Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims the benefit of priority to U.S. Provisional Application No. 60/642,548 filed Jan. 11, 2005, the contents are incorporated by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to factory built residential and commercial structures, and more particularly, to an apparatus and a method of supporting buildings.  
       BACKGROUND  
       [0003]     Factory built residential and commercial buildings have become increasingly popular. As the cost of new construction rises, the relatively lower cost of factory built residential and commercial buildings has attracted many new buyers. Similarly, the design and use of these buildings has changed over the past years. These new designs and uses have made factory built buildings more aesthetically attractive to consumers. Factory built buildings are now widely used in place of traditionally-styled buildings including residential housing, office buildings, such as permanent and portable office buildings, classrooms and transportable hospitals.  
         [0004]     Factory built buildings are traditionally built upon a frame containing two or more longitudinal members and/or several transverse beams that support the floors of the building. Support systems for these factory built buildings typically include concrete blocks or a plurality of support stands placed under the frame for supporting it and securing it to a type of foundation. Skirting, extending from the factory built building&#39;s rim joist to a point within the ground, is commonly used to secure and hide the foundation support system and provide a more aesthetic appearance. However, conventional foundation support and skirting systems may not provide adequate support to the factory built building in response to the lateral forces created by heavy winds, seismic activities or heavy snow. Unfortunately, those systems that may provide adequate support can be costly to produce and install. Additionally, these systems may be aesthetically unattractive. Further, when a cement foundation/footing is poured for aesthetic purposes, the poured concrete must be allowed to set at the job site, thereby delaying the assembly of the building at the job site.  
         [0005]     There is a need in the art for an apparatus useable with factory built buildings to provide ease of assembly and support.  
       SUMMARY OF THE INVENTION  
       [0006]     The present invention relates to a method of supporting a building, such as a modular home or site built homes.  
         [0007]     In one aspect there is provided a method of supporting a building by securing one end of a support stand having a telescopic structure to a movable concrete footer. The support stand may have another end with a support assembly mounted to the telescopic structure. The method includes supporting the building with support assembly of the support stand.  
         [0008]     In one aspect, there is provided a method of supporting a building by a framing member and a support assembly having an upper plate and lower plate, the upper plate and the lower plate having a first set of apertures and the framing member having a second set of apertures, the method includes a step of positioning the frame member between the upper plate and the lower plate and securing a plurality of fastener members to the framing member and the support assembly via the first set of apertures and the second set of apertures.  
         [0009]     In another aspect of a method of supporting a building, a plurality of fastening members have a threaded cylindrical portion which mates with a threaded nut, a method includes a step of securing the fastening members with the upper plate keeping the threaded cylindrical portion stationary while advancing the threaded nut thereon.  
         [0010]     In one aspect, there is provided a method of supporting a building by a framing member and a supporting assembly has a support plate, support plate having a first set of apertures and the framing member having a second set of apertures, the method including a step of positioning the frame member on the support plate and securing the framing member with a plurality of fastener members via the first set of apertures and the second set of apertures.  
         [0011]     In another aspect of a method of supporting a building, a plurality of fastening members have a threaded cylindrical portion which mates with a threaded nut, the method including a step of securing the fastening members by the framing member keeping the threaded cylindrical portion stationary while advancing the threaded nut thereon.  
         [0012]     In another aspect, there is provided a support stand for a supporting a building. The stand includes tubular structure including a telescopic adjustment portion for adjusting a height of a building. A support assembly mounted to the telescopic adjustment portion, the support assembly having a support plate with a plurality of apertures in a shape configured for retaining a threaded portion of a fastening member in a stationary position while a threaded nut is rotated on the threaded portion.  
         [0013]     The above and other aspects, features and advantages of the present invention will be readily apparent and fully understood from the following detailed description illustrative embodiments in conjunction with the accompanying drawings, which are included by way of example, and not by way of limitation with regard to the claimed invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]      FIG. 1  is a perspective exploded assembly view of one embodiment of a support system;  
         [0015]      FIG. 2  is a perspective exploded assembly view of an alternative embodiment of a support system; and  
         [0016]      FIGS. 3 and 4 A- 4 E illustrate alternative embodiments of a support system.  
