Patent ID: 12215499

Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

While the overall construction system of the present invention will be disclosed in detail, it is worthwhile to first discuss the various individual components of the system. With reference toFIGS.1and2, a preferred embodiment of a panel member or panel10is depicted. The panel10is preferably formed monolithically, such as by extrusion, but assembly of a panel10from a plurality of components may be possible. The panel10includes two oppositely disposed faces12supported by a plurality of webs15. The faces12also define a long edge1of the profile of the panel10. The panel10also includes a ridge member13and a valley member14defining a short edge2of the profile of the panel10. The ridge member13and valley member14also serve to facilitate a mating relationship between consecutive, adjoining panel members10when utilized for construction of a wall, floor, or ceiling, for example. It will be understood that the precise shape of the ridge member13and valley member14are not critical, so long as they can facilitate a mating relationship. In the Figures, they are represented as simple shapes. The webs15at least partially define a plurality of channels11that run lengthwise along the panel10and terminate in open ends16at each end of the panel10. The panels10may also include a plurality of mounting apertures17located where desired, and as discussed further below, may be placed to coordinate with other mounting apertures on the various components of the system of the present invention.

Turning toFIGS.3through6, two corner brackets20,20′ are presented which may be employed with one embodiment of the present invention, though they are not required or necessary. As can be seen the corner bracket20,20′ is essentially an enclosed channel21,21′ with a ridge member23,23′ and valley member24,24′ disposed on faces to facilitate the adjoining of panels10at angles other than zero (i.e., not in a straight line). A relatively standard corner angle in building construction is ninety degrees, which is represented inFIGS.3and4. As can be seen, the ridge member23and valley member24are orthogonal to each other, which facilitates the adjoining of consecutive panel member10at ninety degree angles. However, virtually an adjoinment angle may be accommodated as represented byFIGS.5and6.

FIG.7represents a track30according to a preferred embodiment of the present invention. The track includes a channel33at least partially defined by two webs31, as well as an external flange32. Panel members10may be inserted into the channel33to facilitate alignment and fastening when construction walls, floors, or ceilings. In that regard, the mounting apertures35may be aligned with the mounting apertures17of the panel members (as depicted inFIG.1) in order to facilitate fastening of a panel10to the track30.

Turning now toFIG.8, a frame40in accordance with a preferred embodiment of the present invention is depicted. The frame40may serve as an end cap when required, such as when framing window openings with panels10. As such it includes a channel42at least partially defined by webs41, and is distinguished from the track by the lack of an external flange. The frame40may also include a plurality of mounting apertures43in order to facilitate fastening to a panel10.

FIG.9depicts a ridge plate50to facilitate adjoinment of panel members along the ridge of a gabled roof.FIG.10depicts an insert60, essentially an enclosed channel or box beam, which may be inserted into a channel11of a panel10in order to provide structural reinforcement for the panel10, e.g., when used as a support beam or girder. The insert60may also be used to increase the safety margin for a free-standing span or cantilevered configuration of panels10.

Now that several of the individual components have been described, the interconnectivity of the components can be discussed. With reference toFIGS.11through16, several partial, detail views of assemblies created with the foregoing components can be seen. In each of the views, a plurality of panels10, tracks30, and frames40are disposed in various configurations on top of a foundation500for a structure such as a home or building. As can be seen, the panels are used to form the various external and internal walls, ceilings, upper story floors, and the roof of the building. The tracks30are utilized to secure the panels10to the foundation500and to each other when two panels are joined to form a ceiling/floor or roof connection with a wall. The frames40serve as an “end cap” when framing a window, otherwise the interior opening of the window would not be a uniform, flat surface given the existence of the valleys14and ridges13on the panels10.

InFIG.11, a plurality of tracks30are fastened to a foundation500and are being utilized to support a plurality of panel members10in a vertical orientation to be utilized as wall members. InFIG.12, two panel members can be seen in a “T” configuration to show that the panel members may also be used as columns and support beams. Also, inFIG.12, the panels10have been arranged to form a window by suspending a panel10as a lintel across two other panels10acting as columns. It may also be seen that frames40are fastened to the interior of the window in order to prepare a flat surface for installation of the window and/or window jamb.

FIG.13depicts a plurality of tracks30that have been fastened to the top of a plurality of vertically oriented panel members10. In this regard, the structure is being prepared for the addition of a second story or flat roof.FIG.14shows a panel member10in a horizontal orientation employed as a first story ceiling and second story floor. As will be disclosed in further detail below, the horizontal panel member10is secured to the tracks30by fasteners, such as self-drilling screws, bolts, or rivets inserted through the external flange32. InFIG.15it can be seen that another vertically oriented panel member10′ has been installed in the track30to create a second story wall. It may also be seen that the horizontally oriented panel member10is cantilevered outside of the structure, and may act as an awning or balcony. Finally, inFIG.16, it can be seen that yet another panel member10has been mounted in an angled configuration in order to create a peak or gabled roof. It is secured to the vertically oriented panel member10via a track30.

