| United States Patent | 3,831,335 |
| Ary | August 27, 1974 |
PREFABRICATED CAST REINFORCED FRAMED CONCRETE WALL SECTION WITH CLIPS TO
ATTACH THE FRAME TO THE REINFORCING
Abstract
A prefabricated building includes prefabricated wall, ceiling, roof and gable sections, stringer members, partition beams and various arrangements for interconnecting the abovementioned parts to form an assembled structure. An adjustable molding table is provided for use in manufacturing the aforementioned prefabricated sections. In constructing a building, the prefabricated sections are transported to a building site and there mounted and assembled on a foundation. During assembly, various steps are performed to provide a finished structure. Strongbacks are provided for moving the prefabricated sections about at the manufacturing and building sites.
| Inventors: | Ary; Thomas L. (Holtville, CA) |
| Appl. No.: | 05/306,525 |
| Filed: | November 15, 1972 |
| Current U.S. Class: | 52/601 ; 52/220.2; 52/712 |
| Current International Class: | E04B 1/04 (20060101); E04B 1/02 (20060101); E04B 1/61 (20060101); E04C 2/38 (20060101); B28B 7/02 (20060101); E04c 002/04 (); E04c 005/18 () |
| Field of Search: | 52/600,601,606,228,295,238-242,220,582-587,221,712 248/57 24/81CC |
| 1031926 | July 1912 | Hansbrough |
| 2128375 | August 1938 | Millard |
| 2176213 | October 1939 | Duffy |
| 3072227 | January 1963 | Baker |
| 3449879 | January 1969 | Bloom |
| 3729889 | May 1973 | Baruzzini |
| 221,003 | Apr., 1910 | DD | |||
Assistant Examiner: Ridgill, Jr.; James L.
Attorney, Agent or Firm:
I claim:
1. A prefabricated wall section comprising a plurality of frame members connected together at their ends to form opposite edges of a wall section, a plurality of hollow stud tubes connected at their ends to opposite frame members and disposed parallel to others of said frame members, means comprising a plurality of clamps disposed along the length of each of a plurality of said hollow stud tubes for anchoring said tubes to an adjacent parallel frame member; opposite frame members paralleling said tubes being provided with complementary coupling means for connecting any two such sections together, and wall filler material cast in place within said frame members around said stud tubes and clamp means to define the walls of said wall section.
BACKGROUND OF THE INVENTION
The present invention relates to the construction of buildings. More particularly, the present invention relates to the manufacture and assembly of prefabricated components to form buildings, structures and the like.
Heretofore, it has been known to construct prefabricated buildings and structures. The purpose behind the prefabricated construction of buildings is to reduce building costs. Therefore, it is important that the prefabricated components and parts used to construct prefabricated structures be relatively inexpensive to manufacture, readily transportable to building sites and easily assembled to form the building structures. Unfortunately, prior art prefabricated building systems have generally not satisfied all these requirements and thus the economic benefits of using prefabricated components and parts have not been fully realized. Further, many arrangements for constructing prefabricated structures are unsightly. Additionally, some prefabricated building systems are only designed for building structures with rooms of predetermined sizes in predetermined locations and are not arranged to permit variations in individual structures built.
SUMMARY OF THE INVENTION
It is, accordingly, an object of the present invention to provide an improved method for constructing a structure from prefabricated components characterized by being efficient and relatively inexpensive.
It is also an object of the present invention to provide improved prefabricated building sections, such as wall, ceiling, roof and gable sections.
It is further an object of the present invention to provide an improved method of forming prefabricated building components, such as wall sections, ceiling sections, roof sections, and gable sections.
It is additionally an object of the present invention to provide improved arrangements for interlocking building components, such as wall, ceiling, roof and gable sections, to form building structures.
It is another object of the present invention to provide improved method and apparatus for constructing buildings in an economical and efficient manner by using prefabricated components which are convenient to transport to work sites and easy to assemble to form sightly building structures which may be tailored to suit the tastes of individual builders.
It is still another object of the present invention to provide an improved strongback for moving prefabricated building sections from one place to another.
In accomplishing these and other objects, there is provided in accordance with the present invention prefabricated wall, ceiling, roof and gable sections. Also provided are stringer members for supporting the assembled roof sections, partition beams for supporting adjacent ceiling sections at places where no bearing wall is provided and various arrangements for interconnecting the aforementioned prefabricated sections, the stringer members and the partition beams to form an assembled house or other building structure. A molding table having selectively positionable form members is provided for use in manufacturing the aforementioned prefabricated sections. In constructing a prefabricated house or building in accordance with the present invention, the prefabricated sections are formed on the molding table at a manufacturing site, transported from the manufacturing site to the building site, and mounted and assembled on a foundation at the building site. During the assembly of the prefabricated structure various finishing steps are performed so that a finished house suitable for moving into is provided. Additionally, strongbacks are provided for moving the prefabricated sections from place to place at the manufacturing and building sites.
Additional objects of the present invention reside in the specific construction of the exemplary prefabricated sections and the building formed thereby and also in their methods of formation and/or assembly hereinafter particularly described in the specification and shown in the several drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of an adjustable molding table arranged for use in manufacturing prefabricated wall, ceiling, roof and gable sections of a building structure in accordance with the present invention.
FIG. 2 is a view taken along the line 2--2 of FIG. 1.
FIG. 3 is a view taken along the line 3--3 of FIG. 2.
FIG. 4 is a top plan view of the molding table of FIG. 1 illustrating assembled thereon a skeletal wall section according to the present invention.
FIG. 5 is a view taken along the line 5--5 of FIG. 4 illustrating the prefabricated wall section filled with wall filler material.
FIG. 6 is a side elevation view of another skeletal wall section according to the present invention which has incorporated therein various conduits.
FIG. 7 is a view taken along the line 7--7 of FIG. 6.
FIG. 8 is a view taken along the line 8--8 of FIG. 6.
FIG. 9 is a view taken along the line 9--9 of FIG. 6.
FIG. 10 is a view taken along the line 10--10 of FIG. 6.
FIG. 11 is a view taken along the line 11--11 of FIG. 6.
FIG. 12 is a view partially in section taken looking along the line 12--12 of FIG. 6 illustrating the wall section filled with wall filler material.
FIG. 13 is a view taken along the line 13--13 of FIG. 6 illustrating hanger slots formed in the side frame member of a wall section.
