Modular building panels and enclosures

Claim 2

A building structure including foundation means supporting a plurality of load-bearing wall panels assembled in side-by-side relationship, each said panel extending the full height of a wall of said structure, and each panel including: a core of foamed, high density organic resinous material formed as a generally rectangular panel having spaced major surfaces; a surface layer bonded to at least one of said major surfaces to provide a finished wall surface; interlock means on each side edge of said panel for aligning and interlocking said panel with adjacent panels upon assembly of said structure; top channel means formed in and extending across the top edge of said panel, said top channel means being narrower than the thickness of said panel and having a trapezoidal cross section; a top beam having a trapezoidal cross section corresponding to the cross sectional shape of said top channel means; tension means secured at one end to said foundation and extending vertically through said panel and said top beam; and means adjustably securing said tension means to said top beam to draw said top beam down into said top channel means to place said panel in compression and fasten it in position on said foundation, the complementary cross sectional shapes of said top beam and said top channel means preventing splitting of said panel and distributing the compressive load produced by said tension means.

Claim 3

The building structure of claim 1, wherein each of said wall panels includes corner notches extending the length of said panel, the notches on adjacent panels cooperating to provide a recess at the juncture between adjacent panels, said structure further including a cover strip for each said recess for covering said juncture.

Claim 4

The building structure of claim 1, wherein each of said wall panels incorporates at least one cavity extending from said top edge channel means through said panel to the bottom thereof, said cavity being adapted to receive said tension means.

Claim 5

The building structure of claim 1, wherein said top beam spans the juncture between adjacent panels to align said panels.

Claim 6

The building structure of claim 1, wherein said top channel means is formed in said panel by a flat base and upwardly and outwardly tapering sidewalls; and wherein said top beam is formed with a flat base adapted to engage the flat base of said top channel and tapered sidewalls adapted to engage the sidewalls of said channel when said top beam has been drawn into said channel by said tension means.

Claim 7

The building structure of claim 5, further including: locator means secure to said foundation, said locator means having a trapezoidal cross sectional; and a locator channel formed in and extending across the bottom edge of each of said panel, said locator channel being narrower than the thickness of said panel and having a trapezoidal cross section corresponding to the cross sectional shape of said locator means, said locator channel being adpated to receive said locator means to align said panels on said foundation.

Claim 8

The building structure of claim 6, wherein said tension means further extends through said locator means to draw said panel down onto said locator means, thereby rigidly securing said panel to said foundation.

Claim 9

The building structure of claim 7, wherein said interlock means comprises tongue means for one side edge of each panel and groove means for the other side edge of each panel.

Claim 10

The building structure of claim 1, further including a plurality of ceiling panels adapted to engage the tops of said wall panels to form a building enclosure, and wherein said top beam comprises a lintel beam integrally formed on each said ceiling panel.

Claim 11

The building structure of claim 9, wherein each said ceiling panel includes two spaced lintel beams adapted to engage the channel means formed along the top edges of spaced wall panels, said ceiling panel spanning said spaced wall panels to form an enclosure.

Claim 12

The building structure of claim 9, wherein each said ceiling panel includes an arched upper surface adapted to form a roof surface, and interlock means on each side edge of each panel for aligning said pane with adjacent panels.

Claim 13

The building structure of claim 9, wherein each of said ceiling panels has a tongue formed on one side edge and a groove formed on the opposite side edge, whereby each ceiling panel is interlocked with adjacent ceiling panels upon assembly of said enclosure.

Claim 14

The building structure of claim 9, wherein each said lintel beam includes a central portion of generally trapezoidal cross-section depending from the lower surface of said ceiling panel and a groove on each side of, and parallel to, said central portion, whereby the surface of said lintel beam defines a return curve.

Claim 15

The building structure of claim 13, wherein said tension means extends through said ceiling panel, whereby said tension means draws said lintel beam down into said channel means, the top of said panel adjacent said channel engaging said lintel beam grooves.

Claim 16

The building structure of claim 9, wherein each of said ceiling panels is constructed of a foamed material having at least its lower surface finished by a skin layer which provides the desired ceiling appearance for said enclosure.

Claim 17

The building structure of claim 15, wherein said foamed material is a high density foamed urethane.

Claim 18

The building structure of claim 9, wherein each of said lintel beams includes a centrally located portion of generally trapezoidal cross section depending from the surface of said ceiling panel and a groove formed in the said under surface on each side of said depending portion, whereby the surface of said lintel beam defines a return curve, said depending portion of said lintel beams being adapted to intimately engage corresponding channels in said wall panels, and said grooves on each side of said depending portion being adapted to engage the upper edge portions of said wall panels adjacent said channel and to engage the interior and exterior surface faces of said wall panels.

