US20050246968A1 - Patio enclosure - Google Patents
Patio enclosure Download PDFInfo
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- US20050246968A1 US20050246968A1 US11/116,081 US11608105A US2005246968A1 US 20050246968 A1 US20050246968 A1 US 20050246968A1 US 11608105 A US11608105 A US 11608105A US 2005246968 A1 US2005246968 A1 US 2005246968A1
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- wall
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- beams
- channel
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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
- E04B1/0046—Loggias
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Abstract
An enclosed structure, such as a patio enclosure, sunroom, or solarium, is attachable to the exterior wall of a building, has a high proportion of windows and a roof, and constructed from a framework of composite members and insulating wall panels, the panels and wall members being extruded from material having improved thermal characteristics and stability.
Description
- This application is a completion application of co-pending U.S. Provisional Patent Application Ser. No. 60/566,673, filed Apr. 30, 2004, the entire disclosure of which is hereby incorporated by reference.
- 1. Field of the Invention
- This invention relates to an enclosed structure that may be attached to the exterior wall of an existing or new building, such structure typically being referred to as a patio enclosure, sunroom, or solarium. More particularly, the invention relates to a patio enclosure having a high proportion of windows and a roof and constructed from a framework of composite members and insulating wall panels. Even more particularly, this invention relates to composite plastic members extruded from material having improved thermal characteristics and stability.
- 2. Description of Prior Art
- Patio enclosures and sunrooms are not new to the building industry. When adding onto or remodeling an existing home or other structure, many people turn to the patio enclosure or sunroom. Such rooms are relatively easy for trained technicians to construct and are inexpensive when compared to other improvements that can be made to a home, such as remodeled bathrooms or kitchens. These enclosures have traditionally been constructed of an aluminum frame with windows or glass sections. Aluminum sunrooms are shaped with vertical walls that have a curved transition to the roof, although most may have a marquee roof or gable type roof.
- The following U.S. Patents and Patent Publication illustrate various enclosures, non-metallic structural elements used in constructing these enclosures, and the materials used in forming the non-metallic structural elements: Nos. 5,497,594 to Guiseppe et al.; 5,848,512 to Conn; 6,003,279 to Schneider; 6,015,611 to Deaner et al.; 6,117,924 to Brandt; 6,248,813 to Zehner; 6,412,227 to DeZen; 6,337,138 and 6,344,504 to Zehner et al.; 6,460,309 to Schneider; and 2002/0066248 to Buhrts et al.
- As discussed in Schneider U.S. Pat. No. 6,003,279 and U.S. Pat. No. 6,460,309, aluminum framed enclosures have several disadvantages. The main problem is poor thermal efficiency. Due to the high rate at which aluminum conducts heat, a room constructed from aluminum cannot stay comfortably cool in the summer, without air conditioning, or warm in the winter, without supplemental heating. This drawback results in dramatically increased cooling and heating costs. Further, a high rate of heat transfer can lead to condensation on the interior surfaces of the aluminum structures. Moreover, many of the windows in aluminum frame type sunrooms are generally installed in such a way that the windows cannot be opened and no screens are present.
- Another disadvantage is high maintenance. Aluminum must be painted if chipped and is easily dented. Construction of aluminum rooms is a major disadvantage as well. Because of the nature of the metal, the aluminum pieces must be assembled with external fasteners. External fasteners increase the time of assembly and degrade the overall aesthetics of the room.
- In light of these various deficiencies, Schneider U.S. Pat. No. 6,003,279 discloses various structural members, which include reinforced and non-reinforced polyvinyl chloride extrusions, which are joined together at joints using hardware which cannot be seen from inside or outside the enclosure, thereby enhancing the aesthetic appeal of the enclosure. Further, Conn U.S. Pat. No. 5,848,512 and Schneider U.S. Pat. No. 6,460,309 disclose an I-beam that is extruded from plastic and configured such that the vertical spacer wall defines a central passageway that extends between the opposite ends of the beam. Schneider U.S. Pat. No. 6,460,309 is directed to a vinyl roofing system utilizing the channel beam to interconnect roof panels with a roof cap.
- In obviating certain of the problems associated with unwanted condensation and thermal conductivity, many framing enclosure designs have used a “sleeve” approach wherein the aluminum elements and sections are enclosed within PVC frames. A drawback to this approach is that the aluminum reinforcing still has to be properly insulated from the rest of the vinyl profile. This approach results in massive, bulky sections with high material costs.
- A need continues for a low maintenance sunroom/patio enclosure that is economical, has improved thermal efficiency and minimizes thermal condensation arising from thermal transmittance, provides sliding or double hung windows and/or doorway, has an aesthetic appearance, conceals connecting fasteners, and employs fastening components that are easy to use when erecting the enclosure.
- Accordingly, a primary object of this invention is the provision of a sunroom/patio enclosure that obtains the benefits of framing elements and sections of polymeric and like material, and achieves the above noted needs.
- Another object of this invention is the provision of a sunroom/patio enclosure using frame elements formed of composite PVC to allow parts to have smaller cross-sections without a great degree of internal reinforcing.
- As is known, steel has much lower conductivity to thermal loss than aluminum, and has higher strength properties with lower cost.
