CA1199773A

CA1199773A - Extruded structural system

Info

Publication number: CA1199773A
Application number: CA000421117A
Authority: CA
Inventors: Jay R. Auer
Original assignee: Corflex Inc
Current assignee: Corflex Global LLC
Priority date: 1982-02-10
Filing date: 1983-02-08
Publication date: 1986-01-28
Also published as: GB2115452B; GB8303389D0; JPS58199956A; HK53291A; MX158749A; GB2115452A; JPH0246733B2

Abstract

" EXTRUDED STRUCTURAL SYSTEM"

Abstract of the Disclosure A structural system including a panel having a pair of parallel planar outer walls, reinforcing ribs joining the outer walls with reinforced shoulders at the intersection of the ribs with the walls, and a panel connecting member for joining the panel to an adjacent panel by slidably engaging an interlocking panel joining member. The panel connecting member includes a head portion and a neck portion which form a pair of opposed keyways and permits interlocking with the interlocking lips of variously configured panel joining members. A variety of interlocking panel joining members allow assembly of the structural panels in end-to-end configurations, T-intersections, cross-intersections and other configurations to form structural systems. Also disclosed are interlocking end trim members, bolted interlock members and edge insert members which may be used to assemble a complete structure.

Description

77~

1~ 1 n EXTRUDED STRUCTURA.L SYSTEMn l -~g~ . .
lS 1. Field of the InYention :
~ The present invention relates .
generally to structural systems, and specifically relates to extruded ~tructural systems which include extruded structural panels and extruded panel joining members for assembling a structural .
system ~ith a plurality of panels.

2 Descri tion of the P~ior ~rt . ~ .
Extruded structural system components are known in the art and have been fabricated for such widely varying purposes such as window. .
mullions, doorst outer belt panels for buses, fluid flumes, ducting, cable trays, and the likeO Hollow extruded structural panels haYe been m~de for upward-acting doors for refriyerated trucks to replace bonded assemblies of metal or wood frames with external s}ieet skins~ 5uch strllctllral panels are usually constructed with tongue and ~roove edges which allow relati~e motion between panels~
There have not heretofore been ~ .

.9~3 constructed extruded structural panel components which rigidly fasten together in an interlocking fashion so.to facilitate construction of immovable structures such. as walls, floors, and the like~
Moreover, prior art extruded structural components, although sometimes made with integral reinforcing ribs, have not exhibited sufficient longitudinal and transverse strengths to be seriously considered for structural applications requiring load-bearing capability.

Summary of the Inventlon The present invention provides an improved extruded s~ructural system which includes a structural panel havi~g a pair of planar outer walls, at least on~ reinforcing rib joining the outer walls, a reinforcing shoulder formed at each .. . .
intersection of a rib with the outer walls, and panel connecting means on the outer edge of the panel which allows joining the panel to an adjacent panel in a rigid structure. A preferred Pmbodiment of the pan~l connecting mean~ comprises a panel connecting member which extends outwardly from the walls along the longi~udinal edge in a head portion and a neck portion. The head and neck portions slidably engage and interlock with mating panel joining members which allow assembly of several panels into structures. Varisusly conf igured panel joining members allow the panels to be assembled edge-to-edge in co-planar, orthogonal, angular, cross, and T-shaped intersectionsO
. . The structural system disclosed herein is extremely versatile and possesses unusual strength because of the unique features o the structural panel. The structural panel ~9~773 _ demonstrates a remarkable resistance to compressive and shear forces due to the uniq~e reinforcing ribs which are integrally formed with the panel. The unique interlocking panel connecting members, also integrally formed along each longitudinal edye of the panel, further contribu~e to the overall strength and versatility of any structure built using the system.
Structural assemblies made with the preferred embodiment of the present invention may be successfully employed in such diverse applications as electrical utility cooling tower - louvres, floating covers for oil and other petroleum product storage tanks, anti-corrosive ~15 structures or use in harsh chemical plant environments, computer room flooring, self-supporting conduit for electrical and utility cabling, energy efficient insulated building siding for storage shelters and refrigerated enclosuresS
- 20 air intake housings and ducting, architectural room dividers~ and beavy e~uipment hoods and enclosures.
A superior structural system can be made if the preferred embodiment is extruded from fiberglass reinforced plastic~ Such a system will be lighter than aluminum yet nearly as rigid, and will be a good insulator of both heat and electricity~ Moreover; the system will not rust, rot, corrode, or oxidize, and will be resistant to most corrosive environments.
The preferred embodiment presents hollow cross-section which may be filled with foam or insulation in order to provide additional fire resistance, thermal insulAtion, or floatability.
Moreover, a c~ble may be routed through the cross-section and used to lash together several ~977;:~