FIG. 14 is a perspective view of a locking bar for interlocking two side frame members of adjacently positioned wall sections.
FIG. 15 is a partially cutaway top view of two wall sections according to the present invention interconnected to form a straight wall.
FIG. 16 is a partially cutaway top view illustrating one wall section according to the present invention interconnected to extend from the side of another such wall section.
FIG. 17 is a partially cutaway top view of two wall sections according to the present invention interconnected to form a corner.
FIG. 18 is a side elevation view of a portion of still another wall section according to the present invention partially cutaway to illustrate a door frame included therein mounted on a foundation.
FIG. 19 is a view taken along the line 19--19 of FIG. 18.
FIG. 20 is a view taken along the line 20--20 of FIG. 18.
FIG. 21 is a side elevation view of a portion of yet another wall section according to the present invention cutaway to illustrate a window frame included therein.
FIG. 22 is a view taken along the line 22--22 of FIG. 21.
FIG. 23 is a view taken along the line 23--23 of FIG. 21.
FIG. 24 is a view taken along the line 24--24 of FIG. 21.
FIG. 25 is a top plan view of two interconnected prefabricated ceiling sections according to the present invention.
FIG. 26 is a view taken along the line 26--26 of FIG. 25.
FIG. 27 is a view taken along the line 27--27 of FIG. 25.
FIG. 28 is a top plan view of a prefabricated roof section according to the present invention.
FIG. 29 is a view taken along the line 29--29 of FIG. 28.
FIG. 30 is a view taken along the line 30--30 of FIG. 29.
FIG. 31 is a view taken along the line 31--31 of FIG. 28.
FIG. 32 is a perspective view of a prefabricated housing structure according to the present invention.
FIG. 33 is a partially cutaway side elevation view of the lower portion of one wall section of the housing structure of FIG. 32.
FIG. 34 is an elevation view partially in section of one ceiling section mounted on a wall section in the housing structure of FIG. 32.
FIG. 35 is a view taken along the line 35--35 of FIG. 34.
FIG. 36 is an end elevation view partially in section of the roof of the housing structure of FIG. 32.
FIG. 37 is an enlarged scale view of the portion of FIG. 36 encircled by the line 37.
FIG. 38 is a partially cutaway end elevation view of the gable of the housing structure of FIG. 32.
FIG. 38a is a view taken along the line 38a--38a of FIG. 38.
FIG. 39 is an elevation view partially in section of a partition beam mounted on a wall section in the housing structure of FIG. 32.
FIG. 40 is a view taken along the line 40--40 of FIG. 39.
FIG. 41 is a side elevation view of a strongback for moving prefabricated wall sections according to the present invention shown connected in engagement with a side wall section.
FIG. 42 is a view taken along the line 42--42 of FIG. 41.
FIG. 43 is a perspective view of a stringer.
FIG. 44 is an exploded perspective view of a bolt mechanism for securing a roof section on a stringer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-5, a molding table generally designated by the numeral 10 is there shown. The table 10 has a lower frame portion 11 and a top table portion 12 tiltably mounted thereon. The frame 11 preferably includes a plurality of laterally spaced apart rectangularly shaped upright sections 13 interconnected and braced by cross members 14. Forward and rear sets of casters 15 are mounted on the bottom of each upright section 13 so that the molding table 10 may be rolled from one place to another.
The table top 12 is preferably rectangular having flat upper and lower surfaces 16 and 17, respectively. Arch-shaped ears 18 defining pivot structure are secured to the lower surface 17 in position to interfit within fork structure 19 defined on the upper ends of the uprights 13. Horizontally aligned holes are formed through the ears 18 and fork structure 19, and a pivot rod 20 extends through these horizontally aligned holes to pivotally connect the table top 12 on the frame 11. As shown in the drawings, the fork structure 19 is defined along one edge of the frame 11 and the ears 18 are positioned on the top 12 so that the table top 12 can be tilted from a horizontal at rest position to a substantially vertical position. Mounted along the other edge of the frame 11 is latch mechanism 25. The latch mechanism 25 functions when latched to hold the table top in a horizontal position and is unlatched by moving handle 26 downward as indicated by the arrow. The table top 12 is shown in phantom in FIG. 1 being tilted in the direction indicated by the arrow from its horizontal position towards an upright position.
The table top 12 has a plurality of holes 21 formed in its flat upper surface 16, as shown in FIG. 5, into which pegs or pins 22 may be inserted. The pegs 22 extend through molding form members 23 and function when inserted in the holes 21 to secure the forms 23 in selected positions on the table top 12. By positioning the forms 23 as shown in FIG. 4, a pattern or template for casting a selected building section may be defined. The forms 23 are positioned to define the outer perimeter of the building section to be cast and the side walls of the forms which are positioned inwardly preferably extend vertically so that the frame of the building section to be cast rests stably thereagainst. It is noted that a plurality of suitably positioned holes 21 are formed in the table top surface 16 so that by use of appropriately dimensioned forms 23 a pattern may be defined for any selected prefabricated building section, such as a wall section, a roof section, a ceiling section or a gable section. It is also noted that the height of the form members 23 is no greater than necessary to hold the frame members of the building sections to be cast in place during molding so that conduits and flanges may be incorporated in the building sections which extend outside of the building section frame members.
Skeletal wall sections generally designated by the numerals 30 are shown in FIGS. 4 and 6. The wall sections 30 each have an outer frame preferably made of aluminum which includes a top cap or frame member 31, a bottom plate or frame member 32 and a pair of identical side frame members 34. The skeletal wall section 30 in FIG. 4 is shown assembled on the molding table top surface 16 with the frame members 31, 32 and 34 held in place to define the wall section to be cast by the appropriately positioned molding forms 23. The wall section 30 in FIG. 6 is not shown assembled on the table top surface 16 but in forming this prefabricated wall section 30 or any of the hereinafter described prefabricated building sections the molding table 10 would preferably be employed. It is noted that while aluminum frame members are described for purposes of illustration the wall section frame members could be made of any suitable material.
Positioned to extend between the top and bottom members 31 and 32 of each wall section 30 are a plurality of preferably aluminum cylindrical hollow stud tubes 35, selected ones of which are designated. The hollow stud tubes 35 are preferably held in parallel disposition with respect to each other and are held in place on the upper frame members 31 by means of inwardly extending cylindrical flanges 36, as shown in FIGS. 5 and 7, which fit within the hollow stud tubes 35. Circular holes 37 are formed through the top frame member 31 in alignment with the hollow interior of the stud tubes 35 to provide a path of access to the cylindrical channels defined by the stud tubes 35. The flanges 36 illustrated are formed by punching or pushing the circular holes 37 inwardly through the frame member 31, thereby to form the flanges 36 by the portion of the frame members 31 pushed inwardly.
