EP3045599A2 - Frameless construction using single and double plenum panels - Google Patents
Frameless construction using single and double plenum panels Download PDFInfo
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- EP3045599A2 EP3045599A2 EP16150440.2A EP16150440A EP3045599A2 EP 3045599 A2 EP3045599 A2 EP 3045599A2 EP 16150440 A EP16150440 A EP 16150440A EP 3045599 A2 EP3045599 A2 EP 3045599A2
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/38—Connections for building structures in general
- E04B1/388—Separate connecting elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
- E04B1/10—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of wood
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/7608—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising a prefabricated insulating layer, disposed between two other layers or panels
- E04B1/7612—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising a prefabricated insulating layer, disposed between two other layers or panels in combination with an air space
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/72—Non-load-bearing walls of elements of relatively thin form with respect to the thickness of the wall
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
- E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
- E04B5/023—Separate connecting devices for prefabricated floor-slabs
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B7/00—Roofs; Roof construction with regard to insulation
- E04B7/20—Roofs consisting of self-supporting slabs, e.g. able to be loaded
- E04B7/205—Roofs consisting of self-supporting slabs, e.g. able to be loaded the slabs having non-structural supports for roofing materials
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
- E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/38—Connections for building structures in general
- E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Civil Engineering (AREA)
- Electromagnetism (AREA)
- Structural Engineering (AREA)
- Wood Science & Technology (AREA)
- Life Sciences & Earth Sciences (AREA)
- Acoustics & Sound (AREA)
- Load-Bearing And Curtain Walls (AREA)
- Building Environments (AREA)
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Abstract
Description
- This application claims priority to
United States Provisional Patent Application Nos. 62/210,616 filed August 28, 2015 62/100,660 filed January 7, 2015 - This invention relates to methods and devices for frameless building construction utilizing single and multi-plenum panels with various spacing structural elements.
- Conventional wood homes and structures are built in stages, with wood framing erected first, and sheathing attached at a later date. Usually, homes and other wooden structures are built using "2 by" framing, normally from the ground up. For example, 2x10's are normally used for joists for floors, typically 16 inches on center, and are covered with sheathing for a floor deck, typically in 4' x 8' sheets of OSB or plywood.
- Walls are then constructed using 2x4 or 2x6 lumber with a continuous sill plate, a double top plate, and vertical studs every 16 inches. Openings for windows and doors require double studs and jack studs to hold headers and sills.
- Once the wall frames are erected, they are then usually sheathed with an OSB or plywood product typically in 4' x 8' sheets. Sometimes this sheathing is also utilized in the resistance of shear force. Holes must be cut for windows and doors. For two story homes, this floor and wall framing / sheathing process is repeated.
- A roof structure is then constructed using 2x lumber for rafters - typically 2x8's or 2x10's or 2x12's depending on snow load. The rafters are typically 16 inches on center. The roof is then covered with sheathing of 3/8" thickness to 5/8" thickness, typically in 4' x 8' sheets of OSB or plywood. Waterproof roofing material can then be applied to the roof deck.
- Ceiling joists must also be installed to support interior finishes. Ceiling joists are typical 2x6 or 2x8 and installed at 16 inches on center.
- The framing of a building involves cutting, nailing, erecting and attaching studs, headers, jack studs, joists, rim joists, trusses, and rafters. All of this framing incurs costs of time, labor, materials, and extended exposure of the interior building materials to the elements while the building remains uncovered.
- And although traditional modular construction results in an expedited house once the modular pieces are at the construction site, modular homes still use stick framing at the factory and still has the associated time, labor, materials and cost as stick built or conventionally framed buildings. Additionally, modular homes incur extra costs and special requirements for transporting the modular pieces to the construction site.
- Similarly, manufactured housing, whether single wide, double wide or triple wide, is also constructed using traditional use stick framing at the factory and still has the associated time, labor, materials and cost as stick built or conventionally framed buildings. Additionally, manufactured homes incur extra costs and special requirements for transporting the modular pieces to the construction site.
- In all cases, insulation is typically applied around the existing framing members. The framing members cause a thermal short in the thermal envelope and also allows for incomplete insulation installation because of framing members and the many of corners, blocking, headers, as well as the many hap-hazard holes drilled for the installation of plumbing, mechanical and electrical systems. The result with conventional framing is an insulating layer that is incomplete with leaks and thermal breaks at the studs; all reducing thermal performance.
- Wherefore, it is an object of the present invention to overcome the above mentioned shortcomings and drawbacks associated with the prior art.
- The disclosed inventive methods and devices allow construction of primarily and / or substantially wooden structures of sufficient strength such that conventional framing with lumber is not necessary. This will save time, cost, and resources in constructing structures while providing for better insulation. The disclosed methods and devices utilize single and multi-plenum structural panels as described in
United States Patents 8,490,355 ,8,534,018 ,8,635,822 ,8,615,945 ,9,091,049 9,050,766 - The single plenum panels comprise two parallel and substantially overlapping sheets connected to one another by spacing structural elements. The spacing between the two sheets forms a plenum that air may pass through. The combined strength of the single plenum panel is typically greater than the sum of the strength of the two individual sheets. The spacing structural elements are typically blocks or matrix members and are arranged to provide a plurality of unobstructed passageways through the plenum from one edge of the panel to another. The single plenum panels have a height and width typically around 4 feet by 8 feet in measurement, but can be larger depending on manufacturing ability and structural need. The depth of the single plenum panels is typically between one and six inches.
- The multi-plenum panels comprise three parallel and substantially overlapping sheets. A first sheet is connected to a first surface of the second sheet by spacing structural elements creating a first plenum, similar to a single plenum panel. The third sheet is connected to a second opposite surface of the second sheet by spacing structural elements creating a second plenum. As the second sheet is connected to both the first and the third sheet, a combined multi-plenum panel is created. The height and width of the multi-plenum panel is comparable to that of the single plenum panel. The depth of the multi-plenum panel is typically between two and eight inches.
- The inventive methods and devices described herein provide a method of constructing homes and similar wood framed structures without conventional framing. Because the disclosed single and multi-plenum panels have very high inherent strength, they are able to span considerable distances and carry significant loads. As such, conventional framing is not necessary in most situations.
- The walls of a building constructed of single plenum panels, without framing, have more bearing area than conventionally framed walls. For example, a ½" inside bearing sheet of a single plenum panel wall has more bearing area than conventional 2x4 studs at 16" on center, and has approximately the same area as 2x6 framing at 16" on center. Single plenum panels can also be used for a roof without framing and providing similar strength. Similarly, multi-plenum panel flooring has considerable and typically even greater span and load carrying capacity than single plenum panels.
- In addition to the inherent ventilation attributes of single plenum panels and air distribution capabilities of multi plenum panels, these panels can be constructed in large continuous panels allowing a home to be assembled in about a day. The panels may be preassembled in a factory, transported to the build site, and assembled with a crane. A crane at construction sites is becoming a more common piece of equipment that is used for a variety of purposes and sometimes a crane is at the site throughout the construction period.
- These panels are strong and offer more potential than just a normal sheathing panel. With continuous manufacturing mills, it is possible to use full undivided continuous sheets to construct single plenum panels and multi plenum panels that span an entire face of a building, or span of a wall, floor, ceiling, or roof. The Single plenum panel load-bearing walls could be a single, long panel with perforations for windows and doors. Additionally, the windows and doors themselves could be constructed in the factory and added in the factory or at the building site.
- The single plenum panels are very strong. Long span panels can be used for roofing together with the roof connecting device and/or in conjunction with conventional framing.
- Continuous panel ceilings are also possible with either single plenum panels or multi-plenum panels.
- The benefits of frameless single and multi-plenum panel construction include easy transportation of materials to the field, especially compared to modular homes, and providing a home that can be assembled in the field in one day. The savings associated with just these two benefits are significant in materials, time and labor.
- Additionally, using exterior weatherproof sheathing on the exterior sheet of the panels, such as the Zip System (a product and trademark of Huber), or applying weather-tight materials to one or more sheets of the panel in the factory and having the windows and doors pre-installed means the structure can be erected and closed to the weather in one day.
- Having the home closed in one day means the trades can start the next day. This is again a significant savings in time and money.
- This technology is ideally suited for the modular and manufactured home industries with immediate benefits. Of course, it is also suitable and valuable for everyday home construction, as well as other currently conventionally framed structures such as apartments, schools, motels, hotels, restaurants, churches, etc.
- Single plenum panels can have an EI value per foot exceeding 15,000,000 lb-in2, and can be easily double that value depending on spacing structural members, sheet thickness and makeup, and methods of attachment. Multi-plenum panels are significantly greater. This allows significant loads and spans, which means most walls, roofs, ceilings and floors can be spanned with one continuous panel. The limiting factor is the manufacturing width.
- The inherent configuration of single plenum panels with two sheets and an interior matrix for use as a load bearing wall has the additional feature of stabilizing the load-bearing sheet from buckling so that it can bear its capacity in compression and with little concern for instability.
- The disclosed frameless construction method also substantially eliminates thermal breaks which always exist with conventional framed construction. There are no studs making a thermal short-cut to the outside. Nor are there rafter's shortcutting an occupied upper space. The disclosed method provides a full thermal envelope with full exterior ventilation. A significant benefit in building safety, comfort, and stability.
- Ventilation is assured for code compliance where applicable and health and energy efficiency in the walls and roofs. Air distribution with multi-plenum panels eliminates the need for ductwork.
- There are various devices described herein such as roof connectors and insulation gauges. It is intended, though not required, that these devices be constructed from extruded, formed or folded or otherwise constructed from a material including, but not limited to aluminum, other metals, plastics, wood fiber, carbon fiber, fiberglass, magnesium oxide, sheet metal or composites of a combination of any of the above.
