Abstract:
A panel connector has a central elongated structural member and two pairs of flanges projecting generally outward from the central elongated structural member and toward one another. The flanges hold corresponding flanges from panels. The panel connector may also have two spines attached thereto with the flanges attached to the spines. The central elongated structural member mats have differing configurations.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates generally to a panel connector and a panel assembly using the panel connector and, more specifically, to a panel connector that connects two panels together with flanges extending therefrom to create a structural panel assembly.  
         [0003]     2. Technical Background  
         [0004]     The use of panels in construction for roofs and walls for houses, sheds, rooms, and other buildings is known. The panels, which are usually only on one side of the wall are typically joined together with cleats., clips, or fasteners. A second set of panels are needed for the second side of wall, particularly if the wall is to be load-bearing wall or an outside wall. The clips used to hold the panels together typically do not have sufficient strength to be the only structural members joining the panels in the wall. This complicates and makes the building process slower and more expensive than it needs to be. A panel connector is needed that allows panels to be easily and structurally secured to one another to allow for rapid and secure construction of walls for buildings.  
       SUMMARY OF THE INVENTION  
       [0005]     Disclosed herein is a panel connector that allows for panels to be interconnected in a safe, sound, and structural manner as well as a panel assembly using the panel connectors.  
         [0006]     In one aspects a panel connector is disclosed that includes a central elongated structural member having an outer surface and a length, a first pair of flanges extending away from a first portion of the outer surface of the central elongated structural member, each of the flanges in the first pair of flanges projecting generally outwardly from the central elongated structural member and projecting inwardly toward one another at a predetermined angle relative to the central elongated member, and a second pair of flanges extending away from a second portion of the outer surface of the central elongated structural member, each of the flanges in the second pair of flanges projecting generally outwardly from the central elongated structural member and protecting inwardly toward one another at a predetermined angle relative to the central elongated member  
         [0007]     In some embodiments the central elongated structural member is annular in cross section.  
         [0008]     In one embodiment the predetermined angle is about  400 .  
         [0009]     In other embodiments, the central elongated structural member has an opening extending therealong to receive electrical and optical cabling.  
         [0010]     In another aspect, a panel assembly, is disclosed that includes at least two panels, each of the at least two panels having a first outer covering and a second outer covering spaced from one another, each of the first and second outer coverings having flanges along opposing sides and projecting inward toward each other and backward toward the panel and at least one panel connector, the at least one panel connector comprising a central elongated structural member and two pair of flanges extending outwardly from the central elongated structural member, each flange in each of the pair of flanges engaging one flange from each of two of the at least two panels to secure the at least two panels to one another.  
         [0011]     Additional features and advantages of the invention will be set forth in the detailed description which follows and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein, including the detailed description which follows the claims, as well as the appended drawings.  
         [0012]     It is to be understood that both the foregoing general description and the following detailed description of the present embodiments of the invention, and are intended to provide an overview, or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the invention, and together with the description serve to explain the principles and operations of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]      FIG. 1  shows in cross section a prior art cleat attached to two pieces of sheet metal.  
         [0014]      FIG. 2  shows in cross section another prior art cleat attached to two pieces of sheet metal;  
         [0015]      FIG. 3  is a cross sectional view of one embodiment of a panel connector according to the present invention engaging one side of two panels;  
         [0016]      FIG. 4  is exploded view of a part of a panel assembly according to the present invention showing one embodiment of a panel connector and a portion of two panels that are to be joined by the panel connector;  
         [0017]      FIG. 5  is a cross sectional view of another embodiment of a panel connector according to the present invention engaging one side of each of the two panels, and  
         [0018]      FIGS. 6-12  illustrate alternative embodiments of panel connectors according to the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0019]     Reference will now be made in detail to the present preferred embodiment(s) of the invention, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.  