The stud tubes 35 are held in place on the bottom frame members 32, as shown in FIGS. 5, 8 and 9, by means of a cup 39 having an inwardly extending flange. The flange defines a cylindrical socket into which the lower end of the stud tubes 35 fit or seat. The cups 39 are secured by rivets 40 to the base frame members 32. May be molded into some materials that may be used.
With the stud tubes 35 in position between the upper and lower frame members 31 and 32, the end frame members 34 are positioned between opposite ends of the frame members 31 and 32. The end frame members 34 each have inwardly extending flanges 41 on their ends which fit against the inner surfaces of the upper and lower frame members 31 and 32. The frame members 34 are secured in place between the frame members 31 and 32 by riveting the flanges 41 thereto. With the frame members 34 riveted in place on the frame members 31 and 32, clamps 42 are passed around the stud tubes 35 nearest to the frame members 34. These clamps 42 are attached by rivets 43 to the inside surfaces of the frame members 34 and function to securely anchor the end frame members 34 in place.
With the end frame members 34 secured in the wall sections 30, crossed cables 44 are attached, as shown in FIG. 4, between the top and bottom frame members 31 and 32 to pull the skeletal frame of the wall section into a true rectangular shape. Reinforcing wire 45, plastic mesh, or other suitable material, is intermeshed between or passed around or over the stud tubes 35 to form reinforcing structure within the wall section 30. With the reinforcing structure in place, a wall filler material 46 is poured into the wall section 30 to the level shown in FIG. 5.
It is noted that the wall filler material 46 employed may be any suitable material or combination of materials, such as vermiculite or other expanded mica product, asbestos waste, spun glass, plastic bubbles and/or styrofoam. It is also noted that the table top surface 16 defines the outside wall portion of the wall section 30 and that the wall filler material 46 is poured within the frame defined by the frame members 31, 32 and 34 to a point slightly below, such as 1/4 inch below, the upper edges of the frame members 31, 32 and 34 to leave room for a coat of plaster or other covering material for the inside wall surface. The wall filler material 46 which should be quick setting is then allowed to set. Once the material 46 has set, plaster or another suitable wall covering is applied to the upper surface of the wall filler 46 to form a smooth finished inside wall surface. After the wall section 30 has completely set, it may be readily removed from the molding table 10 by tilting the table top 12 in the manner shown in phantom in FIG. 1.
During the transporting of a prefabricated wall section 30 to a building site, the finished inside wall covering should be covered over by a protective material, such as a plastic covering which could be peeled off, to protect it from being scratched or otherwise damaged. Further, while the above described prefabricated wall section 30 had an inside and outside wall surface, interior wall sections 30 may be formed by laying a 1/4 inch spacer on the table surface 16 within the skeletal wall frame so that a space for receiving an inside wall covering is defined on the downwardly facing wall side as well as on the upwardly facing wall side. After the coating of plaster applied to the one side of the wall section 30 dries the wall section 30 is turned over on the table 10 to plaster the other wall side. It is noted that in order to provide a better surface for the plaster to adhere to that holes could be punched in the filler material 46 before it has fully set. Further, at the time of casting any of the prefabricated building sections herein described, the table surface 16 and any other necessary molding parts are coated with a conventional material suitable to isolate and separate the filler material 46 from the molding forms. Also any unused peg holes 21 into which the filler material 46 might run are plugged or covered over.
Referring specifically to FIG. 6, the wall section 30 there shown in addition to being constructed like the wall section shown in FIG. 4 also has incorporated therein various conduits identified by the numerals 50-54. The conduit 50 is for conducting water to a toilet. The conduit 51 is made up of upper and lower vertically aligned sections 51a and 51b and defines a sewer-vent arrangement. The conduits 52-53 are pipes for hot and cold water. The conduit 54 has an electrical outlet box 55 connected on its lower end and defines a channel through which electrical leads 56 are run to the outlet box 55.
One end of each of the conduits 50-54 extends through the upper frame member 31 preferably to a point slightly above it. The other ends of the conduits 50-54 are positioned at predetermined locations in the wall section 30 and are clamped thereat by clamping arrangements 57.
Each clamping arrangement 57 shown in FIG. 6 is made up of a rigid cross bar or member 58 having spring clamps 59 riveted on its ends to extend from the same side thereof. The length of each cross member 59 is appropriately dimensioned with respect to the horizontal distance between stud tubes 35 so that the spring clamps 59 are positioned to engage and clamp over adjacent stud tubes 35. Bulges or protuberances 60 are formed on the stud tubes 35 for vertically supporting the clamping arrangements 57. The protuberances 60 are formed at appropriate positions in the stud tubes 35 below the position of the spring clamps 59 so that the spring clamps 59 rest thereon and are vertically supported thereby. The protuberances or projections 60 may be formed by inserting a suitable tool into a stud tube 35 through the opening 37 in the upper frame member 31 and then operating the tool to push out the portion of the wall of the stud tube located at the point a protuberance 60 is desired.
Appropriately sized clamps 61 which form part of the clamping arrangements 57 are fitted around each of the conduits 50-53. These clamps 61 are riveted to their associated cross members 58 to secure the conduits 50-53 thereto. The clamping arrangement 57 securing the conduits 50 and 51 in place in the wall section 30 is shown in FIG. 10 while FIG. 12 illustrates the clamping structure 57 securing the conduit 52 in place. The electrical outlet box 55 connected to the conduit 54 is secured to the cross bar 58 of its associated clamping structure 57 preferably by rivets 62, as shown in FIG. 11. The cross bar 58 to which the outlet box 55 is secured preferably is bent to have a set back portion 63 upon which the outlet box 55 is secured. The cross bar portion 63 is set back to hold the front of the outlet box 55 substantially flush with the side wall surface of the wall section 30, as shown in FIG. 11.
