US 3722171 A
A building roof structure including adhered together panels defining a finished interior ceiling for space within the building and trusses structurally supporting a roof covering for the building is assembled by arranging the panels in horizontal array, superposing an arrangement of trusses above the panels, adhering the panels and trusses together into a unitary roof and ceiling structure and then superposing the unitary roof and ceiling structure on side walls for the building.
Claims available in
Description (OCR text may contain errors)
, United States Patent 1191 Godley 154 BUILDING ROOF STRUCTURE AND METHOD  Inventor: Fred Darroll Godley, Charlotte,
. N.C. ,v
73 Assignee: Modular Wall Systems; 1116., Charlotte, NC.
22] Filed: Oct. 6, 1971  Appl. No.: 186,836
521 user ..52/745, 52/90, 52/220, M 52/309  Int; Cl. ..E04b 1/00, E04g 21/00, E04b 7/02  FieIdofSeai-ch ..,....52/90-92, 309,
' 6 .[56 References Cited UNITED STATES PATENTS I 2,222,037 11/194o ma ..52/745 2,604,060 7 1952 Hansen ..52 745 3,268,999 8 1966 Wiggins ..52 745 2/l967 Lang ..52/309 FOREIGN PATENTS OR APPLICATIONS 768,344; 10/1967 Canada 52 90 6,915,-l55 4 1971 Netherlands ..52 309 723,621 2 1955 Great Britain ..52 309 Primary Examiner-Henry C. Sutherland Att0rney-Daniel E. McConnell et al.
 ABSTRACT A building roof structure including adhered together panels defining a finished interior ceiling vfor space within the building and trusses structurally supporting a roof covering for the building is assembled by arranging the panels in horizontal array, superposing an arrangement of trusses above the panels, adhering the panels and trusses together into a unitary roof and ceiling structure and then superposing the unitary .roof and ceiling structure on side walls for the building.
7 Claims, 7 Drawing Figures PATENTFmmznm SHEET 2 BF 3 "as v one step in the method in accordance with BUILDING ROOF STRUCTURE AND METHOD Conventional procedures for constructing a building include the steps of erecting side walls, constructing a roof structure above the side walls and thereafter finishing the interior of the building structure by applying ceiling and wall finishing panels or the like. Such conventional practice in the erection of roof structures I has been adhered to even with progress in the prefabrication of building side wall structures and with the development of prefabricated trusses for roof struc- It is an object of the present invention to facilitate a' reduction in the time and expense required to achieve a finished ceiling in a building structure. In accomplishing this object of'the present invention, the conventional practice of erecting a roofing structure over building side walls, enclosing the building and thereafter applying a ceiling finish is obviated by a novel and advantageous method by which interior ceiling finish 'work following erection of a building structure is eliminated. In, particular, trusses are preassembled with ceiling finish panels prior to superposition of the roof structure on the building side walls.
A further object of the present invention is to assem ble a building structure in which a unitary roof and ceiling structure economically provide enhanced thermal insulation qualities as compared with conventional building structures. In accomplishing this object of the present invention, reliance is placed upon a thermally insulating material for adhering together a plurality of ing and a plurality of trusses which provide the structural components of the building roof system.
Somev of the objects and advantages of the invention having. been stated, others will appear as the description proceeds, when taken in connection with the accompanying drawings, in which FIG. 1 is an exploded perspective view of a building structure in accordance with this invention;
FIG. 2 is an elevation view, partially in section, illustrating adhered together ceiling panels and trusses at this invention; FIG. 3 is a perspective view somewhat similar to FIG. 1 illustrating the superposition of a unitary roof and ceiling structure in accordance with this invention on building side walls during the assembly of a building structure;
FIG. 4 is a plan view, partially in section, through the structure of FIG. 2, taken generally along the line 44 in that figure;
FIG. 5 is an elevation view,- partially in section, through a portion of a building structure assembled in accordance with the present invention; i
FIG. 6 is a reduced elevation view of a side wall panel as used in a building structure in accordance with this invention; and
' FIG. 7 is a perspective view of a unitary roof and ceiling structure in accordance with this invention.
' ceiling panels which provide the finished interior ceil-' In the detailed description which follows, reference will be had to the accompanying drawings which illustrate a representative embodiment of this invention. At
the outset, however, it is to be understood that the drawings and the detailed description with reference to the drawings are set forth as illustrative of and not as limiting upon this invention, as it is contemplated that persons skilled in the construction trades will be able to apply the teaching of this invention broadly to assemblies other than that specifically described hereinafter.
In the illustrated embodiment of this invention, a re- .sidential building structure generally indicated at 10 is assembled by positioning a plurality of precast concrete wall panels 11, 12, 14, 15, 16 and 18 about the periphery of a cast concrete foundation slab 19. While such use of a cast concrete foundation slab 19 and pre-cast wall panels is particularly advantageous for residential building structures intended to have a low initial cost, the present invention contemplates that the foundation and building side wall structures, as well as building interior walls, may be constructed, erected, or assembled in accordance with any known practice considered desirable by the builder assembling the building structure.
