US3436885A - Prefabricated wall structure elements and assembly thereof - Google Patents

Description

APril 8, 1969 J. H. ROTHERM-EL 3,436,885

PREFABRICATED WALL STRUCTURE ELEMENTS AND ASSEMBLY THEREOF Filed Dec. 14, 1966 Sheet g of 3 240 28 24b 38 60 [3am April 1969 J. H. ROTHERMEL 3,436,885

PREFABRICATED WALL STRUCTURE ELEMENTS AND ASSEMBLY THEREOF Filed Dec. 14, 1966 Sheet 5 of5 United States Patent 3,436,885 PREFABRICATED WALL STRUCTURE ELEMENTS AND ASSEMBLY THEREOF John H. Rothermel, Lake George, N.Y., assignor t0 Integral-Structures, Inc, a corporation of New York Filed Dec. 14, 1966, Ser. No. 601,649 Int. Cl. E041) 1/04; E06b 3/54 US. Cl. 52207 11 Claims ABSTRACT OF THE DISCLOSURE This invention relates to building construction and more particularly to a novel set of wall elements which may be fastened together to form a wall structure.

In the art of building light commercial buildings, common construction includes light metal framing, such as aluminum framing, large wall panel areas of glass and other panel areas of a lightweight translucent material. Such buildings are typically used to house service stations, hamburger stands, small business establishments and light duty public buildings and the like. Typically building the wall panels of such buildings requires the use of the usual building trade skilled craftsmen and the necessary tools which are utilized by such craftsmen in cluding saws, hammers, devices for driving and securing threaded fasteners and the like.

This invention is directed, in brief, to the provision of a plurality of interlocking engageable wall members which serve as frames for captivating different wall panels and which fur ther may be locked together to form a common integral wall held together by interfitting parts without the need for common fastening elements such as bolts, screws, nails, and the like.

It is a primary object of this invention to provide a novel prefabricated wall assembly for use in light commercial buildings.

It is another object of this invention to provide a novel prefabricated wall assembly wherein the several elements of the wall may be interlocked together by interfitting 0 parts, eliminating the need for conventional assembling tools and construction equipment for assembling and erecting such a wall.

It is a further object of this invention to provide a prefabricated wall assembly of interlocking parts which is easily erectable by unprofessional, semiskilled labor.

It is still a further object of this invention to provide a prefabricated wall assembly comprising intertfitting, interlocking parts which may be disassembled and reerected without damage or deterioration of any of the components.

Yet a further object of this invention is to provide a novel prefabricated wall assembly of interlocking, interfitting parts which may be easily assembled in any type of weather condition.

Still a further object of this invention is to provide a set of prefabricated wall members including interfitting elements which may be locked together to provide wall units for containing different types of wall panels, the several wall units being capable of being locked together by different prefabricated members.

3,436,885 Patented Apr. 8, 1969 Other objects, features and advantages of the present invention will be apparent from the following description of the preferred embodiments illustrated in the accompanying drawings, in which:

FIGURES 1-15 are section views of the several prefabricated interfitting wall elements of this invention which may be utilized to form wall frame units which secure wall panels of different characteristics, the several wall units formed thereby being capable of being locked together by some of the members shown in FIGURES l-15 to form an integrally connected common wall;

FIGURE 16 is a fragmentary, broken, generally horizontal section view through a wall assembly utilizing some of the prefabricated wall elements shown in FIG- URES 1-15;

FIGURE 17 is a continuation of the wall shown in FIGURE 16;

FIGURE 18 is a fragmentary section view of a portion of a wall assembly using the wall elements shown in FIGURE 14 and illustrating a 'threadable locking means for drawing two wall units together;

FIGURE 19 is a fragmentary vertical section view showing the relationship between horizontal wall elements illustrated in FIGURES l, 2 and 15 and a wall supporting surface;

FIGURE 20 is a fragmentary vertical section view showing wall elements from FIGURES 3 and 15 in use in tying portions of the wall to a supporting surface;

FIGURE 21 is a fragmentary sectional view similar to FIGURE 20 showing yet a different arrangement of elements from FIGURES 13 and 14 in use in tying the wall to a supporting structure; and

FIGURE 22 is a fragmentary section view showing the utilization of elements illustrated from FIGURES 13 and 14 in use in the top of a wall line adjacent the roof line of a building.