FIG. 12 also illustrates a cavity 64 formed in the wall section 30 around the lower end of the conduit 52. The cavity 64 is formed by placing an appropriately shaped plug or molding form around the conduit end and then pouring the wall filler material 46. After the filler material 46 has substantially set, the form is removed from its position around the conduit end to leave the cavity 64 in the wall section. It is noted that to permit easy removal the molding form is coated with a conventional material or substance which operates to isolate it from the filler material 46. The cavity 64 is formed in the wall section 30 around the lower end of the conduit 52 in order to provide the space necessary to connect the pipe of a lavatory thereto. A similar type of cavity would be formed in the prefabricated wall section 30 around the lower end of the conduit 53.
In order to provide a suitable support for mounting a wash basin on the wall section 30, a transversely extending hanger plate or member 65 is bolted onto the stud tubes 35 adjacent the water pipes 52 and 53. The hanger plate 65 is positioned in the wall section 30 to be flush with its side wall surface. A lavatory may be mounted on the hanger plate 65 by being bolted thereto.
It is noted that wherever desired or necessary mounting plates similar to the hanger plate 65 could be included in a prefabricated wall section 30. Further, it is noted that cavities would be formed in the wall section 30 wherever needed, such as adjacent the ends of the conduits 50 and 51 positioned within the wall section 30 by using an appropriately dimensioned removable molding plug or plugs. Also, a plug or cover would be placed over the electrical outlet box 55 at the time of pouring the wall filler material 46 to prevent the material 46 from running therein.
Referring to FIG. 13, one of the side frame members 34 of a wall section 30 is there shown. The frame member 34 has a substantially flat outer face 66 with hanger slots 67 formed therein. The hanger slots 67 are formed in the frame member 34 at spaced apart points along its vertical length, preferably have uniform widths and extend substantially vertically parallel to the side edges of the frame member 34. Secured on the inside surface of the frame member 34 to extend the length thereof is an inwardly extending cover or envelope 68. As shown in FIGS. 15-17, the cover 68 defines a cavity adjacent the hanger slots 67 into which locking hooks 69 of a locking bar 33 interfit. The cover 68 is designed to extend the entire length of the side frame member 34 and functions to prevent filling material 46 from flowing into the cavity defined adjacent the hanger slots 67.
The locking hooks 69 formed on the locking bar 33 are shown in FIG. 14. The hooks 69 are positioned in vertically spaced apart positions along the length of the bar 33 to correspond in position and alignment with the complementary hanger slots 67. The locking bar 33 has preferably a rectangular cross-section, a length approximately equal to the length of the side frame members 34, and is dimensioned for longitudinal insertion into the envelopes 68. The locking hooks 69 are uniformly dimensioned for engaging and mating with the hanger slots 67, as shown in FIGS. 15, 16 and 17, and extend substantially perpendicularly from the flat face 70 of the locking bar 33.
Each locking hook 69 is preferably formed by a shoulder 71 having a downwardly extending arm 72 depending therefrom. The shoulder 71 and arm 72 are of a uniform thickness less than the width of the hanger slots 67 so that they may be inserted therein. The downwardly extending arm 72 has a tip portion 72a and a body portion 72b. The body portion 72b interconnects the shoulder 71 and the tip 72a. The shoulder 71 and body portion 72b define a downwardly opening locking slot 73 of uniform dimension sized to receive and tightly hold together two side frame members 34. The hook tip 72a is shaped to slope inwardly and upwardly and functions to guide the side frame members 34 into the locking slots 73.
FIGS. 15, 16 and 17 each illustrate two prefabricated wall sections 30 tightly joined together by means of the interlocking mechanism provided by the locking bar 33 and side frame members 34. The side frame members 34 are locked together by the locking bar 33 by positioning the locking bar 33 in one of the envelopes 68, laterally inserting the locking hooks 69 in hanger slots 67 and then pushing downwardly on the locking bar 33. Thereby, the sloped or slanted tip portions 72a of the locking hooks 69 are guided into the hanger slots 67 to lock the hooks 69 on the side frame members 34 and the flat surfaces 66 of the frame members 34 are pulled tightly together and clamped in the locking slots 73.
FIG. 15 illustrates the joinder of two prefabricated wall sections 30 to extend the length of a building wall. The wall sections 30 shown in FIG. 15 are aligned in the same vertical plane and have the flat planar surfaces 66 of the interconnected frame members 34 positioned perpendicularly to this vertical plane of alignment.
FIG. 16 illustrates the joinder of two prefabricated wall sections 30 to form two inside corners of a building structure. A frame member 34 is shown mounted to extend along and form part of one side surface of a wall section 30. The frame member 34 is illustrated mounted at a location between the wall section ends. The frame member 34 is shown clamped by the clamp 42 around two closely spaced apart stud tubes 35 which are incorporated in the wall section 30. The frame member 34 on the end of another wall section 30 is interlocked to the first frame member 34 by the hooking bar 33 so that the other wall section 30 extends perpendicularly from the side wall of the former prefabricated wall section. Thereby, two right angled corners are formed.
FIG. 17 illustrates the joinder of two prefabricated wall sections 30 to form an outside corner of a building structure. The frame members 34 are mounted so that their planer surfaces 66 define wall section ends at 45.degree. angles to the plane of the wall sections. Thereby, an outside corner of 270.degree. and an inside corner of 90.degree. are defined by interlocking the frame sections 34.
Referring to FIGS. 5 and 13, a pair of parallel calking grooves 75 are formed in the planar surfaces of each of the frame members 31, 32 and 34 of the wall sections 30. The calking grooves 75 are preferably formed by being pressed into the frame members to form unbroken longitudinally extending indentations therein. Each of the grooves 75 is formed a predetermined distance from and parallel to one longitudinal edge of the frame members. When the frame members 31, 32 and 34 are assembled to form the outside frame of a wall section 30, the calking grooves 75 adjacent each side edge of the wall frame thereby formed are aligned in the same plane. Thereby, by filling the calking grooves 75 between interconnected building sections with a conventional calking material, such as an appropriately treated cord, substantially weathertight barriers are formed between the interconnected building sections.
FIGS. 18-20 illustrate a door frame incorporated in one of the prefabricated wall sections 30. The door frame is made up of a lintel 80, a liner 81 and a strong sill tread 82. The tread 82 is riveted in the base frame member 32 of the wall assembly. The base frame member 32 overlaps the tread 82 and the tread 82 is riveted to the overlapping frame member portions 79. The tread 82 has a length greater than the width of the door opening 83 being formed and may, for example, be dimensioned to extend one foot beyond each side of the door opening 83.
