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Description  |
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BACKGROUND OF THE INVENTION
Although multiple-unit housing has long been recognized for its space
efficiency and maximum utilization of land, the last 20 years has seen a
significant increase in the number of multiple-unit housing starts wherein
the building modules are substantially preconstructed in a plant and then
transported to a location where they are assembled.
Representative of this type of construction and concept is the housing
arrangement disclosed in my prior U.S. Pat. No. 3,629,983. This prior
patent discloses a particular arrangement of dwelling units wherein the
units are arranged in such a manner as to generally enclose an open-air
court. The units have a staggered assembly. corner to corner, in the shape
of a square or quadrangle where an end of one unit abuts the side of an
adjacent unit, and so forth until the courtyard area is enclosed by a
total of four units. Alternatively, a single-family dwelling may have its
individual rooms arranged in a sequential single-file manner on three or
four sides of the courtyard, thereby preserving the same housing concept.
The preconstructed, multiple-unit housing disclosed in my prior patent
included variations such as adding a second story and creating walkways to
and from the open-air court. While still utilizing the basic concepts of
an enclosed courtyard, it is envisioned that improvements can be made to
the structure in the type of construction and architectural designs which
are possible.
Although the atrium courtyard which is able to be created by arranging such
units in a surrounding manner provides one benefit to this type of
housing, the overall cost effectiveness is another benefit. The concept of
preconstructed building modules which are remotely built and then moved to
the site location enables more of a production line approach and less
skilled labor at the site location.
One cost factor though which has remained a concern, whether or not the
units are preconstructed and whether or not the units are single-wide, is
the cost of roof construction. Generally speaking, a conventional roof
requires seven major steps in its fabrication and construction procedure.
These seven steps are typically the same regardless of whether the housing
units are single-wide, preconstructed or conventional housing of any
width, and the present invention which discloses an improved roof design
for housing units is equally applicable to any type of style of housing
unit.
As is believed to be well known, conventional roof construction requires
that ceiling joists and rafters be individually measured, cut, positioned
and nailed in place. Drywall is applied for the interior ceiling and
insulation is introduced at appropriate locations, such as between ceiling
joists. Sheathing and building paper are applied over the rafters,
followed by the application of shingles. While the time to perform the
above steps is one concern, the necessary skilled labor and material costs
present other concerns. If the focus of a particular construction project
is on low cost and a short construction time, then conventional roof
construction is a significant factor in that it represents higher cost and
more time.
The present invention offers an improved roof design which eliminates all
of the seven basic steps which are required for conventional roof
construction. Although the present invention is illustrated in combination
with single-wide housing and an atrium courtyard arrangement, it is to be
understood that the roof construction which is disclosed herein is equally
applicable to any type of housing or dwelling units regardless of their
overall width and regardless of whether or not those housing units are
arranged so as to define an atrium courtyard.
One reason why the present invention has been illustrated in combination
with a plurality of single-wide dwelling units, arranged as a
single-family dwelling defining an atrium courtyard, is due to the fact
that this type of construction is particularly well-suited to the present
invention. Single-wide, preconstructed housing, may range from 10 to 16
feet in width. The criteria is that the width not excede the maximum
applicable over-the-road width for the particular state or states through
which the housing must be transported from the fabrication site to the
installation site. In view of the fact that many over-the-road width
limitations are either 12 or 14 feet, an individual roof section according
to the present invention need only span the 14-foot width, and individual
roof sections according to the teachings of the present invention can be
easily molded as single, unitary units.
In the event the roof construction according to the present invention is to
be adapted to housing units which are not single-wide, the
tongue-in-groove concept which is used to join individual roof sections
together as they extend along the length of the individual housing units
can be employed along the roof section sides as well as along the section
ends. By using a similar joining concept to place two individual roof
sections side by side along the width of the individual housing units,
virtually any length and any width can be accommodated.
SUMMARY OF THE INVENTION
A molded roof section for use with dwelling units which includes spaced
side walls according to one embodiment of the present invention comprises
a main body portion which is arranged with a leading edge, an opposite
trailing edge and two side edges, the leading edge is designed and
arranged to fit within the trailing edge of a first contiguous roof
section, the trailing edge is designed and arranged to receive the leading
edge of a second contiguous roof section, and the side edges are each
arranged with a downwardly opening channel which is suitably sized and
spaced for receipt of corresponding ones of the spaced side walls of the
dwelling units.
