Static structures (e.g. – buildings) – Facer held by stiffener-type frame – Back-to-back facers spaced by concealed framing
Reexamination Certificate
2000-06-12
2003-10-07
Canfield, Robert (Department: 3635)
Static structures (e.g., buildings)
Facer held by stiffener-type frame
Back-to-back facers spaced by concealed framing
C052S489100, C052S483100, C052S434000, C156S071000, C428S294700
Reexamination Certificate
active
06629392
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to prefabricated structures, and more particularly, to prefabricated wall units using unique concrete formulations and stud and beam configurations for ease of manufacture.
Existing prefabricated structures may be formed of wall units using C-channel studs such as, for example, the wall units disclosed in U.S. Pat. No. 5,524,412. The wall unit is formed by pouring a first layer of cementitious composition into a mold and placing a frame of C-channel steel beams or studs onto this first layer. A second layer of cementitious composition is poured into a mold to a depth sufficient to cover a flange portion of the C-channel to form the wall unit. However, it is often difficult to fill and cover the C-channel flange, resulting in inefficiencies in manufacture.
Further, the cementitious composition should be formulated to provide a durable surface and to be compatible with a steel stud. Existing wall units based on C-channel steel studs generally require flex anchors for attachment because of a difference in the coefficient of expansion between steel and existing compositions.
Accordingly, there exists a definite need for a prefabricated structure having a durable exterior surface that is easily and efficiently attached to support members. The present invention satisfies these needs.
SUMMARY OF THE INVENTION
The present invention is embodied in a structure and unique formulation or composition for the manufacture of prefabricated buildings. The structure includes a panel, a frame of support members, and bonding pads. Each of the support members has a defined length, a center portion of a defined height and thickness, and first and second opposed sides each of a defined width. A cross section of the support members presents a defined shape consisting of the center portion in combination with the first and second opposed sides. The bonding pads bond the panel to the frame by attaching to the frame and to one or more of the first opposed sides of the support members. The panel and the bonding pads are prepared from a cured/hardened moldable building material.
The moldable building material may be a cementitious material. Prior to cure, the cementitious material may comprise a composition, by weight, of about 40.3% cement, about 40.3% sand, about 2.9% glass fibers, about 4.0% acrylic polymer, about 0.4% super plasticizer and about 12.1% water. The cementitious material may contains reinforcing fibers such as steel, fiberglass, polymer, graphite, or Kevlar®. Alternatively, the moldable building material may be a polymer-based resin containing fiberglass. The support members may be of metal, fiberglass, or wood. The bonding pads may enclose one or more segments of the first side(s) of one or more of the support members.
In more detailed features of the invention, the structure may include a connecting member. The connecting member may be interposed between one or more of the support members and the panel at the point where the bonding pads enclose segments of the first opposed side(s) of one or more of the support members. The connecting member may be affixed to the one or more support members. The connecting member may have an extended portion having a width that is greater than the width of the first opposed sides.
The extended portion of the connecting member may have one or more perforations for admitting the moldable building material therethrough, prior to curing or hardening of the moldable building material. The connecting member may be affixed to the support member by one or more fasteners and may be entirely contained within the bonding pad. The connecting member may extend along the length of the support member beyond the enclosed segment of the support member and may wraps around a portion of the support member.
The defined shape of the support members defines a structure that may have a width greater than the thickness of the center portion, thereby providing an anchor point for the bonding pads. The cross section of the support members may appear as an I, an L, an H, a C, a J, a T, a Z, a rectangle, or a pair of opposed triangles separated by the center portion. Finally, the frame may be load-bearing.
Other features and advantages of the present invention should become apparent from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
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Harrel Marcus J.
Schimpf Michael J.
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