Symmetrically mounted on each side of the door opening 83 to extend from the frame member portions 79 vertically to the upper frame member 31 of the wall section 30 are pairs of stud tubes 35. The lengths of these stud tubes 35 are shortened to adjust for the thickness of the overlaps 79 and the stud tubes 35 are preferably mounted in the wall section 30 in the manner hereinbefore described. Mounted inside and against the stud tube pairs are cripples 84. The term cripple as used herein means hollow stud tubes which are dimensioned to not extend the entire height of the wall assembly.
The cripples 84 support the lintel by fitting in downwardly facing sockets 85 defined therein and hence determine the height of the door opening 83. The lintel 80 has forked structure 86 formed on each of its ends. The fork structure 86 fits around the pairs of stud tubes 35, as shown in FIG. 19, and pins 87 are secured through the ends of the forks 86 outwardly of the stud tube pairs, thereby to secure the lintel 80 around the stud tubes 35.
A pair of spaced apart cripples 94 are connected between the upper frame member 31 of the wall assembly 30 and the top surface of the lintel 80. As shown in FIG. 19, spring type clamps 88 are secured to the lintel 80 which clamp onto the cripples 94 to hold them in place. The cripples 84 and 94 function together to hold the lintel 80 in a selected vertical position by, respectively, pushing simultaneously upwardly and downwardly thereon.
With the lintel 80 in position, the liner 81 which defines the top and sides of the door frame is attached in place by means of clamps 89. The clamps 89 extend around the cripples 84, as shown in FIG. 20, and are riveted by rivets 90 to the liner 81. A prefabricated door assembly may now be mounted in the door opening 83. The prefabricated door assembly may be mounted in a manner similar to the way the prefabricated window assembly described hereinafter is mounted in a window opening.
The wall section 30 of FIG. 18 is shown mounted on a foundation 91 by being bolted thereto by J-bolts 92. The foundation 91 may be made of any material, such as concrete, suitable for forming the floor of a building. The J-bolts 92 are anchored in the foundation 91 at selected points with their threaded ends extending vertically upwardly therefrom. The J-bolts 92 extend through the sill tread 82 and the overlapping portions 79 of the frame member 32 into the hollow stud tubes 35 adjacent the cripples 84. The wall section 30 is bolted to the foundation 91 by extending an extremely long handled magnetic wrench carrying a nut 93 and washer, or another suitable tool, downwardly through the hollow stud tubes 35 to screw nuts 93 on the threaded bolt ends 92. It is noted that access is provided to the hollow interiors of the stud tubes 35 through the openings 37, one of which is shown in FIG. 7, formed in the upper wall section frame member 31.
Referring to FIGS. 21-23, a window frame is there shown incorporated in a wall section 30 to define a window opening 100. The window frame includes a lintel 101, a sill 102 and a liner 103. The lintel 101 is mounted in substantially the same manner as the above described door lintel 80. The lintel 101 is vertically supported in place by upper and lower sets of cripples 104 and 105. The upper cripples 104 are connected to the lintel 101 by spring clamps 106, as shown in FIG. 22. The lower cripples 105 seat in downwardly facing sockets 107 formed in the lintel 101. The lintel 101 has forked ends 108 which have bolts 109 inserted therethrough to secure the lintel 101 in place around single stud tubes 35. The sill 102 is supported by a plurality of cripples 110 which extend upwardly from the bottom frame member 32 into downwardly facing sockets 112 formed in the sill 102. It is noted that holes 111 are preferably formed through the window sill 102, as shown in FIGS. 21 and 23, in order to provide a means of access to the hollow cripples 110 so that the wall bottom frame member 32 may be bolted or shot to a foundation by inserting appropriate tools through the hollow interiors of the cripples 110. The liner 103 is rectangularly shaped and is dimensioned to interfit between the cripples 105, the lintel 101 and the sill 102.
FIG. 24 illustrates a prefabricated window assembly 120 clamped in the window frame incorporated in the wall section 30 of FIG. 21. The window assembly 120 is made up of two interfitting rectangular sections 121 and 122, and has a pane of glass 125 mounted within the rectangular section 121 to close the window opening 100. The sections 121 and 122 are inserted into the window frame from opposite sides. Bolts 123 are inserted in holes formed in the section 122 and threaded into threaded openings 124 defined in the section 121. Thereby the prefabricated window assembly 120 is pulled together and secured in place in the window opening 100 of the wall section 30. It is noted that calking grooves 126 are formed in the sections 121 and 122 of the window assembly and are filled with calking material 127 to define weathertight seals around the outside and inside peripheries of the window opening 100.
Referring to FIGS. 25-27, male and female prefabricated ceiling sections 130 are shown interconnected by tongue and groove structure to form the ceiling of a room. The ceiling sections 130 are manufactured on the molding table 10 in substantially the same manner that the wall sections 30 are manufactured. The ceiling sections 130 are substantially rectangular and have frame members 131-134 which define their shape. The frame members 131 and 132 define opposite ends of the rectangle and stud tubes 35 are mounted to extend therebetween. The adjacent ends of the frame members 131 and 132 are interconnected by the frame members 133 and 134.
The frame members 131-133 are formed as shown in FIG. 26 to have a substantially flat vertically extending outer surface 143 with a horizontal flange 135 formed at a predetermined point along its width to extend outwardly therefrom. As shown in FIG. 27, this flange 135 rests upon a wall section 30, thereby the ceiling section 130 is vertically supported by the wall section 30.
Formed in the ceiling frame member 134 is either a tongue 136 or a groove 137. The tongue 136 is dimensioned to mate with the groove 137 in the manner shown in FIG. 27. Calking grooves 148 filled with calking material 149 are provided in the tongue and groove structure to form weathertight seals above and below the mated tongue 136 and groove 137.
It is noted that preferably one of the ceiling sections 130 has a so-called soft spot 138 formed therein. The soft spot 138 is formed by an open cylindrical section 139 secured by clamps 140 around two adjacent supports 35 to extend from the upper surface of the ceiling section 130 to a point adjacent the reinforcing wire 45. A separate piece of wire 45 covers over the lower end of the cylinder 139 and a layer of plaster 144 is shown applied thereto to hide the cylindrical section 139 from view. When an opening is desired in the ceiling 130, for example for the purposes of ventilation, the material covering over the lower end of the cylinder 139 may be readily knocked out. The cylinder 139 then defines a cylindrical opening through the ceiling section 130.