- The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate various embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of the invention. It is to be appreciated that the accompanying drawings are not necessarily to scale since the emphasis is instead placed on illustrating the principles of the invention. The invention will now be described, by way of example, with reference to the accompanying drawings in which:
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Fig. 1 is a partial see through perspective view of a building constructed according to the invention with each of the walls, roof spans, floor, and ceiling panels constructed of continuous single or multi-plenum panels; -
Fig. 2 is a partial see through perspective view of a building constructed according to the invention with each of the walls, roof, floor, and ceiling panels constructed of multiple single or multi-plenum panels; -
Fig. 3 is a sectional view of a building according toFig. 1 also showing two roof connectors; -
Fig. 4 is a sectional view of a roof connector according to the present invention; -
Fig. 5 is a partial perspective view of a roof connector according to the present invention; -
Figs. 6A and 6B are partial perspective views of two additional embodiments of roof connectors according to the present invention; -
Figs. 7A and 7B are side sectional views of two further additional embodiments of roof connectors according to the present invention; -
Fig. 8 is a partial sectional view of a floor, wall, and foundation of a building according to the present invention, were the wall is a single plenum panel and the floor is a multi-plenum panel; -
Fig. 9 is a partial perspective sectional view of a floor, wall, and foundation of a building according to the present invention, were the wall is a single plenum panel and the floor is a multi-plenum panel and holes are present in the exterior sheet of the single plenum panel; -
Fig. 10 is partial sectional view of a of a floor, wall, and foundation of a building according to the present invention, were the wall is a single plenum panel and the floor is a multi-plenum panel and holes in the exterior sheet of the single plenum panel allow for fasteners to be attached directly from the interior sheet of the single plenum panel; -
Fig. 11 is a partial sectional view of an alternate embodiment ofFig. 8 , where both the wall and the floor are single plenum panels; -
Fig. 12 is a partial sectional view of an another alternate embodiment ofFig. 8 , where the wall is a single plenum panel and the floor is conventional flooring with floor joists; -
Fig. 13 is a partial sectional view of a of a wall, ceiling, and roof of a building according to the present invention, where the wall, ceiling, and roof are all single plenum panels; -
Fig. 14A is a partial sectional view of an alternate embodiment ofFig. 11 , where both the wall and roof are single plenum panels and the ceiling is a multi-plenum panel and inFigs. 14A to 14D , details of four embodiments of louvers are shown; -
Fig. 15 is a partial sectional view of a wall and floor/ceiling of a multi-floor building according to the present invention, where the first and second level walls are both single plenum panels and the first level floor/second level ceiling is a multi-plenum panel; -
Fig. 16 is a partial sectional view of an alternate embodiment ofFig. 15 , where the first and second level walls and the first level floor/second level ceiling are all single plenum panels, and the first and second level walls provide a continuous vertical ventilation path; -
Fig. 17 is a partial sectional view of another alternate embodiment ofFig. 15 , where the first and second level walls are both single plenum panels and the first level floor/second level ceiling is a multi-plenum panel, and the first and second level walls provide a continuous vertical ventilation path; -
Figs. 18A and 18B is a partial sectional view and a close-up perspective view of a device to facilitate installing insulation and drywall on an inclined single or multi plenum wall of a building according to the present invention; -
Fig. 19 is a partial sectional view of a of a wall and a roof according to the present invention, where the wall is a single plenum panel and the roof uses conventional trusses -
Fig. 20 is a perspective view of an insulation guide according to the present invention; -
Fig. 21 is a perspective view of three installed insulation guides, including an electric box on the middle depicted insulation guide, according to the present invention; -
Fig. 22 is a perspective view of an installed insulation guide with a "T" wall flange and an electric box according to the present invention; -
Fig. 23 is a simplified perspective view of a door or window frame box according to the present invention; -
Fig. 24 is a perspective view of another embodiment of the door or window frame box according to the present invention; -
Fig. 25 is a partial sectional view of the door or window frame box according toFig. 24 installed in a single plenum panel wall; -
Figs. 26A to 26D are a top, a first partial side omitting the screw shaft, a second partial side omitting front and back cutting teeth, and a bottom view of a two layer self-seating toothed screw according to the present invention; -
Fig. 27 is a first partial sectional view of the self-seating toothed screw according toFigs. 26A to 26D being seated in a single plenum panel; -
Fig. 28 is a second partial sectional view, temporally after the view ofFig. 27 , of the self-seating toothed screw according toFigs. 26A to 26D being seated in a single plenum panel; -
Fig. 29 is a partial sectional view of double-head screw seated in a single plenum panel according to the present invention; -
Figs. 30A to 30C are partial see through and exploded partial perspective views of insertion connecting blocks connecting two adjacent single plenum panels and a perspective view of the insertion connecting block; -
Figs. 31A to 31C are partial see through and exploded partial perspective views of insertion connecting blocks connecting two adjacent single plenum panels and a perspective view of the insertion connecting block; -
Figs. 32A to 32C are partial see through and exploded partial perspective views of H connectors connecting two adjacent single plenum panels and a partial perspective view of the H connector; -
Figs. 33A to 33C are partial see through and exploded partial perspective views of perforated H connectors connecting two adjacent single plenum panels and a partial cut-out perspective view of the perorated H connector; -
Figs. 34A and 34B are partial see through and exploded partial perspective views of a further embodiment for connecting adjacent single plenum panels to one another with blocking and a ridged/tensile strip; -
Fig. 35A and 35B is a partial perspective view of a method of joining two adjacent single plenum panels via spikes and an up close partially see through perspective view of a spike; -
Figs. 36 and37 two temporally spaced partial sectional views of a three layer self-seating long toothed screw for multi plenum panels according to the present invention; -
Fig. 38A is a sectional view of a roof arrangement constructed with single plenum panels with a continuous ridge vent; -
Figs. 38B and 38C are exemplary router bit designs which could form / cut a ventilation strip according to one embodiment of the present invention; -
Figs. 39A is an isomeric view of a single plenum panel with a ventilation strip being cut or formed into the interior sheet of the panel according to one embodiment; -
Fig. 39B and is an isomeric view of an interior of an attic constructed with single plenum panels and including a ventilation strip; -
Fig. 40A is a diagrammatic cross section of two adjacent sheets of two adjacent single or multi-plenum panels with a block edge to edge joint; -
Fig. 40B is a diagrammatic cross section of two adjacent sheets of two adjacent single or multi-plenum panels with a block edge to edge joint with a compressed foam gasket; -
Fig. 41A is a diagrammatic cross section of two adjacent sheets of two adjacent single or multi-plenum panels with an overlap/shiplap joint; -
Fig. 41B is a diagrammatic cross section of two adjacent sheets of two adjacent single or multi-plenum panels with a tongue and groove joint; -
Fig. 42A is a diagrammatic cross section of two adjacent sheets of two adjacent single or multi-plenum panels with a V and V groove joint; -
Fig. 42B is a diagrammatic cross section of two adjacent sheets of two adjacent single or multi-plenum panels with block edge to edge clip joint; -
Fig. 43A is a diagrammatic cross section of two adjacent sheets of two adjacent single or multi-plenum panels with a miter joint; -
Fig. 43B is a diagrammatic cross section of two adjacent sheets of two adjacent single or multi-plenum panels with a miter joint with a snap lock feature having a convex element on one miter edge and a mating concave element on the other miter edge; -
Fig. 44 is a diagrammatic cross section of two adjacent sheets of two adjacent single or multi-plenum panels with a V and V groove joint with a snap lock feature; -
Fig. 45 is a diagrammatic cross section of two adjacent sheets of two adjacent single or multi-plenum panels with a V and V groove joint with a plurality of convex elements or teeth on the V groove and a mating plurality of concave element notches on the V; -
Fig. 46 is a diagrammatic cross section of two adjacent sheets of two adjacent single or multi-plenum panels with a tongue and groove joint with plurality of concave element recesses on the top and bottom of the tongue and a mating plurality of convex element ribs in the groove, and a sealant and/or adhesive and/or gasket on the inner vertical wall of the groove; -
Fig. 47A is a diagrammatic exploded cross section of two adjacent sheets of two adjacent single or multi-plenum panels having a V and V groove joint with a compressible teeth insert attached to the to the male V, with the teeth extending from the surface of the male V; and -
Fig. 47B is a diagrammatic cross section view of a V and V groove joint ofFig. 47A . - The present invention will be understood by reference to the following detailed description, which should be read in conjunction with the appended drawings. It is to be appreciated that the following detailed description of various embodiments is by way of example only and is not meant to limit, in any way, the scope of the present invention. In the various Figures,
single plenum panels 2 andmulti-plenum panels 4 are depicted.Such panels - Turning now to
Fig. 1 , a brief description concerning the various components of the present invention will now be briefly discussed. As shown in this embodiment, a whole house orbuilding 2 is constructed using continuoussingle plenum panels 8 and continuous multi plenum panels 10 for construction. Thistypical home 6 has a front and first/left side wall 12 shown, each constructed of continuoussingle plenum panels 8, back and second/right side wall 12 (partially visible in background) are also each constructed of continuoussingle plenum panels 8. The left sloping portion and right sloping portion of theroof 14 are also each constructed of continuous single plenum panels. The front and back vertical triangular portions of theroof 14 are each also constructed of single plenum panels, with could be the same continuous single plenum panel as the vertical front andback wall 12 beneath eachvertical roof 14 section or could be separate continuous single plenum panels. Theceiling 16 and thefloor 18 are each constructed of multi plenum panels. - This is the preferred embodiment, but other arrangements are possible within the scope of this invention. For example, all of the
walls 12,roof 14,ceiling 16, andfloor 18 can be constructed of a continuoussingle plenum panel 8, or all could be constructed of a continuous multi-plenum panel 10, or some other combination thereof in addition to that described in the preferred embodiment, as desired to fulfill particular space and cost constraints of thebuilding 6. - As shown in
Fig. 1 , holes are cut where desired for openings forwindows 20, doors 22, and other necessary penetrations as for utilities, vents, etc. Further embodiments addressing the installation of doors 22 andwindows 20 is discussed below. - Advantageously, because of the multiple connection points between and distributed across the areas of the two opposing
sheets 24 of the single andmulti-plenum panels window 20 or door 22 hole does not substantially decrease the strength of awall 12. The load is distributed to the multiple connection points surrounding the hole. - Typically, a
single plenum panel exterior sheet 58 of ¼" to ½" and an interior or innerload bearing sheet 54 of 3/8" to 1", but more commonly ½" to ¾". The spacing structural elements 26 for thesingle plenum panel matrix members 60, which are typically elongated rectangular prisms formed of wood extending from one edge of the panel to an opposite or an adjacent edge of the panel and having a with cross sections measuring preferably ¾"×¾". - Typically, a
multi-plenum panel 4, 10 has a top 62, a middle 64, and a bottom 66 sheet, each measuring between ¼" to 1 inch in thickness. It is not uncommon for one or two of thesheets - Turning next to
Fig. 2 , a second embodiment is shown. In this embodiment, thehouse 6 is also built without a frame, but instead ofcontinuous panels 8, 10, itswalls 12,floor 18,ceiling 16, androof 14 are built of smaller single andmulti-plenum panels 2, 4 - typically sized 8 feet by 4 feet, and herein referred to asunit panels unit panels Fig. 1 utilizing continuous panels. - It should also be noted that an embodiment (not shown) utilizing a combination of both
unit single building 6 construction falls within the scope of this invention. As just one example, the building may havewalls 12 withunit panels Fig. 2 , andfloors 18,ceiling 16, androof 14 withcontinuous panels 8, 10 as shown inFig. 1 . - Turning next to
Fig. 3 , a cross section of ahouse 6 such as thehouse 6 ofFig. 1 is shown. Thishouse 6 utilizes continuoussingle plenum panels 8 for thewalls 12 and for theroof 14. Thefloor 18 is a constructed of a continuous multi plenum panel 10. Theceiling 16 may be constructed of a single plenum panel 8 (shown) or a multi plenum panel 10 (not shown) as desired. As can be seen, no framing in present in this building 10. Because of the inherent strength in the single andmulti-plenum panels - This method of construction is ideally suited for manufactured housing as well as conventional site built housing, and any construction built with conventional wood framing, including light construction such as apartment buildings, motels, hotels, restaurants, schools, shopping centers, etc.
- As is described in further detail below, a continuous
single plenum panel 8wall 12 would be installed on thefoundation 28sill plate 30 and be temporarily braced. Once two continuoussingle plenum panel 8walls 12 are installed on thefoundation 28 and joined to one another at an approximately ninety degree angle (for example, the front and firstleft side wall 12 of thehouse 6 inFig. 1 ) the twowalls 12 will be substantially stable. However, it is advisable to retain the bracing until theceiling panel 16 is installed. - Preferably before all the
walls 12 are erected, a continuous multi-plenum panel 10flooring 18 is installed and joined to thesingle plenum panel 8walls 12 currently erected. Then the remaining wall(s) 12 are attached to thefoundation 28sill plate 30, thefloor panel 18, and theadjacent walls 12. - A continuous
single plenum panel 8 or multi-plenum panel 10 is then installed for theceiling 16. As described in greater detail below, theceiling panel 16 will ideally be attached to wall blocking 32 which will have been previously installed adjacent to the top of thesingle plenum panel 8walls 12. After this step, thestructure 6 will be quite stable, and the temporary wall bracing can be removed. - The
roofing 14 is then attached to thestructure 6. Ideally,roof connectors 34 will have been pre-installed to theroofing panels 14. Theroof connector 34 is a preferably continuous structural member having preferably the same length as theroof panel 14 forcontinuous panels 8, 10 or the same length as the entire roof edge when used withunit panels roof connector 34 will be described in greater detail below. If theroof 14 is installed in twocontinuous panels 8, 10 with a joint at the top, thefirst roof panel 14 will preferably be braced or suspended until thesecond roof panel 14 is assembled and attached. - The structure and sheathing is now complete. The
home 6 is a sound structure constructed without conventional framing. - A weather barrier can now be applied, as needed. The roofing (e.g., shingles, felt, etc.) and the wall covering (e.g., siding) can be installed. If not done before hand, penetrations must be cut and finished for
windows 20 and doors 22.Insulation 36 can also be installed. - The savings in time, materials, and labor is significant.
