and the like formed for interlocking assembly for use in creating a modular building on a support base, such extrusions being a coextrusion of a substrate and a thin skin to provide protection against weathering, ultraviolet rays and the like, provide impact resistance, and present an aesthetic appearance for the exposed building surfaces. Such substrate material particularly described comprises a polyvinyl chloride (PVC) with a reinforcing or stiffening and expansion controlling agent which includes, inter alia, calcium carbonate or fibrous material such as fine mineral or glass fibers. The skin of such components may comprise PVC, rigid PVC, non-rigid PVC, ABS, polycarbonates with suitable material being available from G.E. under the trade-marks GELOY and NORYL. The said protective skin may include, inter alia, agents that provide impact resistance as well as protection against ultra violet radiation and weathering and may also include colouring agents.
While the structural components of my earlier applications provided for the erection of permanent buildings capable of withstanding the effects of sun, high and low temperatures, high winds, rain and snowstorms and earth tremors, in jurisdictions which set stringent smoke and fire rating requirements, it has been a problem to meet such requirements while holding down the cost of the structural components.
The present invention is directed to provide such aforesaid thermoplastic structural components which will meet such fire rating requirements while maintaining the low cost of their production.


PRIOR ART

Prior to my aforesaid developments, none of the prior art provided an acceptable or practical thermoplastic structures for permanent low cost housing. For example, EP-A-O 320745 discloses an arrangement of hollow interlocking structural components for a modular building which are formed entirely of a thermoplastic resin preferably reinforced with about 30% by weight glass fibers such as described in U.S. Pat. No. 4,536,630. Not only is it a problem to extrude such proposed components, they are unsuitable for practical housing as they are rough, abrasive, brittle and are subject to fracture and weather deterioration and would not meet normal building code requirements including building code requirements against smoke and fire hazards.
U.S. Pat. No. 3,992,839, for instance, discloses a plastic panel fabricated from separate panel members preferably formed of polyvinyl chloride which snap together to form a thin wall panel. The panels in turn are formed to snap together to provide a wall structure. Such fabricated panels are not only inherently weak and lack the strength and load bearing capacity to form adequate structural components but would not provide adequate smoke and fire properties.
U.S. Pat. No. 4,557,091 discloses a hollow panel member having a width of about one and one-half inches (1 and 1/2") and a complicated interior formed by protrusion, a process involving drawing long glass strands and a plastic binding material forcibly through a dye under heat to form the glass strands into a compacted glass mat bound together by the plastic material. Such a process is prohibitively slow and expensive and the panels themselves do not have adequate smoke and fire retarding properties and do not provide acceptable or practical structures for forming the walls and roofing of a housing system.


SUMMARY OF THE INVENTION

According to the present invention, I have found that by making us

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