- Accordingly, another object of this invention is the elimination of most if not all aluminum components from the enclosure product, such as by replacing some frame connecting elements with galvanized steel.
- Another object of this invention is the provision of an enclosure structure that shows no screw heads on the inside or the outside of the enclosure room.
- A further object of this invention is the provision of an enclosure structure comprised of composite PVC to combine the properties of wood with the maintenance free advantages of vinyl.
- Briefly described the objects of the present invention are achieved, in a room structure for attachment to the exterior wall of a building mounted on a foundation adjacent to said exterior wall, said room structure comprising an upright frame assembly having an upper end and formed by at least one enclosure wall and a roof structure extending between said exterior wall and the upper end of said frame assembly, said frame assembly including at least one vertically disposed support member, the improvement wherein
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- said support member comprises an assembly of an H-beam and a closure member,
- each said support member and H-beam being comprised of a single piece of composite and having a like vertical height,
- said H-beam being formed by a spacer wall and a pair of webs, the spacer wall extending between the webs and disposed inwardly and between the outer edges of the webs wherein to form a pair of outwardly open squared-C channels, and
- said closure member being formed by a pair of sidewalls and a base wall, the sidewalls extending from opposite edges of the base wall wherein to form a squared-C cross-section, the closure member being snap-fittable in a friction fit into one of the squared-C channels of the H-beam to substantially close said channel and in a manner that the exterior base wall of the closure member and the edges of webs of the squared-C channel into which interfitted are substantially coplanar.
- According to an important aspect, the H-shaped beam and C-shaped closure member are extruded from a composite PVC plastic.
- A preferred embodiment according to this invention is the provision of a beam structure for a patio enclosure, the beam structure comprising
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- a support member and a filler member, said members extending longitudinally and each of a generally constant cross-sectional shape,
- said support member having a base wall, first and second walls disposed generally perpendicularly to the plane of said base wall, and outer end faces disposed parallel to the plane of said base wall, the first and second walls cooperating to define an outwardly open longitudinally extending channel sized to receive said filler member, and
- said filler member having a base member and a pair of upstanding sidewalls adapted to frictionally engage and form a snug snap-fit engagement with a respective of said first and second walls, the base member and the outer end faces forming a generally continuous surface following said interfitment.
- According to an aspect of this embodiment, the support member comprises a generally H-shaped beam member and the channel thereof has a squared-C cross-section, the filler member has a squared-C cross-section, and the H-shaped beam member and filler member are extruded, or injection molded from a synthetic wood composition.
- According to another aspect of this invention, the H-shaped beam member has a pair of flange members, each forming a respective of said outer end faces, and the exterior surfaces of the outer end faces and the exterior surface of the filler member are clad with vinyl cap stock.
- Another preferred embodiment according to this invention is the provision of modular wall for a patio enclosure formed as an add-on extension to an existing structure supported on the ground and having framing structure for at least one of a window or door, the modular wall comprising:
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- a longitudinally extending upper and lower track beam, the lower track beam being supported on the ground,
- a pair of vertically extending corner posts, each post having an upper and lower end portion and forming at least one outwardly open channel,
- at least one vertically extending H-beam disposed between the posts and defining a pair of separated wall sections, the H-beam having an upper and lower end portion and forming a pair of opposed outwardly open channels,
- said wall section including a lower and an upper C-shaped cross-beam, a lower and an upper wall panel, and the framing structure sandwiched between said wall panels, said cross-beam having opposite longitudinal ends, a base having an outer surface, and an outwardly open channel, said lower and upper wall panel having, respectively, upper and lower edges engaged with the outer surface of a respective cross-beam, lower and upper edges interfitted within the channel of said lower and upper track beam, and vertically disposed side edges interfitted within the channels of said corner posts and H-beam,
- first means for positioning and securing the lower end portions to the lower track beam and the upper end portions to the upper track beam, wherein said track beams are disposed in generally parallel horizontal relation, said corner posts are secured and positioned at the opposite longitudinal ends of the lower track beam, and the channels of said H-beam and said corner posts are facing one another,
- second means for enclosing the outwardly open channels of said corner posts and said H-beam wherein to cover said first means, at least in part, and
- third means for positioning and securing the opposite ends of the cross-beams to said corner post and H-beam.
- According this embodiment of the invention, the second means comprises a filler beam of predetermined cross-section, which filler beam is frictionally interfit in a snug-fit into the respective channel to form an exterior surface that appears to be unitary.
- Further, and according to an important aspect of this embodiment, the upper and lower track beams, the corner posts, the H-beam, the cross-beams, and the filler beam are extruded or injection molded from a synthetic wood PVC composition and have exterior surfaces selectively clad with vinyl cap stock.