         [0020]     A prior art cleat  1 . 0  is illustrated in  FIG. 1 . The cleat  10  has a central flat portion  12  with two end portions  14 , 16  that are folded back over the central flat portion  12 . Thus, the end portions make an angle of 0° relative to the flat portion. The area  18  between the ends portions  14 , 16  and the central flat portion  12  is slightly larger than the thickness of the pieces of sheet metal  20  that the cleat  10  connects. As can be seen in  FIG. 1 , each of the edges  22  of the pieces of sheet metal  20  are similarly folded back over the sheet metal, allowing the edges  22  to be captured and held in the area  18  of the cleat  10 . Cleat  10  only captures one edge of each of the pieces of sheet metal  20  on a wall, which is insufficient to maintain structural integrity if the pieces of sheet metal were to be used as a wall, especially as a structural or load-bearing wall.  
         [0021]     A second prior art cleat  30  is illustrated in  FIG. 2 . The cleat  30  also has a flat central portion  32  and two flanges  34 . 36  that are folded and have an interior angle of about 40°. The cleat  30  captures the bended portion  38  of the pieces of sheet metal  40 . The bended portion  38  is bent twice, which allows the end of the pended portion  38  to be captured and at least partially secured in the vertices  42  of the cleat  30 . However, cleat  30  only captures one edge of the piece of sheet metal  40  on a wall, which is insufficient to maintain structural integrity if the pieces of sheet metal were to be used as a wall, especially %as a structural or load-bearing wall.  
         [0022]     One embodiment of a panel connector  100  according to the present invention is illustrated in  FIG. 3 . The panel connector  100  includes a central elongated structural member  102  having an outer surface  104  and an inner surface  106 , which defines an opening  108  that preferably, extends the length of the central elongated structural member  102 , making the central elongated structural member  102  an annular member. Panel connector  100  preferably has at least two generally flat surfaces or portions  110  (four are illustrated in  FIG. 3 ) to which an elongated spine  120  is attached. The central elongated structural member  102  is made from steel (preferably 14 to 25 gauge), but any appropriate materials may be used, including for example, aluminum, plastics, and fiber composites. As shown best in  FIG. 3 , two of the elongated spines  120  are preferably attached to generally flat surface  110  or the central elongated structural member  102 . The elongated spine  120  and the central elongated structural member  102  may be welded, molded together, or otherwise secured to one another (e.g., with rivets, bolts, adhesives, fasteners, etc.).  
         [0023]     The elongated spine  120  preferably has two flanges  122 , 124  attached thereto, which extend away from the elongated spine  120  and the central elongated structural member  102 , but towards one another to approximate a triangle. In one preferred embodiment, the elongated spine  120  and the two flanges  122 , 124  are a single, integral piece, but they need not be. The two flanges  122 , 124  preferably, make an internal angle relative to the spine  120  that is less than 70° and more preferably, about 40°.  
         [0024]     As best illustrated in  FIG. 4 , the elongated spine  120  and the two flanges  122 , 124  are preferably the same length, although it is possible for the elongated spine  120  to be either longer or shorter than the two flanges  122 , 124  and still fall within the scope of the present invention. The flanges  122 , 124  preferably extend at least 80% and more preferably 100% of the length of the pamel connector  100 . The elongated spine  120  and two flanges  122 , 124  are also made from steel (14 to 25 gauge), but also be made of any other appropriate material.  
         [0025]     The panel connector  100  attaches to one side of each of two panels  130 . The panels  130  are typically laminated, having a core  132  and two outside coverings  134 , 136 . On at least two opposing sides of the panels  130 , the two outside coverings  134 , 136  extend beyond the edge of the core  132  and project inward toward the core  132  to create flanges  138 . Thus, there will be at least four flanges  138  on each panel  130 , two on each of the edges  140 . As illustrated in  FIG. 3 , each of the flanges  138  preferably have two bends that each make a 90° turn with the prior portion of the flanges  138  to make a generally U-shaped flange. The outside coverings  134 , 136  may be made of any appropriate material, but are preferably made of either steel or aluminum, particularly when the panels  130  are to be used as an outside wall in a building. The flanges  138  from adjacent panels  130  are secured between the flanges  122 , 124  of the panel connector  100  and create a tight seam  142 . The panel connector  100  and the two flanges  122 , 124  provide sufficient structural strength to the panels  130  to support the bending and traverse structural loads that are imposed on the panel assembly. In other words, no other structural elements or devices are needed to secure the panels  130  to one another (the panel assemblies would obviously need to be secured to a floor or trusses however).  