panels. A sealing o-ring may be placed between the panel and panel joining members so as to provide a substantially water-tight structure.
Accordingly, it is an object of the present invention to provide an improved structural system which includes an improved structural pan~l and means for assembling several panels into a construction.
It is another object of the present invention to provide an improved structural system whose components are unitary and integrally formed.
It is another object of the present invention to provide ~or use in a structural system a~ improved structural panel having means affixed to the outer longitudin~l edges of the panel for connection of the panels to other like panels in a variety of different configurations such as corners, T-intersections, angled corners, cross-intersections, and the like.
It is another object of the present invention to provide for use in a structural system an improved structural panel having panel connecting members affixed to the ends of the panels which are formed of a n~ck portion and a head portion which allows interlocking the panel with various different}y configured panel joining members such as corner connectors, T-intersection connectors, angled . corner connectors, cross-intersection connectors, and the like.
It is another object of the present invention to provide for use in a structural system an improved structural panel having a pair of outer walls separated by at least one reinforcing rib joining th~ walls having reinf~rcing shoulders for providing improved resistance to shear and _ compressive forces.
It is another object of the present invention to provide an improved structural system which includes means for slidably engaging a series S of struc~ural panels in various configurations including joining panels end to end, joining panels in a corner and angular intersections, joining panels in a T~shaped intersection, joining panels in a cross intersection, and joining panels by means of a bolted interlock when it is not feasible to slidably engage a panel joining interlock member.
It is another object of the present invention to provide an impr.oved structural system having a flush exterior appearance at the joints between structural panels and the interlocking panel joining members which are used to join the outer edges of the panels~
It is another object of the present invention to provide an improved structural system which includes a plurality of structural panels having channels formed in the outer edges for receiving reinforcing cable along the length of the panel~
It is another object of the present invention to provide an improved structural system which includes sealing means between structural panels and interlocking panel joinin~ members so as to facilitate assembly of a structure which is substantially water- or fluid-tight.
It is another objert of the present invention to provide an improved structural system which includes structural panels joined by interlockin~ panel joining members which slidably engage and interlock with the stru~tural panels so _ as to form an extremely strong structural joint~
It is another object of the present invention to provide an improved structural system which presents a hollow cross-section which may either be filled with foam, insulatior!, or the like so that the structural system possesses fire resistance, high electrical insulation properties, floatability, thermal insulation, or may alternatively be used hollow as conduit for electrical cabling or other utilities.
It is another object of the present invention to provide ~n Lmproved structural system which possesses extremely high tensile strength, compressive strength, flexural strength, bearing stress resistance, interlaminar shear resistance, and punch shear resistance by virtue of its unitary and reinforced cross-section.
It is another object of the present invention to provide an extruded structural system which possesses extremely high strengths in both longitudinal and transverse directions~ and thus may advantageously be used to construct load-bearing floors, walls, or ceilings.
It is another object of the present invention to provide an improved extruded fiberglass-reinforced plastic structural system which is extremely strong, light-weight, and substantially impervious to corrosive environments.
It is another object of the present invention to provide an improved structural system in which heatin~ means may be employed so as to maintain the entire structural system at a predetermined temperature for heating or cooling a structure in which the structural system is ~mployed ~:ag9'~3 6a In accordanc~ with the principal object, the invention contemplates a structural panel having a thickness of a first dimension which co~prises a pair of parallel planar outer wall members whose oute~ surfaces are separated by the first dimension, and at least one r~inforcing rib of generally I-shape joining the pair of wall members. A reinforcing shoulder means is formed at each intersecti~n of a surface of the rib with a surface of one of the pair of wall members for imparting rigidity to the panel. A flange means formed along the longitudinal edges of the wall ~ember~ extends inwardly from each of the wall members toward the opposite wall member. At least one panel connecting member ~oins the panel to an adjacent panel, and extends outwardly ~rom the flange means orming an outer longi-tudinal edge of thè panel and includes a neck portion extending outwardly from the flange means and between the wall members.
A head portion i~ attached to the neck portion and has a thickness of a sec~nd dimension less than the first dimension.
The head portion i~ludes on the interior surface of the head portion opposite t~e wall members an inwardly extending tab.
The tab and the in~r surface of the head portion define a pair of opposed channels for receiving therein elongate reinforcing cable means.

'~ ~

These and other objects, features, and advantages of the present invention may be more clearly understood and appreciated from a review of the following de~ailed description of the disclosed embodiments and by reference to the appended drawings and claims.

Brief Description of the Drawin~s Fig. 1 shows a perspective view of a preferred embodiment of the improved structural system of the present invention, which includes an - impr~ved structural panelO
Fig. 2 is a detailed cross-sectional view of the system shown in ~ig. 1.
FigO 3 is a cross-sectional view of a panel end trim member which may be used with the panel shown in Fig. 1.
Figr 4 is a cross-sectional view of a square corner interlocking panel joining member~
Fig. 5 is a cross-sectional view of a~
angled interlocking panel joininy member.
Fig~ 6 is a cross-sectional view of a T-intersection interlocking panel joining member~
~ig. 7 is a cross sectional view of an interlocking panel joining member which may be used to join four panels in a cross-intersection.
Fig. 8 is a cross-sectional view of a bolted interlocking panel joining member.
Fig. 9 is a cross-sectional view of an interlocking panel end tri~:member whi~h includes a moun~ing lip ana further shows how reinfor~ing cables may be used in the present invention~
Fig~ 10 shows how several panels may be lashed together with cables.
Fig. 11 is a cross-sectional view of an 1~L99~3 _ edge trim insert member for the transverse or cut longitudinal edge of a panel. -Fig. 12 is a cross-sectional v~ew of an edge interlocking insert member for the transverse or cut longitudinal edge of a panel.
Fig. 13 is a cross-sectional view of a C-shaped edge panel end insert member for the transverse or cut longitudinal edge of a panel.
Fig~ 14 is a cross-sectional view of a rounded corner edge panel end insert member~
Fig, 15 is a cross-sectional view of an angled corner edge panel end insert member~
Fig. 16 is a cross-sectional view of a rounded angled corner edge panel end insert member. , Fig~ 17 is a cross-sectional view of an edge panel insert member which may be used to join in a cross-intersection the edges of four panelsO
Fig. 18 is a cross-sectional view of an edge panel insert member which may be used to jo;n in a T-inter~ection the edges three panels.
Fig. 19 is a cross-sectional view of a double edge panel end insert member.
Fig. 20 is a cross-sectional view of a s~uare corner e~ge panel end insert member.
FigO 21 is a cross-sectional view of a double lip edge panel end insert member.
Fig. 22 is a cross-sectional view of a bolted edge panel joining member~
Fig. 23 is a cross-sectional view of a double pane window mullion member which may be used to support panes of glass in a construckion~
Fig. 24 is a cross-sectional view o a hinge edge panel end insert member.
Fig. 25 is a hinge interlocking panel end member.