Referring now to the drawings, in FIGURE 1 there is shown a section view of wall element 10 which may be utilized for forming frames for captivating different wall panels. Preferably the element 10, and all other elements to be described, are made of relatively hard, slightly resilient material, such as extruded aluminum. Element 10 is intended for use as a thin panel frame member or window frame or window mullion, it being understood that this member could be used as an upright member and also as a horizontal member, forming the sides of a framework which serves to captivate a relatively thin panel such as a windowpane or the like. Window frame mullion 10 includes a generally fiat panel receiving surface 12 which is flanked by a pair of grooves 14a and 14b, generally U-shaped in section, which, in turn, are flanked by fiat wall portions 16a and 1612, respectively, generally coplanar with the panel receiving surface 12. Grooves 14a and 141) have opposed splines 14a and 14b, respectively. Each of wall surfaces 16a and 16b terminates in a right angularly or rearwardly extending side wall 18a and 18b, respectively, which terminate in inwardly returned portions 20a and 20b, respectively, generally parallel to, and spaced from, portions 16a and 16b. Each inwardly returned portion 20a and 20b terminates in an inwardly spaced, rearwardly extending portion 22a and 22b, respectively, each of which is parallel to and inwardly spaced from, side walls 18a and 1812, respectively. Locking fingers 24a and 24b project outwardly from each of the portions 22a and 2211, respectively, each of said locking fingers being generally parallel to and closely spaced from the surfaces 20a and 20b and terminating short of the line defined by a continuation of side walls 18a and 18b. One face of the fingers 24a and 24b is provided with a small notch such as 24a and 24b for receiving a generally mating spline of a locking member (to be described later) which is inserted in space 25a and/or space 25b between each of fingers 24a and portion 20a and finger 24b and portion 201), respectively.

Panel retention mullion 27 is illustrated in FIGURE 2. This mullion includes an outer surface 27a, a first panel retaining portion or surface 27b, and a second panel retaining portion or surface 270, each of which extends outwardly from the same side of opposite ends of surface 27a generally parallel to each other. Portion 27c termimates in a returned portion 27d which extends generally normal to portion 270 and generally parallel to surface 27a. Portion 27d, in turn, terminates in locking finger 272 which is generally parallel to portion 27c and the adjacent longer finger portion 27 of portion 27b. Each locking finger includes opposed grooves 27g generally of a size and location to engage splines 14a and 14b of grooves 14a and 14b to retain the retaining mullions 27 therein with either portions 27b facing each other to retain thick panels therebetween or portions 270 facing each other to retain thin panels therebetween. Cushion .means in the form of a thin, tape-like strip may be applied to either surface 27b or 270 to serve as a cushion when retaining panels such as windowpanes between retention mullions 27.

Shown in FIGURE 3 is a panel edge member or frame member or enlarged panel retaining mullion 28. This member is generally U-shaped in section and includes a panel receiving surface 30 generally flanked by two outwardly extending side wall members 32a and 32b which extend outwardly from the same side of each end of the face 30 generally parallel to each other. The cross sectional thickness of mullion 28 is generally the same as that of mullion and the distance between interior and exterior of side wall members 32a and 32b is substantially the same as the distances between the corresponding portions of side Walls 18a and 18b of mullion 10.

The opposite side of panel receiving surface 30 includes rearwardly extending portions 34a and 34b which are generaly parallel to the members 32a and 32b, respectively, spaced inwardly therefrom the same distance as portions 22a and 22b are spaced inwardly from side walls 18a and 18b. Locking fingers 36a and 36b extend laterally from portions 34a and 34b, closely spaced from, and generally parallel to, the adjacent portion of the panel receiving surface 30 approximately the same distance as locking fingers 24a and 24b are spaced from portions 20a and 20b. In like manner, locking fingers 36a and 36b are provided with locking grooves 36a and 36b for receiving splined surfaces of a locking element in spaces 37a and 37b, respectively, to look similar panels together.

For example, if a mullion 28 is turned. so that the portions 34a and 34b abut portions 22a and 22b of .mullion 10, the two sets of locking fingers 24a and 36a and 24b and 3612 would be in a position to receive a generally U-shaped locking member to lock mullions 10 and 28 together. This, in fact, is one of the intended uses of the two members and for this purpose, the locking element or locking mullion 38, shown in FIGURE 4, is provided.

Locking mullion 38 is generally U-shaped and includes a base portion or side wall portion 40 and two parallel spaced outwardly projecting locking legs 42a and 42b each being of a size to snugly fit in the space, such as 25a or 37a, between a locking finger, such as 24a or 34a, and its companion wall surface 20a or 3011, respectively. In addition, each of the legs 42a and 42b includes a mutually inwardly facing rib or spline portion 42a and 42b, one of which is intended to occupy one of the grooves such as 24a of one of two mullions, such as 10 and 28, when abutted together, the other of which is intended to occupy the other of the grooves, such as 36a, to thereby lock the two mullions as a unit. In addition, the length of legs 42a and 42b is intended to be generally coextensive with the offset distance of the portions on which the fingers are supported, such as 22a or 34a, so that the portion 40 of the lock mullion 38 will be a general continuation of the side Wall Surface afforded by 4 side walls, such as 18a and 18b or 32a and 32b. Finally, the cross sectional thickness of legs 42a and 42b is about the same as the width of spaces 25a, 25b, 37a, 37b, and the like.