Claim 19

The building structure of claim 17, wherein each of said ceilIng panels incorporates trough means on its upper surface aligned with said spaced lintel beams, and further including tie bar means for said trough means.

Claim 20

The building structure of claim 18, wherein said tension means comprises a plurality of tension rods extending vertically through said tie bar means, said roof panels, said lintel beams, said wall panel channels, and said wall panels to draw said lintel beams and adjacent grooves into rigid contact with said channels and the upper edges of said panels.

Claim 21

The building structure of claim 18, wherein each of said wall panels incorporates two spaced cavities extending from said top edge channel through said panel to the bottom thereof, said cavities being adapted to loosely receive said tension means.

Claim 22

The building structure of claim 20, wherein each of said wall panels incorporates a lower channel formed across its bottom edge.

Claim 23

The building system of claim 21, further including locator means secured to said foundation for engaging said lower channels of said wall panels, said locator means defining the location of said enclosure walls.

Claim 24

The building structure of claim 22, wherein said tension means further extend through said locator means and through said foundation to rigidly secure said enclosure to said foundation.

Claim 25

The building structure of claim 23, further including partition panels for constructing walls within said enclosure, said partition panels having interlocking side edges and top edges and bottom edge channels for assembly to adjacent partition and wall panels and to said locator means.

Claim 26

The building structure of claim 24, further including ceiling locator strips for said upper channels and tension bands securable between said locator means on said foundation and said ceiling locator strips to hold said partition panel in position.

Claim 27

The building system of claim 25, wherein said enclosure is a mobile home.

Claim 28

The building system of claim 25, wherein said foundation is a vehicle bed, said enclosure forming a vehicle body.

Claim 29

The building system of claim 25, wherein said roof panels overlap the junctures between said wall panels, whereby said lintel beams bridge said junctures, and wherein said tie bars overlap the junctures between said roof panels, whereby said enclosure panels are secured against racking and twisting due to externally applied forces.

Claim 30

A lightweight, modular wall structure incorporating a plurality of vertical, loadbearing wall panels aligned in edge-to-edge relationship, each said panel comprising: a core of foamed, high density organic resinous material formed as a generally rectangular panel having parallel, sapced major surfaces defining the thickness of said core, said core being bounded by spaced top and bottom edges and spaced first and second side edges; a skin layer bonded to at least one of said major surfaces of said core to provide a finished wall surface; first interlock means formed on and extending substantially the length of said first side edge and adapted to interlock with a first adjacent panel; second interlock means formed on and extending substantially the length of said second side edge and adapted to interlock with a second adjacent panel; a lintel channel formed in and extending the length of said top edge and adapted to be aligned with the lintel channel of adjacent panels, said lintel channel being substantially trapezoidal in cross section; a base channel formed in and extending the length of said bottom edge and adapted to be aligned with the base channel of adjacent panels, said base channel being substantially trapezoidal in cross section, said lintel and base channels being narrower than the thickness of said core and being centrally located in the top and bottom edges respectively, of said core; a lintel beam having a substantially trapezoidal cross section complementary to the shape of said lintel channel; base wedge means having substantially trApezoidal cross section complementary to the shape of said base channel; and tension means connected between said lintel beam and said base wedge to draw said lintel beam into said lintel channel and said base wedge into said base channel to place said panel under a compressive load.

Claim 31

A lightweight, modular wall structure incorporating a plurality of vertical, loadbearing wall panels aligned in edge-to-edge relationship, each said panel comprising: a core of foamed, high density organic resinous material formed as a generally rectangular panel having parallel, sapced major surfaces defining the thickness of said core, said core being bounded by spaced top and bottom edges and spaced first and second side edges; a skin layer bonded to at least one of said major surfaces of said core to provide a finished wall surface; first interlock means formed on and extending substantially the length of said first side edge and adapted to interlock with a first adjacent panel; second interlock means formed on and extending substantially the length of said second side edge and adapted to interlock with a second adjacent panel; a lintel channel formed in and extending the length of said top edge and adapted to be aligned with the lintel channel of adjacent panels, said lintel channel being substantially trapezoidal in cross section; a base channel formed in and extending the length of said bottom edge and adapted to be aligned with the base channel of adjacent panels, said base channel being substantially trapezoidal in cross section, said lintel and base channels being narrower than the thickness of said core and being centrally located in the top and bottom edges respectively, of said core; a lintel beam having a substantially trapezoidal cross section complementary to the shape of said lintel channel; base wedge means having substantially trApezoidal cross section complementary to the shape of said base channel; and tension means connected between said lintel beam and said base wedge to draw said lintel beam into said lintel channel and said base wedge into said base channel to place said panel under a compressive load.