S Detailed Descri tion of the Preferred Embodiment _ . P _ ~ :
Referring now to the drawings, in which like numerals indic~te like elements throughout the several views, Fig. 1 shows a preferred embodiment of an extruded structural system 10 according to 1~ the present invention in cross-section. The preferred embodiment includes a unitary, integrally formed structural panel 12 which is ~oined to a - similar panel 12' by means of an integrally formed interlocking coplanar panel joining member 14. A
panel connecting member 15 is integrally formed at : each end of panel 12 and runs along an outer longitudinal edge 16 of the panel. The preferred embodiment of panel connecting member 15 comprises a double keyway interlocking portion and prsvides 2~ means for attaching panel 12 to adjacent panels via an interlock in a variety of configurations and shapes. As disclosed herein, a variety of interlQcking extruded panel joining members having different shapes are a part of the present invention and allow assembly of the panels 12 and 12' in a variety of configurations, includiny corner-intersections, T-intersections, cross intersections, and the like.
In the preferred embodimentl panel 12 and the various interlocking panel joining members such as coplanar panel joining member 14 are manufactured by extruding fiberylass-reinforced plastic in a ~pultrusion~ process which is known in the art. The "pultruded" panels and interlocking members produced by pultrusion provide an extremely _ light-weight and strong structural system which is also impervious to many types of corrosive substances. Consequently, pultruded fiberglass reinforced plastic panels manufactured in accordance with the present invention provide structural systems superior to extruded from materials such as aluminum and the like. However, it will be appreciated that the present invention may be manufactured by extruding aluminum or other materials and the advantages a~d features disclosed herein will be similarly achie~ed.
Turning now to Fig. 2, a more detailed partial cross-section of panel 12 and interlocking panel joining member 14 may be seen. Panel 12 includes a pai~ of parallel planar out~r walls 20, -21 which are joined by at least one reinforcing rib 22 which extends across the thickness of the panel between the walls. In the preferred embodiment, rib 22 is of generally I-shape and connects the walls at right angles. Reinforcing shoulders ~3 are intë'grally formed at each intersection of rib 22 with walls 20~ 21. Shoulders 23 provide an enlarged cross-section to walls 20, 21 in the vicinity of the ~ntersèction with rib 22. The ~5 shoulders contribute significantly to the unusual structural strength of the panel and allow use of the structural system in applications requiring an extremely high strength-to-weight ratio.
In the preferred embodiment t as shown

3~ more clearly in Fig. l, there are three reinforcing ribs spaced equally along the width of panel 12.
preferred embodiment of panel 12~ pultruded from fiberglass reinforced plastic, is about 24 inches wide and about l l/2 inches thick, having ribs spaced at about 5-6 inches apart. The wall 773 ~ i1 _ thickness of the preferred embodiment is about 1/8 inch along the non-reinforced portions and about 5/32 inch at the reinforcing shoulders 23. A
fiberglass reinforced plastic panel manufactured .in accordance with the present invention has been found to exhibit in the longitudinal direction a tensile strength in excess of 30,000 pounds per square inch, a compressive strength in excess of 20,000 pounds per square inchJ a flexural strength in excess of 30, oob pounds per s~uare inch, and has demonstrated abilities to withstand bearing stresses in excess of 35,000 pounds per square inchy interlaminar shears in excess of 3,700 pounds per square inch, and punch shears in excess of 15,000 pounds per squar,e inch.
; In the transverse direction along the width, a 24 inch wide fiberglass reinforced plastic pultruded pa~el has exhibited a tensile strength in excess o 12,500 pounds per square inch, a compressive strength in excess of 15,009 pounds per square inch, and a flexural strength in excess of 17,S00 pounds per square inch. The panel of the preferred embodiment of the present invention has additionally demonstrated a longitudinal deflection of but 0.750 inch in the center of an 11 foot long span when loaded with 2~0 pounds in the center of the span. Consequently, it may be seen and appreciated that the present invention provides unique structural properties heretofore unattainable with similar materials and configurations.
Referring again to Fig. 2, panel 12 defines along its outer longitudinal edge 16 a panel connecting member 15 which provides the means for attaching the:longitudina1 edge of the panel to 7~3 _ other portions of a struc~ure in which the panel is assembled. In the preferred embodiment, panel connecting member 15 is a double keyway interlocking portion. Panel connecting member 15 includes a head portion 30 which extends ~utwardly from walls 20, 21 and forms an outer longitudinal edge 16 of the panel 12. A neck portion 31 of connecting member 15 joins'head portion 30 to walls 20, 21 and thereby defines a pair of keyways 32~ 33 which matin~ly interfit with interlocking lips on various panel joining members. Flange means 34, 35 - extend inwardly from each of walls 20, 21 toward the opposite wall and join with neck portion 31 of connecting member 15.
lS ~ead portion,30 of connecting member 15 - includes on its interior surface a tab 40 which extends inwardly toward walls 20, 21. Tab 40 has a thickness in the direction of panel thickness less than the interior thickness of the head portion 30 and thus divides the interior of the head portio~
30 a~d defines with the in~erior surface of head portion 30 a pair of opposed channels 41, 42 for receiving a reinforcing cable ~See Fi~s. 9, 13)~
Preferably, ta~ 40 should extend sufficiently into ~5 the interior of head portion 30 so that channels 4i, 42 have suff icient circum~erential surface area to frictionally grip a reinforcing cable which has been inserted iongitudinally through the channels.
In the preferred embodiment, channels 41, 42 are of a size suff icient to allow the insertion ~herethrough of a 1/4 inch steel cable.
Advantayeously, tab 40 provides a thickene'd portion of the outer edge of connecting member 15 w~ich permits attachment or affixation of other structural system components such as screws, 77~