It is noted that in the ceiling section 130 there is no need to have access to the interior of the stud tubes 35 since the ceiling sections 130 are supported by the flange 135 resting upon bearing walls instead of being bolted or riveted in place. Therefore, solid members may be used instead of the stud tubes 35 and the cup arrangement 141 shown in FIG. 26 may be used for securing both ends of the stud tubes 35 or the solid members in place on the ceiling frame members 131 and 132. The cup arrangement 141 forms a cup-like socket for the ends of the stud tubes 35 and is preferably riveted by rivets 142 to the frame sections 131 and 132. The cup 141 could be molded on the frame sections 131 and 132 if a material such as plastic were used.
A prefabricated roof section 150 is shown in FIGS. 28-31. The roof sections 150 are manufactured on the molding table 10 in substantially the same manner as the ceiling sections 130 and wall sections 30. The roof sections 150 are rectangular in shape and their shape is defined by frame members 151-154. The frame member 151 defines the ridge of a roof while the frame member 152 defines the edge of the eaves. The frame members 153 and 154 interconnect the adjacent ends of the frame members 151-152.
Each roof section 150 has stud tubes 35 mounted in cup arrangements 141 to extend between the ridge frame member 151 and the eaves frame member 152. Solid supports may be used instead of the stud tubes 35 if desired and the cup arrangements 141 are the same type as above described in connection with the ceiling section 130.
Included in and formed as a part of the roof section 150 is a roof rest structure 155. The roof rest 155 is a rigid structure designed for supporting a roof section 150 in a prefabricated building structure by engaging and resting upon a rectangularly shaped stringer 156. The stringer 156 is positioned on the building side walls and is hereinafter described in connection with FIGS. 34, 36 and 37. The roof rest 155 is appropriately positioned to engage the stringer 156 and extends the width of the roof section 150 between the frame members 153 and 154 in a substantially parallel disposition to the frame members 151 and 152.
The roof rest structure 155 includes a pair of platelike members 157 through which stud tubes 35 extend, a mounting plate 158, a contact plate 159, upright supporting plates 160 and 161, and a downwardly projecting flange 162. A U-channel is preferably used for forming the plates 157 and 158, and the mounting plate 158 is positioned flush with and forms part of the lower surface of the roof section 150. The plates 157 extend upwardly into the roof section 150, preferably perpendicularly to the plate 158, and the stud tubes 35 extend therethrough. The plates 157 function to anchor the plate 158 to the stud tubes 35.
The contact plate 159 is positioned below the mounting plate 158 and is mounted by the uprights 160 and 161 at a selected angle thereto. The height of the upright 160 is greater than the height of the upright 161 and the angle defined between the plates 158 and 159 is equal to the slope at which the roof section 150 is designed to be mounted. Thereby, the roof section 150 may be mounted in a building structure at the slope for which it is designed by positioning the contact plate 159 in contact with the upper horizontally extending surface of the stringer 156.
Elongated holes 163 are formed in the contact plate 159 through which bolts may be inserted to bolt the roof rest 155 to the stringer 156. Access openings 164 are formed in the upright 160 adjacent the bolt holes 163 to provide access thereto. The downwardly projecting flange 162 may be formed as a continuation of the upright plate 160 and extends downwardly from the contact plate 159. The flange 162 functions as a stop to prevent the roof rest 155 from sliding off the stringer 156. The flange 162 is positioned on the side of the roof rest 155 nearest to the ridge side of the roof section and thus will rest against the stringer side wall 213 positioned towards the inside of a building structure. It is noted that the contact plate 159 preferably has the same width as the width of the stringer top wall 211.
The construction of the ridge defining frame member 151 is shown in FIGS. 29 and 30. The frame member 151 is constructed to have an outer planar surface 170 which has a longitudinally extending semi-cylindrical groove 171 formed therein. The groove 171 is for receiving a ridge seal and extends in a direction parallel to the plane of the contact plate 159. The planar surface 170 extends in a plane substantially perpendicular to the plane of the contact plate 159. Secured to or formed as a part of the frame member 151 is a downwardly depending lug 172. The lug 172 preferably is a continuation of the planar surface 170. The lug 172 has a hole 173 formed therein so that it may be gripped by a hook and pulled downwardly.
The construction of the frame member 152 defining the edge of the eaves is shown in FIG. 29. The frame member 152 preferably is hollow and has a triangular cross-section. The frame member 152 is constructed to have an outer side 175 which preferably extends in a plane substantially perpendicular to the contact plate 159 and a lower side 176 which forms a continuation of the lower side of the roof section 150.
The frame members 153 and 154 of the roof section 150 are best shown in FIG. 31. The frame member 153 defines a tongue 180 and the frame member 154 defines a groove 181 dimensioned to mate with the tongue 180. Aligned calking grooves 182 are formed in the frame members 153 and 154 above the tongue 180 and groove 181. A weathertight seal may be formed between two mated roof sections 150 by filling the calking grooves 182 with a suitable calking material. It is noted that the roof sections 150 used to form the ends of a building roof should be manufactured with their outer side edge 153 or 154 defining a flat vertically extending surface. Therefore, tongue and groove structure is only formed on the inward side edge 153 or 154 of such end roof sections.
As shown in FIGS. 28 and 31, a vent pipe hole may be formed in a roof section 150 by mounting a cylinder 190 to extend therethrough. The cylinder 190 is held in place in the roof section 150 by a cross member 191 having spring clamps 192 secured to its ends. The spring clamps 192 are clamped on acjacent stud tubes 35 so that the cross member 191 extends therebetween. An opening is formed in the cross member 191 through which the cylinder 190 fits. Collar structure 193 is formed on the cross member 191 around this opening for holding the cylinder 190 and the cylinder is secured in a suitable manner thereto. The collar 193 is orientated with its axis substantially perpendicular to the plane of the contact plate 159 so that when the roof section 150 is in situ on a building structure the cylinder 190 defines a vertical vent pipe hole.
Referring to FIG. 32, a prefabricated house or building structure 200 is there shown. The building structure 200 is made of prefabricated wall sections 30, stringers 156, prefabricated ceiling sections 130, prefabricated roof sections 150 and prefabricated gable sections 201. A vent or chimney 202 is shown mounted in the vent hole defined in one of the roof sections 150. Window assemblies 120 are mounted in window openings formed in the wall sections 30 and a door 203 is hung in a door opening formed in one of the wall sections 30.