The lock member or lock mullion 44, shown in FIG- URE 5, may be used instead of the lock mullion 38 where it is desirable or necessary to lock two mullions together farther apart than permissible with mullion 38. Lock mullion 44 is a generally U-shaped structure having a base or side wall portion 45 and two spaced, parallel, outwardly extending legs 46:: and 46b, each of which, in the interior thereof, is provided with a spline 46a and 46b which may engage companion notches in the fingers in the same manner as described with reference to mullion 38.

Next shown in FIGURE 6 is a cap or edge member or cap mullion 48 which is generally U-shaped in section including a base portion 49 and two spaced, parallel, forwardly extending side wall portions 50a and 581), said portions being spaced apart generally the same distance as the aforedescribed similar portions 18a and 18b on mullion 18 and 32a and 32b on mullion 28.

The side wall portions 50a terminate in rearwardly extending and slightly inwardly offset fastening fingers 52a and 52b, respectively, each of which is provided with a splined portion 52a and 52b on the outwardly facing wall surface thereof. The portions 52a and 52b are inwardly offset a distance generally corresponding to the mullion cross sectional thickness so that they will generally matingly engage the interior of the wall surfaces such as 32a and 32b. In the case of the mullion 28, such engagement would be possible with the splines 52a and 52b occupying the grooves 32a and 32b on the interior of the side walls 32a and 32b, respectively, of mullion 28. In this fashion, mullion 48 would be fastened to mullion 28, providing a cap therefor by means of the surface portion 49.

In FIGURE 7 there is shown a corner member or corner mullion 54. Corner mullion 54 is a right-angular structure including a first wall portion 56a and a second wall portion 56b extending generally perpendicularly from one end of wall portion 56a. Both portions 56a and 56b are generally coextensive in length, each being provided with a generally perpendicularly inwardly extending locking finger 58a and 58]), respectively, spaced inwardly from the free end of each wall portion substantially the same distance. Each locking finger 58a and 58b is provided with a small splined portion 58a and 58b, respectively, facing inwardly or toward the other wall of the mullion. Each finger 58a and 58b is spaced from the corner formed by the juncture of the two walls a distance substantially equal to the width of the several mullion members disclosed herein such as mullions 10, 28 and 48, which have already been described. When it is desired to join two right angularly disposed wall sections, mullion S4 is utilized with finger 58a engaging a finger such as 24a or 36a on the mullion of one wall along the outer edge thereof and with the finger 58b engaging a finger such as 24b or 36b on the outer edge of the mullion of a wall disposed at generally right angles to the first wall. This connects the two walls together and provides a mask or cap for the corner juncture of the two walls.

Shown in FIGURE 8 is the door jam-b member or door jamb mullion 60. This mullion includes side walls 62a and 62b extending outwardly from the ends of wall surface 64 generally parallel to each other so that the two side walls are spaced apart a distance substantially the same as or slightly more than, the distance between the interior of side walls 32a and 32b 50 that door mullion maybe snugly received between the interior of the side walls such as 32a and 32b of mullion 28 to be securely nestably held therein. Surface 64 is provided with an outwardly projecting portion 66 which serves as the door jamb against which the edge of a door may rest. Side wall surfaces 62a and 62b terminate in inwardly extending portions 68a and 68b which are generally parallel to, and spaced from, wall 64. These wall portions 68a and 68b, in turn, terminate in rearwardly trailing parallel portions 70a and 7012, each of which has a splined outer portion 70a and 70b.

Shown in FIGURE 9 is the window frame member or window mullion 74 which is similar to mullion 10. Mullion 74 includes a panel receiving surface 76 and two lock member receiving grooves 78a and 7812 on either side of surface 76.

Each of the grooves 78a and 78b is splined at the opposite sides of the groove as at 78a and 78b, respectively. On either side of the grooves the wall portions 80a and 80b extend generally coplanar with the central panel receiving portion 76.

Fingers 82a and 82b extend rearwardly from portions 80a and 80b, respectively, generally parallel to each other from a point near the free end of each wall portion 80a and 80b. It is intended that the dimension across mullion 74 would be generally the same as that across mullions 10, 28 and 48 while the fingers 82a and 82b would be set in from the ends of the portions 80a and 801: a distance substantially equal to the thickness of the several extrusions disclosed herein. Each of the fingers 82a and 82b is provided with a splined outwardly facing surface 82a and 82b for locking engagement with a mating grooved surface of another member, such as the grooves 32a and 32b in the locking members 32a and 32b of mullion 28. Thus, by assembling mullions 74 and 28 together, one would arrive at a mullion assembly similar to the mullion 10, suitable for use as a window or similar panel frame.

