Patent Publication Number: US-2009223157-A1

Title: Mate line closure and aesthetic structural embellishment

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to a mate line closure for modular buildings and the like, as well as an architectural embellishment that can be installed anywhere in a structure, whether a modular building or otherwise. 
     Modular buildings and modular housing, as the names suggest, are formed of elements that are joined together in one fashion or another. Often, the joints in the interior of the structure are hidden by conventional means, such as applying drywall mud to seal any cracks where modular sections are joined. However, due to the modularity of the structures, and temperature variations, as well as settling, often cracks reappear resulting in an unsightly final structure. 
     SUMMARY OF THE INVENTION 
     The invention is directed to an aesthetic structural embellishment, comprising a pair of elongated modular elements, each modular element comprising a portion of a modular unit, with the modular elements having junction ends proximate one another when comprising the modular unit. A key is provided, forming a union of the modular elements at the junction ends, with the key covering at least a portion of the modular elements at the junction ends. 
     In accordance with the preferred form of the invention, each modular element comprises spaced opposite panels. A panel spreader is located between the panels, maintaining a pre-determined spacing between the panels, and the panels are affixed to the spreader. A cover is provided for, and extending essentially co-terminally with, the panels. A filler, such as foam, may be added, substantially occupying space between the panels. 
     In one form of the invention, the key comprises opposite side plates and a bottom plate. A spreader segment may be provided, extending between and normal to the side plates. 
     Preferably an end cap is provided for each of the modular elements. Depending on the architectural requirements, in one form of the invention, the cap comprises a bonnet. In another form of the invention, the cap comprises an architectural pillar. For further architectural interest, an architectural column may be associated with each modular element. 
     To accommodate irregularities in structures, an elongated spacer can be provided for one side of the modular unit. The spacer is just as its name suggests, something to fill what otherwise would be a void. 
     In all forms of the invention, it is preferred that an under support be first secured to the structure with the modular elements then secured to the under support. The under support comprises a top member and opposite side members. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention is described in greater detail in the following description of examples embodying the best mode of the invention, taken in conjunction with the drawing figures, in which: 
         FIG. 1  illustrates installation of the invention extending across a building, 
         FIG. 2  illustrates installation of the invention extending longitudinally in a building, 
         FIG. 3  illustrates certain elements of one form of the invention, in the fashion in which they are installed, 
         FIG. 4  is a view opposite to that shown in  FIG. 3 , 
         FIG. 5  shows installation of the underlying support, which may be of wood, to cover a mate line, 
         FIG. 6  shows completion of installation of the support in joining of two modular elements, 
         FIG. 7  illustrates installation of a modular element according to the invention, 
         FIG. 8  is a side elevational illustration showing the installation of  FIG. 7 , 
         FIG. 9  illustrates final assembly of the embodiment of  FIGS. 7 and 8 , 
         FIG. 10  illustrates an interior building structure, before installation of the invention has begun, 
         FIG. 11  illustrates installation of the under support for the modular elements of the modular unit according to the invention, 
         FIG. 12  is an illustration similar to  FIG. 11 , somewhat enlarged, showing installation of under supports, 
         FIG. 13  illustrates placement of modular elements on an installed under support, 
         FIG. 14  illustrates further steps of installation, including the key and end caps, 
         FIG. 15  illustrates addition of architectural columns, 
         FIG. 16  is a view similar to  FIG. 14 , but with the modular elements farther separated, 
         FIG. 17  illustrates addition of architectural columns to the version of the invention shown in  FIG. 16 , 
         FIG. 18  is a slightly modified version of the form of the invention shown in  FIG. 4 , 
         FIG. 18A  is an enlarged perspective view of a portion of a modular element illustrated in  FIG. 18 , in assembly form, 
         FIG. 18B  is similar to  FIG. 18A , as ultimately assembled, 
         FIG. 19  schematically illustrates installation of a modular element, including addition of a foam filler, 
         FIG. 20  illustrates installation of a portion of a modified version of the invention, 
         FIG. 21  shows completion of installation of the version shown in  FIG. 20 , 
         FIG. 22  is a view similar to  FIG. 5 , but showing initial installation of the under support where adjacent wall elements are not flush, 
         FIG. 23  shows continued installation of that shown in  FIG. 22 , with a spacer in place, 
         FIG. 24  shows completion of installation of the under support of  FIG. 22 , 
         FIG. 25  shows installation of a modular element to the under support of  FIGS. 22 through 24 , 
         FIG. 26  shows completion of the installation shown in  FIG. 25 , 
         FIG. 27  is a perspective view of a modular element of another embodiment of the invention, 
         FIG. 28  is an end perspective view of an end cap of the invention, 
         FIG. 29  is a perspective view of completed installation of another form of the invention, having openings in the modular elements, and 
         FIG. 30  is a perspective view illustrating yet another version of the invention. 