- Turning now to
Fig. 4 , a first embodiment of theroof connector 34 is shown. Theroof connector 34 is anticipated to be continuous hollow triangular prism, most likely formed of the same material along each side. The roof connectors are designed to resist downward and upward forces as well as lateral or horizontal sheer forces and bending forces or moments. Theroof connectors 34, via mechanical and/or adhesive connections to adjacent single and/or multi plenum panels, are designed to be an integral part of the structural system increasing the structural strength of the building. - This is a
typical roof connector 34 made of wood. It is anticipated that it would be constructed of long strips of plywood or OSB with staggered joints, and / or finger-jointed material. Theroof connector 34 could also be constructed from typical "2x" lumber of 1-1/2" thickness. - The
roof connector 34 will typically have at least one roofadjacent surface 38 that attaches to theroof panel 14. Forroof connectors 34 used at theroof 14/ceiling 16 connection, there will also be a ceiling adjacent surface that attaches to theceiling panel 16 and an innerbuilding facing surface 42 that faces the interior of the building, typically an attic space. An angle formed by the roofadjacent surface 38 and the ceilingadjacent surface 40 will preferably have the same desired slope as theroof 14. - For the
roof connector 34 used at theridge 44 of theroof 14 in addition to a first roofadjacent surface 38 there will be a second roofadjacent surface 38 and an innerbuilding facing surface 42. Theroof ridge 44roof connector 34 would have an apex (top most) angle formed by the two roofadjacent surfaces 38 that matches the interior angle formed by the tworoof panels 14 joining one another. Thesame roof connector 34 can be used for both theroof 14/ceiling 16 eve location as well as theridge 44 location if the slope is the same on both sides of theroof 14. Salt-box style homes 6 - withroofs 14 of different angle in the front and back of thehouse 6, would useroof connectors 34 of different angled measurements. - Though the
roof connector 34 is shown as an isosceles triangle, other triangle cross sections could be used. For example, in instances where theroof 14 is steep, an isosceles triangle would cause the ceilingadjacent surface 40 base to be narrower than may be desired. In such an instance, a non- isosceles triangle with a larger apex angle may be desired, causing the non-adjacent innerbuilding facing surface 42 to extend further into the interior of the building, causing the base to be wider. Alternatively, a lateral extension extending from the ceilingadjacent surface 40 base past a point where the innerbuilding facing surface 42 intersect the base may be provided, to allow for a larger base while maintaining a smaller apex angle. Conversely, with a very lowsloping roof 14, a more acute apex angle than would be present for an isosceles triangle may be desired to keep the ceilingadjacent surface 40 base from being longer than necessary. However, if a non- isosceles triangle is used for theroof connectors 34 at a location where theroof 14 connects to theceiling 16, a differentangled roof connector 34 will most likely be required at theroof ridge 44. - Ideally, the
roof connector 34 is attached to the adjoiningpanels single plenum panel roof 14 and either the single ormulti plenum panel ceiling 16 or thesingle plenum panel walls 12. In some embodiments, the roof connector may be at least mechanically fastened to each of the wall, ceiling, and roof panels. - It is anticipated that the
roof connector 34 for theroof 14 /ceiling 16 connection would be filled withinsulation 36, foam or fiberglass or other typical insulating material. However, theroof connector 34 for theroof 14 /roof 14ridge 44 connection could be hollow and / or haveperforations 46 to enhance the escape of hot attic gasses to acontinuous ridge vent 48. - Additionally, or alternatively,
perforations 46 can be made in thesingle plenum roof panels 14 near theroof connector 34 to facilitate a ventilation flow to theridge vent 48. - The bottom / ceiling
adjacent surface 40 dimension of theroof connector 34 is anywhere between 6" and 72" as required for strength. Wider bottom lengths are anticipated where the bottom of theroof connector 34 is also serving as theceiling 16 for the upper level of a "cape cod"style home 6. - Turning next to
Fig. 5 , another embodiment of theroof connector 34 is shown. In this embodiment, theroof connector 34 is formed from an extrusion or mold of, for example, aluminum, plastics, wood fiber, fiberglass, composites, or carbon fiber. Additionally, theroof connector 34 could also be formed of bent sheet metal, plastics, fiberglass, and carbon fiber. - The
roof connector 34 is ideally a continuous structural member and has the same length as theroof panel 14 orroof 14 /ceiling 16 edge. Similar to the embodiment shown inFig. 4 , theroof connector 34 of this embodiment would preferably have the same desired slope as theroof 14, and thesame roof connector 34 would be able to be used for both theroof 14/ceiling 16 eve location as well as theroof ridge 44 location. However, just as in the previous embodiment, there are instances whereroof connectors 44 having non-isosceles triangle sections may be preferable. - Ideally, as in the previous embodiment, the
roof connector 34 is attached to the adjoiningpanels single plenum panel roof 14 and either the single ormulti plenum panel ceiling 16 or thesingle plenum panel walls 12. In some embodiments, theroof connector 34 may be at least mechanically fastened to each of thewall 12,ceiling 16, androof 14 panels. - As in the previous embodiment it is anticipated that the
roof connector 34 shown inFig. 5 for theroof 14 /ceiling 16 connection would be filled withinsulation 36, foam or fiberglass or other typical insulating material. However, theroof connector 34 for theroof ridge 44 connection could be hollow and / or haveperforations 46 to enhance the escape of hot attic gasses into acontinuous ridge vent 48. - Additionally, or alternatively, as in the previous embodiment,
perforations 46 can be provided in thesingle plenum roof panels 14 near theroof connector 34 to facilitate a ventilation flow into theridge vent 48. - As in the previous embodiment, the bottom / ceiling
adjacent surface 40 dimension of theroof connector 34 is anywhere between 6" and 72" as required for strength. Wider bottom lengths are anticipated where the bottom of theroof connector 34 is also serving as theceiling 16 for the upper level of a "cape cod"style home 6. - Turning next to
Figs. 6A and 6B , two further embodiments of theroof connector 34 are shown. These embodiments are ideal for attaching inclinedsingle plenum panels 2, 8 (likely roof panels 14) to vertical surfaces (likelysingle plenum roof connector 34 are essentially a "half roof connector" as previously described. That is, they are hollow triangular prisms, but they have a cross section shaped like one half of an isosceles triangle, or a right triangle. Both embodiments inFigs. 6A and 6B are formed or extruded from aluminum, plastics, wood fiber, carbon fiber, fiberglass, composites, sheet metal, etc. - In the embodiment shown in
Fig. 6B , avertical flange 50 extends below the main body to allow for easier connection of the roof connector to the adjacent vertical surface. This flange can also extend upwards onto a vertical wall for a better connection where the adjacent vertical wall extends further upward. - These two embodiments allow the
roof connector 32 to be attached to thesingle plenum roof panel 14 on the exterior portion of the building, or, for example, with a soffit the interior of an attic space. Additionally, these embodiments allow theroof connector 34 to be directly adhesively and mechanically attached to theexterior sheet 58 of thesingle plenum wall panels 12, especially the embodiment with thevertical flange 50. It is understood that if desired, both aroof connector 34 as shown inFig. 5 and aroof connector 34 as shown in one of the embodiments ofFigs. 6A and 6B could be used at asingle wall 12 /roof 14 /ceiling 16 connection - aroof connector 34 fromFig. 5 where theroof 14 is adjacent to theceiling 16 / edge blocking 70 (seeFig. 13 ), and a roof connector fromFigs. 6A and 6B where the roof is adjacent to thewall 12 / edge blocking 70. - Turning next to
Figs. 7A and 7B , another two additional embodiments of theroof connector 34 are shown. These two embodiments are essentially the same as the two roof connectors previously described inFigs. 6A and 6B , but the roof connectors inFigs. 7A and 7B are made of wood. - Turning now to
Fig. 8 , one embodiment of the connection between thewall 12, thefloor 18, and thefoundation 28 of abuilding 6 according to the invention is shown. In this embodiment thewalls 12 are constructed of continuoussingle plenum panels 8 and thefloor 18 is constructed ofmulti-plenum panels 4, 10. The load bearing singleplenum wall panels 8 would have as their main structural compressive member the inside facinginterior sheet 54. Theinterior sheets 54 would bear on a top surface of thesill plate 30, adjacent to an outer edge of thesill plate 30. Theinside sheets 54 would be located adjacent a 2x4 sill plate blocking 56 installed on top of thesill plate 30. The sill plate blocking 56 would preferably be installed in the field. - Connections would then be made between the
single plenum 8wall panel 12 and the 2x4 sill plate blocking 56. Ideally, this would be both a mechanical and adhesive connection.Mechanical connectors 74 such as screws can penetrate the fullsingle plenum panels exterior sheet 58 of thesingle plenum panels screws 74 directly into the interior sheet 54 (as shown in later figures) at desired locations. - Next, the
flooring 18 system would then be installed on the 2x4 sill plate blocking 56. Theflooring 18 shown in this embodiment is amulti-plenum panel 4, 10. Themulti plenum panel 4, 10 has a 2x4 edge blocking 70 installed along its outer edge in thetop plenum 78 andbottom plenum 80 to facilitate attachment to thewall 12 and thesill plate 30 and sill plate blocking 56. The height of the edge blocking 70 in this embodiment matches the height of therespective plenums floor panel 18 adjacent to thewall 12, but it may be shorter and/or in multiple spaced units. The edge blocking 70 in this embodiment is present in both the top andbottom plenum - The
single plenum panel flooring system 18, ideally with both adhesive and mechanical means. As shown, screws 74 can be driven through the entiresingle plenum panel wall 12, directly mechanically fastening both the interior andexterior sheets floor panel 18 edge blocking 70. Additionally or alternatively, as described below, connector holes 76 can be provided in theouter exterior sheet 58 to facilitatescrews 74 driven directly through the load bearinginterior sheet 54 of thesingle plenum panel floor panel 18 edge blocking 70, with the head of thescrew 74 adjacent the load bearinginterior sheet 54. - Although it is anticipated that screws 74 will be primarily used in fastening, it should be noted that unless the text states "only screws," the term screw used in this disclosure is not meant to be limiting, and shall include other
mechanical fasteners 74 including, for example, nails, bolts and braids, as would be apparent to one of skill in the art. - Turning now to
Fig. 9 , a further embodiment of thefloor 18 /wall 12 /foundation 28 connection ofFig. 8 is shown. This Figure shows perforations or through connector holes that can be provided in theexterior sheet 58 of thesingle plenum panel single plenum panel wall 12 to theflooring 18 andfoundation 28 system. The connector holes 76 can be provided either in the factory or field. Thescrews 74 used to mechanically attach the various elements to one another are not shown in this Figure to show greater detail. - Additionally, a bottom portion of the
exterior sheet 58 of thesingle plenum panels interior sheet 54 to theinterior structure 6, especially theflooring 18 andfoundation 28 system. - Turning now to