Takeoff plate or takeoff mullion 84 is illustrated in FIGURE 10. Mullion 84 is a generally planar structure substantially coextensive in width with the width across the mullions 10, 28, 48 and 74. This mullion includes a base portion 86 and two rearwardly extending portions 88a and 88b, each of which is set inwardly from the ends of the base portion 86 a distance substantially the same as the portions 34a and 34b on mullion 28. In addition, each portion 88a and 88b includes an outwardly extending finger 90a and 9012 which is generally parallel to, and closely spaced from, the base 86 substantially the same distance as fingers 36a and 36b on mullion 28, providing a space 91a and 9112, respectively. Each finger 90a and 90b is grooved or notched at 90a and 90b so that the takeoff plate 84 may be fastened to mullion or mullion 28 by means of the locking mullions 38 or 44 as disclosed herein.

Takeofi plate 84 is substantially the same as the rear wall portion 30 of mullion 28 without the side walls 32a and 32b. The intended use of this mullion is, as shown in FIGURE 16, where it is desired to run a wall course offset from the main wall courses, the takeoff plate or mullion 84 may be secured by means such as threaded fasteners 92 to the exterior of the wall and, with the aid of the locking fingers 90a and 9012, a similar prefabricated wall may be run from the point of takeoff.

Common panel mullion or common panel joiner 96 is illustrated in FIGURE 11. Mullion 96 is generally H-shaped in section, including a cross-bar 98 and side wall members 100a and 1020 which extend forwardly and rearwardly from one end of bar 98, and side wall members 1001) and 10212 which extend forwardly and rearwardly from the opposite end of crossbar 98. The dimension across the exterior of mullion 96 is the same as that with mullions 10, 28, 48, 74 and 84. The dimension between the interior of the pairs of side wall surfaces 100a, 1001) and 102a and 102]; is the same as the dimension between similar surfaces in mullion 28 and also the same as the outer dimension between side walls 62a and 62b of mullion 60 as well as the outer dimension between fingers 82a and 82b of mullion 74. The interior of each of the side walls 100a, 10Gb and 102a, 1021: is provided with a groove 100a, 1001) and 102a and 1021), respectively, so that mullion 96 may snugly receive the door jamb mullion 60, engage fingers 6 82a and 82b of mullion 73, or engage the finger portions 52a and 52b of mullion 49.

Shown in FIGURE 12 is the end cap or end mullion 104. End mullion 104 is generally U-shaped in section and includes a base portion 106 and outwardly extending parallel side walls 108a and 108b, spaced apart generally the same distance as corresponding elements of mullions 96, 84, 74, 48, 28 and 10. Each side wall 108a and 1081) is grooved on the inside thereof as at 108a and 10817. Thus the end cap mullion 104 may be matingly engaged with window frame mullion 74 or mullion 49 to enclose the rear of the same. In addition, door jamb mullion 60 may be frictionally held between the interior of fingers 108a and 1081) of mullion 104.

Further included as part of the wall structure elements of this invention is transom means or horizontal rail 110, shown in FIGURE 13. Rail 110 includes a base portion 112 of reduced width relative to the previously described mullions. Forwardly extending and inwardly turned spaced side walls 114a and 11411 extend outwardly in one direction from opposite ends of base 112. Side walls 116a and 1161) extend outwardly from the opposite face of each end of base 112, generally parallel to each other. At the free end of side walls 116a and 11612, a seal retention leg 118a and 118b is provided, spaced generally inwardly from the outside of walls 116a and 116b, respectively. Each seal retaining leg 118a and 11812 is provided with a seal retaining cavity 120a and 1201;, respectively, for receiving a resilient sealing member. The intended use of the transom member 110 is as a horizontal beam member, such as adjacent the supporting base for the wall structure or adjacent the roof structure which might cover the enclosure defined by the wall structure comprised of the prefabricated elements of this invention.

Another horizontal beam member or transom member is the aligning rail or panel head 122 shown in FIG- URE 14. Panel head 122 has a generally U-shaped configuration and includes a crossmember 124 and two spaced, generally parallel, outwardly extending side walls 126a and 1261:. The exterior dimension of member 122 is substantially the same as the interior dimension between the side wall members of mullions 28, 96 and 104 so that member 122 can be snugly, matingly received and held therein.

Each side wall 126a and 12615 of member 122 terminates in an inturned hooked end 128a and 128b, respectively. In addition, the face of crossmember 124 is also provided with short stubs or projections 130a and 13011 which are in opposition to, and alignment with, the inturned ends 128a and 1281) of walls 126a and 126b. It is intended that the dimension between stubs 130a and 130k as well as inturned ends 128a and 128b would be substantially the same as the exterior dimension across the transom member 110 so that member 122 could be snugly, matingly telescoped over the transom means 110 and securely held thereon.

Another transom member or aligning rail 132 is shown in FIGURE 15. Aligning rail 132 includes a base portion 134 connected by diverging portions 136a and 136b to first generally parallel offset portions 138a and 1381). Second diverging connecting portions 140a and 1401) extend outwardly from portions 138a and 138b, respectively, each terminating in a seal retention portion 142a and 142b, respectively. Each seal retention portion includes a seal retention cavity 144a and 14417 which is intended to receive a resilient sealing member so that when transom member 132 is abutted against a roof line or supporting base, the member will be in sealing engagement therewith.