_ bolts and the like~ In the preferred embodiment, tab 4n is of suficient thickness to allow drilling and tapping for a 1/4-20 threaded screw or bolt.
The panel of the preferred embodiment has demonstrated that a 1/4-20 bolt drilled and tapped into tab 40 can withstand a pulling torque of up to about 1,250 pounds.
Formed along the outer longitudinal edge 16 of connecting member 15 disposed away from walls 20, 21 is an indentation 43 or receiving a sealing member 44 when panel 12 is assembled in a structure. Sealing member 44 in the preferred embodiment is an elastic or rubber O-ring gasket which seats itself firmly in indentation 43 when compressed. It will be appreciated that a structural system which includes sealing members 44 at each iunction between panel 12 and an interlocking panel joining member such as member 14 will he substantially water- or fluid-tight.
On the interior surface of walls 20, 21, at the point of intersection between flanges 34, 35 with the interior surfaces of the walls, are formed additional rein~orcing shoulders 37, 38. Shoulders 37, 38 provide addi~ional resistance to -1 interlaminar shear and compressive forces and ,, further provide a solid base along walls 20, 21.
upon which flanges 34, 35 may be affixed. ' Also shown in ~ig. 2 is an H-snaped coplanar interlocking panel joining member 14 which is used to join two panels 12 and 12' in an end-to~end conf iguration in the same plane. The preferred embodiment of coplanar joining member 14 has a pair of parallel planar outer side members 50l 51 which are connected by a bar member 52 whieh joins~ side members 50, 51 orthogonally and ~9~3 _ intermediate the outer ends of the side members.
Each of side members 50, 51 includes on its outer opposite ends an inwardly extending interlocking lip 53 having a dimension A slightly smal?er than the length of neck portion 31 of panel 12~ It will be appreciated that the interlocking lips 53 of coplanar joining member 14 matingly interfit with keyways 32, 33 of a panel 12, and allow slidable engagement there between.
19 I~ may be observed in Fig. 2 that the thickness (dimension B~ of the longitudinal edge 16 of head portion 30 of pan~l 12 i5 less than the overall thickness (dimension C) of pa~el 12 between walls 20,21. Thus, when panels 12 and 12' are joined by coplanar joi~ing member 14, the outer sur~ace of panel 12 between longitudinal edges is flush with the outer surface of side members 50, 51 of coplanar joining member 14. It will be appreciated that the flush outer surfaces present an aesthetically pleasing structural assembly and contribute o the unique features of the structural system of the present inventionO
As stated above, the structural system of the present invention includes several structural components which may be used to assemble the structural panels 12 into a variety of configurations. AIso, certain applications of the system may cali for the use of decorative trim in order to improve the appearance of the functional portions of the system. FigO 3 shows C-shaped integrally formed interlocking panel end trim member 60 which ~atingly interfits with panel connecting member 15 of panel 12 and provides an attractive cov2rin~ for the panel connecting member. The panel end trim member 60 covers the :1199773 head portion 30 and neck portion 31 and includes a .
pair of parallel planar outer side members 61, 62 which extend orthogonally from the ends o.f wall member 63. The ends of side members 61, 62 each include an inwardly extending interlocking lip 64, .
65 which interfits within keyways 32, 33 of panel 12. .
An interlocking panel joining corner .
member 70 is shown in Fig. 4 and may be used for 10joining the outer edge of a panel 12 to the outer .
- edge of an orthogonally adjacent panel 1~' in a struct.ural system. Corner member 70 generally comprises a square tubular member 68 which has a pair of C-shaped members 60a, 60b extending at 15right angles from adjacent sides. In the preferred : embodiment, C-shaped members 60a, 6Qb include the .
elements of panel end tr;m member 60 (Fig. 3) and are integrally extruded or pultruded together with tubular member 68.
20More particularly described, corner member 70 includes a first wall member 71 which has an interlocking lip 72 which interfits with keyway .
3~ of panel 12~. A second wall member 73 is formed at the end of wall member 71 opposite lip 72 and 25extends at right angles to form together with first wall member 71 the outer surface of a structure which includes panels 12 and 12'. Second wall member 73 also includes an interlocking lip 74. A
third wall member 75 parallel to the first wall 30member 71 extends at right angles from and intermediate the ends of second wall member 73 and intersects with a fourth wall member 76 which extends at riyht angles from irst wall memb~r 71 intermediate the ends thereofO ~all members 75, 76 35meet at an orthogonal intersection 77. A ifth ~ ' ~9~'~73 -_ wall member 78 is formed parallel and opposite to the first wall member 71 and includes an interlocking lip 79 for matingly interfitting with panel 12. Finally, a sixth wall member 80 parallel to and opposite the second wall member 73 extends at right angles from wall members 7S and 78 and includes an interlocking lip 81 for interfitting with panel 12'.
Fig. 5 shows an interlocking angular panel joining member 90 which may be used to join a pair of panels 12, l~' at an angle other than 90 degrees. Angular panel joining member 90 generally comprises a pair of C-shaped members 6~c, 60d which are connected at one corner at an angular intersection 95. Si~e member 61c of C-shaped member 60c includes an extension 104 which extends at right angles to wall member 63c of C-shaped member 60c opposite intersection 960 Side member 61d of C-shaped member 60d likewise include~ an extension 93 which extends at ri~ht angles to wall member 63d o~ C-shaped member 60d, opposite intersection 96, and intersects with extension 104 at an obtuse intersection 106~
More particularly descr.ibed, angular ~5 panel joining member 90 includes a first wall member 91 which includes on one end an interlocking 1 ip 92 for interf itting with a panel 12. A second wall member 93 is formed at the end of the first wall member opposite lip 92 at an obtuse angle lQÇ
and together with first wall member 91 forms an outer surface for the panel structure. Second wall .member 93 also includes an inwardly extendin~
interlocking lip 94 for interfitting with a se ond panel 12' in the panel assembly~ A third wall member 9 5 extends inwardly at right angles fr~m 1~9~7~73 _ intermediate the ends of first wall member 91 and intersects at 96 in an acute angle with a fourth wall membe~ 97 which extends at riyht angles from intermediate the ends of the second wall member 93.
A fifth wall member 100 opposite and parallel to the first wall member 91 extends at right angles from the third wall member 95 and includes on the ¦
end opposite the intersection 96 an interlocking lip 101. Finally, angular panel joining member gO
includes a sixth wall member 102 opposite and parallel to the second wall member 93 which extends at right angles from the fourth wall member 97 and includes an inwardly extending lip 103. Although , ~ig. 5 shows an angular panel joining member which allows joining two panel6 at an angle of 45 degrees, it will be understood that the present invention contemplates that panels may be joined at any angle.
Fig. 6 discloses an interlocking 2U integrally formed T-intersection panel joining member 110 which may be used in a structural system for joining three panels 12, 12`, 12'' in an essentially T-shaped intersection. The T-intersection panel joining member 110 generally comprises an H-shaped member 14a which includes the eIements of panel joining member 14 (Fig. 2), with a C-shaped member 60e formed at a right angle on one side member of H-shaped member 14a~ .
~ore p a r t i c u 1 a r 1 y d e s c r i ~ ed , T-intersection member 110 comprises a ~irst wall member 11~ which includes on opposite ~nds inwardly extending in~erlocking lips 113, 114 or interfitting within the keyways of panels 12 an~
12'. A second wall member 115 joins the first wall member 112 at a right angle intermediate the ends 9~773 _ thereof to a third wall member 120 which is parallel to the first wall member. At each end of the third wall member 1~0 is formed ourth wall member 121 and a fifth wall member 122, respectively, of generally L-shape which are parallel to the second wall member 115. The fourth and fifth wall members ~21, 122 include inwardly extending interlocking lips 123, 124 opposite lips 113, 114 for interlocking with panels 12 and 12~
respectively, L-shaped fourth and fifth wall members 121, 122 further include inwardly extending interlocking lips 125, 126 opposite to each other which mat~ with the third structural panel 12' ' .
Fig. 7 shows an interlocking integrally formed panel cross joining member 130 which may be .~ used in a structural system to join four panel s in a cross intersection. The panel cross join.ing member 130 incl~des~a irst member 131 of generally ~-shape having a pair of parallel opposite side walls 132,133 joined by a cross wall 134 intermediate the ends of the side walls. At the ends of each of side walls 132~133 are formed L-shaped members 135, 136, 137, and 13B. Each of the L-shaped members includes a first leg 140, 141, 142, 143 parallel to the cross wall 134, and a second leg 144, 145, 146, 147 parallel to the side walls 132,133 of the first member 131. The second legs 144--147 extend inwardly parallel to side walls 132, 133 and form interloc~ing lips which interfit with panels 12' and 12'l~ Each leg of L-shaped members 135~-138 has a thickness which permits interfitting within the keyways of panel connecting member 15 of the panels to which the cross joining member is assembled. At the ends of L-shaped me~bers 135--138 opposite the second leg, i9 _ the first legs 140--143 extend inwardly beyond the point of attachment with the fi~st member 131 so to form an interlocking lips 150, 151, 152, 153 which interfit with the keyways of panels 12 and 12'''.
S It will be appreciated and understood that the structural systems shown in Fig. 1 through Fig. 7 contemplate a slidable engagement between the panels and the panel joining members along the outer longitudinal edges of the panels. In some.
applications, however, it may be impractical or infeasible to slidably engage the panels to the panel joining members in order to assemble a structure. Consequently, Fig. 8 shows a bolted interlocking coplanar joining member 160 which may be used to join a pair of panels 12, 12' in a ~: coplanar end~to-end configuration, similar to that accomplished by panel joining member 14 described above, without having a slidable engagement. The bolted jo;ning member 160 includes a first outer side member 161 which has a generally GreeX letter ~pin~shape. The first outer side member 161 has an outer wall 162, at the ends of which are formed interlocking lips 163, 164 for interfitting with the keyways of panels 12 and 12'. A pair of ~5 parallel bar members 165, 166 extend at right angles from the outer ~all 162 on the same side as~
lips 163, 164, intermediate the ends of the outer wall 162.
Bolked joining member 160 further includes a separate second outer side member 170 which is mounted parallel to the first outer side .member 161 and includes on each opposite end thereof interlockin~ lips 171; 172 for interfitking with t~e keyways of panels 12 and 12' opposite the keyways which receive lips 163l 1640 Coaxial _ apertures 173, 174 for receiving fastening means 175l such as a bolt, rivet, screw, or the like, are formed intermediate the ends of outer side members 161, 170. Thus, it will.be appreciated that bolted joining member 160 may be used in applications in which it is desirable to assemble a structural system without slidably engaging the panel with the panel joining member.
Fig. g shows a panel end trim member 180 substantially similar to the panel end trim member 60 ~shown in Fig. 3) except that bar member 63' . includes in extension 185 which extends beyond the end of wall member 61' and the~eby provides a surface to which accessor~es may be bolted, screwed, or otherwise ~ttached. Fig. 9 also shows a pair of rein~orcing ~able members 181, 182 which are received in channels 41, 42 of panel 12. Cables 181 r 182 may be steel or other suitable reinforcing cable, or alternatively may be electrical cables for carrying electrical current.
Fig. 10 shows how a plurality of panels 12a--12f may be joined together by reinforcing cables in a stacking fashion. Panels 12a--12c are joined longitudinal edye-to-edge by panel joining members 14a and 14b. Panels 12d~ f are similarly joined longitudinal edge-to-edge by panel joining members 14c and 14d. The panel ~ssemblies of 12a--12c and 12d--12f are then stacked by aligning the assemblies on the transverse edges of the panels along the width of the panels (not shown~.
Cables 181, 182 are then serpentined through the .opposed channeis 41, 42 ~not shown in Fig. 1~), and joined at a pair of 'curnbuckles 183~ 184 which may be used to tighten the cablesO
Fig. 11 shows an edge insert 190 which is ~9~i73 _ formed of an outer wall 191 and a pair o~ inner ledges 192, 193 which are inwardly offset from the outer surfaces so as to interfit with the transverse edge of a panel or with an edge of a S panel 1~ which has been longitudinally cut so as to remove a portion thereof. The edge insert 190 may be placed along the width of a panel, i~
appropriate notches are cut to receive the ribs of the panel. Also shown in Fig. 11 is a pair of flat heater strips 194, 195 which may be attached to the interior walls of a panel so as to provide temperature control of a structure made with the system. The heater strips may be attached to run . longitudinally along any wall of the panel. It will also be understood that,cooling coils (not shown) ~ may be placed within the hollow portions of the panel so as to provide cooling capability.
Fig. 12 shows an interlocking edge insert 200 having essentially the same outer shape as the panel connecting member 15' of a panel~ The interlocking edge insert 200 includes a head portion 3~' and a neck portion 31' (together forming a panel connecting member 15'), a pair of keyways 32', 33', an inw~rdly extending tab 40', and a pair.of opposed channels 41', 42', all of the same dimensions as in panel 12. A pair of recessed.
extending ledges 201, 202 extend outwardly away from the panel connecting member lS' and interf it with the edge 203 of a panel 12. Thus, it will be appreciated that the interlocking cut edge insert 200 may be used to attach a panel connecting member 15' to the longit~dinal edge of a panel 12 which has had a portion cu'c away so as to prov ide a transverse ~idth less than the width of a complete panel. It will also be appreciated that insert 200 ~99~'~3 _ may be used along the transverse width of a panel if appropriate notches are cut to receive the ribs of the panel.
Fig. 13 shows a C-shaped edge panel end insert member 210 which may be used to attach an interlocking C-shaped portion to the transverse edge of a panel or to the edge of a panel which has been longitudinally cut. The C-shaped insert member 210 generally comprises a C-shaped member 60f substantially similar to the shape shown in Fig. 3, which is integrally connected to an edge insert portion l9Oa similar to edge insert 190 shown in Fig~ 11. The C-shaped insert member 210 further comprises a pair of inner ledges 212, 213 lS which are inwardly offset from the outer surfaces ~of C-shaped portion 60f so as to interfi~ with an edge 214 of a panel 12.
Fig. 14 shows a rounded orner edge panel end-insert member 220 which may be used to join the edge of a panel 12 to the edge of an orthogonally adjacent panel 12'. Rounded corner insert member 220 comprises a quarter-section tubular member 221 which has a pair of edge insert members l90b, l90c extending at right angles from adjacent sides of t~bular member 221. Edge insert members l90b, l90c include the elements of edge insert member 190 shown in Fig. 11 and are integrally extruded or pultruded together with quarter-section tubular member 221. It will be appreciated that a lower edge insert member such as shown in ~ig. 14 may be used to form an upper surface or ceiling for a construction by placing the insert member/ notched to receive the panel ribs~ along the transverse width of the panels in the construction~
More particularly describPd~ rounded edge , ~9~773 ~.~

_ panel insert member 220 includes a first wall member 222 which has ledges 223, 224 which are inwardly offset so as to interfit with edges 225, 226 of panel 12. A second wall member 227 is formed at a right angle to first wall member 222 at an intersection 233 and also includes a pair of ledges 228t 229 which are inwardly offset so as to interfit with edges 230, 231 of panel 12'. A
rounded wall member 232 joins first wall member 2~2 and second waIl member 227 opposite intersection ~33 where first wall member 222 and second wall member 227 meetO
Fig. lS shows an angled corner edge panel end insert member 240 which may be used to join at an angle other than 90' a pair of pa~els 12, 12l.
; Angled corner insert member 240 generally comprises a pair of edge inserts l90d, l90e which include all the elements of edye insert 190 shown in Fig. 11.
Edge inserts l90d, ~9Oe are joined at an angled intersection~ 241. Edge insert member l90d includes an extension 242 which extends ~t right angles to edge insert member l90d opposite intersectior. 241a Edge insert member l9Oe likewise includes an extension 243 which extends at right angles opposite intersection 241 and intersects with extension 242 at an obtuse angled intersection 244.
~dge insert member l9Od includes a pair of inner ledges 245, 246 which are .inwardly offset so as to interfit with the edge of a panel 12~ Similarly, edge insert member l9ne includes a pair of ledges 247, 248 which are inwardly offset so a5 to interfit with the edges of a panel 12'.
Fig. 16 shows a rounded angled corner edge pan~l end insert member 250 substantially similar to the angled corner edge panel end insert ~.~L95~t7~3 member shown in Fig. 15, except that the edge insert portions are joined by a rounded edge as opposed to an angled edge-. The rounded angled panel end insert member 250 cornprises a pair of edge insert members l90f, 1909 which inciude all the elements of edge insert 190 shown in Fig~ 11 and which are joined at an angled intersectiorl 251.
A rounded wall member 252 joins edge insert members l90f, l90g opposite intersection 251 and forms a rounded outer w 11 surface. Cut edge insert member l90f includes a pair of inner ledges 253, 254 which interfit with an edge of a panel 12~ and edge insert member 190g likewise includes a pair of ledges 255~ 256 which interfit with the edge of a panel 12~. Although Figs. 15 and 16 show angled corner edge panel insert members which allow joining two panels at an angle of 45 degrees, it will be understood-that the present invention contemplates that panels may be joined at any angleO
Fig~ 17 shows an edge panel insert cross ~oining member 260 which may be used to join the edges of four panels 12, 12', 12' ', 12' ' ' in a cross intersection. The edge cross joining member 260 includes an H-mémber 261 having a pair of parallel opposite side walls 262, 263 joined by a cross wall 264 intermediate the ends of the side walls. An edge insert member l90h having a pair of ledges 265, 266 for interfitting with an edge of a panel 12 is formed on the outer surface of side wall 262. Similarly, a edge insert member 19 0 i having a pair of ledges 267, 268 is formed on the outer surface vf side wall 263 for interfitting with the edge of a panel 12'~l~ Edge insert members l90h, l90i include all the elements of edge insert 190 shown in Fig. 11. The edges of panels 12' and 12'' overlap-and interfit with opposite ends, respectively, of side walls 262, 263.
~ig~ 18 shows a T-intersection edge panel insert member 270 which may be used for joining the edges of three panels 12, 12', 12'l in an essentially T-shaped intersection. The T-intersection edge insert member 270 generally comprises an H-shaped member 271 having a pair of parallel opposite side walls 272, 273 joined by a cross wall ~74 intermediate the ends of the side walls. An edge pane~ end insert member l90j having the elements of edge insert 190 shown in Fig. 11 is formed along the outer surface of side wall 273 and includes a pair of ledges 275, 276 which are inwardly offset so as to interfit with the edge of a panel 12'. Ledges ~77, 278 are formed on opposite ends of side wall member 272 so as to interfit with the edge of panels 12 and 12' respectively.
~ig. 19 shows a double edge panel end insert member which may be used to join the edges of two panels 12, 12~ în a coplanar end-to-end ~onfiguration. The double edge insert member 280 has a pair of parallel planar outer side members 281, 282 which are connected by a bar member-283 which joins side members 2~1, 282 orthogonally and intermediate the outer ends of the side members.
Side members 281, ~82 include offset ledges 284, 285 which interfit with the edge of panel 12, and ledges 2B6, 287 which interfit with the edge of a panel 12~o FigO 2~ ~hows a square corner edge panel end insert member 290 which may be used for joining - the edge of a panel 12 to the edge of an orthogonally adjacent panel 12'. Square corner edge panel end insert member 290 generally :~
comprises a square tubular member 291 which has a ~
pair of edge panel end insert members l9Ok, 1901 ~,.
extending at right angles from adjacent sides. ~
Edge panel end insert members l90k, 1901 include .Y~,.
the elements of edge panel end insert 190 shown in Fig. 11. Panel end insert member ~9Ok interfits with the edge of a panel 12' while panel end insert member 1901 interfits with an edge of a panel 12. 3 . . Fig 0 21 shows a double lip edge panel end insert member 300 ~hich may be used to interfit with the cut edge of a panel 12 so as to provide a surface to which ac.cessories may be bolted, : screwed, or otherwise attached. Double lip insert member 300 comprises a planar wall member 301 and a pair of orthogonally extending ledges 302, 303 which interfit with the edge of panel 12.
. Fig. 22 shows a bolted edge panel ~oining member 310 which may be used to join in a coplanar end-to-end configuration a pair of panels 12, 12'.
The function accomplished by bolted cut edge joining member 310 is similar to that accomplished by interlocking coplanar member 160 shown in Fig.
80 The bolted edge joining member 31Q includes a irst outer side member 312 which has a generally Greek letter "pin-shape. The first outer side.
member 312 has an outer wall 313 and a pair of parallel bar members 314~ 315 which e~tend at right angles from one side of outer wall 313 intermediate the ends of the outer wall. Bolted edge joining member 310 further includes a separate second outer side member 316 which has a insert portion 317 which înterfits between parallel bar members 314, 315. Coaxial apertures 318, 319 for receiving fastening means 320 such as a bolt, rivet, screw, or the like, are formed intermediate the ends of outer side members 312, 316. Thus, it will be appreciated that bolted edge joining member 310 may be used in applications in which it is desirable to assemble a structural system without slidably engaging the panel with any panel joining members.
Fig. 23 shows a double panel window mullion member 330 which may be used to mount a pair of planes of glass 331, 332 in a structural system by mounting atop a panel or along a longitudinal edge of a panel. Window mullion member 330 includes a pair of opposite side walls 333, 334 which are separated by a distance greater than the thickness of a panel 12 so that the window mullion member 330 may straddle the overall thickness of a panel such as shown by dimension C
in Fig. 2. It will be appreciated that window mullion member 330 may be used as either a mullion, a header, or a sill for supporting panes of glass or other panels in a construction by simply placing the window mullion member across the overall thickness of a panel or across a cut edge of a panel.
Fig. 24 shows a hinge edge panel end insert member 340 which may be used to attach a hinge to the cut edge of a panel 12. Hinge edge panel end insert member 340 generally comprises an edge panel end insert member 190m having the elements of edge panel end insert 190 shown in Fig.
11, which interfits with the edge of a panel 12.
The hinge edge member 340 further includes hinge means 341 formed integrally with edge panel end insert member 190m.