As shown in FIG. 33, one of the wall sections 30 of the house 200 is shown mounted on a foundation 204 by means of J-bolts 205 and spikes 206. The foundation 204, which is preferably made of concrete, provides the floor for the house 200 and the J-bolts 205 are set in the foundation 204 at selected locations at the time it is poured. The nuts 207 are screwed on the bolts 205 by inserting a long handled tool operable to do the same through the top end of the stud tubes 35. The spikes 206 are shot into the concrete foundation 204 through the base frame member 32 of the wall section 30 by use of a conventional tool for shooting spikes. The spike shooting tool is designed for insertion into the stud tubes 35 and may be appropriately positioned by inserting it through the top ends of the stud tubes 35.
FIG. 34 illustrates one of the side wall sections 30 of the house 200. A ceiling section 130 is shown supported by its flange 135 on the wall section 30 with the stringer 156 mounted on the top of the wall section 30 to overlap the flange 135.
The stringer 156 is hollow and has a substantially rectangular cross-section defined by upper, lower and side walls designated by the numerals 211-214, respectively. The portion of the stringer wall 212 overlapping and contacting the flange 135 is upwardly offset from the plane of the remainder of the wall 212 a distance substantially equal to the width of the flange 135 so that the flange 135 fits thereunder. A perspective view of one of the stringers 156 is shown in FIG. 43.
The stringer 156 has openings 215 in its lower wall 212 appropriately positioned for alignment with the open upper ends of the stud tubes 35. The stringer 156 is secured on the top of the wall section 30 by a slip toggle 216 inserted through the hole 215 into the stud tubes 35. A dog washer 217 is positioned around the hole 215 on the stringer lower wall 212 and the dog washer 217 functions to support the head of the bolt 218. The bolt 218 is part of the slip toggle 216. Elongated openings 199 are also formed in the lower stringer wall 212 through which pipes and the like protruding from the top of a wall section 30 may extend.
The slip toggle 216 has upper and lower cylindrical sections 219 and 220 which contact each other along slanted surfaces 221 and 222. The sections 219 and 220 have rasplike outer surfaces designed for frictionally gripping the interior of the stud tube 35. A central bore 223 is formed through the cylindrical sections 219 and 220. A nut 224 designed to mate with the bolt 218 is mounted in the bore 223 by means of pins 225 which extend into lateral slots 226 formed in the lower cylindrical section 220, as shown in FIG. 35. This slot-pin arrangement for mounting the nut 224 permits the sections 219 and 220 to slide relative to each other and relative to the nut 224.
The stringer 156 is tightly secured to the wall section 30 by tightening the bolt 218. Tightening the bolt 218 pulls the lower cylindrical section 220 upwardly in the stud tube 35 and the upward movement of the section 220 causes the sections 219 and 220 to slide laterally relative to each other along surfaces 221, 222, thereby moving the rasplike outer surfaces of the sections 219, 220 into tight gripping contact with the inner wall of the stud tubes 35. Thus, the stringer 156 is tightly secured on the wall section 30. It is noted that access holes are provided in the stringer 156 to permit the tightening of the slip toggles 216 and that calking material 227 is shown tightly held in the calking grooves 75.
FIGS. 36 and 37 illustrate the roof portion of the prefabricated house 200. An outer wall 230 and a parallel extending inner bearing wall 231 are shown formed from prefabricated wall sections 30. A pair of ceiling sections 130 are interfitted and mounted to extend between the outer and inner building walls 230 and 231. A stringer 156 is mounted on the central bearing wall which is constructed for overlapping flanges 135 of ceiling sections 130 positioned on both sides of the bearing wall 30.
Structure 232 is mounted on the upper stringer wall 211 to which is connected roof braces 233 and a turnbuckle 234. Flange structure 235 is formed on the underside of the roof sections 150 and the braces 233 are connected thereto to brace the roof. A hook 236 is hooked through the lugs 172 on adjacent roof sections 150. A cable 237 is attached between the turnbuckle 234 and the hook 236. Thereby, by tightening the turnbuckle 234, the roof sections 150 may be pulled downwardly and towards each other.
A longitudinal extending ridge seal 240 preferably made of resilient neoprene is shown interfitted in the grooves 171 of the roof sections 150. The ridge seal 240, as viewed in cross-section, has an upper umbrella or roof shaped portion 241 which fits over the upper adjacent edges of the roof sections 150. The umbrella shaped portion 241 is interconnected by a relatively narrow interconnecting strip 242 with a substantially cylindrical body portion 243. The body portion 243 is dimensioned to tightly interfit in the roof section seal grooves 171. Depending from the cylindrical body portion 243 is a downwardly extending flat portion 244 which extends to the undersides of the roof sections 150.
FIG. 37 illustrates the roof rest 155 of the roof section 150 positioned on the stringer 156 on the side wall 230. It is noted that the flange 162 prevents the roof section 150 from sliding out of position and that a square shouldered bolt 250, as shown in FIG. 44, is inserted through the elongated bolt hole 163 in the roof rest and secured by a washer 253 and nut 254 in engagement with the upper stringer wall 211 to secure the roof rest 155 thereon. As shown in FIG. 43, elongated slots or bolt holes 198 are formed in the upper stringer wall 211 to receive the shafts 256 of the bolts 250. The head 255 of the bolt 250 is elongated to fit through the slots 163 and 198 when aligned therewith. A bolt 250 may be secured in place by inserting it through the slots 163 and 198 to position the cylindrical shaft 256 of the bolt in the slots 163 and 198. The bolt 250 may then be turned to position the bolt head 255 so that it extends transversely relative to the bolt slots. The square shoulder 257 of the bolt 250 is then seated in the bolt slots and the washer 253 and nut 254 are secured on the shaft 256. The bolt 250 is now secured in place and is held against turning by the square shoulder 257 seated in the slots 163 and 198. Access is provided to the bolt 250 through the access opening 251 in the stringer 156. Vent and access openings 251 are shown formed in both side walls 213 and 214 of this stringer 156. Screens 252 are provided for securing over the openings 251.
Referring to FIG. 38, a gable section 201 of the house 200 is there shown. The gable section 201 is manufactured on the molding table 10 in the same manner as the wall sections 30. The gable section 201 is triangular in shape and its shape is defined by upper, side, and lower frame members 261, 262 and 263. The gable section 201 includes stud tubes 35 mounted to extend between the upper and lower frame members 261 and 263. The stud tubes 35 are held in place by flange structure on the frame members 261 and 263.