- Another preferred embodiment according to this invention is the provision of a wall joint for a patio enclosure, which enclosure is formed as an add-on extension to an existing structure, supported on the ground, and has framing structure for at least one of a window or door, the wall joint comprising:
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- a first pair of longitudinally extending upper and lower track beams and a second pair of longitudinally extending upper and lower track beams, the first pair of track beams being disposed at a right angle to the second pair of track beams and each said lower track beam being supported on the ground,
- a vertically extending corner post, said post having a lower and upper end portion and forming outwardly open first and second channels, the channels being disposed at right angles to one another,
- a vertically extending first and second wall section, each said wall section including upper and lower end portions that are juxtaposable with and extend along a respective pair of said lower and upper track beams, said first wall section having a first vertical edge that is juxtaposable with the first channel of said corner post and at least one framing structure, and said second wall section having a second vertical edge that is juxtaposable with the second channel of said corner post and at least one framing structure,
- first means for securing and positioning the lower end portion of said corner post and said lower track beams to said support wherein the first and second channels are juxtaposed with the ends of the lower track beams,
- second means for securing and positioning the upper end portion of said corner post to said upper track beams,
- third means for enclosing the outwardly open first and second channels of said corner post wherein to cover each said first and second means, at least in part, and
- fourth means for connecting the wall sections to the track beams and said corner post.
- Another preferred embodiment according to this invention is the provision of a new and improved extruded article, said article produced by extruding a cellulosic inorganic filled plastic composite, the composite consisting of a bound together mixture of polyvinyl chloride, a cellulosic material, selected from sawdust, finely pulverized dried wood, and wood flour, baking flour, and a binder.
- A further preferred embodiment according to this invention comprises a kit for constructing an enclosure to the exterior wall of an existing structure, said kit comprising:
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- a plurality of wall panels of predetermined height, width, and thickness,
- framing structure, such as for providing at least one window or door, as required,
- a plurality of elongated track beams, the track beams forming upper and lower end caps of front and side walls formed by the kit and each having a central track,
- a plurality of vertical uprights of H-shaped cross section, the H-beam forming two opposed outwardly opening C-shaped channels,
- a plurality of C-shaped cross-beams, the cross-beam having an outwardly open C-shaped channel,
- a plurality of corner posts of generally square cross section and forming two outwardly opening channels of squared-C cross-section,
- means for positioning and securing the wall panels, framing structure, track beams, H-beams, C-shaped cross-beams, and corner posts to one another and the support structure, and
- a plurality of closure members of squared-C cross-section, the closure members being snap-fittable into a respective C-shaped channel provided in the H-beam and corner post, wherein to close the channel and form a unitary appearing exterior.
- Preferably, and according to this embodiment of the invention the track beams, H-beam, corner-post, C-shaped cross-beam, and closure members of the kit are extruded or injection molded of a composite PVC, with predetermined exterior surfaces of each clad with a protective surface of vinyl.
- These and other objects, advantages and features of the invention will become apparent from the following description taken in conjunction with the accompanying drawings, which illustrate specific embodiments of the invention. In the drawings:
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FIG. 1 is an exploded perspective view of a patio enclosure positioned for assembly using a variety of frame members and structural elements according to this invention; -
FIGS. 1A-1E are cross-sectional views of structural elements used in assembling the enclosure ofFIG. 1 ; -
FIG. 2 is an elevation view showing the front side of the patio enclosure ofFIG. 1 , following assembly to an exterior wall of a house; -
FIG. 3 is an elevation view showing the left side of the patio enclosure ofFIG. 2 ; -
FIG. 4 is an elevation view showing the right side of the patio enclosure ofFIG. 2 ; -
FIG. 5 is a section view of the front wall taken along line 5-5 ofFIG. 2 showing an H-beam disposed vertically, C-shaped upper and lower track members disposed horizontally, L-shaped flanges securing the opposite ends of the beam to the track members, and connections that extend along the top and bottom ends of the front wall of the enclosure and connect the upper track member to the lower front end of the roof structure and the lower track member to the ground structure; -
FIG. 6 is a section view of the front wall taken along line 6-6 ofFIG. 2 showing a C-shaped channel member disposed horizontally, the bottom edge of a window channel supported on the channel member, the upper and lower edges of a front wall panel received in the channel member and lower track member, and a connection, which extends along and connects the front wall of the enclosure to the ground structure; -
FIG. 7 is a section view of the front wall taken along line 7-7 ofFIG. 2 showing the upper track member, the top edge of the window channel supporting a channel member, the upper and lower edges of a the front wall panel received in the upper track member and the channel member, and a the connection between the upper track member and the roof structure; -
FIG. 8 is a section view of the right side wall taken along line 8-8 ofFIG. 4 showing a channel member, the top edge of a window channel supporting the channel member, the upper and lower edges of a right side wall panel received in the upper and channel members, and a connection between the upper track member and the roof structure, which extends along and between the lower front and upper rearward end of the roof structure of the enclosure; -
