Prefabricated buildings, components and methods of erection of prefabricated buildings

Abstract

This invention is a new concept in prefabricated buildings, components and methods of making the components and methods of erecting the buildings. A typical wall of the new building consists of a plurality of alternately positioned wall panels and support columns, where each support column is situated between two adjacent facing side edges of two wall panels. Coupling elements connect the support column to the two panels, and a single activation element on the support column causes these coupling elements to pull the wall panels into correct elevation and secure engagement with the support column and also secures the support column to an anchor pin in the foundation directly below the support column. This support column consists of an outer tube and a shaft slidable within the tube. First coupling elements extending from each side edge of the support column, and mating second coupling element are situated in the side edges of each panel for cooperation with the first coupling elements. Drawing the shaft upward causes mutual engagement of the first and second coupling elements and causes secure engagement of the support column with the anchor pin.

1 . A prefabricated wall comprising:
 a. a plurality of wall panels and a plurality of columns for supporting said wall panels, where each of said columns and panels has top and bottom parts, inner and outer surfaces and opposite side edges, and said panels and columns are adapted to be alternately spaced and joined together with each of said columns situated between two of said panels to form a wall section,   b. coupling means for each of said wall sections for releasably attaching one side edge of each of said two panels to each side edge of said column, and   c. activating means on said column of each of said wall sections for activating each of said coupling means,   wherein each of said coupling means comprises:   (1) at least one 1 st  coupling element situated on one side edge of said column, and   (3) at least one 2 nd  coupling element on the side edge of the panel being coupled thereto, said column and panels being laterally movable relative to each other until said 1 st  and 2 nd  coupling elements of said column and of said wall panels respectively come into engagement,   said activating means being adapted to drive said 1 st  coupling element generally vertically which drives said 2 nd  coupling elements generally horizontally, thus driving said side edges of said panels and column toward each other.   
   
   
       2 . A prefabricated wall according to  claim 1  wherein said column of each of said wall sections comprises:
 a. an outer tube having top and bottom parts and a bore extending lengthwise, and   b. an inner shaft having top and bottom parts and opposite side edges and being axially slidable upwardly in said outer tube bore,   C. said activating means being adapted to drive said inner shaft axially between an initial open position to a closed position where said wall panels are drawn toward said column.   
   
   
       3 . A prefabricated wall according to  claim 2 , wherein (a) said activating means of each of said wall sections comprises an external lead screw on said top part of said inner shaft and a mating threaded nut at said top part of said outer tube whereby rotation of said nut draws said shaft upward. 
   
   
       4 . A prefabricated wall according to  claim 2 , wherein
 a. said first coupling element of each of said wall sections comprises: a 1st wing that is:
 (1) fixed to each of said side edges of said inner shaft and extending laterally outward therefrom and terminating in and end part which includes a cam surface inclined inwardly toward said inner shaft, and 
 (2) movable upward when said inner shaft is driven upward, and 
   b. said side edge of said wall panel defines a recess extending inward into said panel and thus extending away from said shaft, and   c. said second coupling element comprises a pin fixed in said recess in said wall panel and extending in the inside-to-outside direction, said cam surface of said first coupling element, when said inner shaft is driven upwardly by said activating means, camming said pin and associated wall panel toward to said inner shaft.   
   
   
       5 . A prefabricated wall according to  claim 4 , further comprising a second wing situated on said side edge of said outer tube axially above said first wing on said inner shaft, said first wing when driven upward by upward movement of said inner shaft, capturing said pin between it and said second wing fixed to said outer tube. 
   
   
       6 . A prefabricated wall according to  claim 4 , adapted to be erected on and attached to a foundation which includes anchor means secured in said foundation, wherein:
 (d) said column outer tube comprises walls extending from said top part of said column downward to and engaging said foundation, and   (e) said activating means driving said inner shaft upward relative to said outer tube, puts said inner shaft in tension relative to said outer tube and puts said outer tube walls in compression relative to said foundation, said upward movement of said inner shaft relative to said outer tube also lifts said 1 st  wing and its cam surface therein which cams said pin and panel attached to said pin inwardly toward said inner shaft.   
   