Fig. 10 , this figure shows a side view of the embodiment shown inFig. 9 . As can be seen the connector holes 76 allow for easy access to directly screw thescrews 74 into theinterior sheet 54 of thesingle plenum panel wall 12. This facilitates the connection of thesingle plenum panel wall 12 to theflooring 18 andfoundation 28 system. The connector holes 76 can be provided either in the factor or field. Additionally, as shown inFig. 12 , in thesame wall 12, screws 74 can be driven both through the exterior andinterior sheets single plenum panel wall 12 and into the sill plate blocking 56 and also through connector holes 76 directly into the load bearinginterior sheet 54 and into the sill plate blocking 56. - Turning now to
Fig. 11 , an additional embodiment of afloor 18 /wall 12 /foundation 28 connection of abuilding 6 according to this invention is shown. In this embodiment a load bearingsingle plenum panel wall 12 is attached to asingle plenum panel floor 18 system, instead of themulti plenum panel 4, 10floor 18 system shown inFigs. 6-8 . - The
single plenum panel wall 12 is located with a 2x4 sill plate blocking 56 attached to the preferably pressure treatedsill plate 30. The connection is ideally both mechanical and adhesive. In the shown embodiment screws 74 are driven through the bothsheets single plenum panel floor 18 edge blocking 70 and sill plate blocking 56 in thesingle plenum panel flooring 18. - As with the previous embodiments the size and continuity of the
floor 18 edge blocking 70 may vary based on strength need. Also as with the previous embodiments, connector holes 76 may be provided in theexterior sheet 58 of thesingle plenum panel wall 12 or a lower portion of theexterior sheet 58 of thesingle plenum panel wall 12 may be removed to allow for direct screwing ofscrews 74 into the load bearinginterior sheet 54 of thesingle plenum panel wall 12. - Turning now to
Fig. 12 a still further embodiment of thefloor 18 /wall 12 /foundation 28 attachment is shown. In this embodiment a frameless load bearingsingle plenum panel wall 12 is attached to a conventionally framed flooring system made of2x10 joists 72. In this embodiment there would be arim joist 82 to which thesingle plenum panel - This embodiment also shows
screws 74 being driven both through the entiresingle plenum panel rim joist 82, and via providedconnector holes 76 being driven directly into the load boardinginterior sheet 54 and into therim joist 82. - Turning now to
Fig. 13 , a first embodiment of awall 12 /roof 14 /ceiling 16 connection of abuilding 6 according to the invention is shown. In this embodiment the load bearingsingle plenum panel wall 12 is connected to asingle plenum panel ceiling panel 16 and asingle plenum panel roof 14. - A 2x4 or larger wall blocking 32 is attached to the top of the load bearing
single plenum panel wall 12 continuously along its length. This wall blocking 32 is ideally attached from the inside of the building to theinterior sheet 54 of thesingle plenum panel screws 74 or othermechanical fasteners 74 but could also be attached from theexterior sheet 58 of thesingle plenum panel adhesive 84. - The
ceiling panel 16 can be made of eithersingle plenum panels 2, 8 (shown) ormulti plenum panels 4, 10 (shown inFig. 12 ) and has edge blocking 70 of approximately 2x4 size.Screws 74 are then run through theceiling panel 16 into the wall blocking 32 attached to the load bearingsingle plenum panel wall 12. Ideally, the connection is both mechanical and with adhesive 84. In contrast to thefloor panel 18 edge blocking 70, which is preferably laterally adjacent to thewall panel 12, the ceiling panel edge blocking 70 in this embodiment is vertically above thewall panel 12. - The
roof panel 14 is connected using the previously describedcontinuous roof connector 34 that has been ideally previous attached to theroof panel 34 or theceiling panel 16 with both mechanical and adhesive means. In attaching theroof panel 14 to theceiling panel 16, ideally anadhesive connection 84 is established between any of theroof panel 14 and theceiling panel 16 that have not previously be attached to theroof connector 34. Theroof connector 34 is screwed into theroof panel 14. Onescrew 74 is ideally longer and screws into the 2x4 edge blocking 70 in the edge of theceiling panel 16. Theceiling panel 16 can have a Mag/Ox bottom layer /interior sheet 54, or ¼" OSB/plywood and ¼" drywall or wood for ceiling tile or ornamented wood patern. - Turning now to
Fig. 14A , a second embodiment of awall 12 /roof 14 /ceiling 16 connection of abuilding 6 according to the invention is shown. In this embodiment the load bearingsingle plenum panel wall 12 is connected to amulti plenum panel 4, 10ceiling 16 andsingle plenum panel roof 14. Themulti plenum panel 4, 10 ceiling panel 16 (or ceiling-floor panel 16/18 for the multi-story building) has edge blocking 70 that is connected to 2x4 (or larger) wall blocking 32 that was preferably previously attached on theinterior sheet 54 of thesingle plenum panel - A 2x4 or larger wall blocking 32 is attached to the top edge of the load bearing
single plenum panel wall 12 continuously along its length. The wall blocking 32 is ideally attached from the inside of thebuilding 6 withscrews 74 but could also be attached from the outside. Ideally, the wall blocking 32 is also attached withadhesive 84. -
Screws 74 are then run through thetop sheet 62 of themulti plenum 4, 10ceiling panel 16, passing through the upper edge blocking 70, themiddle sheet 64, the lower edge blocking 70, thebottom sheet 66, and into the wall blocking 32 attached to the load bearingsingle plenum panel wall 12. Ideally, the connection is both mechanical and with adhesive 82. In contrast to thefloor panel 18 edge blocking 72, which is preferably laterally adjacent to thewall panel 12, theceiling panel 16 edge blocking 72 in this embodiment is vertically above thewall panel 12. Theroof panel 14 can now be connected. - The
roof panel 14 is connected using the previously describedcontinuous roof connector 34 that has been ideally previous attached to theroof panel 14 or theceiling panel 16 with both mechanical and adhesive means 74, 82. In attaching theroof panel 14 to theceiling panel 16, ideally anadhesive connection 82 is established between any of theroof panel 14 and theceiling panel 16 that have not previously be attached to theroof connector 34. Theroof connector 34 is screwed into theroof panel 14. Onescrew 74 is ideally longer and screws into the 2x4 edge blocking 72 in the edge of theceiling panel 16. - Also shown in
Figs. 14A to 14D are four different embodiments of louvers or fascia or otherpermeable occlusions 88 that provide limited passage into theplenum 88 of theroof panel 14. Thesepermeable occlusions 88 or end details could be accomplished with aluminum or vinyl and stapled 74 on the end of thesingle plenum panels fascia 88 is to provide a finished end of thesingle plenum panels roof panel 14plenum 88, or along a gap provided in the lower (interior)sheet 54 of theroof panel 14. Other types of permeable occlusions and similar locations may be used. - Turning now to
Figs. 15 -17 , three different embodiments are shown ofwall 12 and ceiling-floor 16/18 attachments formulti-level buildings 6 according to the present invention. - In
Fig. 15 , an upper and a lowersingle plenum panel wall 12 are joined to amulti plenum panel 4, 10 ceiling-floor 16/18. The section shown is similar toFig. 14A in that it shows the method of connectingceiling panels 16 to thesingle plenum panel load bearing wall 12 by placing the ceiling-floor 16/18 edge blocking 70 vertically above the lowersingle plenum panel wall 12. This, in turn, has the uppersingle plenum panel wall 12 directly above the ceiling-floor 16/18 edge blocking 70. - A 2x4 or larger wall blocking 32 has been attached to the top of the lower load bearing
single plenum panel wall 12 continuously along its length. This is ideally attached from thebuilding 6 inside withscrews 74 but could also be attached from the outside. Ideally, this attachment is also made with adhesive 84. - The ceiling-
floor panel 16/18, having edge blocking 70 inserted therein, is then placed on top of thelower wall panel 12 and lower wall blocking 32 and (not shown) screws 74 are screwed down through the ceiling-floor panel 16/18 from the top and into the lower wall blocking 34. Ideally, the ceiling-floor panel 16/18 will also be attached to the lower wall blocking 32 withadhesive 84. - Next, a 2x4 upper wall blocking 32 is attached to the top of the
multi-plenum panel 4, 10 ceiling-floor panel 16/18 and is inset so that the thickness of thesingle plenum panel upper wall 12 matches that of thesingle plenum panel lower wall 12 below. Theinterior sheet 54 of the upper and lowersingle plenum panels interior sheet 54 of theupper wall panel 12 can be attached withscrews 74 from the building interior or the building exterior (shown) through the upper wall blocking 32. Ideally, theupper wall panel 12 is also attached to the upper wall blocking 32 withadhesive 84. Vertical alignedvertical perforations 46 could be provided in the ceiling-floor panel 16/18 edge blocking 70 and the in the top, middle, andbottom sheets plenum 88 of thelower wall panel 12 to pass upward through the vertically alignedvertical perforations 46 of the edge blocking 70 andsheets plenum 88 of theupper wall panel 12, allowing continuous vertical wall ventilation. - Alternatively or additionally,
permeable occlusions 86 could be located in the upper portion of theexterior sheet 58 of thelower wall panel 12 and in the lower portion of theexterior sheet 58 of theupper wall panel 12, as shown. This venting gasses and in to thewall 12plenums 88 thoughpermeable occlusions 86 allows for a vertical movement of gasses through theplenum 88 of thewall panels 12, though not directly from the lower to the upper. - For a two story structure, the top of the
upper wall panel 12 could then be as shown inFigs. 13 or14A , where the ceiling androof panels wall panel 12. - Turning to
Fig. 16 , a second embodiment of awall 12 and ceiling-floor 16/18 attachment for amulti-level building 6 is shown. In this embodiment, a load bearingsingle plenum panel lower unit panels 2 as shown, or continuous 8) is attached tosingle plenum panel floor 16/18. A plane marking the level of the lower andupper wall panel 12 intersection is marked by the horizontal dashed line L-U. A lowersingle plenum panel wall panel 12 is assembled using methods previously described as aload bearing wall 12. Lower wall blocking 32 is preferably mechanically and adhesively attached adjacent to the top of theinterior sheet 54 of the lowersingle plenum panel wall 12 to support a horizontalsingle plenum panel lower level ceiling 16 and theupper level floor 18. This horizontalsingle plenum panel - After installation of the horizontal
single plenum panel single plenum panel wall panel 12 is placed on and vertically aligned with thelower wall panel 12, as shown inFig. 16 . Theupper wall panel 12 is preferably mechanically and adhesively attached to the edge blocking 70 and an additional upper wall blocking 32 is added to the second floor level. The upper wall blocking 32 is preferably also mechanically and adhesively attached to the edge blocking 70. - This embodiment allows the continuous and substantially unobstructed ventilation and air/
gas flow 90 along thesingle plenum panel walls 12. - Turning next to
Fig. 17 , a third embodiment of awall 12 and ceiling-floor 16/18 attachment for amulti-level building 6 is shown. Similar to the first embodiment shown inFig. 15 , this third embodiment includes upper and lowersingle plenum panel multi plenum panel 4, 10 floor-ceiling panel 16/18, with the plane marking the level of the lower andupper wall panel 12 intersection marked by the horizontal dashed line L-U. But, similar to the second embodiment the upper and lowersingle plenum panel walls 12 are directly adjacent to one another and the edge blocking 70 for the ceiling-floor panel 16/18 is horizontally adjacent to the wall panel(s) 12, not vertically adjacent. - In this third embodiment, a lower
single plenum panel wall panel 12 is assembled using methods previously described as aload bearing wall 12. Lower wall blocking 32 is preferably mechanically and adhesively attached to top of theinterior sheet 54 sheet of the lowersingle plenum panel wall 12 to support a horizontalmulti plenum panel 4, 10, which is used for both thelower level ceiling 16 and theupper level floor 18. This horizontalmulti-plenum panel 4, 10 has edge blocking 70 to facilitate mechanical and adhesive attachment to the lower wall blocking 32. - After installation of the horizontal