FIG. 9 is a section view of the front wall taken along line 9-9 ofFIG. 2 showing two window channels separated by an H-beam, and a pair of L-shaped flanges and a pair of E-shaped filler channels interfitted into oppositely facing outwardly open channels of the H-beam, the flanges for connecting the H-beam to the a track member, and thus to the ground structure; -
FIG. 10 is a section view of the front wall taken along line 10-10 ofFIG. 2 showing opposite edges of front wall panels and an L-shaped flange for connecting the beam to the ground structure interfitted into oppositely facing outwardly open channels of the H-beam; -
FIG. 11 is a section view of the right side wall taken along line 11-11 ofFIG. 4 showing a C-shaped track member connected to the exterior wall, a window channel, and an E-shaped filler and an L-shaped flange interfitted into an outwardly open channel of the track member; -
FIG. 12 is a section view of the right side wall taken along line 12-12 ofFIG. 4 showing a track member disposed vertically and connected to the exterior wall and a vertical edge portion of an enclosure panel interfitted into the track member; -
FIG. 13 is a section view of the left side wall taken along line 13-13 ofFIG. 3 showing a C-shaped track member disposed vertically and connected to the exterior wall, a C-shaped track disposed vertically and connected by an L-shaped flange to the lower track, and thus to the ground structure, and a wall panel having opposite vertical edges interfitted into opposed channels of the track members; and -
FIG. 14 is a section view taken along line 14-14 ofFIG. 3 showing a box-shaped corner post having opposed channels for connecting the left and front wall panels to one another, and L-shaped flanges for connecting the corner post to a track member of the enclosure. - Referring to
FIGS. 1 and 2 -4 there is shown an exemplary patio enclosure, generally indicated at 10, constructed according to the present invention. Theenclosure 10 is supported from below by a load-bearing substrate 12 and laterally by theexterior wall 14 of an existing structure, such as a house (not shown). Theload bearing substrate 12 may be a concrete slab, wood decking, or the like. - As shown in
FIG. 1 , theenclosure 10 comprises afront wall 16, a pair oflateral side walls sloping roof 22. Thewalls substrate 12 where they are joined to theroof 22. Thesidewalls front wall 16. - The walls and roof of the
enclosure 10 are formed by a framework of joined horizontal and vertical structural members, such as structuralfiller wall panels 24 androof panels 26, multiple pairs of slidingglass windows 28, framedscreens 30 for each pair of windows (one shown), and an optionalconventional door assembly 32. - Each
wall panel 24 is generally rectangularly shaped and has acentral body 24 a of polymeric material, such as foam, andouter layers wall panel 24 is such that the lateral edges thereof may be interfitted into the squared-C channel of a structural element according to this invention (described in detail below). Preferably, both of thelayers - Preferably and according to this invention, certain of the structural elements used in this assembly are shown and identified on
FIGS. 1A-1E . These structural elements include acorner post 34, a post or H-beam 36, abase track 38, across-beam channel 40, and afiller 44. As will be discussed below, nails, screws and like threaded fasteners, flanges and like connecting elements are used to connect the structural elements together and form modular wall portions and thepatio enclosure 10. - Preferably and according to this invention, each of these structural elements are comprised of a composite PVC material and extruded into the desired cross-section and length. Subsequent to extrusion, a vinyl surface is clad to the exterior surfaces of the structural elements. The resulting element is sometimes referred to a composite PVC element. The structural elements made from the composite PVC material are generally stronger than wood, metal, or vinyl, has no adverse heat conduction, and has the durability of vinyl. Although extrusion is a preferable method, these elements may be injection molded.
- According to one aspect, the composite material is comprised of a bound together mixture of cellulosic material (esp. sawdust or like finely pulverized dried wood, such as wood flour) and baking flour (e.g., the fine powdery foodstuff obtained by grinding and sifting the meal of a grain, especially wheat, used chiefly in baking). Suitable woods for sawdust are resin-free softwoods such as pine, fir and spruce, and to a lesser extent, hardwoods. The percentage of sawdust to baking flour, measured by weight or volume, and a binder and/or mixer ingredient used to hold the composition together is determined, in part, on a cross-section property of the structural element that is desired (i.e., thickness and area moment of inertia of the cross-section).
- Referring to
FIG. 1A , thecorner post 34 is box-like, in cross-section, axially elongated, and formed bywalls central opening 54 and outwardly open squared-C shapedchannels wall panel 24. Thewalls surfaces - Referring to
FIG. 1B , the post or H-beam 36 is axially elongated and includes acentral body 60 and a pair oftransverse flanges channels flanges central body 60 is hollow and defines a central rectangular-shapedpassageway 66. - Referring to
FIG. 1C , thebase track 38 is axially extending and includes aflat base member 68 having oppositelateral edges arms track 73 therebetween. The L-shapedarms base member 68 and define opposed squared-C shapedchannels central track 73. Thearm 70 extends along and upstands from thelateral edge 68 a of thebase member 68. Thearm 72 extends along and upstands from thebase member 68 at a location inwardly of thelateral edge 68 b of thebase member 68 wherein to define an offsetbase portion 69. The exterior surfaces 70 b, 72 b, and 69 a, respectively, of theupstanding arms base portion 69 are clad with vinyl. - Referring to