In accordance with important features of the present invention, a finished interior ceiling and a roof system for the building structure 10 are provided by a unitary roof and ceiling structure generally indicated at 20. In accordance with the present invention, the unitary roof and ceiling structure 20 comprises a plurality of trusses 21, which may be of a prefabricated timber construction as presently known and used. Adhered to the plurality of trusses 21 are a plurality of ceiling panels 22 which together define the finished interior ceiling of the building structure 10. The ceiling panels 22 and trusses 21 preferably are adhered together into the uni-' tary roof and ceiling structure by, a body of foam material 24 which additionally provides thermal insulation and fire-proofing for the building structure 10. Desirably, the foam material 24-is a urethane foam spray applied as will be described hereinafter.
In assembling a building structure in accordance with the method of this invention, a suitable horizontal surface is'provided, preferably as by casting-a slab 19' to serve as a foundation for an adjacent building structure. Thereafter, a plurality of ceiling panels 22 are arranged on the horizontal surface in horizontal array, with the interior finish surface of the panels facing downwardly (FIG. 2). A plurality of trusses 21 are then superposed on the plurality of panels and are arranged in upright position thereabove. The plurality of trusses are spaced apart one from another at such distance as may be required by applicable building codes.
Following superposition of the plurality of trusses on It is to be noted that the spray application of foam material 24 extends across the entire upper surface area of the ceiling panels 22 and extends over the lower ,trusses 21 and the plurality of ceiling panels 22, together with any utility services which may be incorporated in the structure at that time, a roofing cover may be applied to the unitary roof and ceiling structure -if desired. Such a roofing cover may adopt conventional practices through the use of plywood sheathing 26 and shingles applied thereto, if desired, as the present invention contemplates that any satisfactory covering for the roof structure may be employed.
Either before or after a covering for the roofing structure is applied, the structure is raised from the slab 19' on which it was assembled and is superposed on building side walls tocomplete assembly of the building structure. Such raising and'superposition of" the ceiling structure may be accomplished by a crane or similar equipment, inasmuch as the unitary nature of the roof and ceiling structure 20 will accommodate the loads and force distributions which occur. Further, while it is contemplated that the unitary roof and ceiling structure 20 would be raised from one slab 19. to be superposed on building side walls 11, 12, 14, 15, 16, 18 which have been erected. on an adjacent slab l9,-it .is understood that the unitary roof and ceiling structure 20 may be held in the raised position for such time as may be required to position prefabricated building side I walls on the slab which earlier supported the unitary structure 20, if lifting equipment such as a crane may be made available for such periods of time. v
- Particularly in application of the method of this invention to the assembly of a low cost residential build ingstructure, it may be advantageous to provide in the unitary roof and ceiling structure 20 and in the side wall panels, such as the panel 18 (FIG. 6), electrical wiring which will cooperate in facilitating completion of utility services to the building structure 10. That is, it is contemplated that wiring harnesses having necessary conductors and junction boxes may be installed in the unitary roof and ceiling structure 20 and in wall panels such as the panel 18 prior to superposition of the unitary structure 20 on the building side walls. Where such a practice is followed, interconnection of the previously installed wiring is relatively simple and quick and full utility service to the building structure 10. may be promptly completed.
In the drawings and specification, there has been set forth a preferred embodiment of the invention, and although specific terms are employed, they are usedin a generic and descriptive sense only and notfor purposes of limitation. H
That which is claimed is:
1. A method of assembling a building structure comprising the steps of arranging a plurality of ceiling panels in horizontal planar array and in such outline and dimensions as to span an interior area of the building structure, arranging a plurality of prefabricated trusses in superposition on the panels, applying foam material to the 'up er surface of the panels and adhering the panels an trusses together into a unitary roof and ceiling structure, and then superposing the unitary roof and ceiling structure on the side walls of a building structure. I
2. A method according to claim 1 wherein the steps of applying foam material and adhering the panels and trusses together are preceded by a step of installing utility service in the superposed trusses and panels.
3. A method according to claim 1 wherein the step of superposing the unitary roof and ceiling structure on the side walls comprises lifting the unitary structure from an assembly location and transporting the unitary structure to a remote building construction location.
4. A sub-assembly for use in a building structure and comprising:
ceiling panel means disposed in a horizontal plane and having a lower surface fordefining an interior finished ceiling for the building structure, truss means overlying said panel means for supporting said panel means and for defining a roof system structure, and foam 'means adhered to an upper surface of said ceiling panel means and to at least portions of said truss means, said foam means con stituting the primary joining means for adhering said panel means and said truss means together into a unitary roof and ceiling structure and imparting thermal insulation characteristics to said unitary roof and ceiling structure said sub-assernbly being prefabricated and adaptable for movement to and installation on the upper terminals of vertically disposed building supports as an integral unitv 5. A building structureaccording to claim 4 further comprising utility service means penetrating at least portions of said truss means for distributing service through said building structure and further wherein said foam means is adhered to said utility service means for securing the same in said unitary roof and ceiling structure.
6. A building structure according to claim 4 wherein said truss means comprise a plurality of fabricated trusses each having an elongate lower member engaging said upper surface of said ceiling panel means and encased by said foam means.
7. A building structure according to claim 4 wherein said ceiling panel means-comprises a plurality of ceiling panels arranged in a predetermined horizontal planar array.