Claim 32

The wall structure of claim 29, further including cavity means extending vertically through said panel, said tension means extending through said cavity for connection to said lintel beam and to said base wedge.

Claim 33

The wall structure of claim 29, wherein said lintel channel includes a flat base and upwardly and outwardly tapered sidewalls centered in said top edge of said panel and spaced from said major surfaces thereof; and wherein said lintel beam includes a flat base adapted to engage the flat base of said lintel channel and tapered sidewalls adapted to engage the sidewalls of said lintel channel.

Claim 34

The wall structure of claim 31, wherein said lintel beam and said base wedge means extend across adjacent panels to align said panels.

Claim 35

A lightweight, modular wall structure incorporating a plurality of vertical, load-bearing wall panels aligned in edge-to-edge relationship, each said panel comprising: a core of foamed, high density organic resinous material formed as a generally rectangular panel having spaced major surfaces defining the thickness of said core, said core being bounded by spaced top and bottom edges and spaced first and second side edges; a surface layer bonded to at least one of said major surfaces of said core to provide a finished wall surface; first interlock means formed on and extending substantially the length of said first side edge and adapted to interlock with an adjacent panel; second interlock means formed on and extending substantially the length of said second side edge and adapted to interlock with an adjacent panel; a lintel channel integral with, formed in, centrally located in, and extending the length of, said top edge and adapted to be aligned with the lintel channel of adjacent panels, said lintel channel being substantially trapezoidal in cross-section and narrower than the thickness of said core; a base channel integral with, formed in, centrally located in, and extending the length of, said bottom edge and adapted to be aligned with the base channel of adjacent panels, said base channel being substantially trapezoidal in cross-section and narrower than the thickness of said core; a lintel beam having a substantially trapezoidal cross-section complementary to the shape of said lintel channel; base wedge means having a substantially trapezoidal cross-section complementary to the shape of said base channel; and tension means connected between said lintel beam and said base wedge to draw said lintel beam into the lintel channel and said base wedge into said base channel to place said panel under a compressive load which is distributed continously across the width of said panel, said core providing support at the sides of said lintel beam and said base wedge.

Claim 36

A lightweight, modular wall structure incorporating a plurality of vertical, load-bearing wall panels aligned in edge-to-edge relationship, each said panel comprising: a core of foamed, high density organic resinous material formed as a generally rectangular panel having spaced major surfaces defining the thickness of said core, said core being bounded by spaced top and bottom edges and spaced first and second side edges; a surface layer bonded to at least one of said major surfaces of said core to provide a finished wall surface; first interlock means formed on and extending substantially the length of said first side edge and adapted to interlock with an adjacent panel; second interlock means formed on and extending substantially the length of said second side edge and adapted to interlock with an adjacent panel; a lintel channel integral with, formed in, centrally located in, and extending the length of, said top edge and adapted to be aligned with the lintel channel of adjacent panels, said lintel channel being substantially trapezoidal in cross-section and narrower than the thickness of said core; a base channel integral with, formed in, centrally located in, and extending the length of, said bottom edge and adapted to be aligned with the base channel of adjacent panels, said base channel being substantially trapezoidal in cross-section and narrower than the thickness of said core; a lintel beam having a substantially trapezoidal cross-section complementary to the shape of said lintel channel; base wedge means having a substantially trapezoidal cross-section complementary to the shape of said base channel; and tension means connected between said lintel beam and said base wedge to draw said lintel beam into the lintel channel and said base wedge into said base channel to place said panel under a compressive load which is distributed continously across the width of said panel, said core providing support at the sides of said lintel beam and said base wedge.

Claim 37

The structure of claim 33, wherein said lintel beam comprises a ceiling locator strip and wherein said tension means comprises a tension band.

Claim 38

The structure of claim 33, wherein at least one of said panels is generally L-shaped to provide a corner section for said wall.

Claim 39

The structure of claim 33, wherein at least one of said first and second interlock means is located on a major surface of said panel, whereby said panel may be aligned with an adjacent panel to form intersecting wall panels.

Claim 40

The strucure of claim 33, wherein said first and second interlock means comprise tongue means for one side edge of each panel and groove means for the other side edge of each panel.

Claim 41

The structure of claim 33, wherein said first and second interlock means comprises groove means formed in the side edges of said panel and nailing strip means for each groove, said nailing strip extending betWeen and being received in the groove means of adjacent panels.