     
    
    
     DESCRIPTIONS OF EXAMPLES EMBODYING THE BEST MODE OF THE INVENTION 
       FIGS. 1 and 2  illustrate installation of an aesthetic structural embellishment  10  according to the invention in a building  12 ,  FIG. 1  showing the embellishment  10  installed laterally in the building, such as across a mate line, and  FIG. 2  illustrates installation of the embellishment  10  longitudinally in the building  12 . While only a single embellishment  10  is illustrated in each of  FIGS. 1 and 2 , it will be evident to one skilled in the art that any number of such structures can be installed in a building  12 , as desired. 
       FIGS. 3 and 4  illustrate one form of the invention. An under support  14  is provided, comprising at least one top member  16  and opposite site members  18  and  20 . The top and side members  16  through  20  can be made of multiple elements and, although preferably of wood as illustrated, can be made of any appropriate material sufficient to support installation of the embellishment  10 . 
     A pair of elongated modular elements  22  and  24  comprise portions of a modular unit. The modular elements  22  and  24  may be identical, each comprising spaced opposite panels  26  and  28  with a horizontal panel spreader  30  and vertical panel spreader  32  to which the panels  26  and  28  are appropriately affixed, such as by conventional means, whether it be adhesives, fasteners or any combination thereof, or any other type of fastening of two elements together. 
     Although not illustrated in  FIGS. 3 and 4 , but illustrated in  FIG. 7 , each of the modular elements  22  and  24  also include a cover  34 , which extends co-terminally with the panel  26  and  28  to aesthetically complete each of the modular elements  22  and  24 . While not always necessary, each of the panels  26  and  28  can include further covers  36  and  38 , if desired. 
     Also if desired, each of the modular elements  22  and  24  may be filled with an appropriate filler  40 , such as foam or any other similar material. The filler  40  occupies space between the panels  26  and  28 , substantially filling any voids between the panels, lending to structural stability of the structural embellishment  10 . 
       FIGS. 5 through 9  illustrate installation of the embellishment  10 . First, the top member  16  and side members  18  and  20  are affixed by appropriate means, such as screw fasteners  42 . 
     Once the under support  14  is in place, the modular elements  22  and  24  are then mounted, as illustrated in  FIG. 9 . One of the primary elements of the invention is a key  47  forming a union of the modular elements  22  and  24 . The key  47  covers portions of the modular elements  22  and  24  at junction ends  44  and  46  thereof. While the key  47  can include multiple parts for aesthetic purposes, the basic portions of the key  47  include opposite side plates  48  and  50 . A spreader segment  52  extends between and normal to the side plates  48  and  50 , filling any gap between the opposite junction ends  44  and  46  of the modular elements  22  and  24 . In versions of the invention with greater spacing between the junction ends, a bottom plate can also form part of the key, as illustrated in the embodiments below. 
       FIGS. 10 through 13  further illustrate installation of the invention in a building  10 . As explained above, first the under support is secured in place. In  FIG. 11 , the under support composes a top member  16  and opposite, full length side member  18 ′ and  20 ′. In  FIG. 12 , the side members  18  and  20  are as illustrated in  FIGS. 3 through 9 . However, in  FIG. 12 , the top member  16  is shown as comprising more than one part. 