multi-plenum panel 4, 10, an upper (vertically oriented) load bearingsingle plenum panel wall panel 12 is placed on and vertically aligned with thelower wall panel 12, as shown inFig. 17 . Theupper wall panel 12 is preferably mechanically and adhesively attached to the edge blocking 70 and an additional upper wall blocking 32 added to the second floor level. The upper wall blocking 32 is preferably also mechanically and adhesively attached to the edge blocking 70. The blocking shown in this third embodiment includes twoupper wall blockings 32, one horizontal wall blocking 32 adjacent to theupper wall panel 12 and themulti-plenum panel 4, 10 ceiling-floor 16/18 and a second vertical wall blocking 32 adjacent to theupper wall panel 12 and the horizontal wall blocking 32. The extra upper wall blocking 32 could also be used for the second embodiment ofFig. 16 and vice versa. - This third embodiment also allows the continuous and substantially unobstructed vertical ventilation and flow of air/
gas 90 along thesingle plenum panel walls 12. - Turning now to
Figs. 18A and 18B , a flangedcircle guide device 92 is shown to aid installation of drywall andinsulation 36 on the inside of inclinedsingle plenum panel walls 12 orroofs 14. - The flanged
circle guide device 92 can be extruded or formed from plastics, metal, vinyl, fiberglass, composites, and many other materials. A cross section has acircular portion 94 and a protrudingflange portion 96 extending tangentially from thecircular portion 94. It has a rounded edge and thecircular portion 94 has a diameter anywhere from ½" to 6". The protrudingflange portion 96 extends 2" to 8" from thecircular portion 94. The flangedcircle guide device 92 is manufactured in substantial lengths, such that it can be installed in continuous lengths anywhere from 4' to 40'. - The flanged
circle guide device 92 is used for to retainbatt insulation 36 on an inclined surface. This flangedcircle guide device 92 is also used as a gauge forfoam insulation 36 so that thefoam insulation 36 is installed to a certain desired depth. This depth would be consistent with the insulation guides 98 discussed further in this description. - The flanged
circle guide device 92 are installed with screws, staples or nails or othermechanical connectors 74 and/oradhesives 84 along theflange portion 96. - Turning now to
Fig. 19 , a third embodiment of awall 12 /roof 14 /ceiling 16 connection of abuilding 6 according to the invention is shown. In this embodiment the load bearingsingle plenum panel wall 12 is connected to aroof 14 andceiling 16 of conventional construction building 6 (with trusses 100). - This embodiment shows three different methods of connecting the top wall blocking 32 to the
single plenum panel wall 12 to facilitate the installation of theceiling 16 androof 14 panels (in the embodiments ofFigs. 11 and12 ) or trusses 100 and rafters of the embodiment ofFig. 19 . - Three different methods of screwing the top wall blocking 32 are shown - a first method where the
screw 74 passes through the completesingle plenum panel building 6 with the head of thescrew 74 seated on the outer surface of theexterior sheet 58 and the tip of thescrew 74 in the wall blocking 34, a second method where thescrew 74 passes through aconnector hole 76 through theexterior sheet 58 of thesingle plenum panel building 6 with the head of thescrew 74 seated on the inner surface of the inner plenum facing surface of theinterior sheet 54, and the third, and likely easiest method where the screw passes from the wall blocking 32 to the load bearinginterior sheet 54 of thepanel screw 74 seated on the wall blocking 32. One, two, or all three of the methods may be used in this and other embodiments ofwall blockings 32. - The top wall blocking 32 is attached to the load bearing
interior sheet 54 of thesingle plenum panel screws 74 in one or more of three methods described above, ideally in conjunction with adhesive 84. The wall blocking 32 can be 2x4, 2x6, and 2x8 or other dimensions such as 4x6 or 4x8. The wall blocking 32 will be preferably hidden by theinsulation 36 which is installed later. - In the embodiment shown in
Fig. 19 , theceiling 16 androof 18 construction is conventional and atruss 100 is shown to be attached to the top of thesingle plenum panel wall 14 and the wall blocking 32. Thetruss 100 could be toe-nailed in, but most likely would be attached with metal clips, sometimes called "hurricane clips" for a better connection and one that can offset uplift, or some othermechanical connector 74. - It is also noted that a permeably occluded 86 upper terminal gap may be provided in the exterior sheet 58 (as shown in
Fig. 15 ) of this andother wall panels 12 at thewall 12 /ceiling 16 /roof 14 connections to allowwarm air flow 90 to exit theplenum 88. Alternatively a fluid connection, through vertical perforations, for example, can be made between the upper portion of theplenum 88 of thewall panel 12 and the lower edge of an abovesingle plenum panel roof 14. - Turning now to
Fig. 20 , an insulation guide orgage 98 is shown. Theinsulation guide 98 is used to install either batt orfoam insulation 36 against a flat surface. The depth of theinsulation guide 98 would match either the thickness of thebatt insulation 36 or the desired depth of thefoam insulation 36. The rear face orexpanse 102 of theinsulation guide 98 would be stapled or nailed to the adjacent vertical flat surface, which is shown here as awall 12, for a vertical orientation of theinsulation guide 98. - Other non-vertical orientations for the
insulation guide 98 could be for aceiling 16 in the horizontal orientation or for a sloped surface, such as theinside wall 12 of a so called "cape cod"style house 6. It is anticipated that there are situations where theinsulation guide 98 and/or the flangedcircle guide device 92 shown inFigs. 18A and 18B above could be used to aid in installinginsulation 36 in aframeless building 6 constructed of single andmulti-plenum panels - Holes or chases 104 are preferably provided in the
transverse expanse 106 of theinsulation guide 98 at intervals for the trades to install plumbing, heating, electrical, data wires, communication and other services and utilities as would be commonly installed and hidden in thewalls 12. Thechases 104 could be rounded or chamfered so that a doughnut would not have to be installed for wire installation as would be required if the edges of thechases 104 were sharp. - The
insulation guide 98 can be made of extruded plastic, vinyl, aluminum, composite or any other material that could be extruded or made continuously. Theinsulation guide 98 can also be made from bent metal or formed from a variety of materials including vinyl, plastic, aluminum, corrugated products, carbon fiber, fiberglass, composites, or any planer materials. - The
insulation guide 98 is installed to thewall 12 orceiling 16 surface with staples or nails 74. It can be cut horizontally or vertically as necessary to avoid obstacles such as blocking 34, 72. Although theinsulation guide 98 may stretch fromfloor 18 toceiling 16, it is not necessary that it do so. - For
foam insulation 36 applications, theinsulation guide 98 will serve as the guide for the trimming of thefoam insulation 36 after application. - For
batt insulation 36, the guides or gauges 98 would preferably be installed at a certain increments along thewall 12 orceiling 16 determined by the width of theinsulation batts 36. Forfoam insulation 36 applications, the insulation guides 98 would preferably be installed at an increment less than the length of the cutting/trimming device forfoam insulation 36. - An optional "T" shape flange 108 - shown in
Fig. 22 and in dotted lines inFig. 20 - can be incorporated to therear expanse 102 for stability if necessary. Similarly, thefront expanse 110 may be T shaped as well, but will normally have a single flange extending from thetransverse expanse 106 in an opposite direction as the flange extending from the rear expanse 102 (seeFig. 21 ). It is to be noted that the insulation guides 98 normally do not carry any load of thestructure 6. Indeed, there may be a gap provided between the upper edge of theinsulation guide 98 and theceiling 16 to allow wide wire harnesses or pipes through. Additionally, there may be a gap between the lower edge of theinsulation guide 98 and thefloor 18 to allow passage of wide wire harnesses or pipes. Finally, there may also be a complete break along the vertical length of theinsulation guide 98 to allow for passage of wide wire harnesses or pipes. Any of these scenarios would substantially prevent any load being carried by the insulation guides 6. - Turning now to
Fig. 21 , and embodiment is shown where numerous insulation guides or gauges 98 are installed along a wall 12 (three shown). Oln the middle insulation guide 98 anelectric box 112 is attached for an electrician to install an electrical outlet. Electrical ordata boxes 112 can be attached to thetransverse expanse 106 or side of the insulation guides 98 as needed. - Turning next to
Fig. 22 , a view of an insulation guide having a "T" shapedflange 108 on therear expanse 102 is shown. This drawing is similar to themiddle insulation guide 98 ofFig. 21 , but theinsulation guide 98 depicted in this drawing also has the optional "T" shapedflange 108, which can be used for added rigidity when required. The electrical /data box 112 is also shown installed on theinsulation guide 98. -
Figs. 23-25 describe embodiments for installingwindows 20 and doors 22 into the unit and continuous load bearingsingle plenum panel walls 12. - Turning first to
Fig. 23 , this figure shows a simple method of providing for the framing and installation ofwindows 20 or doors 22 in the load bearingsingle plenum panel wall 12. The desired opening is first cut in thewall 12. Abox 114 of the desired rough opening is then attached to the inside of the single plenum panel wall with screws or nails. This design is made of nominal 2" lumber and with a depth as required. - Turning next to
Fig. 24 , a second embodiment forwindow 20 and door 22 installation is described. In this embodiment,windows 20 and doors 22 are installed in a load bearingsingle plenum panel wall 12 using a nestedshell 116 with a depth desired for insulation. The entire nestedshell 116 opening can be pre-made, especially for certain standard rough openings ofwindows 20 and doors 22 and used as appropriate. Alternatively, the nestedshell 116 can be made in various lengths and cut and assembled as required for the desired opening. - The desired opening is cut through the
single plenum panel window 20 or door 22. Aninterior shell 118, either as a single unit or in sections, is then installed through the opening or, as shown aninterior flange 120 is stapled 74 to the outer surface of theinterior sheet 54 of the wall panel 12 (the surface shown in the Figure). Only threestaples 74 are shown to maintain clarity of the drawing. Thisinterior shell 118 is the portion of the nestedshell 116 that extends into the interior of thebuilding 6. - An
exterior shell 122 is then installed form the outside and fits inside theinterior shell 118 previously installed. Theexterior shell 122 has an exterior flange 124 (shown in dashed lines) which is stapled to the outer surface of theexterior sheet 58 of the wall panel 12 (outer surface facing away in the drawing). The joint between theexterior flange 124 and thewall panel 12 to the can be caulked, sealed or taped as desired to be waterproof, or flashing can be installed at a later time when thewindow 20 or door 22 is installed. Theexterior shell 122 can interlock with theinterior shell 118 or otherwise be mechanically or adhesively secured one to the other. - Turning next to
Fig. 25 , a cross section of the second embodiment forwindow 20 and door 22 installation, described inFig. 24 , is shown. - An optional shell blocking 126 can be installed across the top of the opening should it be required or desired for extra strength.