_ It will be understood and appreciated that the panel accessory members shown in Figs.
11--24 may be used along the transverse width of panels, if notches are cut for th~ ribs of the S panels, or along the longitudinal edges of panels which have had a portion cut away so as to provide a transverse width less than the width of a complete panel. It will be further understood and appreciated that the panel accessory members may be 1~ combined as desired to create structural assemblies of many different shapes, configurations, and sizes. For example, entire enclosed structures having walls, floors, ceilings, a roof, doors, and' windows may be assembled by combin;ng the various ¦'.
disclosed accessories with the disclosed structural panel.
Fig. 2~ shows a hinge interlocking panel end member 350 which includes'an interlocking panel end member 60g having' all'the elements of panel end trim member-60 shown in Fig. 3 and further includes hinge means 351 which may be used to attach a panel connecting member 15' of a panel 12 to a pivoting hinge mechanism so that a door may be formed in a structure.
~5 The preferred embodiment of the present invent;on has been disclosed by way of example and it will be understood that other modifications may occur to those skilled in the art without departing from the scope and the spirit of the appended claims.

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A structural panel having a thickness of a first dimension, comprising:
a pair of parallel planar outer wall members whose outer surfaces are separated by said first dimension;
at least one reinforcing rib of generally I-shape joining said pair of wall members;
reinforcing shoulder means formed at each intersection of a surface of said rib with a surface of one of said pair of wall members for imparting rigidity to said panel;
flange means formed along the longitudinal edges of said wall members and extending inwardly from each of said wall members toward the opposite wall member; and at least one panel connecting member for joining said panel to an adjacent panel, said connecting member extending outwardly from said flange means and forming an outer longitudinal edge of said panel and including a neck portion extending outwardly from said flange means and between said wall members, and a head portion attached to said neck portion and having a thickness of a second dimension less than said first dimension, said head portion including on the interior surface of said head portion opposite said wall members an inwardly extending tab, said tab and the inner surface of said head portion defining a pair of opposed channels for receiving therein elongate reinforcing cable means.

2. The structural panel of Claim 1 further comprising second reinforcing shoulder means formed at each intersection of a surface of said flange means with a surface of one of said pair of said wall members.