FIG. 1D , thecross-beam channel 40 is axially extending and forms a generally squared-C shape in cross-section. Thechannel 40 includes abase member 76 and a pair of opposedupstanding legs 78 wherein to define a squared-C shapedchannel 80 having a width adapted to receive the lateral edge of awall panel 24 interfitted therewithin. Thebase member 76 is hollow and defines a central rectangular shapedpassageway 77. Theexterior surface base member 76 and thelegs 78 are clad with vinyl. - Referring to
FIG. 1E , thefiller 44 is axially extending and generally E-shaped in cross-section. Thefiller 44 includes aflat base 82 and threeupstanding legs legs leg 86 being a central leg upstanding from a central location of thebase 82. Thelegs legs channels exterior surface 82 a of thecentral base member 80 is clad with vinyl. - As shown in
FIGS. 1 and 2 -4, the front, left, andright walls enclosure 10 are assembled by he formed by various of thestructural elements wall panels 24. As shown inFIG. 2 , thefront wall 16 is defined by and extends between two box-beams 34 and includes two H-beams 36 wherein to define three modular wall portions, each portion including awindow framing 28 andwall panels 16. As shown inFIGS. 3 and 4 , the left andright side walls box beam 34 and abase track 38. Theright side wall 20 includes an H-beam 36 and defines two modular wall portions and theleft side wall 18 includesoptional door framing 32. - As shown in
FIG. 5 , the modular wall portion of thefront wall 16 includes elongated lower and upper base tracks 38, denoted as 38 a and 38 b and disposed horizontally, and an H-beam 36 disposed vertically. L-shapedflanges 90 are secured at predetermined locations along the lower and upper base tracks 38 a and 38 b and serve to properly space and position the H-beams 36 and the corner box-beams 34 in a manner to receivewall panels 24, or door orwindow framing - The
lower base track 38 a is positioned atop thesubstrate 12 and secured thereto by an L-shapedflange 90 and at least one threadedfastener 92. Theflange 90 hasopposite legs track 73 formed between the opposed L-shapedarms base member 68 with theflange leg 90 a seated atop thebase member 68 of thebase track 38 a and theflange leg 90 b extending vertically upwardly from the base track.Fasteners 92 extend through theflange leg 90 a, thebase member 68, and into thesubstrate 12. - The
upper track 38 b forms the upward vertical extension of thefront wall 24 and is secured, at least in part, to the upward vertical extension of the H-beam 36. As with thetrack 38 a, theupper track 38 b is provided withpositioning flanges 90. - The lower and upper ends 36 a and 36 b of the H-
beam 36 are nested into arespective track 73 formed between the opposed L-shaped arms of eachrespective track flanges 90 secured to the lower andupper tracks flange leg 90 b extending upwardly from thelower track 38 a is threadably secured to the lower end portion of the H-beam, and theflange leg 90 b extending downwardly from theupper track 38 b is threadably secured to the upper end portion of the H-beam. - A
wall panel 24 is inserted downwardly into the opposed squared-C channels of successive H-beams 36 orcorner post 34 and H-beam 36. As can be seen inFIG. 5 , the protectiveouter layers panel 24 are generally coextensive (i.e., flush) with the outward extension of theflanges beam 36. - The
upper track 38 b forms a closure cap and support for a forward lower front end of theroof structure 22. To provide support and sealing, an axially elongated, generallycylindrical strand 94 of elastomeric material is supported atop theupper track 38 b, on the extended base portion 74 thereof, and supports and moisture seals theroof structure 22 of theenclosure 10. - As shown in
FIG. 6 , across-beam channel 40 is interfitted onto and supported atop the upper lateral horizontally extending edge of thewall panel 24. Further, window framing 28 is thereafter supported atop thecross-beam channel 40. - As shown in
FIG. 7 , across-beam channel 40 is interfitted onto the lower lateral horizontally extending edge of thewall panel 24. Further, window framing 28 is thereafter abutted against thecross-beam channel 40. In a manner described in connection withFIG. 5 , theupper track 38 b andstrand 94 are shown in relation to theroof structure 22. - As shown in
FIG. 8 , theupper track 38 b of theright wall 20 is shown supporting theroof structure 22. Theright wall 22 includes anupper track 38 b, awall panel 24, andwindow framing 28. Because the upper end of theright wall 20 angles upwardly and is supporting relation with the bottom surface of theroof structure 22, thesupport strand 94 is not needed. Further, the base portion 74 extends in a direction outwardly of theenclosure 10. - As shown in
FIG. 9 , an H-beam 36 is shown separating twowindow framing sections 28, and L-shapedflanges 90 are connected to opposite sides of thecentral body 60 extending between theflanges E-shaped filler 44 is inserted into each of the two opposed squared-C channels - According to this invention, the cross-sections of the
filler 44 and the squared-C channels filler 44 forms, with the flanges and channels of the H-beam, a closure that makes the beam and filler elements appear as one unitary structure. That is, thebase surface 82 a of thefiller 44 and the surfaces formed by the lateral edges of therespective flanges outer legs filler 44 and the interior facing walls of theflanges - As shown in
FIG. 10 , the opposed squared-C channels beam 36 are shown receiving opposite respective lateral vertical edges of a respective pair ofpanels 24, and aflange 90 positioning the H-beam 36. - As shown in
FIG. 11 , atrack 38 is disposed vertically and connected to the existingstructure 14, and window framing 28 of theleft side wall 18 is shown relative to the track. - Further and according to this invention, the cross-sections of a
filler 44 and thecentral track 73 of abase track 38 are such that thefiller 44 forms, with thecentral track 73, a closure that makes the two elements appear as one unitary structure. The interfitment between theouter legs filler 44 and the interior facing ends of the L-shapedarms base track 38 results in a snug snap-fit frictional interengagement. - As shown in
FIG. 12 , abase track 38 is threadably fastened to theexterior wall 14 and the vertical lateral edge of awall panel 24 is interfitted within thetrack 73 formed between the opposed L-shapedarms base track 38. - As shown in