One object of the present invention is to provide an improved roof
structure.
Related objects and advantages of the present invention will be apparent
from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a housing unit arranged so as to define an
atrium courtyard and including molded roof sections according to one
embodiment of the present invention.
FIG. 2 is a perspective view of a single roof section comprising a portion
of the FIG. 1 dwelling unit.
FIG. 3 is an end elevation view in full section of a single roof section as
assembled onto housing unit side walls.
FIG. 4 is a side elevation view in full section of one roof section and
illustrating the assembly concept to contiguous roof sections according to
a typical embodiment of the present invention.
FIG. 5 is a perspective view of an alternative housing unit including
molded roof sections according to a typical embodiment of the present
invention.
FIG. 6 is a partial, top plan section view of the joint between roof panels
as taken along line 6--6 in FIG. 5.
FIG. 7 is a partial perspective view of a spline insert which is used in
the FIG. 6 joint.
FIG. 8 is a perspective view of a roof panel according to a typical
embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of promoting an understanding of the principles of the
invention, reference will now be made to the embodiment illustrated in the
drawings and specific language will be used to describe the same. It will
nevertheless be understood that no limitation of the scope of the
invention is thereby intended, such alternations and further modifications
in the illustrated device, and such further applications of the principles
of the invention as illustrated therein being contemplated as would
normally occur to one skilled in the art to which the invention relates.
Referring to FIG. 1, there is illustrated a single-family, atrium-courtyard
dwelling 20 which is constructed of single-wide housing units 21, 21a and
21b. These three housing units are arranged on three sides of the atrium
courtyard 22 while the fourth side is configured with a garage 23 and
security gate 24. Within each housing unit there is an arrangement of
individual rooms which are sequentially arranged in single-file manner and
these individual rooms may be selectively arranged in sequence according
to the preference of the owner (dweller). Although a single-wide
arrangement of housing units has been selected as the housing concept for
use in combination with the present invention, it is to be understood that
the roof construction disclosed herein may be just as easily applied to
conventional housing units which are not single-wide and which are not
arranged so as to define an atrium courtyard. The preference for the
arrangement of FIG. 1 is that it enables the disclosure of a variety of
individual roof section shapes and uses, all as part of a single dwelling
and a single illustration. A further factor in the selection of
single-wide housing units to use in combination with the roof structure of
the present invention is the overall width of such housing units. Since
these types of housing units are typically fabricated at a remote location
and then moved over the road to the construction site, individual state
laws regulate how wide the individual housing units may be for
over-the-road transportation. Typically, the maximum over-the-road width
which is permissible is 14 feet, though the regulated width may vary
between 12 and 16 feet, depending on the state. Assuming a somewhat
standard width of 14 feet, it is to be understood that the individual roof
sections disclosed herein may be molded in 14-foot wide sections thus
enabling a single, unitary roof section to span each housing unit from
side wall to side wall.
While there is virtually an infinite number of room arrangements which are
possible within each housing unit, the width of each unit remains
substantially the same and the enclosing configuration of units 21-21b
which defines the atrium courtyard remains unaffected by the arrangement
of the individual rooms within each housing unit. The uniformity in
housing unit width enables a standardized roof construction to be employed
which saves construction time, skilled labor and material costs. Although
there are only seven basic roof section configurations illustrated in FIG.
1, the teachings of the present invention can be utilized to improvise and
create a much wider variety of individual roof sections. The roof sections
are molded as single, unitary, homogeneous members with a tongue in groove
jointing concept for contiguous roof sections and downwardly opening
channels for receipt of the side walls, and these features remain
consistent regardless of the roof section style. Granted, if the roof
sections must span a width dimension for the particular dwelling unit
which excedes the dimension which can be safely and reliably molded as a
single member, then a tongue-in-groove jointing arrangement or similar
assembly technique must be employed not only on the ends of the individual
roof sections, but as well on one of the side edges. In this arrangement,
in lieu of having two oppositely disposed downwadly opening side edge
channels for receipt of the side walls, one of the side edges is
configured with one-half of the tongue-in-groove joint and the
corresponding roof section which completes the overall width includes the
other half of the tongue-in-groove joint. The opposite side edge of the
second roof section is thus configured with a downwardly opening channel
for receipt of the opposite side wall of the housing unit.