Openings 264 are formed in the lower frame member 263 in alignment with complementary holes 215 in the upper stringer wall 211 and slip toggle 216-dog washer 217 arrangements as hereinbefore described are used to engage the stud tubes 35 to secure the gable section 201 in place on the upper stringer wall 211. Access openings 265 are formed in the gable section 201 adjacent the upper frame member 261. Bolt holes are formed in the frame member 261 at the access openings 265 and a support member 266 having complementary threaded bolt openings formed therein is secured on the underside of the end roof section 150 to rest in contact with the gable section frame member 261. As shown in FIG. 38a, the support member 266 is anchored by clamps 290 to a stud tube 35. Bolts 267 are inserted in the bolt openings and tightened to hold the frame and support members 261 and 266 together, thereby to secure the end roof section 150 on the gable wall section 201.
A vent opening is formed in the gable sections 201 shown in FIG. 38. A louvered and screened vent 268 is shown mounted in the vent opening.
FIGS. 39 and 40 illustrate a partition beam 270 mounted in the prefabricated house 200. A partition beam 270 is incorporated in the house 200 where necessary to permit the formation of rooms having a size greater than the size of two assembled standard sized ceiling sections 130. The partition beam 270 takes the place of one or more interior wall sections 30 and provides a bearing surface for supporting the flanges 135 of ceiling sections 130.
A wall section 30 is shown in FIGS. 39 and 40 arranged for supporting the partition beam 270. This wall section 30 has an opening defined along its top edge for receiving the partition beam 270 and holding the upper edge of the beam 270 against the upper frame member 31 of the wall section 30. The partition beam 270 has preferably a rectangularly shaped cross-section, is hollow and has its end designed for fitting in the opening defined in the wall section 30 so that the upper side of the portion of the partition beam extending from the wall section 30 is level with the wall section upper edge. The opening formed along the top edge of the wall section 30 for receiving the partition beam 270 is formed by a rectangular liner 271 riveted to the frame member 31 and supported by a cripple 272. Stud tubes 35 are positioned in the wall section 30 to each side of the liner 271 for reinforcing the wall section. The stud tubes 35 are horizontally braced by a bracing member 273 clamped thereto to extend therebetween. It is noted, as shown in FIG. 39, that the opening defined in the wall section for receiving the partition beam 270 does not extend across the entire width of the wall section 30. The outside wall of the wall section 30 extends the full height of the wall to define an outwardly positioned stop 274 to hold the partition beam 270 laterally in place.
FIGS. 41 and 42 illustrate a strongback for use in moving prefabricated wall sections at the site of manufacture and at the site of construction. The strongback 280 is made of a rigid strong longitudinal member 281 which preferably has a rectangular cross-section. The longitudinal member 281 opens along its bottom side and has mounted at selected locations along its length depending slip toggles 282.
As shown in FIG. 42, the slip toggles 282 are mounted on the longitudinal member 281 by bolts which extend through bores 283 formed in bearing blocks 286. The bearing blocks 286 are secured to the inside of the member 281 to depend therefrom. A wall section 30 is shown being engaged by the strongback 280 in FIG. 42.
The slip toggle 282 is constructed and operates in the same manner as the above-described slip toggles 216. It is noted that since the slip toggles 282 are used time after time for picking up prefabricated wall sections that they must be made of a durable strong material. The slip toggles 216, however, since they are used only once, i.e., to secure the prefabricated wall sections together, need not be as strong or durable as the slip toggles 282 and therefore may be made of inexpensive materials, such as plastics or the like.
Once the strongback 280 is secured to a prefabricated wall section, as showin in FIG. 41, the wall section may be moved by using a crane to pick up the strongback 280 through the hoisting cables 284 attached to the strongback. It is noted that since the bottom of the strongback 280 is open, except at the points where the slip toggles 282 are mounted, the strongback 280 may be used to pick up wall sections even though pipes and the like protrude from the edge upon which the strongback 280 is positioned. The protruding pipes and the like extend into the open space 285 defined within the strongback.
In constructing the prefabricated building structure or house 200, the following procedure may be employed. The prefabricated wall, ceiling, gable and roof sections are manufactured on the molding table 10 at the site of manufacture. These prefabricated components are transported along with other necessary components, such as stringers, toggles, etc., to the building site. The strongback 280 is used when necessary for moving the prefabricated components at the manufacturing and building sites.
At the building or construction site, the foundation of the house 200 is cast with J-bolts in place to form the floor. J-bolts are preferably placed to be positioned under each third stud tube 35 of the outside walls.
In assembling the walls of the house 200, the center bearing wall is first calked and set in place. Partition walls and then outside walls are calked and set in place as necessary. The locking bars 33 are put in place but not pushed down. Partition beams, and the ceiling panels are next placed in position. Now the locking bars 33 are pushed down to firmly interlock adjacent wall sections 30 and nuts are screwed on the J-bolts to firmly anchor the wall sections 30 in place. Spikes are thereafter shot into the foundation through the other stud tubes 35.
Stringers 156 are next secured in place. The electrical, water, gas and other connections are made and tested. After this testing, the gable sections 201 are secured in place and the roof sections 150 are installed along one side of the house starting from one end. The roof sections are loosely braced and then the ridge seal 240 is adhesively secured in place. The other side of the roof is then mounted in place, loosely braced and tightened down by the turnbuckle-cable arrangements. It is noted that slots 291 are formed in the lower ends of the braces 233 to permit the braces to move when the roof is tightened down and that the braces 233 are not tightly clamped in position until after the roof has been tightened down.
With the house 200 erected, a finishing roof coat is applied. The window and door openings are closed and a protective finishing coating is then applied to the outside of the house. Windows and doors are thereafter set into place, and kitchen cabinets, sinks, toilets and other fixtures are mounted. Floor coverings are then laid and final tests of the utilities are made. The prefabricated house 200 is now ready for moving into and completed.
It is noted that the prefabricated sections may be made of various lengths and thicknesses. For example, the sections could be approximately 3-5 inches thick and 7 or 8 feet long so that they could be conveniently transported to the building site. The sections may, however, be any predetermined dimension desired.
Although I have described my invention in what I have conceived to be the preferred embodiment, it is recognized that departures may be made therefrom within the scope of my invention.
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