   
       7 . A prefabricated wall according to  claim 2  adapted to be erected on and attached to a foundation which includes anchor means secured in said foundation, wherein,
 a. said inner shaft further comprises 1 st  first means for engaging said anchor means,   b. said outer tube comprises 2 nd  means fixed to said outer tube for engaging and driving said inner shaft upward relative to said outer tube, which puts said inner shaft in tension and creates an opposite downward force on said outer tube when it is urged against said when outer tube against said foundation, and   c. where said upward movement of said inner shaft and 1 st  coupling element thereon creates a cam force for urging said 2 nd  coupling element laterally inward toward said outer tube when said inner shaft is moved upward.   
   
   
       8 . A prefabricated wall according to  claim 1 , wherein said wall panel end edge defines therein a recess with said pin mounted in said recess, and said 1 st  coupling element is extendable into said recess to engage said pin. 
   
   
       9 . A prefabricated wall according to  claim 1 , wherein said 1 st  coupling element includes an inclined cam surface for driving said pin laterally toward said column when said shaft is driven upwardly. 
   
   
       10 . A prefabricated wall according to  claim 2 , wherein said outer tube is formed by walls, two of which form said opposite side edges of said column, each of these two walls defining therein an elongated slot through which said 2 nd  coupling element carried by said inner shaft can extend, and said wing is fixed to said side wall of said outer tube above said slot. 
   
   
       11 . A prefabricated wall according to  claim 1 , wherein said wall panel is formed as a laminate having length in said top-to-bottom direction, width in said side-to-side direction, thickness in said inner-to-outer direction and has exposed side edges,
 each of said side edges having a plurality of pocket-like recesses extending inwardly and spaced apart along said length, and   said wall panel further comprises in each of said recesses a pin situated inward of said side edge and extending in said inner-to-outer direction, said pin configured to be engagable by said 1 st  coupling element extending from said inner shaft.   
   
   
       12 . A prefabricated wall according to  claim 11 , wherein each of said wall panels comprises:
 a. a generally rectangular frame formed by top, bottom and side edge beams which define between then a central space,   b. a core of heat insulation material substantially filling said central space and secured therein, and   c. inner and outer skins covering said inner and outer sides respectively of said frame and core.   
   
   
       13 . A prefabricated wall according to  claim 12  wherein for each of said wall panels:
 a. said frame is injection molded of plastic,   b. said core comprises heat insulating expandable urethane, and   c. said skins comprise fiber glass, Kevlar® carbon fiber or other composite.   
   
   
       14 . A prefabricated wall according to  claim 4 , wherein said top wing has a bottom surface that is generally horizontal extending outward from said outer tube and then tapers upward at its end part to easily receive said pin in said wall panel recess. 
   
   
       15 . A prefabricated wall according to  claim 4 , wherein on each side edge of said outer tube and adjacent side edge of said inner shaft said top wing and bottom wing are displaced relative to each other in the inner-to-outer direction. 
   
   
       16 . A prefabricated wall according to  claim 4 , wherein said top wing on one side edge of said outer tube is displaced forward of said top wing on the opposite side edge of said outer tube, and said bottom wing is displaced rearward of said bottom wing on the opposite side edges of said inner shaft. 
   
   
       17 . A prefabricated wall according to  claim 1  adapted to be erected on and attached to a foundation which is secured in the ground and includes anchor means fixed in said foundation and spaced apart to locations corresponding to each of said columns, where each of said columns comprises an outer tube with a bore extending lengthwise, and an inner shaft axially slidable upward in said outer tube bore, said inner shaft having a bottom end adapted to releasably engage one of said anchor means, and said inner shaft when pulled upwardly relative to said column, pulls upwardly on said anchor means causing tension on said inner shaft and a downward force of said outer tube on said foundation as said wall panels are drawn toward said column. 
   
   
       18 . A wall according to  claim 17 , wherein said activating means further comprises adjustment means (a) to allow upward movement of said inner shaft while said inner shaft draws inward said wall panels toward said column, and thereafter (b) to couple said inner shaft to said anchor means which resists further upward movement of said inner shaft, which thereafter goes into tension as said outer tube walls go into compression. 
   