     
    
     DETAILED DESCRIPTION  
       [0017]     The following embodiments and aspects thereof are described and illustrated in conjunction with systems and methods which are meant to be illustrative and non-limiting in scope. In a brief overview, an aspect of the present invention relates to a method of supporting a modular building, such as a modular home. Modular buildings according to the present invention include modular “factory built” buildings and “site built” (stick built) buildings. Modular factory built buildings used with this method include those buildings built in a factory in modules. The modules are then transported to the erection site on temporary “carrier” chassis that are removed before the building is completed. After arriving at the erection site, the modules are connected together to form a complete building. Site built buildings include those buildings that are constructed using raw materials on the site in which they are intended to remain permanently.  
         [0018]     Both modular factory built buildings and site built buildings include outer, lower framing members that form the outer framing support structure of the building and part of the flooring system. These framing members are substantially planar and located along the outer sides of the buildings. These lower framing members are also positioned proximate the lowest points of the building. As a result, vertical and horizontal support stands can be located under the building and secured to the appropriate framing members in order to hold the building in place. These framing members are typically planar members aligned with the lower surface of the building or vertically spaced from the lower surface of the building. Examples of these planar members include wooden boards, such as 2×8&#39;s or 2×10&#39;s. Other known framing boards can also be used. Alternatively, the framing members can be formed of metal or other materials that can include holes, including threaded holes.  
         [0019]      FIG. 1  illustrates a support system  10  for a modular building that can be used in a method of the present invention. The modular building is generally constructed and assembled with framing members  80  ( FIG. 2 ) that form the outer lower framework of the modular building and a support structure for the flooring system of the modular building, as discussed above. The support system  10  includes support stands  30  that are spaced about the perimeter of the building. Preferably, the support stands  30  are spaced approximately 10 and 12 feet apart, depending on the under structure of the building. However, the number and placement of the stands  30  are typically dictated by local building codes.  
         [0020]     As illustrated in  FIGS. 1-4A , an embodiment of the support stand  30  includes a clamping assembly  40 , a head unit  45  and base  70 . The base  70  includes base plate  72  and a plurality of fasteners  74  which secure the plate  72  to light-weight concrete footers  20 . The fasteners  74  can include nuts and bolts, masonry screws or other similar fasteners. The footers  20  support the support stands  30  above leveled ground or a poured slab, such as a poured concrete pad.  
         [0021]     In one embodiment, the plate  72  is 8″×8″ and ¼ inch thick. For this embodiment, the footer  20  can be 24″ wide×48″ long and is 4″ thick in the center. This footer  20  is produced using a concrete mold in a factory under controlled conditions so that the size and shape are controlled. The footer  20  has an 8″×8″ flat square top surface that includes two plastic inserts poured into the footer  20 . These plastic inserts receive the fasteners  74 .  
         [0022]     In an embodiment, the clamping assembly  40  positively locks the support stand  30  to the framing members  80  of the modular building. In an embodiment illustrated in  FIG. 1 , the clamping assembly  40  includes a support plate  42  for receiving and supporting the lower surface of at least one framing member  80  and a second plate  43  that can be positioned on an upper surface  82  of the supported framing member  80 . This clamping assembly is similar to that disclosed in U.S. Pat. No. 5,862,635 to Linse that is herein incorporated by reference. Fasteners  41  extend through the framing member  80  and the first and second plates  42 ,  43  to secure the framing member  80  to the support stand  30 . In a preferred embodiment, the fasteners  41  include nuts and bolts; however, any conventional fastener for securing two plates together may be used. If desired, circular rods  44  may be added to the plate  42 . ( FIG. 1 )  
         [0023]     In an embodiment illustrated in  FIG. 2 , the second plate  43  is not utilized. Instead, the fastener  41  is directly in contact with the top side of the framing member  80 . In this embodiment, the bolt or nut head would engage the framing member  80  in place of the second plate  43 .  
         [0024]     In a third embodiment illustrated in  FIGS. 3 and 4 A- 4 E, the clamping assembly  40  includes the support plate  42  for at least one framing member  80  and a plurality of fasteners  41 , such as lag bolts, that can extend through the support plate  42  and be secured directly into the framing member(s)  80 . In the illustrated embodiment, the first plate  42  is 8″×10″×¼ thick. The top plate has a series of holes or apertures  59  (see  FIGS. 4A-4E ) formed in a predetermined pattern that, with the fasteners  41 , provides a secure connection between the first plate  42  and the framing member  80 . Different hole  59  patterns can be provided for plates  42  used at different locations along the framing member  80 . Each hole  59  in the plate  42  receives an elongated threaded fastener  41 , such as a screw. An example of such a screw is a lag screw, also known in the industry as a lag bolt. These screws (lag bolts) can be 2½″ long×½″ in diameter.  