Each sealing leg portion 142a and 142b includes a rearwardly extending side wall portion 146a and 146b, respectively, each of which, in turn, is provided with a groove 146a and 1461) on the interior wall thereof. The dimension between the exterior of side walls 146a and 146b is the same as the dimension between similar portions of the mullions 28, 48, 84, 96 and 104 so that the side walls of the aligning rail 132 will be in alignment with the side walls of any such mullions which may be placed thereupon.

A composite wall section utilizing the several structural members shown in FIGURES 1-15 together with other panel structures is shown in FIGURE 16.

The elements Will be described beginning at the top right hand corner of the drawing and proceeding to the left and then downwardly. Mullion 49 is utilized as an end cap or cover in engagement with the mullion 96, the splines on fingers 52a and 52b of mullion 48 engaging the grooves in the interior of side walls 102a and 10212 of mullion 96. The offset of fingers 52a and 5212 from side walls 50a and 50b of mullion 48 provides a smooth continuity to the exterior wall surface defined by the juncture of side walls 102a, 50a and 10212, 50b.

The other side walls 100a and 10012 of mullion 96 frictionally embrace a wall panel 147 which is held therebetween. Preferably panel 147 is a block of insulating material, such as an expanded foam plastic, or the like, generally indicated 147a, which is held between tw thin sheets of rigid material such as aluminum outer skins 2147b and 1470 which are bonded to the insulating material. It is intended that the exterior dimension across the outside of block 147 should be slightly greater than the interior dimension between the side walls 100a and 10012 and of mullion 96 and similar side walls of other similar mullions so that the panel may be securely held between the interior of the side walls in a force fit relationship therewith.

The other end of panel 147 is similarly snugly held between the side walls 32a and 32b of mullion 28. This mullion is spaced from the window frame mullion and secured together therewith by means of two lock mullions 44, the fingers 46a and 46b of each lock mullion 44 occupying spaces 37a and 37b of mullion 28 and spaces 25a and 25b of mullion 10, thereby engaging the fingers 36a and 36b of mullion 28 and 24a and 24b of mullion 10.

As previously described, the takeoff plate mullion 84 is shown secured by fastening means 92 to the outside wall defined by side wall portions 18a of mullion 10 and 32b of mullion 28.

The mullion 10 adjacent mullion 28 is spaced from a second uprightly disposed mullion 10 and rests on top of a third horizontally disposed mullion 18 (see FIG. 19) defining a window frame, or the like, for receiving a thin panel or thin windowpane 148. Windowpane 148 is held between the several windowpane lock members 27 that are positioned in the several grooves 14a and 14b in each of the mullions 10 with portions 27c opposing each other for retaining a narrow panel, thereby holding windowpane 148 in abutment with the panel receiving surfaces 12 of each mullion 10 defining the frame. To complete the frame, a fourth mullion 10 is extending horizontally would be positioned adjacent the roofline of the wall.

Another mullion 28 is situated generally at a right angle to the left-most mullion 10 at the top of FIGURE 16, creating a generally right angular turn in the wall assembly. Corner mullion or cap 54 is utilized to secure the corner and mask the rear edges of the right angularly associated adjacent mullions 10 and 28 with fingers 58b of mullion 54- in engagement with finger 24a of mullion 10 and finger 58a in engagement with finger 36a of the right angularly oriented mullion 28. In addition, a right angle brace member 149 may be inserted between the closely adjacent fingers 24b of mullion 10 and 36b of mullion 28 to secure the two together at the interior of the corner.

The side walls 32a and 32b of mullion 28 snugly embrace, in a force fit relationship, the outer metal skin 14712 and 1470 of the block-like wall panel 147 to hold the same oriented at a right angle relative to the previously described wall structure. The other end of wall panel 147 is similarly captivated between the side wall members 32a and 32b of another spaced mullion 28.

Proceeding along the wall, aligned with previously mentioned mullion 28 is a window frame mullion 10. Mullion 18 is connected to mullion 28 by two lock mullions 38, the fingers 42a and 42b of each of which occupy spaces 37:: and 37b to interlock with the fingers 36a and 36b of mullion 28 and also occupy spaces a and 25b to interlock with fingers 24a and 24b of mullion 10. The base surface 40 of lock mullion 38 provides a continuation of the wall surface between the side wall members 32a and 18a of mullions 28 and 10 and the opposite side walls 32b and 18b of the same mullions.

Again, in the window construction, another upright window mullion 10' is also spaced across from the first mullion 10 and horizontally disposed mullions 10 are utilized at the top and the bottom to form a frame-like enclosure with the several grooves 14a and 14b occupied by the window lock mullions 27. This time, the window lock mullions 27 are reversed in their orientation with portions 27b opposing each other so that the space between them is enlarged to accommodate a thickened panel or thickened windowpane 148a which abuts against the panel receiving surface 12 of the several mullions 10.

