HELD OF THE INVENTION

The present invention relates to novel thermoplastic building components for use in the erection of modular building structures, and more particularly such structures as are erected from interconnecting extruded thermoplastic structural components disclosed and claimed in my copending application serial number 2,070,079.

In my said copending application serial number 2,070,079, there is disclosed a novel building system which for the first time enables the erection of permanent, affordable, high quality housing and other building structures essentially totally from polymeric components which can be easily and rapidly assembled to provide an essentially indestructible maintenance free structure.

In particular, the structural components of the said novel building system comprise extruded thermoplastic components incorporating a reinforcing constituent imparting structural strength and expansion control thereto and flowable with the thermoplastic material through an extrusion die to produce an integral essentially rigid structural shape configured to present means for interconnection with adjoining structural components, the components having the reinforcing constituent distributed throughout the thermoplastic material.

Such components include extruded rectilinear hollow panels and beams having internal cells and box connectors extruded to have a

thermoplastic core or substrate having reinforcing and expansion controlling material distributed therethrough and a smooth coextruded thermoplastic skin on the exposed exterior surfaces of said core. As disclosed in said copending application, particularly advantageous reinforcing material for incorporation and distribution throughout the core or substrate consisting of a vinyl chloride, eg. a polyvinyl chloride, comprises fine short glass fibers with the said skin embedding and interlocking with the glass fiber portions that are exposed at the interface between the reinforced core and the coextruded skin.

A suitable glass fiber containing core material providing structural strength and expansion control may be obtained from B.F. Goodrich Company of Akron, Ohio, such material being described in detail in B.F. Goodrich's U.S. Patent 4,536,360.

The coextruded skin may, for example, be PVC, rigid PVC, semi-rigid PVC or ABS. Suitable skin thermoplastics are available from G.E. under the trade-marks "GELOY" or "NORYL".

According to the present invention, there is provided elongated extruded thermoplastic components for use in the building system characterized in that such components have a first hollow chamber having a closed perimeter running lengthwise thereof, a second chamber running lengthwise thereof open at one side and having spaced interlocking means running lengthwise thereof at said open side for interlocking engagement with an elongated mating closure member, said components further having means outwardly of said first closed chamber adapted for engagement with other components of the building system.

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BRIEF DESCRIPTION OF THE DRAWINGS

The scope of the invention will be more particularly understood with reference to the accompanying drawings in which:

Figure 1 is a perspective view of a house erected employing extruded interlocking thermoplastic structural components as disclosed in my copending application serial number 2,070,079 and discussed above and in respect of which the present invention is applicable.

Figure 2 is a broken away perspective view of an interlocking wall structure showing a wall cap and a box connector both embodying the invention.

Figure 3 is a planned view showing how the closure for the interiorly facing abbreviated chamber of the box connector provides a means of protecting wiring or other services when the box connector and first chamber of the closure are filled with concrete.

Figure 4 is a perspective view of a closure member embodying the invention for closing the lower end of a roof panel.

Figure 5 is a broken away perspective view of a wall cap beam embodying the invention and showing the use of weather stripping closures for the open sided chambers.

Figure 6 is a diagrammatic view illustrating the employment of intermediate beams in a house structure such as illustrated in Figure 1.

Figure 7 is a sloping cap member embodying the invention for use on an intermediate beam.

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DETAILED DESCRIPTION ACCORDING TO THE PREFERRED EMBODIMENTS

With respect to Figure 1, there is shown a house erected from hollow extruded wall panels 1 and box connectors 2 formed into the walls of the house and similar roof panels 3 and box connectors 4 formed into the sloping roof portions of the house and meeting at a vent cap 5.

As shown in Figures 2 and 3 the wall panels 1 and 2 are of rectilinear form and are adapted to interlock with the inturned ledges 6 of the outwardly extending leg 7 of the box connector engaging in mating grooves 8 in the adjoining wall panels.

The sloping wall cap member or beam 9 is formed in accordance with the invention with an internal chamber arrangement comprising a large central chamber with a closed perimeter 10 and adjoining closed perimeter chambers 11 and 12.