     Once the modular elements  22  and  24  are in place, the key  47  is applied by means of the side plates  48  and  50 , and then, to cover the full length side members  18 ′ and  20 ′, opposite end caps  54  and  56  are applied. The end caps  54  and  56  are full length, comprising architectural pillars. To complete the installation, architectural columns  58  associated with each of the modular elements  22  and  24  conclude the installation. 
       FIGS. 16 and 17  illustrate a form of the invention quite similar to that of  FIGS. 15 , except that the modular elements  22  and  24  are formed to lap slightly onto the building  12 , thus having a greater gap between the junction ends  44  and  46  of the modular elements  22  and  24 . In the version of  FIG. 16 , the end cap  54  and end cap  56  (not illustrated) are ultimately applied. They are absent in  FIG. 17 . Also, as shown in  FIG. 16 , for additional support, angles  60  can be installed prior to installation of the side members  18 ′ and  20 ′. Columns  58  are included as desired. 
       FIG. 18  illustrates a slightly modified version of the invention, in which the side members  18  and  20  of the under support  14  include respective extensions  62  and  64  which fit in notches  66  in the modular elements  22  and  24 .  FIGS. 18A and 18B  show a portion of the same structure, with the addition of elongated horizontal spaces  68  and vertical spaces  70  applied to the modular element  24  as shown. The spacers  68  and  70  can be applied, or not, to accommodate variations in modular sections of which the building  12  is constructed. 
     Also illustrated in  FIG. 18  is a modified key  47 . The key  47  is composed of opposite side plates  48  and  50 , and a bottom plate  72 .  FIG. 18  illustrates one other feature, and that is an end cap  74  in the form of a bonnet. One end cap is installed at the bottom of each of the modular elements  22  and  24 , and is constructed to include a notch  76  to accommodate the extensions  62  and  64 . 
       FIGS. 19 through 21  illustrate installation of the invention when employing the bonnet end caps  74 . Once the modular elements  22  and  24  are in place, the filler  40  is installed while the modular elements are held in place, such as by jacks  78 . The end caps  74  and key are installed, and the final structure is as illustrated in  FIG. 21 . 
       FIGS. 22 through 26  illustrate installation in a building, such as along a mate line  80 , where adjoining modular sections  82  and  84  of the building do not align in a flush manner. Once the top member  16  of the under support  14  is installed on the protruding modular section  18 , the elongated spacer  86  is installed in the gaps between the top member  16  and the modular section  84 . Final fasteners  42 , with washers  88 , complete the installation of the top member  16 . 
     Once the top member  16 , and side members  18  and  20 , are in place, the modular elements  22  and  24  are then installed, and to accommodate the uneven junction between the modular sections  82  and  84 , one side of the modular elements  22  and  24  also includes an elongated spacer  90 . 
     In the version of the invention illustrated in  FIG. 27 , all elements remain the same, except that mounting brackets  92  and  94  are included in each of the modular elements  22  and  24 . The mounting brackets  92  and  94  include apertures, as appropriate, for passage of fasteners. 
     A bonnet end cap is shown in  FIG. 28 . The end cap  74  is the same as that shown in  FIG. 18  and, preferably, is composed of wood, although other materials can be used, as well. 
       FIG. 29  illustrates a modified form of the invention, where the aesthetic structural embellishment  10 ′ includes openings  96  and  98 . Otherwise, the embellishment  10 ′ is constructed as described above, and for aesthetic purposes, the key  47  includes an additional side plate  100  on either or both sides, as shown. The end caps  74 ′ are simply horizontal plates. Primes have been applied to the numbers where elements are modified. Similarly, in  FIG. 30 , a modified aesthetic structural embellishment  10 ′ is shown. 
     Various changes can be made to the invention without departing from the spirit thereof or scope of the following claims.