The next upright mullion 10 is connected to a mullion 28 by means of a lock mullion 38 along either side wall, the fingers 42a and 42b of lock mullion 38 engaging the fingers 24a and 24b of mullion 10 and 36a and 36b of mullion 28 with the side wall portions 40 of the mullions 38 forming a continuation of the wall surface defined by the side walls 18a, 32a of mullions 10 and 28, and 18b and 32b of the same mullions. Mullion 28 mounts the door jamb mullion by snugly retaining, in a force fit relationship, the outer side walls 62a and 62b of mullion 60 within the interior of the side walls 32a and 32b, respectively, of mullion 28. Blocking means such as block 149 may be inserted between mullions 28 and 60 to insure that mullion 60 will not be pushed inwardly relative to mullion 28. In addition, the block 149 may beheld by suitable fastening means such as countersunk screw 149a which extends through mullion 60, block 149, and into mullion 28. The door jamb surface 66 of mullion 60 is in a position to engage a rear face 150a of a door panel 150 which preferably is of a thickness generally corresponding to the offset of door jamb 66 from the outer wall surface so that the front face 15% of door 150 is generally in alignment with the wall surface defined by the several side wall portions of the joined mullions; Another upright door jamb mullion 60 is positioned opposite the first mentioned door jamb mullion 60 and retained in the aligning rail 122 which is used to perform a mullion function by gripping the fingers a and 70b of the door jamb mullion on the interior of the inturned end portions 128a and 12%. Again a blocking means, such as block 159, may be inserted and held by suitable fastening means (not shown) as described with reference to block 149 and screw 14912.

A hinge 152 may be secured by means such as threaded fasteners 154 to one edge of door and to a face 64 of the one mullion 60 so that the door may be pivotally mounted with respect thereto, the opposite edge of the door abutting the jamb portion 66 on the opposite mullion 60 thereby providing a means for gaining access from one side of the wall structure to the other side intermediate the ends thereof.

The vertically disposed aligning rail 122, in serving a mullion function, is frictionally retained in 'a force fit relationship in the interior of the metal skin side walls 147a and 147b which embrace the side walls 126a and 126b, thereby securely mounting the wall panel 147 along the course of the wall, it being remembered that the exterior dimension across the aligning rail 122 is substantially the same as the interior dimension between the side wall portions such as 320 and 32b of mullion 28 and similar side wall portions of mullions 96 and 104.

FIGURE 17, a continuation of FIGURE 16, shows a continuation of the wall course from the broken portion of the previously described wall panel 147, with the opposite end of the wall panel having its outer metal skin 147b and 1470 snugly received in a force fit relationship between the side walls 32a and 32b of a rnullion 28. This rnullion is, in turn, secured to another window frame structure including an opposite upright window frame mullion 74, as well as horizontal rnullion as previously described and as indicated in FIGURE 5. Upright mullion 10 closely adjacent the previously described mullion 28 is secured thereto by means of the lock mullions 38. A thin panel 148 is secured within the frame described by the several window mullions by means of the lock mullions 27 which are in the same orientation as shown in the short wall portion at the top of FIGURE 16, and reversed with respect to the orientation shown in the longer wall portion in the middle of FIGURE 16, so that they snugly retain the thin panel 148 within the frame defined by the window mullions.

Fingers 82a and 82b of windowmullion 74 are frictionally retained in a force fit relationship to the interior of the side walls 108a and 108b of an end cap mullion104 with the base portion 106 of mullion 104 serving to enclose the end of the wall course. It should be understood that if a four-sided enclosure were to be created, the several corners would be formed in a fashion to that shown at the top of FIGURE 16, but, as illustrated herein, if it is desired to form a wall structure with free ends, then the mullions 104 and 48 may be used to suitably enclose the ends and provide a clean appearance thereto.

FIGURE 18 illustrates a means for joining two adjacent panel walls 147. In FIGURE 18, the two panels 147 are each secured in a force fit relationship to an aligning rail 122 which is used to perform a mullion function. As previously described, the outer skins 1471) and 1470 of each of the panels 147 snugly embrace, in a force fit relationship, the side walls 126a and 1261;, respectively, of each of the aligning rails 122 to join the panels to the rails. The interior 147a of each of the panels 147 preferably being a light weight expanded foam plastic material, there is nothing inherent in the material 147a itself which would permit it to receive conventional fasteners and securely grip the same. For this reason, holes 156 may be generally centrally bored in the base portions 124 of aligning rails 122 to receive the opposite threaded fasteners 157A and 15717 for holding locking means 158. Means 158 includes two portions 159 and and 1-60, portion 159 including rotatable element 1590. A workman may first secure one portion, such as 160 to the portion 124 of one aligning rail 122. The next panel 147 may then be abutted in alignment with the first panel 147 and with the portion 159 secured thereto, elements 159a is rotated so that it is received in portion 160 thereby snugly drawing the two panels 147 together so that their side wall portions 1471: and 1470 form a substantially smooth wall surface.