Referring to FIGS. 2 and 3, there is illustrated a standard roof section 27
according to a typical embodiment of the present invention. Section 27 is
molded out of a synthetic material which in the exemplary embodiment is a
high-density polymer foam whose characteristics are similar to that of
wood in that it can be worked like wood, sawed, nailed, sanded, painted
and glued. The ability of this polymer foam to be molded enables the
duplication of intricate designs and elaborate moldings. Due to the fact
that the density of this polymer foam can be varied, it actually enables
the foam a broader range of use than that enabled by wood. For the
exemplary embodiment, a 14-pound per cubic foot density has been selected
and this provides both strength and insulation benefits.
The material selected has an R value of 6 per inch of thickness and a
compression strength which is greater than most construction woods which
would typically be used in roof construction. The material also has a
self-extinguishing fire rating and there is no warpage when the material
is exposed to water and sun. There is also an ultraviolet screening which
is equivalent to that of the paint applied to the outer surface and a
weight factor which makes it lighter than most woods. At the present time,
this material is offered by Fypon, Inc., 22 West Pennsylvania Avenue,
Stewartstown, PA 17363.
The "standard" roof section 27 which is illustrated in FIGS. 2 and 3
measures approximately 14 feet by 4 feet and is 3 inches thick at most
points. The 14-foot dimension is actually the projected dimension between
side edges 28 and 29 and the main body portion 30 of section 27 is curved
or domed upwardly to a maximum height of approximately 30 inches above the
lowermost portion of side edges 28 and 29. Each side edge is configured
with a wall-receiving channel 31, each of which are bounded by
channel-defining sides 32 and 33.
Inasmuch as the individual housing unit side walls 34 and 35 would
typically be 31/2 inches thick (2.times.4 lumber), each receiving channel
31 is correspondingly approximately 31/2 inches wide and each side 32 and
33 is approximately 3 inches wide. The overall width is thus approximately
91/2 inches and this width tapers as roof section 27 curves upwardly such
that at the highest point, the thickness of body portion 30 is
approximately 3 inches.
As should be understood by reference to FIGS. 1-3, the various roof
sections are installed as single units and are suitably sized and arranged
to fit down over the individual unit walls which are, in the exemplary
embodiment, set to a dimension of 14 feet between outside surfaces.
Corresponding, channels 31 have a outside edge to outside edge width
dimension which corresponds to this 14-foot dimension and each individual
channel has a width which is compatible with the thickness of each side
wall such that the roof section may be easily lifted and lowered in place
onto the housing unit side walls in one quick and simple step. The FIG. 1
illustration should be considered as more of a schematic diagram inasmuch
as certain smaller details of the roof sections have been omitted for
drawing clarity.
In accordance with normal or anticipated construction techniques, an
appropriate sealant or caulk is applied up into and against the base of
each channel 31 for approximately the full extent of each channel so that
as the roof section is lowered onto the housing unit side walls, the
sealant flows into and around all cracks, crevices and gaps which may
exist between the individual roof sections 27 and the housing unit side
walls. Any excess sealant which is squeezed out of the joint may be
removed and the result is a liquid-tight interface which provides not only
sealing against wind and water, but also provides structural stability.
Since the individual single-wide housing units 21-21b typically extend for
several feet and since each roof section, in the exemplary embodiment,
extends for only approximately 4 feet, several roof sections must be
joined together in order to construct a complete roof for each unit.
Referring to FIG. 4, the end configuration of a standard roof section is
illustrated. In the particular illustration of FIG. 4, the dome or
curvature of the body portion 30 extends into and out of the plane of the
paper and although portions of the undersurface of this main body portion
would technically be visible based upon the location of cutting plane
4--4, this undersurface has been eliminated in this full section view
simply for drawing clarity. It is not intended to confuse or mislead as to
what is actually being viewed, but since FIG. 4 focuses primarily on the
joint between contiguous roof sections, it is believed that elimination of
this visible undersurface will benefit the illustration.
