Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This is a non-provisional application based upon U.S. provisional patent application Ser. No. 60/548,060, entitled “QUICK FRAME CONSTRUCTION METHOD”, filed Feb. 26, 2004. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to a method of wall construction, and, more particularly, to a method of joining structural members in a wall.  
         [0004]     2. Description of the Related Art  
         [0005]     Construction of frames and walls are often undertaken utilizing a jig for the placement of metal members, which are then subsequently welded together to form the structural frame or wall unit. Welding is a technique requiring a high skill level in order to yield high quality welds for a structural unit. The high skill level equates to a high level of pay for individuals who are employed as welders. The heat from welding can sometimes cause a warping in the frame even though it is laid out at a jig.  
         [0006]     In the recreational vehicle industry, long structural walls are utilized for the exterior framing of the recreational vehicle. The exterior of the vehicle includes a skin which is connected to the frame with adhesive and/or fasteners. The recreational vehicle industry is highly competitive and requires adaptive methods to produce new models each year.  
         [0007]     What is needed in the art is an adaptive, cost effective method for constructing wall systems.  
       SUMMARY OF THE INVENTION  
       [0008]     The present invention provides a frame construction method that requires only a low skill level for implementation.  
         [0009]     The invention comprises, in one form thereof, a structural wall system including a structural wall system including a plurality of structural members, a plurality of preformed connecting elements and a skin positioned thereover. The plurality of structural members include a first structural member having a first receiving channel and a second structural member having a second receiving channel. The plurality of preformed connecting elements including a first connecting element positioned in the first receiving channel and in the second receiving channel. The skin is positioned over a side of the plurality of structural members and the first connecting element.  
         [0010]     An advantage of the present invention is that the structural members may be positioned and connected with a low skill level worker.  
         [0011]     Another advantage of the present invention is that welding is not required for the connection of the structural members.  
         [0012]     Yet another advantage is that the structural system of the present invention does not require a cool down from a welding operation before the application of the skin thereover.  
         [0013]     Still another advantage of the present invention is that it is very cost effective as compared to convention construction methods. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:  
         [0015]      FIG. 1  illustrates a side view of an embodiment of the structural wall system of the present invention;  
         [0016]      FIG. 2  is a perspective view of the detail of one of the joints of the system of  FIG. 1 ;  
         [0017]      FIG. 3  is a perspective view of the wall system of  FIGS. 1 and 2  additionally showing a laminate applied thereover;  
         [0018]      FIG. 4  is an enhanced perspective view of a structural element of the wall system of  FIGS. 1-3 ;  
         [0019]      FIG. 5  is a perspective view of a connecting element of the wall system of  FIGS. 1-4 ; and  
         [0020]      FIG. 6  is a cross-sectional view of the wall system of  FIGS. 1-4 . 
     
    
       [0021]     Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0022]     Referring now to the drawings, and more particularly to  FIGS. 1-3 , there is shown a structural wall assembly  10  including structural members  12 , gussets  14  and a skin layer  16 . Wall assembly  10  can be any structural construct even though here illustrated as a side panel for a recreational vehicle. Structural members  12  are positioned on a jig (not shown) and gussets  14  are installed utilizing a hammer to completely seat gussets  14 , thereby connecting gussets  14  to structural members  12 . Gussets  14  are applied to at least one side of each intersection of structural members  12 . When an intersection of a structural member with another structural member is utilized to enclose an opening for a window, door or an access opening, gussets  14  may be omitted on one side of the intersection of structural members  12 . Even though structural members  12  may additionally be held in place with a welding operation, significant strength of wall assembly  10  comes from the unitizing of the assembly by way of the adherence of skin  16  over a surface of structural members  12  and gussets  14 .  
         [0023]     Now, additionally referring to  FIG. 4 , structural members  12  may be an extrusion having a hollow core. Structural members  12  each include channels  18  each having a first wall  20  and a second wall  22 . First wall  20  includes at least one protrusion  24  along the length thereof. Additionally, first wall  20  is shorter than second wall  22 , and does not extend to the level of the surface of structural member  12 , in order to accommodate the thickness of gussets  14 . Gussets  14  are installed against a end of wall  20 , the outer side of gusset  14  being substantially coplanar with a surface of structural members  12 . This advantageously provides for a flat surface for the lamination of skin  16  over both structural members  12  and gussets  14 . Protrusions  24 , although only shown on first wall  20  may also be positioned on second wall  22 . Protrusions  24  interact with a feature of gusset  14  to enhance the retaining of gusset  14  in channels  18 .  
         [0024]     Now, additionally referring to  FIG. 5 , a gusset  14  is illustrated including an angular portion  26 , a first engaging portion  28  and a second engaging portion  30  all shown in a perspective view. Angular portion  26  provides structural strength to wall assembly  10  when gusset  14 , also known as connecting element  14 , is assembled with structural members  12 . As can be seen in  FIG. 2 , first engaging portion  28  interacts with a channel  18  of one structural member  12  and second engaging portion  30  interacts with another channel  18  of another structural member  12 .  
         [0025]     Connecting element  14  additionally includes an edge enhancement  32  along an edge of both first engaging portion  28  and second engaging portion  30 . Edge enhancement  32  may be simply a bending of the edge to effectively increase the cross section, which interacts with channel  18  and protrusions  24  therein. Additionally, edge enhancement  32  may be a thickened portion of material positioned along an edge of gusset  14 .  
         [0026]     Now, additionally referring to  FIG. 6 , during the assembly of wall assembly  10 , structural members  12  are precut and positioned on a fixture (not shown). Where structural members  12  intersect, gussets  14  are positioned with engaging portions  28  and  30  positioned to enter channels  18  of adjacent structural members  12 . A hammering operation, utilizing a mallet (not shown), seats gusset  14  in channels  18  thereby connecting structural members  12  together. The thickness of the material used in forming gusset  14  may be the same width as channel  18  or somewhat thinner. Edge enhancement  32  interacts with protrusions  24  to retain gusset  14  in channels  18 . Advantageously, the skill level of the individual applying gussets  14  to structural members  12  is only that of a semi-skilled worker rather than a skilled worker such as a welder.  
         [0027]     A skin  16  is laminated over the assembly of structural members  12  and gussets  14  utilizing an adhesive and/or mechanical fasteners. Skin  16  may be a plastic, a composite material, a thin metal and/or a combination thereof The lamination of skin  16  provides structural integrity of structural members  12  along with gussets  14  to thereby unitize wall assembly  10 . While this method is described and illustrated for one side of structural members  12 , the method also applies equally to an opposite side of structural members  12 .  
         [0028]     Although the structural method has been illustrated in the use of substantially perpendicular intersections between structural members  12 , any angle of interaction accompanied by a gusset of a corresponding angle can likewise be utilized in wall assembly  10 . Additionally, even though illustrated in a planar sense, structural members  12  can have three-dimensional variations with appropriate gussets applied thereto.  
         [0029]     Advantageously, no special tools are required for assembly and no specially trained workforce is needed for producing the assembly. This advantageously allows for a start-up manufacturer to make framing with very little investment in tools. Once the joint between gusset  14  and structural members  12  is made, shorter wall  20  allows gusset  14  to be substantially coplanar with a surface of structural members  12 . This allows for easy lamination of the assembly of members  12  and gussets  14 . Additionally, an insulation or filler may be placed between structural members  12 , which can likewise be adhered or laminated to skin layer  16 .  
         [0030]     While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.

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