         [0026]     It should be noted that the construction of the panel connector  100  makes the seam  142  relatively tight and generally waterproof. However, in the event that water does make it between two adjacent panels  130  at seam  142 , the water would be trapped within the confines of the elongated spine  120  and two flanges  122 , 124 . The water would then run down to the bottom of the panel connector  100 , where it can be properly channeled out of the wall.  
         [0027]     Another embodiment of a panel connector  200  is illustrated in  FIG. 5 . The panel connector  200  includes a central elongated structural member  202  having an outer surface  204  and an inner surface  206  that defines an opening  208  that preferably extends the length of the central elongated structural member  202 . The central elongated structural member  202  preferably has an opening  218 , giving the central elongated structural member  202  generally a C-shaped configuration in cross section. Panel connector  200  preferably has at least two generally flat surfaces or portions  210  to Which the elongated spines  120  are attached. The central elongated structural member  202  is made from steel (14 to 25 gauge), but any appropriate materials may be used, including for example, aluminum, plastics, and fiber composites. As with the prior embodiment, two of the elongated spines  120  are preferably attached to the generally flat surfaces  210  of central elongated structural member  202 . The panel connector  200  is attached to the panels  130 ′, which are the same as panels  130 , but have different flanges  138 ′, As illustrated in  FIG. 5 , the flanges  138 ′ also extend inward and toward one another, but are only bent once into a V-shaped configuration. This configuration also allows for increased contact between the flanges  138 ′ and the panel connector  200 .  
         [0028]     Alternative embodiments of panel connectors are illustrated in  FIGS. 6-12 . In  FIG. 6 , the panel connector  300  is of a unitary construction. The panel connector  300  has a central elongated structural member  302 , an outer surface  304 , and an inner surface  306  that defines an opening  308  that preferably extends the length of the panel connector  300 , making the panel connector  300  annular and generally rectangular, although it may be of any appropriate configuration or shape. For example, it may have a C-shaped configuration as illustrated in  FIG. 5 , or be more square, I-shaped, or U-shaped as discussed in more detail below. It may also have a round or even an irregular shape as long as it is structurally sound to provide support to the panels. The flanges  322 , 324  are also integrally formed, rather than being attached as separate elements to a central member. The flanges  322 , 324  also preferably make an internal angle B with the flat, outer surface  304  that is less than  7 (r and more preferably about 40°.  
         [0029]     Another embodiment of a panel connector  400  according to the present invention is illustrated in  FIG. 7 . The panel connector  400  is similar to panel connector  100  except that the elongated spine  420  has a different configuration. In particular, panel connector  400  includes a central elongated structural member  402  having an outer surface  404  and an inner surface  406  that defines an opening  408  that preferably extends the length of the central elongated structural member  402 , making the central elongated structural member  402  an annular member. Panel connector  400  preferably has at least two generally flat surfaces  410  to which the elongated spine  420  is attached. As noted above, central elongated structural member  402  and elongated spine  420  may be welded, molded together, or otherwise secured to one another (e.g., with rivets, bolts, adhesives, fasteners, etc.).  