         [0025]     As shown in  FIGS. 1-4A , and  4 C, the head unit  45  is positioned below the clamp assembly  40  and attached thereto. The unit  45  includes a U-shaped channel member  46  secured to the underside of the first plate  42 . In a preferred embodiment, the channel member  46  is welded to the first plate  42 , however, other well known securing techniques may be used. The channel member  46  defines a space  47  between its inner bottom floor  48  and the underside of the first plate  42  which contains a support member  49 , an end  52  of a threaded rod  51  and a bushing  57 . The support member  49  is secured to the end  52  of the rod  51  and rotates with the rod on bushing  57  for ease of turning. Preferably, support member  49  is a threaded nut that is welded to the end of the threaded rod  51 . As shown in  FIG. 2 , tolerance exists between support member  49  and the underside of first plate  42  before the framing member  80  is fully loaded on the first plate  42  so that clamping assembly  40  can tilt slightly relative to support member  49 , thereby facilitating the contact between the first plate  42  and the framing member  80 . When the framing member  80  is properly positioned on first plate  42 , support member  49  contacts first plate  42  and distributes the load of the building over the entire head unit  45  so the forces experienced by any one portion of the support stand  30  are lower when compared to conventional support stands. This distribution of the load extends the life of the support stand  30  and reduces its chance of failure.  
         [0026]     A fine height adjusting mechanism  50  and a stepwise height adjusting mechanism  60  are provided between the clamping assembly  40  and the base  70  for leveling the building. These mechanisms  50 ,  60  vary the distance between the building and the foundation to compensate for uneven terrain or the movement of the foundation over time. The stepwise height adjustment mechanism  60  varies the height of the building in predetermined increments. Increments of approximately two to five inches are preferred, with the most preferred increment being approximately three inches. The fine height adjustment mechanism  50  varies the height of the building within the increments of the stepwise adjustment mechanism  60 .  
         [0027]     Fine height adjusting mechanism  50  includes the threaded rod  51 , a tool engaging member  53  secured to rod  51  and a rod receiving member  54  operatively attached to base  70 . The tool engaging member  53  supports the underside of the U-shaped channel member  46  and initially receives the load of the building frame when it is placed on the first plate  42 , to prevent failure of the rod  51  and allow for the clearance discussed above between the underside of the first plate  42  and the support member  49 . In a preferred embodiment, the tool engaging member  53  is a nut secured to the threaded rod  51  by welding or other known techniques. Gradual and fine adjustment of the building height relative to the foundation is accomplished by rotating rod  51  within a receiving member  54  using tool engaging member  53 . The tool engaging member  53  receives a wrench or other such tool for rotating the rod  51 . Receiving member  54  is preferably a threaded nut which fixed to an upper end  61  an inner tube  62  of the stepwise adjustment mechanism  60 . The receiving member  54  could also be positioned within the inner tubular member  62 .  
         [0028]     The stepwise height adjusting mechanism  60  includes the inner telescopic tubular member  62  carrying the receiving member  54  and an outer tubular member  64  which telescopically receives inner tubular member  62 . A plurality of apertures  63  are vertically spaced along opposite sides of the inner tubular member  62  at intervals which achieve the predetermined, incremental height adjustment discussed above. As shown, apertures  65  are also located on opposite sides of the outer tubular member  64 . A bayonet pin or bolt  67  is placed through the apertures  65  when they are properly aligned for a given height with a pair of the apertures  63  in the first tubular member  62 . The outer tubular member  64  also includes an anti-rattle aperture  68 . A bolt  69  is inserted through aperture  68  and frictionally engages the inner tubular member  62  to prevent it from rattling within the outer tubular member  64 . It is also contemplated that the telescopic relationship between the tubular members  62 ,  64  could be reversed.  
         [0029]     The method according to the present invention includes a step of supporting a modular building at a predetermined erection site. The building can be a factory built or site built building as discussed above. The method includes the steps of securing the support stand  30  to the light-weight concrete footer  20  as shown in the figures. The footer  20  and support stand  30  are then positioned at appropriate locations on a properly graded site for supporting the building. When secured on top of the support stand  30 , the building is supported against applied vertical and lateral loads. The position of these footers  20  and support stands  30  is determined by the building manufacturer&#39;s instructions or engineer instructions.  