FIG. 13 , abase track 38, awall panel 24, and across-beam channel 40 extend vertically upwardly from their connection to a horizontally extending lower base track (not shown). The opposite lateral vertically disposed edges of thewall panel 24 are interfitted within thecentral track 73 and squared-C channel 80 formed by the vertically disposedbase track 38 andcross-beam channel 40. Aflange 90 positions and secures the lower end of thecross-beam channel 40 relative to the lower base track. Further, thecross-beam channel 40 positions associatedwindow framing 28. - As shown in
FIG. 14 , acorner post 34 connects the vertical edges of the left andfront walls corner post 34 extends vertically upwardly from thesubstrate 12 and is connected to twobase tracks 38 a, the base tracks extending horizontally along the substrate and at right angles to one another. The twobase tracks 38 a are connected to thesubstrate 12 by L-shapedflanges 90 in a manner described above. One L-shapedflange 90 is disposed in onebase track 38 a and has avertical leg 90 a received in the squared-C channel 56 and threadably fastened to thewall 48 of the corner post beam. The other L-shapedflange 90 is disposed in theother base track 38 a and has avertical leg 90 a received in the squared-C channel 58 and threadably fastened to thewall 50 of the corner post beam. - An
E-shaped filler beam 44 is snugly interfitted within the squared-C channels corner post 34 with a clean aesthetic appearance. - As shown in
FIG. 1 , theroof 22 is generally rectangularly shaped, angles downwardly from theexterior wall 14, and is generally coextensive with the front andside walls enclosure 10. The roof structure includes severally generally rectangularly shapedroof panels 26, arearward channel bracket 98, aforward channel bracket 100, left andright end brackets roof panels 26 are as described for thewall panels 24. Further, thechannels brackets - The
rearward channel bracket 98 is mounted to theexterior wall 14 and has an outwardlyopen channel 98 a adapted to receive rearward lateral edges of theroof panels 26 and rearward end portions of the H-beams 36. - The
forward channel bracket 100 has an outwardlyopen channel 100 a adapted to receive forward lateral edges of theroof panels 26 and forward end portions of the H-beams 36. Further, thechannel bracket 100 includes an upwardlyopen channel 100 b which forms a gutter or trough for directing water from the roof - The left and
right end brackets 102ands 104 have outwardlyopen channels 102 a and 104 a, respectively, for receiving the lateral edge of aroof panel 26. - As assembled, the
rear channel 98 is connected to theexterior wall 14. Therectangular roof panels 26 have their opposite longitudinal edge portions interfitted within thechannel beam 36, or left andright end bracket channel forward channel brackets channel brackets right end brackets - As contemplated herein, the
patio enclosure 10 may be advantageously supplied to the user in kit form, ready to go and for assembly to an existing structure. The kit for constructing an enclosure to the exterior wall of an existing structure would generally comprise the various structural elements as described in detail herein above. - In particular, the kit would comprise a plurality of
wall panels 24 of predetermined height, width, and thickness, framingstructure side walls vertical uprights 36 of H-shaped cross section, a plurality of corner posts 34, a plurality of C-shapedcross-beams 40, a plurality ofclosure members 44 of squared-C cross-section, the closure members being snap-fittable into a respective C-shaped channel provided in the H-beam and corner post, andfasteners - Preferably, and according to this embodiment of the invention, the track beams, H-beam, corner-post, C-shaped cross-beam, and closure members of the kit are extruded or injection molded of a composite PVC, with predetermined exterior surfaces clad with a vinyl.
Claims (20)
1. A room structure for attachment to the exterior wall of a building mounted on a foundation adjacent to said wall, said room structure comprising an upright frame assembly having an upper end and formed by at least one enclosure wall and a roof structure extending between said exterior wall and the upper end of said frame assembly, said frame assembly including at least one vertically disposed support member, the improvement wherein
said support member comprises an assembly of an H-beam and a closure member,
each said support member and H-beam being comprised of a single piece of composite and having a like vertical height,
said H-beam being formed by a spacer wall and a pair of webs, the spacer wall extending between the webs and disposed inwardly and between the outer edges of the webs wherein to form a pair of outwardly open squared-C channels, and
said closure member being formed by a pair of sidewalls and a base wall, the sidewalls extending from opposite edges of the base wall wherein to form a squared-C cross-section, the closure member being snap-fittable in a friction fit into one of the squared-C channels of the H-beam to substantially close said channel and in a manner that the exterior base wall of the closure member and the edges of webs of the squared-C channel into which interfitted are substantially coplanar.
2. The room structure according to claim 1 , wherein the spacer wall of said H-shaped beam is centrally apertured, the aperture extending between the opposite ends of the beam.
3. The room structure according to claim 1 , wherein the H-shaped beam and C-shaped closure member are extruded from a composite PVC plastic.
4. A beam structure for a patio enclosure, the beam structure comprising
a support member and a filler member, said members extending longitudinally and each of a generally constant cross-sectional shape,
said support member having a base wall, first and second walls disposed generally perpendicularly to the plane of said base wall, and outer end faces disposed parallel to the plane of said base wall, the first and second walls cooperating to define an outwardly open longitudinally extending channel sized to receive said filler member, and
said filler member having a base member and a pair of upstanding sidewalls adapted to frictionally engage and form a snug snap-fit engagement with a respective of said first and second walls, the base member and the outer end faces forming a generally continuous surface following said interfitment.