   
       19 . A wall according to  claim 18 , wherein said adjustment means comprises a blade with an elongated axial slot therein connected to said anchor, and a pin mounted to said inner shaft and extending transversely through said slot, where axial movement of said inner shaft moves said pin to the top end of said slot. 
   
   
       20 . A kit for constructing a prefabricated wall, said kit comprising:
 a. a plurality of wall panels and a plurality of columns for supporting said wall panels, where each of said columns and panels has top and bottom parts, inner and outer surfaces and opposite side edges, and said panels and columns are adapted to be alternately spaced and joined together, with each of said columns situated between two of said panels to form a wall section,   b. coupling means for each of said wall sections for releasably attaching one side edge of each of said two panels to each side edge of said column, and   c. activating means on said column of each of said wall sections for activating each of said coupling means,   wherein each of said coupling means comprises:
 (1) at least one 1 st  coupling element situated on one side edge of said column, and 
 (2) at least one 2 nd  coupling element on the side edge of the panel being coupled, said column and panels being laterally movable relative to each other until said 1 st  and 2 nd  coupling elements of said column and of said wall panels respectively come into engagement, and
 said activating means being adapted to drive said 1 st  coupling element generally vertically which drives said 2 nd  coupling elements generally horizontally, thus driving said side edges of said panels and column toward each other. 
 
   
   
   
       21 . A kit for a prefabricated building adapted to be erected above a floor area which includes anchor elements spaced apart and secured in said floor area, said kit comprising a plurality of wall panels and columns for constructing walls as defined in  claim 18 , each of said walls having opposite ends which are releasably joinable to define an enclosure, and said inner shafts of said columns of said walls being releasably connectible to said anchor elements. 
   
   
       22 . A kit according to  claim 20 , wherein said 2 nd  coupling element comprises a pin mounted in said wall panel, said pin being engagable by said 1 st  coupling element. 
   
   
       23 . A generally rectangular prefabricated building erected on a floor area and attached to anchor means in said floor area, comprising:
 a. four walls as defined in  claim 2 , where each of said walls extends upright and laterally to predetermined lengths respectively and terminates in opposite ends,   b. corner columns for joining adjacent ends of two walls, and   c. a roof secured to said top parts of at least two of said walls, and   d. for each of said walls each of said inner shafts has a bottom end engagable to one said anchor elements and a top part adapted to be pulled upward relative to said outer tube top part, thereby causing said inner shaft to be in tension and said outer tube bottom part to press downward against said floor area, and said 1st coupling elements to be urged upward, thus driving said wall panels toward said column.   
   
   
       24 . A prefabricated building according to  23  wherein, each of said columns comprises:
 (1) an outer tube,   (2) an inner shaft axially movable within said outer tube,   (3) 1 st  means at the bottom part of said inner shaft adapted to engage one of said anchors,   (4) 2 nd  means carried by said inner shaft and adapted to engage said adjacent panels, and when driven upward to pull said engaged panels laterally inward toward said inner shaft, and   (5) 3 rd  means adapted to draw said 2 nd  means upward while bearing downward against said outer tube, thereby putting said inner shaft in tension and urging said outer tube downward against said foundation when said inner shaft is pulled upward and said adjacent wall panels are pulled laterally toward said outer tube.   
   
   
       25 . A building according to  claim 23  further comprising a roof truss formed of a plurality of roof beams extending across said building between the tops of two opposite walls, each of said roof beams releasably coupled to one of said columns at the top part in a haunch connection comprising:
 a. a threaded rod extending upward from said inner shaft and freely through said nut plate,   b. an apertured transverse plate fixed to said outer tube,   c. a nut drawing said threaded rod and inner shaft upward, and   d. said rod extending further upward and through an aperture in said end of said roof beam, and a further nut to secure same.   
   
   
       26 . A building according to  claim 23 , wherein each of said corner columns comprises an outer tube and inner shaft wherein said side edges of said outer tube are 90 degrees apart, and side edges of said inner shaft correspond to said side of said outer tube. 
   