3. A structural system including a structural panel as recited in Claim 1, and further comprising an integrally formed panel joining interlock member cooperative with said panel connecting member for joining an outer longitudinal edge of one of said panels to an outer longitudinal edge of a coplanar adjacent one of said panels, comprising:
a pair of parallel planar outer side members, each of said side members including on each opposite end thereof an interlocking lip for mating with said neck portion of said panel connecting member of said panel, and a bar member transversely adjoining said pair of said side members intermediate the ends of said side members.

4. A structural system including a structural panel as recited in Claim 1, and further comprising an integrally formed panel end interlocking trim member of substantially C-shape for covering said head portion and said neck portion of said panel connecting member of said panel, comprising:
a pair of planar outer side members, each of said side members including on one end an interlocking lip for mating with said neck portion of said panel connecting member of said panel, and a bar member joining said pair of said side members at the ends of said side members opposite said interlocking lip.

5. A structural system including a structural panel as recited in Claim 1, and further comprising an integrally formed interlocking panel joining corner member for joining an outer longitudinal edge of one of said panels to an outer longitudinal edge of an adjacent orthogonal one of said panels, comprising:
a first wall member including on one end thereof a first interlocking lip for mating with said neck portion of said panel, a second wail member formed at the end of said first wall member opposite said first lip and extending at a right angle therefrom, said second wall member including on the end opposite said first wall member a second interlocking lip for mating with said neck portion of said orthogonal one of said panels, a third wall member parallel to and opposite said first wall member and extending at a right angle from said second wall member intermediate the ends thereof, a fourth wall member parallel to and opposite said second wall member and extending at a right angle from said second wall member intermediate the ends thereof toward said third wall member, said third wall member and said fourth wall member meeting at an intersection, a fifth wall member parallel to and opposite said first wall member and extending at a right angle from said fourth wall member and including on the end thereof opposite said fourth wall member a third interlocking lip for mating with said neck portion of said panel, and (claim 5 cont'd.) a sixth wall member parallel to and opposite said second wall member and extending at a right angle from said third wall member and including on the end thereof opposite said third wall member a fourth interlocking lip for mating with said neck portion of said orthogonal one of said panels.

6. A structural system including a structural panel as recited in Claim 1, and further comprising an integrally formed interlocking angular panel joining member for joining an outer longitudinal edge of one of said panels to an outer longitudinal edge of an angularly adjacent one of said panels, comprising:
a first wall member including on one end thereof a first interlocking lip for mating with said neck portion of said panel, a second wall member formed at the end of said first wall member opposite said first lip and extending angularly outwardly therefrom, said second wall member including on the end opposite said first wall member a second inwardly extending interlocking lip for mating with said neck portion of said angularly adjacent one of said panels, a third wall member extending at a right angle from said first wall member intermediate the ends thereof, a fourth wall member extending transversely inwardly from said second wall member intermediate the ends thereof toward said third wall member, (Claim 6 cont'd.) said third wall member and said second wall member meeting at an angular intersection, a fifth wall member parallel to and opposite said first wall member and extending at a right angle from said third wall member and including on the end thereof opposite said third wall member a third inwardly extending interlocking lip for mating with said neck portion of said panel, and a sixth wall member parallel to and opposite said second wall member and extending at a right angle from said fourth wall member and including on the end thereof opposite said fourth wall member a fourth interlocking lip for mating with said neck portion of said angularly adjacent one of said panels.

7. A structural system including a structural panel as recited in Claim 1, and further comprising an integrally formed interlocking panel cross joining member for joining an outer longitudinal edge of one of said panels to an outer longitudinal edge of three adjacent ones of said panels in a cross intersection, comprising:
a first member of generally "H"-shape having a pair of parallel opposite side walls and a cross wall joining said side walls intermediate the ends thereof, a second member of generally L-shape attached at each end of each one of said side walls, (Claim 7 cont'd.) said second member including a first leg parallel to said cross wall of said first member and a second leg parallel to said side walls of said first member, each of said second legs extending inwardly parallel to said side walls of said first member and forming an interlocking lip for mating with the neck portion of a panel, said second member forming at the end opposite said second leg an interlocking lip parallel to said cross wall of said first member for mating with the neck portion of a panel.

8. A structural system including a structural panel as recited in Claim 1, and further comprising an integrally formed panel joining T-intersection member for joining the outer longitudinal edge of one of said panels to the outer longitudinal edges of two adjacent ones of said panels in an essentially T-shaped intersection comprising:
a first wall member including on each end thereof an interlocking lip for mating with the neck portion of a panel, a second wall member parallel to said first wall member, a third wall member joining said first wall member and said second wall member intermediate the ends of said first wall member and said second wall member at a right angle, and a pair of fourth wall members of generally L-shape formed at the ends of said second wall member and including (Claim 8 cont'd.) a long leg attached at a right angle to said end of said second wall member and forming an interlocking lip for mating with the neck portion of a panel, and a short leg attached at a right angle to said long leg on the same side that said long leg is attached to said second wall member and forming an interlocking lip for mating with the neck portion of a panel.

9. A structural system including a structural panel as recited in Claim 1, and further comprising a fastenable interlocking panel joining member for joining the outer edge of one of said panels to the outer edge of an adjacent one of said panels, comprising:
a first outer side member of generally "pi"-shape including on each opposite end thereof an interlocking lip for mating with the neck portion of a panel and having a pair of parallel bar members joining said first outer side member intermediate the ends thereof at a right angle, a separate second outer side member opposite said first outer side member adjacent said bar members and including on each opposite end thereof an interlocking lip for mating with the neck portion of a panel, and fastening means for detachably attaching said first outer side member to said second outer side member.

10. The structural panel of Claim 1, wherein said outer longitudinal edge of said panel includes an elongate depression for receiving a sealing member, and further comprising a sealing member for interfitting in said depression and sealing said outer longitudinal edge to an adjacent structural member.

11. The structural panel of Claim 1, wherein said structural panel is an integrally formed unitary structural panel.