The first or leading edge 36 of roof section 27 includes a pair of
oppositely disposed strengthening ribs 37 and 38 (omitted in FIG. 1) which
extend in opposite directions from main body portion 30. Strengthening
ribs 37 and 38 define groove 39 which is generally symmetrical to ribs 37
and 38 as well as to main body portion 30. The opposite, trailing edge 40
includes a pair of oppositely disposed strengthening ribs 41 and 42 and a
tongue projection 43 which is symmetrically positioned between ribs 41 and
42 and which is symmetrical to main body portion 30. It is to be
understood that strengthening ribs 37 and 38 are virtually identical in
size and shape to strengthening ribs 41 and 42, while groove 39 is
similarly shaped and dimensioned to tongue 43.
By this particular "tongue-in-groove" assembly concept, the leading edge of
one standard roof section 27 receives the trailing edge of a contiguous
standard roof section 27a by the insertion of tongue 43a into groove 39.
As this reception occurs, strengthening ribs 37 and 38 are brought into
abutment against strengthening ribs 42a and 41a, respectively, and
thereafter a suitable sealant or caulking is applied so as to weatherproof
the interface and seal the joint. Similarly, roof section 27b is joined to
section 27 by the insertion of tongue 43 into groove 39b as ribs 41 and 42
are brought into abutment against ribs 37b and 38b. This particular
assembly technique is utilized throughout the remainder of dwelling 20
although there are a few variations as the style of the individual roof
sections deviates from that of standard roof section 27.
In accordance with sound construction techniques and practices, it is
recommended that some sealant or caulk be placed into the base of the
grooves so as to fill any irregularities or unevenness between the
cooperating tongues and grooves. Any mismatch or gaps are believed to be
minimal in view of the fact that each roof section is molded and there is
an ability to tightly control any tolerance variations, shrinkage and
warpage.
It is also to be understood that roof section 27 can be configured with
either more or less curvature in the main body portion 30 and in fact roof
sections can be configured as completely flat members while still
preserving and maintaining all of the teachings of the present invention.
For example, in the event it would be desirable as part of dwelling 20 to
have a room or series of rooms, a garage or storage area where the roof is
substantially flat, then it is a relatively simple and straightforward
task to simply mold the individual roof sections as substantially flat
members while still preserving the design and configuration of the leading
and trailing edges as well as the side edges and thereafter simply allow
the same assembly technique to be followed for attaching the roof sections
to the side walls and for joining contiguous roof sections to one another.
As previously explained, each roof section, regardless of its size, shape
or configuration, is molded as a unitary, homogenous member. Although
different grades and densities of foam material can be used, the material
is relatively lightweight such that two men can readily and easily lift
each standard roof section for assembly onto the housing unit side walls.
In addition to the time, skilled labor and cost savings which are realized
by the present invention style of roof, as compared to conventional roof
construction, the ability to mold the roof sections enables inner surface
50 of main body portion 30 to be configured with decorative shapes,
molding, texturing and designs. Since surface 50 is in effect the exposed,
interior ceiling surface of each unit, a decorative molding or texturing
provides a desirable aesthetic effect and appearance. Since the foam
material which is used may also be easily and readily painted, with or
without decorative moldings or texturing, the appearance and effect of the
molded roof from the interior of the housing units is that of a
conventional ceiling.
Although the foregoing illustrations and discussions focus primarily on a
single, standard roof section with a curved or domed main body portion, it
is to be noted that in order to complete the entire roof for dwelling 20,
corner roof sections are required. These corner roof sections 54 and 55
are identified in FIG. 1 and due to the leading edge and trailing edge
requirements for the tongue-in-groove assembly of sections 54 and 55 to
their contiguous standard roof sections, sections 54 and 55 are in fact
different. More particularly, section 54 has a diagonal leading edge 54a
while section 55 has a diagonal trailing edge 55a. While these two edges
54a and 55a are still configured with the tongue-in-groove approach, their
corresponding sections are actually different.
While corner sections 54 and 55 are a requirement, window sections 56, 57,
58 and 59 are optional. Sections 56 and 57 are designed for full height
and width extended windows which project out into the atrium courtyard 22.