5. The beam structure according to claim 4 wherein
the support member comprises a generally H-shaped beam member and the channel thereof has a squared-C cross-section, and
the filler member has a squared-C cross-section.
6. The beam structure according to claim 4 , wherein at least one said member is injection molded from a polymeric material.
7. The beam structure according to claim 4 , wherein at least one said member is extruded from a synthetic wood composition.
8. The beam structure according to claim 4 , wherein
the H-shaped beam member has a pair of flange members, each forming a respective of said outer end faces, and
the exterior surfaces of the outer end faces and the exterior surface of the filler member are clad with vinyl cap stock.
9. A modular wall for a patio enclosure formed as an add-on extension to an existing structure supported on the ground and having framing structure for at least one of a window or door, the modular wall comprising:
a longitudinally extending upper and lower track beam, the lower track beam being supported on the ground,
a pair of vertically extending corner posts, each post having an upper and lower end portion and an outwardly open channel extending between the end portions,
at least one vertically extending H-beam disposed between the corner posts and defining in combination with the corner posts a pair of laterally separated wall sections extending vertically between the track beams, the H-beam having upper and lower end portions and a pair of opposed outwardly open channels extending between the end portions thereof,
at least one said wall section comprising a lower and an upper cross-beam, and a lower and an upper wall panel, and said framing structure, wherein said cross-beams have opposite longitudinal ends and an outwardly open channel extending between the respective ends, said framing structure is disposed between said cross beams, said upper wall panel extends between the upper track and the upper cross-beam, and said lower wall panel extends between the lower cross-beam and the lower track member,
first means for positioning and securing the lower end portions to the lower track beam and the upper end portions to the upper track beam, wherein said track beams are disposed in generally parallel horizontal relation, said corner posts are secured and positioned at the opposite longitudinal ends of said lower and upper track beams, and the outwardly open channels of said H-beam and said corner posts are facing one another,
second means for enclosing the outwardly open channels of said H-beam and said corner posts wherein to cover said first means, at least in part, and
third means for positioning and securing the opposite longitudinal ends of said cross-beams to said H-beam and said corner post, wherein the outwardly open channels of the cross-beams, track members, corner posts and H-beam cooperate to form a channel for receiving the respective edges of the upper and lower wall panels.
10. The modular wall according to claim 9 , and further wherein
the second means comprises a filler beam of predetermined cross-section, which filler beam is frictionally interfit in a snug-fit into the respective channel to form an exterior surface that appears to be unitary.
11. The modular wall according to claim 10 , and further wherein the upper and lower track beams, the corner posts, the H-beam, the cross-beams, and the filler beam are extruded or injection molded from a synthetic wood PVC composition.
12. The modular wall according to claim 11 , and further wherein the exterior surfaces of said beams are selectively clad with vinyl cap stock.
13. A wall joint for a patio enclosure, which enclosure is formed as an add-on extension to an existing structure, supported on the ground, and has framing structure for at least one of a window or door, the wall joint comprising:
a first pair of longitudinally extending upper and lower track beams and a second pair of longitudinally extending upper and lower track beams, the first pair of track beams being disposed at a right angle to the second pair of track beams, and each said lower track beam being supported on the ground,
a vertically extending corner post, said post having a lower and upper end portion and forming outwardly open first and second channels, the channels being disposed at right angles to one another,
a vertically extending first and second wall section, each said wall section including upper and lower end portions that are juxtaposable with and extend along a respective pair of said lower and upper track beams, said first wall section having a first vertical edge that is juxtaposable with the first channel of said corner post and at least one framing structure, and said second wall section having a second vertical edge that is juxtaposable with the second channel of said corner post and at least one framing structure,
first means for securing and positioning the lower end portion of said corner post and said lower track beams to said support wherein the first and second channels are juxtaposed with a respective end of one and the other of said lower track beams,
second means for securing and positioning the upper end portion of said corner post to said upper track beams,
third means for enclosing the outwardly open first and second channels of said corner post wherein to cover each said first and second means, at least in part, and
fourth means for connecting the wall sections to the track beams and said corner post.
14. An extruded article, said article produced by extruding a cellulosic inorganic filled plastic composite, the composite consisting of a bound together mixture of polyvinyl chloride, a cellulosic material, selected from sawdust, finely pulverized dried wood, and wood flour, baking flour, and a binder.
15. The extruded article of claim 14 , said article extending longitudinally about a geometrical axis and formed by a cross-section including a base member, and a pair of webs, the webs extending from the base member and forming an outwardly open channel.
16. The extruded article of claim 15 , wherein the article is H-shaped and defines a pair of oppositely facing outwardly open channels.
17. The extruded article of claim 15 , wherein the article is C-shaped.
18. The extruded article of claim 15 , wherein the article is box shaped and includes a central aperture extending between the opposite end of the article.