FIGS.17and18show detail views of a corner configuration according to one embodiment of the present invention.FIG.17depicts the interconnection between two adjoining panels10via a ninety degree corner bracket20, along with the associated mating interface between the panel10ridge and valley members13,14and the ridge and valley members23,24, of the corner bracket10.FIG.18shows a plurality of tracks30fastened to a foundation500via fasteners600through the external flange32. In certain scenarios, it may be desirable to use steel fasteners to penetrate a concrete foundation. However, when the track30is made of aluminum, galvanic corrosion may occur over time. Therefore, a neoprene gasket or washer may be used to insulate the fastener600from the track30to avoid electrical contact between the fastener600and the track30. Additionally, a plurality of fasteners600are disposed through the corresponding mounting apertures in each of the tracks30and panels10in order to secure the panels10to the tracks30.

FIGS.19and20provide a detail view of the system of the present invention utilized to construct a multi-story building. As such a plurality of panels10are utilized to construct the walls as well as the ceiling of the first floor and floor of the second floor. The panel10serving as a ceiling/floor is sandwiched between two tracks30disposed on the panels10serving as walls. In this scenario, fasteners600are disposed through the external flanges32of the tracks and into the panel10serving as a floor. Therefore, the panel serving as a floor can be securely retained in place. In certain embodiments, it may be desirable to use self-tapping screws, bolts, or rivets for this purpose as the panels10may not have mounting apertures appropriately placed.

FIGS.21and21Ashow a partially completed structure in both constructed and exploded form for further exemplification. As can also be seen, several panel members10are adjoined together to create a gabled roof. Thus, two ridge plates50are employed to facilitate the connection of each panel10at the ridge of the roof.

FIG.22depicts a partially completed structure utilizing a membrane100between consecutive panels10. In a preferred embodiment, the membrane100is self-adhering and water resistant. Therefore, particularly with regard to roof construction, the system of the present invention can be employed where resistance to water intrusion is a concern. As can be seen, the membrane100may be applied at the intersection of any two consecutive panels10in order to ensure that water does not weep between the crevice formed therein. The Figure also shows that panel members10may be employed in a cantilevered configuration to create awnings and balconies. Caulking may be employed in addition to, or in lieu of, the membrane100, particularly between adjoining panels10.

FIGS.23through28show how traditional interior and exterior finishes can be used in conjunction with the system by applying them on top of the panel members10. By way of non-limiting example, the exterior finishes may include sheathing, housewrap/mesh, and stucco (FIG.23), rigid insulation, fiberglass mesh, and stucco (FIG.24), or sheathing, high-density polyethylene paper, and siding (FIG.25). Non-limiting examples for interior finish include drywall and paint (FIG.26), cement board and stucco (FIG.27), and furring strips, cement board, and wall tiles (FIG.28).

FIGS.29through34show how traditional roof and floor finishes may be used in conjunction with the system. By way of non-limiting example, such roof finishes may include rigid insulation, sheathing, and TPO (FIG.29), rigid insulation, a moisture barrier, and metal tiles (FIG.30), or rigid insulation, plywood, and asphalt shingles (FIG.31). Flooring finishes may include, by way of non-limiting example building paper/mesh and tile flooring (FIG.32), plastic barrier, foam pad, and laminate wood (FIG.33), or furring strips, foam padding, and hard wood (FIG.34).

FIGS.35through35Ddepict how traditional mechanical, electrical, and plumbing lines may be integrated with the present invention. In particular, water lines1000and electrical conduits2000may be simply routed through the channels11within the panels10. Additionally, the channels11may be used as air conditioning ducts300as shown inFIG.35B.

FIGS.36through41show various insulation options that may be applied to the surface of a panel or disposed within the channel11of a panel10.FIG.36is a depiction of pre-formed or pre-cut insulation3000, such as foam, that may be slid into the channels11during construction.FIG.37depicts a spray insulation4000that may be applied to the face12of a panel10.FIG.38depicts an injection foam insulation5000that can be utilized in channels11where electrical or plumbing lines are utilized.FIGS.40and41show that the insulation may be added in-situ due to the open ends16of the panels10.

FIGS.42and44provides a schematic depiction of how the present invention may be utilized to route cooled air more efficiently from an air conditioning unit via the channels11of the panels10.FIG.43depicts additional components to facilitate this aim. As can be seen, connectors330and elbows320may be used to route the cooled air from the air conditioning unit6000into one or more channels11and between channels11in consecutive panels. While it may be possible to simply provide apertures in the tracks30(and ends of panels10) to facilitate air flow between successive panels10and tracks30, that may hinder construction of the overall structure. The elbows320and connectors330allow for implementation of this benefit after construction. Diffuser grills310can also be employed to introduce cooled air into the room via the wall panels10or ceiling panels10.