The leading and trailing edge designs are preserved so that sections 56
and 57 are compatible with the adjoining standard roof sections. One
additional feature of sections 56 and 57 is the presence of side panels
56a and 57a which are provided in order to connect the top portion of the
roof to the unit side wall. Since the unit side walls are of a uniform
height, and since the top portion of sections 56 and 57 do not curve or
arc over to contact these side walls, a connecting portion, at
substantially a right angle to the top surface, is required in order to
fill the gap between the top surface of the roof and the top or upper edge
of the corresponding housing unit side wall. This connecting portion or
side panel (56a, 57a) is integrally molded as part of the corresponding
roof section. Consequently, for these projected or extended window areas,
the roof section which is molded requires a right-angle mold in order to
create or provide the L-shaped roof sections.
All other aspects or characteristics of sections 56 and 57 are the same as
those provided for the standard roof sections as well as for the corner
roof sections. These other aspects or characteristics include consistent
design of the leading and trailing edges as well as the side edges with
their downwardly opening channels for receipt of the side walls.
Sections 58 and 59 are virtually identical to sections 56 and 57 except
that the windows with which sections 58 and 59 are used do not project
into the atrium courtyard. Instead, these windows are flush with the side
walls of the corresponding housing unit. As a result of this difference,
side panels 58a and 59a are smaller and more triangular in shape than side
panels 56a and 57a. However, all other aspects of sections 58 and 59,
including their side edges and their leading and trailing edges, are of
the same design as the standard and corner roof sections.
As illustrated, sections 56 and 57 cover room 60 which projects into the
atrium courtyard. Since room 60 is wider than 14 feet, the windows and
side walls are assembled on site after delivery of units 21-21b, if the
disclosed dwelling is of a preconstructed nature. This protruding room 60
could be arranged as a bedroom and bath area or as a solarium, and again,
the variations are numerous. By providing a variety of different molded
configurations for the various roof sections, whether by means of changing
the arc or dome of individual standard sections, or by using projecting
sections such as sections 56 and 57, attractive variations in the roofline
of each dwelling can be created.
Referring to FIG. 5, an alternative arrangement of roof sections is
illustrated as part of dwelling 65. Although portions of dwelling 65 may
be brought to the final site as preconstructed housing units, such as
units 66 and 67, the uniquely styled corner units 68, 69 and 70 are
constructed at the final site. Similarly, garage 71 will also likely be
fabricated or constructed at the final site for dwelling 65. Although the
various corner units are to be finished at the final site for the
dwelling, substantial portions of the construction components may be
prefabricated and quickly and easily assembled on site.
For example, roof panels 74 which comprise the outer roof skirt are molded
as unitary, single, homogeneous members out of the same high-density
polymer foam which is used for standard roof section 27. Although
differently configured, shaped and oriented than standard roof section 27,
roof panels 74 indicate one more variation and use of the present
invention. Although each of the four roof panels for each corner unit are
substantially the same, it should be understood that some type of
interface will normally be created on at least one side by a standard roof
section 27 or by a roof section which is designed for a raised window or
window extension. Corner unit 69 illustrates both types of interfaces, and
as should be understood, the interfacing joint is adequately sealed so as
to make it weatherproof.
It should also be understood from reviewing the FIG. 5 illustration and the
arrangement of dwelling 65, that there are certain variations over that of
dwelling 20. Dwelling 65 simply offers one further variation, not only as
to the roofline and arrangement of various roof sections, but it also
offers a variation as to the arrangement of the individual housing units
and the layout which creates the atrium courtyard. Still present as part
of dwelling 65 is the atrium courtyard 75 and the security gate 76.
However, in lieu of a final side arranged or defined by another housing
unit, a security wall 77 is illustrated. Wall 77 may be a wall which is
common to two single-family dwellings or may merely represent the selected
means to close off one side of the atrium courtyard.
Turning more specifically to the design and construction of roof panels 74,
and referring to FIG. 6, it is to be pointed out that each roof panel 74
extends as a full-length, unitary and homogeneous molded foam member from
a first corner seam 80 to a second and opposite corner seam 81. Although
the design and arrangement of each corner seam or joint is substantially
the same. FIG. 6 focuses specifically on seam (joint) 80 which is viewed
in FIG. 6 along cutting plane 6--6 of FIG. 5.