19. A kit for constructing an enclosure to the exterior wall of an existing structure, said kit comprising:
a plurality of wall panels of predetermined height, width, and thickness,
framing structure, such as for mounting an assembly of at least one window or door, as required,
a plurality of elongated track beams, the track beams forming upper and lower end caps of front and side walls formed by the kit and each having a central track,
a plurality of vertical uprights of H-shaped cross section, the H-beam forming two opposed outwardly opening C-shaped channels,
a plurality of C-shaped cross-beams, the cross-beam having an outwardly open C-shaped channel,
a plurality of corner posts of generally square cross section and forming two outwardly opening channels of squared-C cross-section,
means for positioning and securing the wall panels, framing structure, track beams, H-beams, C-shaped cross-beams, and corner posts to one another and the support structure, and
a plurality of closure members of squared-C cross-section, the closure members being snap-fittable into a respective C-shaped channel provided in the H-beam and corner post, wherein to close the channel and form a unitary appearing exterior.
20. The kit according to claim 19 , wherein the track beams, H-beam, corner-post, C-shaped cross-beam, and closure members of the kit are extruded or injection molded of a composite PVC, with predetermined exterior surfaces of each clad with a protective surface of vinyl.
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/116,081 US20050246968A1 (en) | 2004-04-30 | 2005-04-27 | Patio enclosure |
US11/789,092 US7966782B2 (en) | 2004-04-30 | 2007-04-23 | Patio enclosure |
US12/625,732 US8065855B2 (en) | 2004-04-30 | 2009-11-25 | Patio enclosure |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US56667304P | 2004-04-30 | 2004-04-30 | |
US11/116,081 US20050246968A1 (en) | 2004-04-30 | 2005-04-27 | Patio enclosure |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/789,092 Continuation-In-Part US7966782B2 (en) | 2004-04-30 | 2007-04-23 | Patio enclosure |
Publications (1)
Publication Number | Publication Date |
---|---|
US20050246968A1 true US20050246968A1 (en) | 2005-11-10 |
Family
ID=35415082
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/116,081 Abandoned US20050246968A1 (en) | 2004-04-30 | 2005-04-27 | Patio enclosure |
Country Status (2)
Country | Link |
---|---|
US (1) | US20050246968A1 (en) |
CA (1) | CA2505640A1 (en) |
Cited By (8)
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US20060248845A1 (en) * | 2005-04-21 | 2006-11-09 | Hubbard Richard L | Pre-molded window, door and floor frame incorporated into a building wall construction |
WO2007094692A1 (en) * | 2006-02-17 | 2007-08-23 | Habode Ip Limited | A wall system |
US20120233936A1 (en) * | 2010-08-24 | 2012-09-20 | Empire Technology Development Llc | Reinforced concrete dense column structure systems |
US20120304549A1 (en) * | 2011-06-05 | 2012-12-06 | Richard Bruce Rutledge | Handmade Structure System |
GB2497276A (en) * | 2011-11-28 | 2013-06-12 | Soleco Bvba | Panel roofing frame with hook and click connection |
US20140047795A1 (en) * | 2012-08-20 | 2014-02-20 | William Hires | Modular Sheet Metal Building Kit |
US8844223B2 (en) | 2010-08-24 | 2014-09-30 | Empire Technology Development Llc | Prefabricated wall panels |
CN107480333A (en) * | 2017-07-12 | 2017-12-15 | 深圳市彬讯科技有限公司 | A kind of house type method for drafting based on room splicing |
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US2363164A (en) * | 1940-10-18 | 1944-11-21 | Charles C Kirk | Structural joining of walls for cases, partitions, and the like |
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US20060248845A1 (en) * | 2005-04-21 | 2006-11-09 | Hubbard Richard L | Pre-molded window, door and floor frame incorporated into a building wall construction |
WO2007094692A1 (en) * | 2006-02-17 | 2007-08-23 | Habode Ip Limited | A wall system |
AU2007215644B2 (en) * | 2006-02-17 | 2009-10-01 | Habode Ip Limited | A wall system |
US20100218453A1 (en) * | 2006-02-17 | 2010-09-02 | Rodney Mark Gibson | A wall system |
US8863445B2 (en) * | 2010-08-24 | 2014-10-21 | Empire Technology Development Llc | Reinforced concrete dense column structure systems |
US8844223B2 (en) | 2010-08-24 | 2014-09-30 | Empire Technology Development Llc | Prefabricated wall panels |
US20120233936A1 (en) * | 2010-08-24 | 2012-09-20 | Empire Technology Development Llc | Reinforced concrete dense column structure systems |
US9038339B2 (en) | 2010-08-24 | 2015-05-26 | Empire Technology Development Llc | Prefabricated wall panels |
US20120304549A1 (en) * | 2011-06-05 | 2012-12-06 | Richard Bruce Rutledge | Handmade Structure System |
US9206595B2 (en) * | 2011-06-05 | 2015-12-08 | Richard Bruce Rutledge | Handmade structure system |
GB2497276A (en) * | 2011-11-28 | 2013-06-12 | Soleco Bvba | Panel roofing frame with hook and click connection |
US20140047795A1 (en) * | 2012-08-20 | 2014-02-20 | William Hires | Modular Sheet Metal Building Kit |
US8973337B2 (en) * | 2012-08-20 | 2015-03-10 | William Hires | Modular sheet metal building kit |
CN107480333A (en) * | 2017-07-12 | 2017-12-15 | 深圳市彬讯科技有限公司 | A kind of house type method for drafting based on room splicing |
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