Turning toFIGS.45and46another embodiment of a panel10′ is depicted therein. This embodiment finds particular suitability for utilizing the panel10′ as a roof member. As can be seen, the panel member10′ contains the same structure as in previous embodiments, including opposite faces12′ spaced by a plurality of webs15′, which at least partially define channels11′ traversing the open ends16′ of the panel10′. The panel10′ also includes a ridge member13′ and a valley member14′. The additional structure of the present embodiment is a flanged extension19traversing the length of the panel10. Each flanged extension19includes a flange which extends inwardly toward the panel10′. As can be seen inFIG.45, when two panels10′ are adjoined next to one another, the flanged extension19abut one another. A cap200which encompasses the flange portion of the flanged extension can then be disposed about both flanged extensions19, thereby locking the two panels10′ together and creating a water-resistant seal. In this fashion, the assembly approximates the typical crimped construction of existing metal roofs. Utilizing this embodiment of the present invention avoids the need for additional waterproofing steps, such as membranes and caulking, when the panels10′ are employed as roof members.

FIGS.47and48depict an alternative embodiment of a track30′ that may be utilized to facilitate construction of a gabled roof. As can be seen the webs31′ are angled relative to the external flange32′. Therefore, when a panel member10or10′ is positioned at an angle to be used for a gabled roof, it may sit flush against the external flange32′, which facilitates better fastening.

FIGS.49and50depict yet another embodiment of a track30″ which includes two external flanges32″, each projecting perpendicularly from the two webs31″. This embodiment of a track30″ is suitable for certain installation scenarios, such as when an interior wall is used to support a ceiling. The wall can be inserted into the channel between the two webs31″, while the ceiling panels can be secured to each of the two flanges32″.

FIG.51depicts a partially completed structure wherein the panels10are used in a vertically oriented configuration to support longer spans between panels acting as columns. For purposes of aiding disclosure in the context ofFIG.51, the vertically oriented panels are denoted as10′, while horizontally oriented panels are denoted as10″. The vertically oriented panels10′ can also be referred to as those supporting loads in the plane of the panel, while the horizontally oriented panels10″ can be referred to as those supporting loads out of the plan of the panel. It will be appreciated that the bending strength of the panel is much greater around its short edge than its long edge. Thus, the vertically oriented panels10′ are capable of withstanding much greater loads when cantilevered, suspended between two or more points, or otherwise not continuously supported, as compared to the horizontally oriented panels10″. The panels10acting as columns are configured to support axial loading.

FIG.51also depicts a configuration to support a peaked roof using panel members10′ disposed in vertical orientation. With additionally reference toFIGS.52and53, a gusset plate70can be used to facilitate the angled and vertically oriented connection between panel members10and10′. The gusset plate70may include mounting apertures71to support the use of bolts or other fasteners.

FIGS.54and55depict an insert plate80in accordance with one embodiment of the invention. The insert plate includes two webs81at least partially defining an interior channel83. Two flanges82project exteriorly of the insert plate80. As depicted, the flanges82are orthogonal to the webs81, but they may be disposed at any angle that is desired. Turning now toFIG.56, it can be seen that the insert plate80is to be inserted within a channel11of a panel member10. Therefore, the length of the insert plate80distance between the two webs81should be correspondingly configured and dimensioned with the channel11. In a most preferred embodiment, this is approximately a 4 inch square (as disclosed above). Accordingly, as can now be seen, the insert plate80can be used in a similar fashion to the track30,30′, and30″ in any scenario where it is more desirable to have the webs disposed within the panel10. This can be for aesthetic purposes, for water proofing, or other reasons. Additionally, the insert plate80can also be useful for installations where a full length track member may not be suitable, such as when some of the channels11of a panel member10, are used for mechanical, electrical, or plumbing conduits, or a variety of other purposes. Using a plurality of single channel-sized insert plates80may be preferable to cutting a track30to the desired size.

Turning toFIGS.57and58, yet another embodiment of a panel10′ is depicted which includes protrusions or bosses3along the inner faces of the panel. The bosses3provide additional material for a fastener to grip, which can reduce the total number of fasteners per panel necessary to securely retain the panels10″″. The bosses3can take on virtually and size, dimension, or placement that is desired for the purpose. In the depicted embodiment, the bosses3are arranged approximately ½ inch from the side of each panel10“ ” and are approximately ¼ inch in thickness. The bosses3may run the entire length of the panel or may be truncated to the desired length. With specific reference toFIG.58, a visual marker4can be provided on the outer surface to assist users with accurate placement of fasteners.

Turning toFIGS.59and60, further embodiments of tracks30′″ and30″″ are depicted, respectively. Each track30′″,30″″ contains additional flanges32′″,32″″ relative to previously disclosed embodiments to provide a more structurally secure fitment of panels within the channels33′″,33″″ of the tracks30′″,30″″. This is due to the fact that fasteners can be driven into both flanges32″″,32″″ instead of relying on a single flange as previously disclosed.FIG.59shows a “T” shaped track30′″ which can accommodate three panels at each of the three channels33′″.FIG.60shows an “L” shaped track30″″ which accommodates two panels. The tracks30′″,30″″ may be dimensioned and configured to suit any orientation or load capacity. For example, the flanges32′″,32″″ may be lengthened to provide additional support.

Since many modifications, variations and changes in detail can be made to the described embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents.