Static structures (e.g. – buildings) – Intersection of wall to floor – ceiling – roof – or another wall – Laterally related modules; e.g. – spaced surfacing forms corner
Reexamination Certificate
2002-05-31
2003-07-15
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
Intersection of wall to floor, ceiling, roof, or another wall
Laterally related modules; e.g., spaced surfacing forms corner
C052S281000, C052S298000, C052S293300
Reexamination Certificate
active
06591565
ABSTRACT:
TECHNICAL FIELD
This invention relates to a method and apparatus for connecting a building panel to a foundation, and more particularly, a unique form assembly that includes a trough assembly, which remains in the foundation after the concrete foundation cures, thereby improving the connection between the building panel and the foundation.
BACKGROUND ART
Most buildings are constructed of a combination of columns (i.e., posts) and beams, which are covered by plywood or some sort of metal or plastic sheeting. In an effort to reduce the overall construction time, however, contractors often construct buildings, and particularly, the exterior walls of certain types of buildings, with prefabricated building panels. Constructing a building with such panels increases efficiency because rather than assembling individual components on site, entire wall panels are manufactured on the construction site so that they can swiftly be combined and installed. These prefabricated panels are typically manufactured from steel sheet metal such that when placed adjacent to one another, the sides of two panels matingly engage and form a sealed joint. The bottom of the panels are affixed to a foundation, and the pattern is repeated until the desired design building length or width is achieved.
Although utilizing prefabricated building panels reduces the construction time, all of the prefabricated panels are not typically erected in one day. Rather, constructing the entire framework of a building engineered from prefabricated building panels requires a number of days and often weeks to complete. During this time, the only support for the panel may be the connection between it and the foundation. Moreover, during the construction phase, the panel may be exposed to various weather conditions, which impart undesirable lateral and vertical forces on the panel.
For example, a building panel may experience certain lateral forces caused by the wind and snow. Particularly, when the wind blows against a building panel, the wind pushes the building panel in a certain direction, thereby creating lateral forces and moments thereon. These moments, in turn, create uplift (i.e., tensile) and compression forces on the bottom of the panel. The tensile and compression forces eventually transfer to the foundation. If such forces exist for a prolonged period, the foundation or individual panels may become fatigued and ultimately fail. Moreover, if construction occurs during the winter and snow falls upon a partially constructed roof that is supported by a prefabricated building panel, the building panel will experience similar forces and moments as those created by the wind because the weight of the snow will begin to deflect the panel.
The connection between the prefabricated building panel and the foundation, therefore, becomes the focal point when determining whether the building panel can withstand the necessary resistive forces to combat the undesirable weather conditions during construction. One method of connecting a building panel to a concrete foundation includes affixing an angle iron, such as an elongated “L” shaped piece of metal to the bottom of the prefabricated panels. The two are affixed by either being welded, brazed, bolted, etc. Thereafter, the elongated angle iron, itself, is affixed to one or a series of transverse cross members. The panel, angle iron and cross member assembly is then placed within a form and a concrete foundation is poured over such assembly.
The art of constructing foundations is well known and typically includes pouring fluent concrete into a form assembly. The form assembly typically includes two substantially parallel, elongated panel walls and a means for resisting the outward, hydrostatic forces created by the fluent concrete as it is poured between the walls. Such means insures that the panel walls remain at a predetermined gap while the concrete hardens (i.e., cures). Once the concrete hardens, the form panel walls are removed, and earth is moved to surround the foundation, thereby reinforcing it.
When the building assembly is situated within the form, fluent concrete is poured into the form and over the assembly such that the connection between the three components is buried within the concrete. Embedding the assembly within the foundation may, however, impart undesirable stresses upon the building panel, angle iron, and cross members. Specifically, it is important that the building panels maintain their accurate alignment during the construction phase because the building panels represent the exterior wall of the building and the exterior walls must be accurately aligned. As the concrete hardens, however, it may create a force and/or moment on the building panel, which, in turn, could cause it to deflect and/or warp, thereby becoming misaligned.
Furthermore, merely placing the assembly between the two side panels of the form assembly does not provide the assembly with sufficient support while the concrete is being poured into the form. Particularly, placing the assembly within the form does not provide it with any lateral or horizontal support. Moreover, the pressure with which the concrete enters the form assembly often causes the panel to shift, thereby increasing the likelihood that the building panels will be unable to maintain their accurate alignment.
Thus, what is needed is a method and apparatus for improving the method of connecting a prefabricated building panel to a foundation so that the building panel may have increased ability to maintain its alignment and withstand the resistive forces created by undesirable weather conditions.
DISCLOSURE OF INVENTION
The present invention is a method and apparatus for improving the connection between a building panel and a foundation. The improved connection is made possible by a unique form assembly that includes a trough assembly and a novel means for adequately supporting the trough assembly while the concrete is being poured. The trough assembly not only forms a trough within the foundation, but also becomes an integral part of the foundation after the concrete hardens. The trough assembly includes angle irons that are exposed at the surface of the completed foundation. A prefabricated panel sits between the angle irons within the trough assembly, and the prefabricated panel is welded to the angle irons, thereby improving the building panel's lateral and horizontal support and its ability to withstand resistive forces. More importantly, the building panel is placed in the foundation after the foundation is poured rather than before the foundation is poured, thereby reducing the building panels exposure to undesirable stresses caused by the pouring and curing of the concrete.
The trough is an elongated hollow notch at the top of the concrete foundation that resembles the shape of the trough assembly. The trough assembly is designed (i.e., configured) such that its width is approximately equal to the width of the building panel. Similarly to pouring the concrete over assembly of the building panel, angle iron, and cross member, placing the building panel in the trough assembly allows the building panel to sit within the foundation rather than above it. Unlike the assembly, however, the trough assembly is supported by the form assembly to reduce the possibility of subjecting the form assembly to undesirable forces and stresses that could eventually cause it to become warped and misaligned.
Moreover, the trough assembly provides for an improved connection between the building panel and the foundation because the building panel is placed within the trough after the foundation is poured. Delaying placement of the prefabricated building panel into the trough until after the foundation hardens prevents the building panel from being subject to the undesirable forces and stresses created when the concrete hardens. Rather, if any such forces or stresses are created, the trough assembly must endure them rather than the building panel.
The connection between the foundation and the building panel is also improved by buttressing
Blaney Harper Jones Day
Friedman Carl D.
Katcheves Basil
MIC
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