- If more stability to the nested
shell 116 is required, then flangetabs 128 could be included at intervals of 4" to 12" as shown. As can be seen, theinterior shell 118 extends back into thebuilding 6 as far as theinsulation 36 and drywall. As can also be seen, theexterior shell 122 extends through and preferably 1" to 3" past the hole in thesingle plenum panel interior shell 118, atrim flange 130 extends out from theinterior shell 118. Thetrim flange 130 could be attached to the drywall mechanically or adhesively to the inner and/or outer surface of the drywall. - Turning next to
Figs 26A - 29 , these drawings show multiple mechanical connectors orfasteners 74 that are specially designed for fastening single anddouble plenum panels - Turning to
Figs. 26A - 26D , atoothed screw 132 is shown which allows an load bearinginterior sheet 54 of asingle plenum panel wall 12 to be directly fastened to a supporting structure (other panel or blocking, for example), without a pre-drilledaccess connector hole 76 in theexterior sheet 58 of thesingle plenum panel - The Figs. show four views of the toothed screw 132: a top view (
Fig. 26A ), a partial side view with theshank 134 of thetoothed screw 132 omitted (Fig. 26B ), a partial side view with the front and rear cuttingteeth 136 omitted (Fig. 26C ), and a bottom view (Fig. 26D ). In the partial side view ofFig. 26B , thetoothed screw 132 is shown with an enlargedflat head 138 having with cuttingteeth 136 fixedly attached to and extending downward from thehead 138 parallel to theshank 134. The cuttingteeth 136 are 2 to 16 in number, and preferably 2 to 4 in number. The cuttingteeth 136 are of a length equal to the thickness " " of theexterior sheet 58 of thesingle plenum panel wall 12, which is the first layer of thepanel wall 12 to be penetrated. - The partial side view of
Fig. 26C shows thetoothed screw 132 orientation while the partial side view of 26B shows one embodiment of the cuttingteeth 136. This particular example has four cuttingteeth 136, also shown in the bottom view ofFig. 26D . - The diameter of the
top head 138 is as determined for the application and can be anywhere from 1/4" to 3". The diameter of thescrew shank 134 would be as required for strength. - The top view of
Fig. 26A shows astar drive 140, but other screw drives 140, including hex, square, Torx, and Phillips may be used. - Turning to
Fig. 27 and28 , the operation of the toothed screw ofFig. 26A-26D is shown. In the figures, the upper sheet in the drawing is preferably theexterior sheet 58 of thesingle plenum panel interior sheet 54 of thesingle plenum panel Fig. 27 thetoothed screw 132 is first driven into theexterior sheet 58 of asingle plenum panel pre-drilled connector hole 76. - As can be seen, the depth " " of the cutting
teeth 136 is substantially the same thickness " " of theexterior sheet 58. To continue operation of thetoothed screw 132, thetoothed screw 132 continues to be driven downward into theexterior sheet 58 until the cuttingteeth 136 contact theexterior sheet 58. At this point, continued rotation of thetoothed screw 132 causes the cuttingteeth 136 to cut into the exterior sheet. As thetoothed screw 132 is rotated further, the cuttingteeth 136 cut entirely through theexterior sheet 58 and a wood plug 142 (formed from the cut out portion of the exterior sheet 58) is seated in thehead 138 of thetoothed screw 132. At this point, aconnector hole 76 has been automatically provided in theexterior sheet 58 by operation of thetoothed screw 132, and thetoothed screw 132 is no longer restrained by theexterior sheet 58 and may progress downward into theinterior sheet 54, as shown inFig. 28 . - In
Fig. 28 , thetoothed screw 132 is shown after it has been directly screwed in into theinterior sheet 54 all the way down until the cuttingteeth 136 are contacting theinterior sheet 54. However, because thewood plug 142 fills the cavity in thescrew head 138, it spaces and blocks the cuttingteeth 136 from advancing further into theinterior sheet 54. In effect, thewood plug 142 acts as a washer to self-seat thetoothed screw 132 onto theinterior sheet 54 of thesingle plenum panel interior sheet 54 from thetoothed screw head 138 would be some type of structural support (e.g., a blocking 32, 56, 70) for thesingle plenum panel structure 6. - With the disclosed self-seating
toothed screw 132, no special tools are required, other than perhaps an extended screw drill bit. - Turning next to
Fig. 29 , a secondmechanical connector 74 or fastener, in the form of a double-head screw 144, is disclosed to connectsingle plenum panels Figs. 27 and28 , the upper sheet in the figure is anexterior sheet 58 of asingle plenum panel interior sheet 54 of asingle plenum panel 58. As shown in the Figure, a double headedscrew 144 is fully sunk into asingle plenum panel screw 144 has a larger diameter flat upper or "top"head 146 at a terminal end of the doubleheaded screw 144 and has anintermediate head 148, with a twisted bit base 150, spaced at a distance from thetop head 146. The distance between the top of theintermediate head 148 and the bottom of the largertop head 146 is the same as the distance from the inner surface of theinterior sheet 54 and the outer surface of theexterior sheet 58. - Because of the spacing between the two
heads headed screw 144 is screwed into thesingle plenum panel twisted bit portion 150 of theintermediate head 148 will first screw through theexterior sheet 58 and continue downward. Theshank 134 of the doubleheaded screw 144 will screw through the interior sheet 54 (and into a blocking 32, 56, 70, or some other support of the structure) and as thetwisted bit 150 of theintermediate head 148 begins to drill into the interior sheet, the largertop head 146 will seat on the outer surface of theexterior sheet 58, will substantially close off the just formedconnector hole 76 and will preferably provide a compressive force on theexterior sheet 58. - Turning now to
Figs. 30A to 31C , a first and second method of securely connecting adjacentsingle plenum panels coupling blocks 152 are shown. These methods will also work withmulti-plenum panels 4, 10 (not shown). The coupling blocks 152 will aid in constructing abuilding 6 out ofunit panels multi-plenum panels Figs. 30A - 30C and hollow coupling blocks 152 are shown inFig. 31A - 31C , but are otherwise substantially the same. The coupling blocks 152 have a thickness that is preferably either the same as the interior clear dimension between thesheets single plenum panel 2 or the thickness of the clearing between onesheet matrix member 60. The coupling blocks 152 are easily inserted into theplenum 88 of eachpanel screws 74 and/or glues 84. The length of the coupling blocks 152 are determined by the matrix dimensions and strength requirements. - Optional variations of the solid coupling blocks 152 are shown in
Fig. 31C . When inserting inpanels 2 havingmatrix members 60, depending on the spacing of matrix members, the edge of thepanel 2 on one side may have a full clearance between the twosheets 54, 58 (for at least a minimal distance), and the edge of thepanel 2 on the opposing side will have a reduced clearance, part of the clearance being occupied by one matrix member running parallel to the edges of thepanels 2 being coupled. To maximize contact area between the twosheets panels 2, thecoupling block 152 ofFig. 31C has afull clearance side 154, which has a thickness equal to the clearance between the twosheets matrix clearance side 156, which has a thickness equal to the distance between amatrix member 60 and thesheet matrix member 60 is not directly attached to. The portion removed 158 from thematrix clearance side 156 is substantially equal to the height of thematrix member 60 from thesheet full clearance side 156 could also have a portion removed 158 along a portion of its length, especially the portion that is inserted first into theplenum 88. In this way, thefull clearance side 154 of thecoupling block 152 could also fit between at least onematrix member 60 and its opposingsheet matrix member 60 and the edge of thepanel 2. - Additionally, the
coupling block 152 ofFig. 31C has a raisedcenter guide 160 which helps to quickly center the coupling blocks 152, with respect to length, so equal lengths of the coupling blocks 152 are in bothpanels 2, when securing the coupling blocks 152 in therespective panels 2. Also, thecoupling block 152 ofFig. 31C has a plurality of cleats or raisedprotrusions 162 with help to frictionally lock the coupling blocks 152 in place once inserted, without the need for furthermechanical fasteners 74 oradhesives 84. Only ninecleats 162 are shown inFig. 30C to maintain clarity, but preferably the number would be significantly higher, thecleats 162 be located on all sides of the coupling blocks that would contactsheets matrix members 60, and thecleats 162 would be angled toward the raised center guide 160 (or where a raised center guide would be if one was not present) - which would cause the coupling blocks 152 to dig into theadjacent sheets plenum 88 of the twopanels 2, locking the twopanels 2 together. - The solid coupling blocks 152 can be made of wood, wood fiber, aluminum or other metals, plastics, composites, carbon fiber, fiberglass, bent metal or other materials.
- The hollow coupling blocks 152 of
Figs. 31A -31C can be made of wood, wood fiber, aluminum or other metals, plastics, composites, carbon fiber, fiberglass, bent metal or other materials. It is anticipated the blocks could be also extruded or formed from these materials. The variations ofFig. 30C can also be made with the hollow coupling blocks 152. - Although a horizontal connection is shown, the same method could be utilized for a vertical connection as would be required at the gable ends of a
home 6. - Turning now to
Figs. 32A - 33C a first and second method of securely connecting adjacent single plenum panel with "H" shapedcouplers 164 are shown. InFigs. 32A - 32C "H"couplers 164 with asolid mid-portion 166 is shown, and inFigs. 33A - 33C "H"couplers 164 with a mid-portion 166 withperforations 46 is shown. TheseH couplers 164 can be the full length of thesingle plenum panel 2 or (not shown) can be shorter clips of desired length using several to connect the twoadjacent panels 2, or (not shown) could be longer than the full length of thesingle plenum panel 2 and connect more than twoadjunct panels 2 together (two adjacent panels on a first level and twoadjacent panels 2 on a second level directly above the first two panels 2). TheH coupler 164 is inserted in the field and attached using mechanical 74 and/or adhesive 84 methods. - The perforated 46
H couplers 164 facilitate complete ventilation between theadjacent panels 2. - The dimensions and thickness of the
H couplers 164 are determined by strength requirements. Although theH couplers 164 are shown with smooth engagingsurfaces 168 on the parallel opposing cappingportions 170, engagingsurfaces 168 could also be ribbed, rough, or rigged, with the ridges angled inward toward a the mid portion. Additionally, one or many barbs orcleats 162 could be provided on the engagingsurfaces 168, preferably with the barbs or cleats angled inwardly and back toward the mid portion, such that theH couplers 164 were easy to slide on thepanel 2, but where trying to remove theH coupler 164 would cause the barbs orcleats 162 to dig into the surface of the engagedsheet 54, 58 - in a similar fashion to theoptional cleats 162 used in the coupling blocks inFig. 30C . - The coupling blocks 152 and
H couplers 164 can be made of wood, wood fiber, aluminum or other metals, plastics, composites, carbon fiber, fiberglass, bent metal or other materials. It is anticipated that embodiments of each 152, 164 could be also extruded or formed from these materials. - Although a horizontal connection is shown, the same method could be utilized for a vertical connection as might be required at the gable ends of a home.
- In the embodiment shown in
Figs. 32A - 33C , themid-portion 166 of theH coupler 164 spaces theparallel capping portions 170 from one another such that engagingsurfaces 168 of the cappingportions 170 engage the outer surfaces of the interior andexterior sheets adjacent panels 2. That is, the twoengaging surfaces 168 on therespective capping portions 170 face one another. - In another embodiment (not shown), a shorter mid-portion 166 would space the
parallel capping portions 170 such that theirengaging surfaces 168 are on the opposite side, and they 168 engage the inner surfaces of each of the interior andexterior sheets - In a further embodiment (not shown), two spaced
end caps 170 would be positioned at each end of the mid-portion 166 such that the end caps 170 engaged both the inner and the outer surfaces of each of the interior andexterior sheets adjacent panel 2. - In a still further embodiment, the
H couplers 164 instead of just being linier (like a lower case "L"), could can be formed in a "T" shape or a "+" shape to connect three adjacent or fouradjacent panels 2 respectively. The H couplers 164 could be used alone, or with the coupling blocks 152. - Turning next to
Figs. 34A - 34B , an embodiment for connecting adjacent panels using two methods is shown. A first method uses panel blocking 172, which is inserted into theplenum 88 of thesingle plenum panel 2, or, as shown, is attached exterior of one of the twosheets single plenum panels 2, or is used on both sides of the panel 2 (attached to the exterior of bothsheets single plenum panel 2, covering the seams, or used on both sides. The two methods can be combined, such as shownFigs. 34A and 34B , where the panel blocking is attached to one side of the panels seam and the tensile strip 174 is attached to the other side. - The panel blocking 172 and tensile strips 174 are easily installed in the field and attached using mechanical 74 and/or adhesive 84 methods.
- The panel blocking 172 is ideally placed on the exterior surface of the load bearing
interior sheet 54 of thesingle plenum panel 2, since it would be hidden byinsulation 36 installed later. - The tensile strip 174 is anticipated to be of minimal thickness with fibrous strength as well as ridged strength. The strip is applied in the field with adhesives or installed and activated with an additional field treatment such as for a fiberglass or carbon fiber strip. If both panel blocking 172 and tensile strip 174 methods are used in combination at the same side of a panel/panel seam, preferably the tensile strip 174 would be attached first and the 172 blocking attached over the tensile strip 174.
- The dimensions and thickness of the panel blocking 172 and the tensile strip 174 connectors are determined by strength requirements. They could be the full length of the
single plenum panel 2, or just part of the length, and could each 172, 174 be of different length. For example, the tensile strip 174 could be attached from one edge of the seam to the other, and the panel blocking 172 could be attached of the tensile strip 174 and cover just half of length of the seam. - The panel blocking 172 connector can be made of wood, wood fiber, aluminum or other metals, plastics, composites, carbon fiber, fiberglass, bent metal or other materials. It is anticipated the panel blocking 172 could be also extruded or formed from these materials.
- The tensile strip 174 connector is probably a thin strip of aluminum or other metal, plastic, reinforced plastics, composites, fiberglass, carbon fiber or other suitable material.
- Although a horizontal connection is shown, the same method could be utilized for a vertical connection as might be required at the gable ends of a
home 6. - Turning next to
Figs. 35A and 35B , a quick method of mechanically connecting spacing structural elements 26 /matrix members 60 of adjacentsingle plenum panels 2 is shown usingspikes 176 that are ideally initially installed in the edges of thematrix members 60. - Adjacent
single plenum panels 2 are thus connected in the field by the movement of afirst panel 2 toward an already installed second single plenum panel 2 (shown by arrows in theFig. 35A ) by means of applying pressure probably by hammering a wood block to lock the adjacentsingle plenum panels 2 together. Thespikes 176 could be attached in the field, but are ideally preinstalled in the factory. - A design of a
possible spike 176 is shown inFig. 35B . The dimensions and thickness of thespike 176 connectors are determined by strength requirements. Though thespike shanks 178 shown are smooth, they could also be ribbed, twisted, or barbed. The spike also has amidline plate 180 used to aid in forcing aspike 176 into amatrix member 60 and seating thespike shank 178 at a given depth in thematrix member 60. - The
spikes 176 can be made of metals including aluminum, strong plastics, composites, or other materials. - Although a horizontal connection is shown, the same method could be utilized for a vertical connection as might be required at the gable ends of a home.
- Although embodiments of the
connectors Figs. 30A-35B are for shown forsingle plenum panels 2, the connectors and variations of the connectors may be used formulti-plenum panels 4. For example, a variation of theH couplers 164 for themulti-plenum panels 4 could resemble anH coupler 164, except with a transvers engaging edge bisecting the mid-portion 166, with the transverse engaging edge engaging a top or bottom surface of themiddle sheet 64 of the multi plenum panels4. Alternatively, a second variation of theH coupler 164 would resemble anH coupler 164 with two closely spaced transvers engaging edges bisecting themid-portion 166 of theH coupler 164. The two transverse engaging edges would be spaced apart at a distance approximately equal to the thickness of themiddle sheet 64 of themulti-plenum panel 4, and when installed, one transverse engaging edge would engage a top surface of themiddle sheet 64 of themulti-plenum panel 4, and one transverse engaging edge would engage a bottom surface of themiddle sheet 64 of themulti plenum panel 4. Additionally, coupling blocks 152 can be easily inserted in one or both of theplenums multi-plenum panel 4 to connect two adjacentmulti plenum panels 4. These connectors could also be used to securely connect asingle plenum panel 2 adjacent to amulti-plenum panel 4 as part of, for example, asame wall 12,floor 18,roof 14, orceiling 16. - Turning now to
Figs. 36 and37 a self-sealing long-toothed screw 132 formulti-plenum panels 4, 10 is shown, which is similar to thetoothed screw 132 forsingle plenum panels Figs. 26A to 28 . The length of theteeth 136 on thelong tooth screw 132 is substantially equal to the sum of the thickness of the top andmiddle sheet multi-plenum panel 4, 10. Though the top andmiddle sheets middle sheet 64 could be wider or thinner than thetop sheet 62, but the length of thelong teeth 136 would still be the sum of the two thicknesses, whatever that may be. - The long
toothed screw 132 operates in a similar manner as thetoothed screw 132 ofFigs. 26A to 28 , except the longtoothed screw 132 will cut through both the first andmiddle sheets bottom sheet 66. - Turning next to
Figs. 38A to 39B , multiple embodiments of methods to ventilate attic spaces when using the single ormulti plenum panels - Although the
single plenum panels multi-plenum panels 4, 10 provide ventilation in excess of code requirements, in some cases, it may be desirable or necessary to ventilate the adjacent attic space. It is possible some officials may have a strict interpretation of governing official provision, such as International Residential Code (IRC) R806.1 - ventilation required for enclosed attics and enclosed rafter space. - One method to provide additional ventilation of attic space constructed of single and
multi-plenum panels multi-plenum panels - This
ventilation strip 182 would preferably be used in conjunction with an opencontinuous ridge vent 48. Thecontinuous ridge vent 48 is preferable, as it would provide an escape formoist air 90 that may migrate into the attic space. A sketch of acontinuous ridge vent 48 with thesingle plenum panels Fig. 38A . Also shown is aridge gap 184 allowingair flow 90 from the twopanel plenums 88 to exit into theridge vent 48. Other venting, such as whirly birds and horizontal vents from the vertical wall of the attic and perforations in theinterior sheet 54 of thepanel 2 could also be used. - The following example describes the
ventilation strip 182 method used with asingle plenum panel median homes 6, this would normally be approximately 10unit panels 2 that aventilation strip 182 would be cut into. Arouter bit 186 set to remove the thickness of the interior sheet 54 (1/4", 3/8" or other thickness of the sheet) and set to remove a depth of ¾" is used along the long edge ofpanels Fig. 38C , thesepanels insulation 36 blown or installed in the attic. This would not be applicable withinsulation 36 applied to theroof panels 14. - Turning to
Fig. 39A , this figure shows arouter 188 removing the ¾"ventilation strip 182 along the long edge of theinterior sheets 54 of asingle plenum panel 2. As mentioned above, theventilation strip 182 can be cut before or after assembly of thepanel 2, at the factory or at the jobsite. Alternatively, one of thesheets 54 of thesingle plenum panel 2 could be originally sized ¾" shorter than theother sheet 58, thus automatically creating theventilation strip 182 once thepanel 2 is assembled. - Turning next to
Fig. 39B , shows the interior of an attic formed unitsingle plenum panels 2, with theventilation strip 182 running the length of the attic space. Though not shown,panels 2 with perforatedinterior sheets 54 may be used in addition or alternatively to the ventilation strips to increase ventilation in enclosed spaces. - Turning next to
Figs. 35 and36 , multiple router bits which could be used to cut the strip are shown. It is understood that strips greater than or less than ¾" in size could be used depending on the desired amount of increased ventilation. - Turning next to
Figs. 40A - 47B , multiple embodiments for securely joiningadjacent panels multi-plenum panels panels matrix members 60 forsingle plenum panels 2 and blocks 68 or other separators for multi-plenum panels 4). These interconnections provide for the transfer of stresses to adjacent panels. There may be instances where the interlocking offset feature may not be used. - In addition to interconnecting
panels adjacent sheets 24 inadjacent panels interconnected sheets 24 would preferably act to transfer stresses as well as fluidly/gaseously sealing thesheets 24 andplenums plenum sheets 24 betweenadjacent panels sheets 24. - The following methods can be used at the
joints 190 of the single andmulti-plenum panels sheets 24 in a single ormulti-plenum panel sheet 24. - Additionally, these methods can be used with or without the already disclosed offset
matrix members 60 or blocks 68, and various means of connecting adjacent panels disclosed herein. - In
Fig. 40A , two sheets with block edges are just joinededge 190 to edge 190. - In all methods, a sealer such as a foam strip can preferably be utilized. Most usually, it would be adhered to one face on a
first sheet 24 and pressed against another, preferably coplanar, face on an abuttingsheet 24. Similarly, as shown inFig. 40B , agasket 194 of vinyl, plastic, foam, etc. that is extruded or formed compressible, preferably hollow, solid can be utilized in the joint. Additionally, an impermeable tape can be applied to the joints on the faces of the panel joints. - Turning to
Fig. 41A an overlap or shiplap joint 190 can be formed by the twosheet 24 edges 192. This provides an increase surface area of attachment while also providing an edge to prevent horizontal movement. - Turning to
Fig. 41B a tongue and grove joint 190 can be formed by the twosheet 24 edges 192. This provides a significant increase in surface area of attachments, and resists movement in two vertical directions and one horizontal direction. A drawback is that asmall tongue 200 may be more liable to break. - Turning to
Fig. 42A , a V with V grove joint 190 can be formed by the twosheet 24 edges 192. Theconvex V 202 self-centers in the concave V grove, providing increased surface area of attachment, and preventing movement in two vertical directions and one horizontal direction, while likely being more structurally robust than the tongue and grove joint shown inFig. 41B - As shown in
Fig. 42B ,separate clips 196 or external elements can be used to joinadjacent sheets 24. A sealer can be used with theclip 196, and theclip 196 can have multiple teeth orcleats 162 in each top and bottom surface of each side to cleat lock theclip 196 onto therespective sheet 24edge 192 when forced on theedge 192. Theclips 196 could also have one or more horizontally extending and preferably ribbed, toothed, orbarbed elements 198 projecting from the vertical surface of theclip 196. Such horizontally extendingelements 198 would puncture the face of theedge 192 of thesheet 24, and extend horizontally into thesheet 24 when theclip 196 was pressed onto theside edge 192 of thesheet 24. - Turning to
Fig. 43A , amiter joint 190 can be formed by the twosheet 24 edges 192. This provides an increased surface area of attachment, but does not prevent horizontal movement as well as other joints. - Turning to
Fig. 43B , a miter with snap/lock feature joint 190 can be formed by the twosheet 24 edges 192. This provides the increased surface area of a miter joint, but thesnap lock feature 206 also aids in resisting horizontal motion in both directions once thesnap lock 206 is engaged. - Turning to
Fig. 44 , a miter with snap/lock feature joint 190 can be formed by the twosheet 24 edges 192. This provides the increased surface area of a miter joint, but thesnap lock feature 206 also aids in resisting horizontal motion in both directions once thesnap lock 206 is engaged. - Turning to
Fig. 45 , the joints can be both secured to one another and sealed by the use of small teeth orprojections 208 or other shaped convex mechanical attachment elements that could be tooled on both a tongue and groove joint and the V-V joint, for example. Theseprojections 208 would grip theadjacent sheet 24 when joined, providing integrated mechanical connection, and also help to fluidly/gaseously seal the joint 190. - The
projections 208 can also be made out of vinyl, plastic, metal or other material and applied individually or as a unit to the male orfemale edge 192 of the joint 190. Theedge 192 with theprojections 208 would then attach and seal to theadjacent sheet 24edge 192 when joined. Additionally, theprojections 208 could be applied to both male and female sides of the joint 190, either offset so that opposingprojections 208 do not interact as the twosheets 24 are joined, or aligned so that opposingprojections 208 pass over one another and interlock as thesheet 24edges 192 are joined.Fig. 45 shows teeth likeprojections 208 on aconvex V 202 and mating recesses 210 on theconcave V grove 204. - Additionally, the V with V grove and the tongue and groove joint, for example, can also incorporate rib like
projections 208 andmating recesses 210 whereby theprojections 208 and recesses 210 would mesh when joined to attachadjacent sheets 24 and substantially fluidly/gaseously seal them. - The mechanical attachment elements could be formed into the edges, unitary with the sheet and out of the same material as the sheet. Alternatively,
structures 212 with mechanical attachment elements (such asprojections 208 and recesses 210) could be attached onto the blocked or V / V grove edges 192. The dashed lines in Figs. 48 and 49 indicating one potential location where thestructures 212 could be attached. Alternatively, the convex projection elements 208 (e.g., each separate tooth) could be made of different material than the sheet and attached separately to one or both of the male or female edge, with or without concavemating recess elements 210 disposed on the other of the male or female edge. - Preferably concave recesses 210 (e.g., notches) are present on one or both edges with mating convex projections 208 (e.g., teeth) on the other or both edges, but
projections 208 could be used alone. For example, aV groove 204edge 192 withteeth projections 208 could be used with aconvex V 202edge 192 that does not have any notches or recesses 210. Alternatively, aconvex V 202edge 192 withteeth projections 208 could be used with aV groove 204edge 192 that does not have any notches or recesses 210. Or both aV groove 204edge 192 and aconvex V 202edge 192 could have teeth projections with neither having any notches or recesses 210. - In a further embodiment, both the male and
female edges 192 could have interlockingprojections 208, such that when, for example, atooth projection 208 on aconvex V 202edge 192 pushed past atooth projection 208 on aV groove 204 edge, the twoteeth projections 208 would interlock with each other and mechanically attach the twoedges 192 together. - Additionally, the
projections 208 and recesses 210 could be narrow, less than 3 mm wide, or moderate size, 3-50mm wide, or could even be substantially be as wide as the length of theabutting edge 192 of thepanel - Additionally, the teeth/ribs or
other projections 208 can be disposed on onenon-vertical edge 192, and preferably a mating notch orother recess 210 can be disposed on an abuttingnon-vertical edge 192 of asheet 24 of anadjacent panel more rib projections 208, and an overlapped half of a shiplap joint could have one or more mating recesses 210. Once thepanels underlying housing structure 6, themating elements joint 190. - Additionally, one or more horizontally extending convex elements on one sheet can mate with one or more horizontally defined interior concave elements - such as the tongue and grove joint of
Fig. 41B . Such a mating of horizontally aligned concave and convex elements on abutting edges of adjacent panels provides for a mechanically vertically interlocking joint - Turning to
Fig. 46 , a further embodiment ofadjacent edge 192 attachments are shown with a tongue and grove arrangement. In this embodimentconcave recesses 210 are disposed preferably on opposing upper and lower surfaces of a male portion of afirst edge 192, e.g., thetongue 200, andmating rib projections 208 are disposed in opposing upper and lower surfaces of a female portion of asecond edge 192, e.g., thegrove 214. - Foam, gel, or other adhesive 84 and/or watertight, and preferably at least initially liquid or malleable substance inserted in space between two adjacent edges (as shown in the Figure by substance on inner vertical wall of the grove 214). The adhesive 84 could alternatively or additionally be applied to the
inner ribs 208, recesses 210, vertical surfaces / surfaces with noprojections 208 orrecesses 210, or some combination thereof. Alternately a hollow flexible, resiliently compressible, and preferablyhollow gasket 194 could be used instead of or in addition to the adhesive 84. Thegasket 194 itself could be adhesive 84. - Tuning next to
Figs. 47A and 47B , a further embodiment is shown. In this embodiment anedge insert 216 is attached to the edge(s) 192 of one or both of theadjacent sheets 24. Theedge insert 216 would preferably have compressible "teeth"projections 208 that would both grasp theadjacent sheet 24 and provide an air barrier to prevent air from passing from or to theplenum 88 through the joint 190. In the embodiment shown, theedge insert 216 is adhered to theconvex V 202edge 192 of a V and V groove joint 190. Thisedge insert 216 would most likely be produced with vinyl, but could also be made out of metal, plastics or similar materials. In another version of this embodiment, a firstcompressible teeth projection 208insert 216 would be adhered to theconvex V 202edge 192, with the teeth extending from the surface of theconvex V 202 edge192, and a secondcompressible teeth projection 208insert 216 would be adhered to theV groove 204edge 192, with theteeth projections 208 extending from the surface of theV groove 204edge 192. When pressed together, the twocompressible teeth projection 208inserts 216 would interlock, providing increased surface area for the seal, and increased friction and mechanical locking to secure theedges 192 to one another.Glues 84 and / or other chemical and mechanical 74 adhesives and / or sealants can be used in addition to thecompressible teeth projections 208insert 216. - While various embodiments of the present invention have been described in detail, it is apparent that various modifications and alterations of those embodiments will occur to and be readily apparent those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the appended claims. Further, the invention(s) described herein is capable of other embodiments and of being practiced or of being carried out in various other related ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items while only the terms "consisting of" and "consisting only of" are to be construed in the limitative sense.
-
- 2
- Single Plenum Panel, Unit Single Plenum Panel
- 4
- Multi-Plenum Panel, Unit Multi-Plenum Panel
- 6
- Home, House, Building
- 8
- Continuous Single Plenum Panel
- 10
- Continuous Multi-Plenum Panel
- 12
- Wall
- 14
- Roof
- 16
- Ceiling
- 18
- Floor
- 20
- Windows
- 22
- Doors
- 24
- Sheet
- 26
- Spacing Structural Elements
- 28
- Foundation
- 30
- Sill Plate
- 32
- Wall Blocking
- 34
- Roof Connector
- 36
- Insulation
- 38
- Roof Adjacent Surface
- 40
- Ceiling Adjacent Surface
- 42
- Inner Building Facing Surface
- 44
- Ridge
- 46
- Perforations
- 48
- Vent
- 50
- Vertical Flange
- 52
- Wall Facing Surface
- 54
- Interior Sheet
- 56
- Sill Plate Blocking
- 58
- Exterior Sheet
- 60
- Matrix Members
- 62
- Top Multi-Plenum Panel Sheet
- 64
- Middle Multi-Plenum Panel Sheet
- 66
- Bottom Multi-Plenum Panel Sheet
- 68
- Spacing Blocks For Multi-Plenum Panel
- 70
- Edge Blocking
- 72
- Joists
- 74
- Mechanical Connectors
- 76
- Connector Holes
- 78
- Top Plenum
- 80
- Bottom Plenum
- 82
- Rim Joists
- 84
- Adhesive
- 86
- Permeable Occlusions
- 88
- Single Plenum Panel Plenum
- 90
- Air Flow
- 92
- Flanged Circle Guide Device
- 94
- Circular Portion
- 96
- Flanged Portion
- 98
- Insulation Guides
- 100
- Trusses
- 102
- Inner Expanse Of Insulation Guide
- 104
- Chase (Hole In Insulation Guide)
- 106
- Transverse Expanse Of Insulation Guide
- 108
- T Shape Flange
- 110
- Front Expanse Of Insulation Guide
- 112
- Electric / Data Box
- 114
- Box (Door / Window Box)
- 116
- Nested Shell
- 118
- Interior Shell
- 120
- Interior Flange
- 122
- Exterior Shell
- 124
- Exterior Flange
- 126
- Shell Blocking
- 128
- Flange Tabs
- 130
- Trim Flange
- 132
- Toothed Screw
- 134
- Shank, Screw
- 136
- Teeth, Screw
- 138
- Head, Screw
- 140
- Drive, Screw
- 142
- Wood Plug
- 144
- Double Headed Screw
- 146
- Top Head
- 148
- Intermediate Head
- 150
- Twisted Bit Base
- 152
- Coupling Blocks
- 154
- Full Clearance Side
- 156
- Matrix Clearance Side
- 158
- Removed Portion
- 160
- Raised Center Guide
- 162
- Cleats
- 164
- H Couplers
- 166
- H Coupler Mid Portion
- 168
- Engaging Surface
- 170
- Capping Portions
- 172
- Panel Blocking
- 174
- Rigid/Tensile Strip
- 176
- Spikes
- 178
- Spike Shank
- 180
- Midline Plate
- 182
- Ventilation Strip
- 184
- Ridge Gap
- 186
- Router Bit
- 188
- Router
- 190
- Joint
- 192
- Edge
- 194
- Gasket
- 196
- Clips
- 198
- Horizontally Extending Elements
- 200
- Tongue
- 202
- Convex V
- 204
- Concave V Grove
- 206
- Snap Lock
- 208
- Projections
- 210
- Mating Recesses
- 212
- Structure
- 214
- Grove of Tongue and Grove
- 216
- Edge Insert
Claims (15)
- A method of constructing a building comprising the steps of
attaching a first panel to a second panel;
wherein the first panel is one of a single plenum panel and a multi-plenum panel; and
the second panel is one of a single plenum panel and a multi-plenum panel. - The method of claim 1 wherein the single plenum panel comprises matrix members connecting a first sheet to a second sheet forming a single plenum panel plenum, and the multi-plenum panel comprises a top sheet and a middle sheet forming a first multi-plenum panel plenum and the middle sheet and a bottom sheet forming a second multi-plenum panel plenum.
- The method of claim 1 further comprising the steps of
forming one of a wall, a roof, a ceiling, and a floor of the building with the first panel; and
forming one of a wall, a roof, a ceiling, and a floor of the building with the second panel. - The method of claim 1 further comprising the steps of attaching the first panel to a blocking.
- The method of claim 1 wherein one of the first panel and the first panel and the second panel extends across an entire span of one of a wall, a roof face, a floor, and a ceiling.
- The method of claim 1 further comprising connecting the first panel to a roof connector.
- The method of claim one further comprising connecting a third panel to the first panel and the second panel.
- The method of claim 1 further comprising the steps of
providing a connector hole in an exterior sheet of the first panel, and
directly mechanically attaching an interior load bearing sheet of the first panel to the second panel. - The method of claim 1 wherein the first panel allows airflow through an interior plenum.
- The method of claim 1 further comprising the step of
drilling a connector hole through an exterior sheet of the first panel with a toothed screw;
screwing a shank of the toothed screw through an interior sheet of the first panel; and
seating a head of the toothed screw on a plenum facing surface of an interior sheet of the first panel. - The method of claim 1 further comprising the step of
inserting a first portion of a coupling block into a plenum of the first panel;
inserting a second portion of a coupling block into a plenum of the second panel; and
fixedly attaching the first panel to the second panel via the coupling block. - The method of claim 1 further comprising the step of
inserting a first edge of the first panel into a first side of an H coupler;
inserting a first edge of the second panel into a second side of the coupler; and
fixedly attaching the first panel to the second panel via the H coupler. - The method of claim 1 further comprising the steps of
inserting a first portion of a shank of a spike into a spacing structural element of the first panel;
inserting a second portion of the shank of the spike into a spacing structural element of the second panel; and
fixedly attaching the first panel to the second panel via the spike. - The method of claim 1 further comprising the step of providing a ventilation strip along an interior sheet of the first panel.
- The method of claim 1 further comprising the step of one of mechanically and adhesively attaching an edge of a sheet of the first panel to an edge of a sheet of the second panel with attachment means.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201562100660P | 2015-01-07 | 2015-01-07 | |
US201562210616P | 2015-08-27 | 2015-08-27 |
Publications (2)
Publication Number | Publication Date |
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EP3045599A2 true EP3045599A2 (en) | 2016-07-20 |
EP3045599A3 EP3045599A3 (en) | 2016-11-09 |
Family
ID=55168131
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP16150440.2A Withdrawn EP3045599A3 (en) | 2015-01-07 | 2016-01-07 | Frameless construction using single and double plenum panels |
Country Status (3)
Country | Link |
---|---|
US (1) | US20160194864A1 (en) |
EP (1) | EP3045599A3 (en) |
CA (1) | CA2916690A1 (en) |
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US20200248443A1 (en) * | 2019-02-06 | 2020-08-06 | Steve Bates | Structure with integrated insulation |
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US10875218B2 (en) * | 2016-09-01 | 2020-12-29 | Bryan Scott Mello | Method and apparatus for manufacturing building panels |
CN112189073A (en) | 2018-02-12 | 2021-01-05 | 超墙有限公司 | Improvements relating to the joining of structural members to sheet materials |
US20220349195A1 (en) * | 2018-11-26 | 2022-11-03 | The Perfect Space Llc | De-constructible small inhabitable enclosure |
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Also Published As
Publication number | Publication date |
---|---|
US20160194864A1 (en) | 2016-07-07 |
EP3045599A3 (en) | 2016-11-09 |
CA2916690A1 (en) | 2016-07-07 |
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