In FIGURE 19, the aligning rail 132 is shown supporting a window frame mullion 10 which functions in a transom or horizontal beam fashion. The aligning rail 132 is provided with resilient seal members 156 in each of the cavities 114a and 144b for sealing engagement with the horizontal surface 150a or the floor on which the structure rests. FIGURE 19 is illustrative of how the bottom and top portions of the window frames formed by the mullions 10 are utilized as the horizontal members to complete the frame and their relationship with the 'bottom supporting surface or top wall of the building, or the like, with which the wall structure is associated. The portions 22:: and 22b of the Window rnullion 10 rest on top of portions 138a and 13812, respectively, of the aligning rail 132 with diverging portions 136a and 136b of the aligning rail preventing lateral movement of mullion 10 with respect to aligning rail 132 so that the two members are generally held in vertical alignment with the side walls 180 and 18b of mullion 10 generally coplanar with the portions 146a and 14617 of the aligning rail.

In FIGURE 20, the aligning rail 132 is shown supporting mullion 28 which is serving a transom or beam function. The mullion 28 embraces, in a force fit relationship, the metal sides 1471) and 1470 of block-like panel 147 between the side walls 32a and 32b. The base 30 of mullion 28 rests on the base portion 134 of the aligning rail 132, with the fingers 34a and 34b abutting portions 136a, 138a, and 1361), 138b, in a similar manner to that described with reference to corresponding portions of mullion 10 shown in FIGURE 5, thereby retaining the mullion 28 against lateral movement with respect to the aligning rail 132.

Rail 132, as shown in FIGURE 20, may be provided with a cross piece 160 extending between portions 140a and 14012. Crosspiece is provided with an opening 161 for receiving the threaded end of a bolt 162 which may be sunk in supporting floor 163. A nut 164 is threaded on bolt 162 to thereby tie the aligning rail 132 to the supporting surface 163 with the resilient seals 156 in sealing engagement therewith. An access opening 165 may be provided in the portion 134 of aligning rail 132 to gain access to the nut 164 for tightening or loosening the same relative to bolt 162. It is to be understood that while the structure shown in FIGURE 20 has been described with relationship to tying the same to the floor or a similar supporting surface, the same parts could function in generally the same manner for tying the structure to the underside of a ceiling, roof, or the like.

FIGURE 21 illustrates the use of transom means 110 and aligning rail 122 in tying a panel 147 to surface 166 which could be a supporting surface or ceiling or roof line. The side walls 147]) and 1470 of panel 147 snugly embrace, in a force fit relationship, the exterior of the side walls 126a and 126b of the aligning rail 122. Aligning rail 122, in turn, snugly embraces the wall portions 114a, 116a and 114b, 116b, between its opposed stublike surfaces 130a, 128a and 13012, 128b, respectively. In this manner, the block-like panel 136 is securely connected to the transom means 110. In a similar fashion with respect to that described in FIGURE 20 relative to the aligning rail 132, an opening 167 may be formed general- 1y centrally in the portion 112 of the transom 110 for receiving the shank of a bolt 168 which may be sunk in the supporting surface 166. A nut 169 threaded on the bolt 168 ties the transom member 110 to the surface 166 with the resilient seals 156 in sealing engagement with the surface 166.

In FIGURE 22, the structure described in FIGURE 21 is shown abutting a roof line or ceiling 170 but the bolt 171 extends upwardly through the panel 147 and is tied thereto by placement of a nut 172 on the top side of portion 112 of the transom 110 so that the side wall is tied down to a slab such as 166- in which the bolt 171 may be anchored for resisting high wind and uplift forces, or the like.

The set of prefabricated wall elements disclosed herein may be utilized to construct a complete wall structure or a closure bounded by a plurality of such walls, without the use of conventional fastening means. If desired, as illustrated, the transom means located adjacent a supporting surface or roof line may be bolted thereto but otherwise, except for the provision of a door, or the attachment of a take-off rnullion for the offset wall, the entire wall structure, including thick decorative and insulating panels, window frames and the like, may be assembled by inter-engagement of the several interfitting parts of the mullions and transoms disclosed herein.

The foregoing detailed description has been given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, as some modifications may be obvious to those skilled in the art.

I claim:

1. A set of prefabricated wall mullion and transom elements for use in combination with prefabricated panels to form an interlocking prefabricated wall assembly, comprising: lock mullions having locking surfaces thereon for interlocking engagement with mating surfaces of other mullions; said first panel retaining mullions including a large panel retaining mullion having a base portion and two spaced walls extending outwardly from opposite ends of the base portion constructed and arranged to receive the opposite outer walls of a panel therebetween in a force fit relationship, said panel retaining mullion further including spaced locking fingers constructed and arranged for interlocking engagement with the locking surfaces of the lock mullions; transom means constructed and arranged to engage a horizontal surface and being provided with means for retaining an upright wall segment defined by at least one panel retaining mullion, whereby a plurality of said panel retaining mullions may be connected together as a prefabricated wall unit solely by means of interlocking engagement with said lock mullions.