Wall cap 9 depending flanges 12 and 13 adapted to embrace the inner and outer surfaces of the wall structure formed by the wall panels and box connectors to securely support same on top of the wall.

In addition to the closed chamber arrangement of the wall cap, it is provided with a longitudinal inner chamber 15 open at one side to the interior of the house and a smaller outer chamber 16 open to the exterior of the house. Both chambers 15 and 16 have inturned longitudinally extending ledges 17 for cooperation with a locking member shown as a strip 18 having projecting legs with out turned ledges 19 adapted to interlock with the ledges 17 to close the open side of the chamber 15.

A similar strip or other closure member may be employed to close the outer chamber 16.

In the case of the box connector, there is provided a shallow interior chamber 20 formed by inwardly projecting legs 21 having out turned ledges 22, all within the closed chamber of the box connector itself. The closure member for the open side of the chamber 20 comprises a channel

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member 23 having inturned ledges 24 to interlock with the box connector ledges 22. Integral with this channel member 23 are closed passages 25 and 26 for carrying services such as electrical wiring, telephone, cables and the like as illustrated in Figure 2 which shows wiring coming out of the passage 25 and leading into the chamber 15 closed by the strip 18 which covers the wiring but enables access thereto.

As illustrated in Figure 3, to provide a permanency to the housing the wall panels and box connectors are adapted to be filled with concrete and in effect form casing forms into which the concrete can be poured protecting the concrete and providing a smooth ascetic exposed surface. In this connection, it will be understood that such wall members will be extruded with a core having a reinforcing filler and a core extruded outer skin to provide the desired structural characteristics.

It will be further noted that with the arrangement shown in Figure 3 the concrete completely surrounds and protects the services contained in chambers 25 and 26.

Figure 4 illustrates an extruded beam 26 for closing the lower end of a roof structure 27 formed from the extruded hollow components 3 and 4 embodying the invention. The beam 26 has a central closed chamber 28 as well as axillary closed chambers 29 and 30. Projecting outside of the closed chambers are flanges 31 adapted to embrace the upper and lower surfaces of the roof structure 27 to attach the beam thereto.

Beam 26 is also provided with an upper chamber 32 having inturned ledges or fingers 33 to interlock with a suitable closure member not shown and a lower chamber 34 opening downwardly and having similar locking fingers for engaging in the grooves 35 of a closure channel 36 having ventilating openings 37 therethrough.

It will be understood that it is desirable that air be circulated through the hollow cells or chambers of the roofing structure 27 and to this end suitable openings 38 are provided to give access to the chamber 34 and through the openings or slots 37 to the atmosphere.

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Figure 4 also illustrates a connecting sleeve 39 adapted to connect extruded beams 26 in end-to-end relation for an extended length of roof panel.

Figure 5 shows a wall cap 40 similar to that shown in Figure 2 having closed hollow chambers 41, 42 and 43 and outer chambers 44 and 45 open at the sides and closed by weather stripping closure strips 46 and 47 adapted to interlock with the respective chambers 44 and 46, said strips having coextruded flexible tips 48 and 49 to bear against the underside of a roof structure as illustrated.

Figure 6 diagrammatically illustrates the use of intermediate roof supporting beams 50 and on opposite sides of a ridge beam 51.

Figure 7 illustrates another form of extruded beam for capping the roof beams 50 and having a main closed chamber 52 and an axillary closed chamber 53 and, on opposite sides of the main chamber 52, chambers 54 and 55 opening at one side and provided with interlocking fingers 56 for cooperative engagement with a closure member. This cap beam 57 is also provided with interlocking fingers 58 adapted to interlock in slots or grooves 59 provided in the beam 50 as illustrated.

As illustrated, the roof panel supported on the upper side of the beam 57 may be fastened thereto by screws 60 to hold the panel during the erection process.

It will be understood that the extruded members that are required to carry significant loading and have exposed surfaces to the elements will be formed with a reinforced core and a coextruded skin. However, it will be appreciated that many closure strips or other extrusions not subject to load may be extruded simply from polyvinyl chloride.

Although various preferred embodiments of the present invention have been described herein in detail, it will be appreciated by those skilled in the art, that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims.

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