As is illustrated, each roof panel 74 and 74a has a particular molded
thickness and has a seam edge which is molded at a 45-degree angle in the
exemplary embodiment so as to enable a right-angled miter joint with the
corresponding and abutment edge of the contiguous roof panel. Again, this
particular assembly and joint configuration is substantially identical
with all roof panels on all corner units. As is illustrated, the edge of
each roof panel adjacent the resulting seam 80 includes a corresponding
keyway 80a and 80b which have a unique shape with an enlarged portion at
one end and which extend inwardly from the 45-degree bevelled edge of the
corresponding roof panel. The substantially rectangular slot which extends
from the enlarged end to the corresponding bevelled edge is positioned
within the thickness of the corresponding roof panel so as to create the
appearance of a continuously open keyway extending from one roof panel to
the other and making a right-angle turn at the location of seam 80.
This continuously created right-angle keyway is then used to lock these two
roof panels together by means of a key or spline 82 which is illustrated
in FIG. 7.
Spline 82 is an integrally formed homogeneous member which includes two
enlarged end portions 83 and 84 which are connected together by
substantially flat panels which join together to create a right-angle
corner. As intended to be illustrated and as should be understood, spline
82 is sized and configured so as to conform to keyways 80a and 80b with a
sliding, yet snug fit. As the spline is inserted into keyways 80a and 80b
and is driven in place down the full length of seam 80, roof panel 74 and
74a are locked together. This step is repeated at each edge seam or joint
for each of the roof panels of each corner unit.
The roof construction of each corner unit is completed by substantially
flat roof sections 89 and 90 which are joined to one another by a
tongue-in-groove joint. The remaining three sides or edges of sections 89
and 90 do not require any particular contouring inasmuch as they simply
rest in a defined channel and on a defined support shelf which is molded
in as part of each roof panel 74 (see FIG. 8). Referring to FIG. 8,
additonal details of roof panel 74 are illustrated. Again, it is to be
understood that although we have singled out roof panel 74 for the FIG. 8
illustration, all roof panels are substantially identical and will include
the side wall receiving channel and the roof section support shelf and
channel as disclosed herein. Roof panel 74 includes a side wall rib 92
which extends the full length of the roof panel. Rib 92 includes two
downwardly extending side portions which define side wall receiving
channel 93. The illustrated side wall 94 is intended to be representative
of one of the four side walls (or possibly three) of corner unit 68.
However, the receipt of side wall 94 by channel 93 is substantially the
same as the receipt by side walls 34 and 35 by standard roof section 27.
Similarly, sealant or caulk is used to complete the weatherproofing of the
interface.
Extending lengthwise along the opposite side of roof panel 74 is a roof
section support shelf 95 which defines, in combination with the uppermost
edge of panel 74, a roof section receiving channel 96. As previously
indicated, substantially flat roof sections 89 and 90 are merely lowered
in place such that they rest upon shelf 95 as they are extended into
channel 96. A suitable caulk or sealant is used to complete the
weatherproofing of this particular interface and when completed, a
lightweight an durable roof has been assembled by using only
preconstructed molded foam sections which are lightweight yet durable and
which enable housing unit roofs to be constructed and assembled without
necessitating any of the time and cost-excessive steps of conventional
roof construction. Although the multicomponent roof style which is used in
combination with the illustrated corner units is more complex and involved
than the standard roof sections 27, it is also to be noted that much
greater versatility can be afforded yet in all cases the teachings of the
present invention, the manner in which the roof sections join to the
housing side walls and the manner in which the sections are joined to one
another is preserved.
Although the tremendous versatility of the present invention is a
significant factor, the time, skilled labor and materials savings which
are realized are of primary importance. By using molded foam roof sections
in lieu of conventional construction, numerous conventional construction
steps are eliminated, and the layers of conventional roof material are
replaced with a single molded unit.
While the invention has been illustrated and described in detail in the
drawings and foregoing description, the same is to be considered as
illustrative and not restrictive in character, it being understood that
only the preferred embodiment has been shown and described and that all
changes and modifications that come within the spirit of the invention are
desired to be protected.
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