2. A set of prefabricated wall mullion and transom elements for use in combination with prefabricated panels to form an interlocking prefabricated wall assembly, comprising: lock mullions having locking surfaces thereon for interlocking engagement with mating surfaces of other mullions; first panel retaining mullions, said first panel retaining mullions including a large panel retaining mullion having a base portion and two spaced walls extending outwardly from opposite ends of the base portion constructed and arranged to receive the opposite outer walls of a panel therebetween in a forced fit relationship, said panel retaining mullion further including spaced locking fingers constructed and arranged for interlocking engagement with the locking surfaces of the lock mullions; transom means constructed and arranged to engage a horizonal surface and being provided with means for retaining an upright Wall segment defined by at least one panel retaining mullion; second panel mullions engageable with said first panel mullions including a corner mullion having generally normally extending surfaces for locking engagement with interlocking surfaces of said panel retaining members by means of said locking mullions for securing two such panel retaining members together disposed generally at right angles to each other and masking the exteriorly facing adjacent surfaces thereof, whereby a plurality of said panel retaining mullions may be connected together as a prefabricated wall unit solely by means of interlocking engagement with said lock mullions.

3. The set defined in claim 2 wherein said second mullions includes a door jamb mullion which is constructed and arranged for force fit securement within the spaced side walls of the large panel retaining mullion.

4. The set defined in claim 2 wherein said second panel mullions includes a first end cover mullion having a base portion and two spaced side walls extending outwardly therefrom, said first end cover mullion side wall terminating in inwardly offset locking portions adapted to be matingly received between the side walls of said large panel retaining mullion with the side walls of both mullions generally coplanar with each other.

5. The set defined in claim 2 wherein said remainder of said panel retaining mullions includes a second end cover mullion, said second end cover mullion having a base portion and two side walls extending outwardly from the same side of opposite ends of the base, said side walls being spaced apart substantially the same distance as said large panel retaining mullion for matingly receiving therebetween such panels and mullions as may be received by the side walls of said large panel mullion.

6. The set as defined in claim 2 wherein said remainder of said panel retaining mullions includes large panel common retaining mullion, being generally H-shaped in plan and having a base portion and side walls extending outwardly from both faces of opposite ends of the base, the distance between each pair of opposite adjacent side walls being substantially the same as the distance between the side walls of said large panel retaining mullion for matingly receiving therebetween such panels and mullions as may be received between the side walls of said large panel mullion.

7. The set as defined in claim 2 wherein said remainder of said panel retaining mullions includes a second window mullion including a panel receiving surface flanked by spaced notches for connectably receiving panel fastening mullions therein and spaced locking stubs extending from the side opposite said panel receiving surface, the outer surfaces of said locking stubs being spaced apart a distance substantially equal to the distance between said large panel mullion side walls for nesta-bly mating between said large panel mullion side walls or other sets of side walls correspondingly spaced apart.

8. The set as defined in claim 2 including a takeoff mullion having a generally planar base and spaced interlocking fingers on one face thereof substantially similar to the corresponding interlocking fingers of said window retaining mullions and said large panel retaining mullions for connection of said takeoff mullion therewith by means of the interlocking engagement with lock mullions.

9. The set as defined in claim 2 wherein said transom means includes a horizontal aligning rail including a base portion, a mullion supporting portion spaced from said base portion for supporting thereon the interlocking finger surfaces of said some panel retaining mullions, said mullion supporting portion being joined to said base by intermediate wall means, spaced apart a distance sutficient to snugly nest between said interlocking finger portions, and spaced leg portions connected to said mullion supporting portion for engaging a horizontal surface of a building structure to hold a panel retaining mullion adjacent a horizontal building member.

10. The set as defined in claim 2 wherein said transom means includes a large panel head transom member having a generally U-shaped configuration and including a base portion and spaced outwardly extending side walls, the distance between the outer surfaces of said side walls being substantially the same as the distance between the interior of the side walls of said large panel retaining mullion, said large panel head transom member including spaced stubs projecting outwardly from the base slightly inwardly from said side walls, the ends of said side walls being inturned and terminating in stubs generally aligned with said base stubs.

11. The set as defined in claim 2 wherein said transom means also includes a horizontal rail including a base, spaced feet extending from one side of said base for engagement with a horizontal surface of a building structure, and upright walls at opposite ends of the base, the exterior of said walls being spaced apart a distance substantially the same as the distance between the stubs of said panel head transom member for supporting said panel head transom member thereon in snug mating engagement therewith.

References Cited UNITED STATES PATENTS 3,057,444 10/1962 Walberg 52476 3,072,226 1/ 1963 Hardwood 52-281 3,173,179 3/1965 Edwards 52-207 REINALDO P. MACHADO, Primary Examiner.

US. Cl. X.R. 52281, 476, 495

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