         [0030]     The elongated spine  420  preferably has two flanges  422 , 424  attached thereto. Flanges  422 , 424  have a first portion  422   a , 424   a , which extend away from the central elongated structural member  402  (and elongated spine  420 ) and each other, and a second portion  422   b , 424   b , which extend back towards one another. The second portions  422   b , 424   b  of flanges  122 , 124  preferably, make an angle relative to the flat surface  410  (and spine  420 ) that is less than 70° and more preferably about 40°. In one preferred embodiment, the elongated spine  420  and the two flanges  422 , 424  are a single, integral piece, but they need not be. As in prior embodiments, the elongated spine  420  and the two flanges  422 , 424  are preferably the same length, although it is possible for the elongated spine  420  to be either longer or shorter than the two flanges  422 , 424  (and the central elongated structural member  402  as well) and still fall within the scope of the present invention. The elongated spine  420  and two flanges  422 , 424  are made from steel (preferably 14 to 25 gauge), but also be made of any other appropriate material.  
         [0031]     The panel connector  450  is similar to panel connector  400  in that is has flanges  472 , 474  that each have two portions, but the panel connector  450  is or a unitary construction.  
         [0032]     Another the panel connector  500  is illustrated in  FIG. 9 . The panel connector  500  includes a central elongated structural member  502  having an outer surface  504 . The outer surface  504  of panel connector  500  preferably has two generally concave surfaces  506  and two generally flat surfaces  510 . The central elongated structural member  502  is preferably made from steel, but any appropriate materials made be used, including for example, aluminum, plastics, and fiber composites.  
         [0033]     The panel connector  500  also has the elongated spine  120  attached to each of the two generally flat surfaces  510 . As with the prior embodiments, the elongated spine  120  and the central elongated structural member  502  may be welded, molded, or otherwise secured to one another (e.g., with rivets, bolts, adhesives, fasteners, etc.). The spine  120  is preferably the same as noted above with regard to panel connector  100 .  
         [0034]     It should also be noted that the central elongated structural member  502 , the elongated spine  120 , and the two flanges  122 , 124  may be of a unitary construction, i.e., one piece, as with the panel connector  300  illustrated in  FIG. 6  and be within the scope of the present invention.  
         [0035]     Another embodiment of a panel connector  550  is illustrated in  FIG. 10 . The panel connector  550  is similar to the panel connector  500 , but the central elongated structural member  552  generally has an I-shaped configuration rather than the concave configuration of panel connector  500 . The panel connector  550  also has the elongated spine  120  attached to each of the two generally flat surfaces  560 . As with the prior embodiments, the elongated spine  120  and the central elongated structural member  552  may be welded, molded together, or otherwise secured to one another (e.g., with rivets, bolts, adhesives, fasteners, etc.). The spine  120  is preferably the same as noted above with regard to panel connector  100 . Panel connector  550  may also be of a unitary construction rather than having the various components as illustrated in  FIG. 10 .  
         [0036]     Another embodiment of a panel connector  600  is illustrated in  FIG. 11 . The panel connector  600  is similar to the unitary panel connector  300  of  FIG. 6 , but rather than the central elongated structural member  602  having a generally rectangular shape, it has a generally square configuration. The panel connector  600  similarly has integrally formed flanges  322 , 324 .  
         [0037]     It may be more appropriate to use the configuration of panel connector  600  with panels that are thinner than those illustrated in  FIG. 3  or that have longer flanges, allowing for the more square design of panel connector  600 . Panel connector  600  may also be constructed with a separate central elongated structural member and an attached spine with two flanges (e.g.  FIG. 3  or  FIG. 7 ).  
         [0038]     Another embodiment of a panel connector  650  is illustrated in  FIG. 12 . The panel connector  650  is similar to the unitary panel connector  200  of  FIG. 5 , but rather than having a generally rectangular shape, the panel connector  650  has a central elongated structural member  652  that is generally a U-shaped configuration with only three sides. While the panel connector  650  is illustrated with the elongated spines  120  attached to two generally flat surfaces  660  of central elongated structural member  652 , the flanges may be integral with the central elongated structural member  652 . As with the prior embodiments, the elongated spine  120  and the central elongated structural member  652  may be welded or otherwise secured to one another (e.g., with rivets, bolts, adhesives, fasteners, etc.), or they may be a unitary member. The spine  120  is preferably the same as noted above with regard to panel connector  100 .  
         [0039]     It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.