   
       27 . A method of manufacturing a wall panel having inner and outer sides with an injection mold having inner and outer covers and edge covers, at least one edge cover including an injection inlet means and at least one edge cover including outlet vent means, comprising the steps:
 a. positioning a generally rectangular frame having inner and outer sides corresponding to said inner and outer sides of said wall panel in said mold, said frame defining within it a central cavity,   b. positioning inner and outer skins adjacent the inner and outer sides of said frame to enclose said central cavity,   c. covering said skins with said front and rear covers of said mold,   d. securing said inner and outer covers and said edge covers onto said mold,   e. injecting expandable urethane plastic into said cavity,   f. venting said cavity via apertures in said frame and mold,   g. bonding said skins to said frame,   h. cooling said mold and molded panel therein,   i. opening said covers, and   j. removing said panel from said mold.   
   
   
       28 . A method of manufacturing a wall panel comprising the steps:
 a. providing a book-like mold having movable front and rear covers for defining between them a mold space that corresponds generally to the length, width and thickness of a panel to be made,   b. positioning a generally rectangular frame in said mold space, said frame defining within it a central cavity,   c. positioning front and rear skins adjacent the front and rear sides of said frame to enclose said central cavity,   d. covering said skins with said front and rear covers of said mold,   e. covering ends of said frame and closing said mold with end plates,   f. securing said front and rear covers and said end plates onto said mold,   g. injecting expandable urethane plastic into said cavity,   h. venting said cavity via apertures in said frame and mold,   i. bonding said skins to said frame,   j cooling said mold and molded panel therein,   k. opening said covers and end plates, and   l. removing said panel from said mold.   
   
   
       29 . A method of manufacturing a wall panel according to  claim 27 , comprising the steps:
 a. positioning 1 st , 2 nd  and 3 rd  production lines for simultaneously producing 1 st  and 2 nd  skins and one frame every minute,   b. directing from said 1 st , 2 nd  and 3 rd  production lines, every minute, two skins and one frame to a final mold station where each panel is made in a few seconds, and   c. directing the output of panels from said final mold station sequentially at the rate of one per minute to 1 st -10 th  cooling stations, so that after ten minutes the panel at the 1 st  cooling station is completed and this station is ready to receive a new panel to begin its 10 minute cooling phase, thus producing from 10 cooling stations together, one cooled panel every minute.   
   
   
       30 . A method of manufacturing a wall panel according to  claim 27 , comprising the steps:
 a. a. positioning 1 st , 2 nd  and 3 rd  production lines for simultaneously producing “x” quantity of 1 st  and 2 nd  skins and one frame every minute,   b. directing from said 1st, 2 nd  and 3 rd  production lines every minute, “x” number of 1st and 2 nd  skins and one frame to a final mold station where each panel is made in a few seconds, and   c. directing the output of “x” quantity of panels per minute from said final mold station sequentially at the rate of “x” per minute to “y” quantity of cooling stations, so that after “y” minutes the panel at the 1 st  cooling station is completed and this station is ready to receive a new panel to begin its “y” minute cooling phase, thus producing from said final mold station “x” panels per minute and producing in the aggregate from said Y cooling stations “x” cooled panels per minute.   
   
   
       31 . A method of erecting a prefabricated building using prefabricated walls, columns and corner columns as defined in  claim 26 , comprising the steps:
 a. establishing a floor area on which to erect said building,   b. securing anchor means in said floor area at predetermined locations,   c. positioning and erecting a corner column at a corner location for said building above a corresponding anchor means and engaging said inner shaft of said corner column to said anchor means,   d. positioning said first wall panel with one of its end edges adjacent one side edge of said corner column, moving said wall panel laterally until said is 1 st  and 2 nd  coupling elements of said corner column enter said recesses of said first wall panel, and elevating said inner shaft to engage and draw-in said wall panel to said column,   e. positioning and erecting a first of said columns (“first column”) adjacent said opposite side edge of said first wall panel and positioned above said anchor means corresponding to said first column, engaging said inner shaft of said first column to said anchor means, and positioning said first coupling elements of said first column in recesses in said opposite side edge of said first wall panel,   f. elevating said inner shaft of said first column for its first coupling elements to engage and draw together said opposite side edge and said first column, and to simultaneously secure said first column to its anchor means, and   g. successively similarly attaching columns and wall panels to complete said walls of predetermined length and included corner columns to define a building enclosure.