         [0030]     After the position of the footer  20  and support stand  30  have been approximately set, the course height adjustment of the support stand  30  is set for a given height. When each support stand  30  has been set to an appropriate height, the building is either lowered onto the support stands  30  (for a factory built building) or the assembly of the building begins on the support stands  30  (for a site built building). Regardless of which type of building is supported, the clamp assembly embodiments  40  discussed above can be used to secure the building to the support stand  30 .  
         [0031]     For a factory built building, the ground level portions are either craned or in some other way lowered onto the support stands  30 . Typically if the modules are crane set, one corner of the module is set on a support stand  30  and the module is lowered slowly in order to manipulate the module into the correct position in which it will remain permanently. The module is then lowered into its final resting position. Additional modules are set in the same fashion and attached permanently to the modules that are already set. The support stands  30  can be moved in any direction as needed before the building modules are completely at rest in order to obtain the proper positioning. Second-story modules of the building can then be added if applicable on top of the ground level modules. Once the building is in its permanent resting position, the head assemblies are fully secured to the framing member  80 .  
         [0032]     The clamping assembly  40  illustrated in  FIGS. 1-4A  secures the framing member  80  of either the factory built building or the site built building to the support stand  30 . In this part of the method, the plate  42  is positioned under the framing member  80  of either the factory built or site built building so that it supports the framing member(s)  80 . The fasteners  41 , such as lag bolts, are advanced through the openings  59  in the plate  42  and into the framing member  80  (See  FIG. 3 ). This is performed for each of the support stands  30 .  
         [0033]     In an alternative embodiment of the method, the fasteners  41  extended through the plate  42  are bolts that cooperate with nuts to secure the framing member  80  to the support stand  30 . In this embodiment ( FIG. 2 ), the support stand  30  and framing member  80  are positioned so that the framing member  80  is supported by the plate  42 . Then, the bolts are advanced through the openings  59  in the plate  42 . Threaded fastening nuts are secured to the ends of the bolts on the opposite side of the framing member  80  from the plate  42 . In an embodiment, the framing member can include a recess that matches the shape of the nut and bolt head so that a wrench is not needed to hold the nut or bolt head as the nut and bolt are being tightened.  
         [0034]     In another embodiment, the clamping assembly  40  illustrated in  FIG. 1  is used to secure the framing member  80  to the support stand  30 . In this embodiment, the plate(s)  43  is positioned on the opposite side of the framing member from the plate  42 . As a result, after the support stand and framing member are in the proper vertical and horizontal position, the plate  43  is positioned on the top surface of the framing member  80  and bolts are advanced through the plates  42 ,  43  and the framing member  80 . In this embodiment, it may be necessary to have access to the upper surface of the framing member  80  at the time that the nut and bolt are tightened. Alternatively, the plate  43  can include a recess that matches the shape of the nut and bolt head so that a wrench is not needed to hold the nut or bolt head as the nut and bolt are being tightened.  
         [0035]     After the clamping assemblies  40  have secured the framing member(s)  80  to their respective support stands  20 , the final height of the building can be adjusted, where needed, by manipulating the height adjustment mechanisms  50 ,  60 . Also, for the site built buildings, the remainder of the building can be constructed on top of the framing members  80 . For example, if just the floor of the building was constructed above the framing members  80  prior to securing the framing members  80  to the support stands  30 , the remainder of the building would be framed and completed.  
         [0036]     After the height of the building is set and the building is level, skirting panels can be positioned against the supports and/or the building to hide the support stands  30  and increase the aesthetic appearance of the building. Skirting panels that can be used in the method are disclosed in U.S. patent application Ser. Nos. 10/821,837; 10/821,873 and 10/821,874. All of these applications were filed on Apr. 12, 2004 and are hereby incorporated in this application by reference. After the skirting panels are in place, the area around the panels can be backfilled for support.  
         [0037]     In another embodiment, the support plates  42  positioned at the corners of the buildings could include vertical sidewalls on both their outer and inner edges. In such an embodiment, the framing member  80  could be secured to the support stand  30  using both vertically and horizontally positioned fasteners.  
         [0038]     Different sized building frames can be accommodated by the present invention merely by changing the size of the clamping assembly  40 .  
         [0039]     Numerous characteristics, advantages and embodiments of the invention have been described in detail in the foregoing description with reference to the accompanying drawings. However, the disclosure is illustrative only and the invention is not limited to the illustrated embodiments. It will be apparent to persons ordinarily skilled in the art that modifications may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the claims such as to encompass all equivalents, devices, and methods. Therefore, various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention.

Technology Category: 0