Claim 42

The structure of claim 33, wherein said panel surface layer comprises a preformed plastic material simulating natural materials.

Claim 43

The structure of claim 33, wherein said panel surface layer comprises wood paneling.

Claim 44

The structure of claim 33, wherein said tension means comprises a least one tension bar passing vertically through each said panel.

Claim 45

The panel of claim 33, wherein said lintel channel includes a flat base and upwardly and outwardly tapered sidewalls centered in said top edge of said panel and spaced from said major surfaces thereof; and wherein said lintel beam includes a flat base adapted to engage the flat base of said lintel channel and tapered sidewalls adapted to engage the sidewalls of said lintel channel.

Claim 46

The panel of claim 33, wherein said lintel beam and said base wedge means extend across adjacent panels to align said panels.

Claim 47

The structure of said claim 33, wherein each of said panels further includes cavity means extending vertically through said panel between said lintel channel and said base channel, said cavity means being adapted to receive said tension means.

Claim 48

The structure of claim 33, wherein said lintel and base channels each are formed with a flat base and wherein said lintel beam wedge each are formed with a flat base, said tension means drawing the bases of said lintel beam and said base wedge into engagement with the bases of said lintel and base channels, respectively, to compress said panel core between the bases of said lintel beam and base wedge.

Claim 49

The structure of claim 45, wherein said lintel and base channels each are formed with outwardly tapered sidewalls and wherein said lintel beam and base wedge each are formed with outwardly tapered sidewalls complementary to said lintel and base channel sidewalls, respectively, said tension means drawing corresponding complementary sidewalls of said lintel beam and lintel channel and said base wedge and base channel into engagement, whereby the sidewalls of said lintel beam and base wedge are continuously engaged with said channel sidewalls to distribute the compressive load produced by said tension means, the tepering of said sidewalls increasing the area of panel compression between said beam and said base wedge.

Claim 50

The structure of claim 33, wherein at least one of said panels further includes third interlock means, said third interlock means being located on a major surface of said panel for receiving and aligning an adjacent intersecting wall panel.

Claim 51

The structure of claim 47, wherein said third interlock means comprises a wall panel locator strip forming a tongue adapted to engage a corresponding groove on said adjacent intersecting wall panel.

Claim 52

The structure of claim 47, wherein said third interlocking means comprises a groove formed in said major surface of said at least on panel.

Claim 53

The structure of claim 47, wherein said lintel beam is generally T-shaped to engage the lintel channels of said at least one panel and said intersecting panel.

Claim 54

The structure of claim 50, wherein said base wedge means is generally T-shaped to engage the base channels of said at least one panel and said intersecting panel.

Claim 55

The panel of claim 33, futher including a surface layer bonded to both of said major surfaces of said core to provide a finished wall appearance on both sides of said panel.

Claim 56

The panel of claim 52, further including a corner notch at each side edge on each said major surfaces and extending the length of said panel, and a cover strip for each said notch.

Claim 57

The structure of claim 33, wherein said tension means is secured at one end to said base wedge means and extends vertically through said panel and said lintel beam, said structure further including means adjustably securing said tension means to said lintel beam to draw said beam down into said lintel channel to place said panel in compression and fasten it in positiOn on said base wedge, the complementary cross-sectional shapes of said lintel beam and said lintel channel distributing the compressive load produced by said tension means and preventing splitting of said panel.

Claim 58

The structure of claim 54, further including bracket means shaped to conform to the shape of said base wege means for securing said tension means to said base wedge means, and fastener means for said bracket means.

Claim 59

The structure of claim 33, further including foundation means supporting said base wedge means.

Claim 60

The structure of claim 56, wherein each of said wall panels incorporates at least one vertical cavity extending from said base channel through said panel to said lintel channel, said cavity being adapted to receive said tension means.

Claim 61

The structure of claim 57, wherein said tension means is secured at one end to said foundation and extends vertically through said base wedge means, through the vertical cavity in a corresponding panel, and through said lintel beam, and including means adjustably securing said tension means to said lintel beam to draw said lintel beam down into said lintel channel to rigidly secure said panel to said foundation.

Claim 62

The structure of claim 58, wherein said first and second interlock means comprises grooves formed in the side edges of each panel and nailing strip means for each groove, said nailing strips extending between said being received in the corresponding grooves of adjacent panels to vertically align adjacent panels and secure said panels in abutting relationship.

Claim 63

The structure of claim 59, wherein said lintel beam and said base wedge means extend across the junctures of adjacent panels to align said panels.

Claim 64

The structure of claim 59, wherein said tension means comprises at least one tension bar for each panel of said wall structure.