US20250382795A1

US20250382795A1 - Systems and assemblies for connecting panel structures

Info

Publication number: US20250382795A1
Application number: US19/258,556
Authority: US
Inventors: Alain Perez
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-09-21
Filing date: 2025-07-02
Publication date: 2025-12-18
Also published as: US20250327300A1; US20230014278A1; US20250327298A1; US20220090379A1; BR112022003327A2; US20250327299A1; CA3148844A1; US12215499B2; EP3971355A1; JP2023542443A; US11680403B2; WO2022061269A1

Abstract

The present invention is directed to a system for construction using multi-purpose panel member, which may be utilized as any surface or support beam in a structure, along with auxiliary components including track members and corner members. In a preferred embodiment, the track member includes one or more channels for receiving panel members, and may also accommodate fasteners for securing the panel member to the track member. The corner member may be used to adjoin two or more panels at a desired angle, and may also serve as a decorative cap for the interconnection of two or more panel members.

Description

PRIORITY CLAIM

This application is a continuation of U.S. patent application Ser. No. 19/014,149, filed on Jan. 8, 2025, which is a continuation-in-part of U.S. patent application Ser. No. 17/946,274, filed on Sep. 16, 2022, which matured into U.S. Pat. No. 12,215,499 on Feb. 4, 2025, which is a divisional of U.S. patent application Ser. No. 17/221,061, filed on Apr. 2, 2021, which matured into U.S. Pat. No. 11,680,403 on Jun. 20, 2023, which claims the benefit, pursuant to 35 U.S.C. § 119 (e), of U.S. Provisional Patent Application No. 63/081,041, filed on Sep. 21, 2020, and U.S. Provisional Patent Application No. 63/161,678, filed on Mar. 16, 2021. The entire contents of each of the foregoing applications are incorporated herein by reference.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention is directed to systems and assemblies for connecting and assembling multi-purpose structural panels which can be used for any surface or support member within a building or structure. The present invention includes track members and corner members.

Description of the Related Art

The “Structural Insulated Panel” (also referred to as “SIP”) is a relatively new building material consisting of a foam core and two layers of sheathing, typically this is expanded polystyrene sandwiched between two thin metal veneers or oriented strand board. While they present some improvement over the typical lumber frame construction, there are several key issues. One major issue is durability and corrosion resistance. Because the panels are glued together, they tend to delaminate in poor conditions. SIPs also present difficulties when running mechanical, electrical, or plumbing lines through them as cuts through the SIP can reduce the strength of the panel. SIPs also have inadequate fire safety ratings and must be surrounded by a separate fire-rated product.
Intermodal shipping containers have also been utilized as an alloy-based construction system. However, they tend to be difficult to work with and are only manufactured in a few standard sizes, leading to limited options for building configurations made from shipping containers. Therefore, the present invention presents substantial improvements in these and other areas.
The inventor has proposed a construction system that utilizes, as its basic construction component, a panel member which is preferably, though not necessarily, extruded monolithically and reinforced with webbing. The disclosure of the present application addresses this invention as well as auxiliary components, such as track members and corner members, which facilitate assembly of the panel members into various constructions.

SUMMARY OF THE INVENTION

The present invention is directed to improvements in construction technology by way of an inventive, multi-purpose structural panel member and systems and methods for its use. Primarily, the inventive panel member is an improved rectangular profile for aluminum extrusions that can be utilized as virtually any surface or support member within a building or structure. The panel is capable of withstanding load in any direction and includes interior channels for insulation and ventilation. As such, it may be employed as walls, ceilings, roofs, structural supports, girders, lintels, and the like.
In a preferred embodiment the panel is monolithically extruded from aluminum, such as 6082 T6 aluminum alloy. Other materials and construction methods may be employed, however. By way of example, the particular alloy can be customized based on the location or use of the structure, such has high corrosion resistance for marine environments or low thermal coefficient for environments with extreme temperatures. Non-metal materials such as carbon fiber or basalt may be suitable as well. The panel may also be assembled from components, rather than monolithically formed.
The panel may be dimensioned to suit any desired construction element, however, the inventor has determined that a convenient dimension, suitable for a variety of construction techniques, is a rectangular profile approximately 4 inches in thickness by 24.5 inches in width. Another convenient dimension is 6 inches in thickness. The length of the panel can also be as long as desired, particularly if the panel is extruded, but a maximum length of 60 feet allows the panel members to be transported on roadways. The panel can include a plurality of interior channels, approximately 4 inches by 6 inches, separated by webs spanning the two faces of the panel. The wall thickness of the panel member may be uniform in order to facilitate extrusion. The inventor has determined that an aluminum alloy of 6082 T6 need only ⅛^thinch uniform wall thickness in order to provide the strength and load resistance for hurricanes, high wind speeds, snow loading, and earthquakes.
Another aspect of the invention employs the inventive panel with a variety of other components to create a system in which buildings may be assembled, rather than constructed in the traditional sense. To elaborate, the panel members include male and female interlocking components, which are not critical, but facilitate alignment of the panel members. Tracks may be used to fasten the panel members to foundations and to one another in order to form ceiling, floor, and roof structures. Frame elements may be employed to cap off panel members in order to create flat surfaces on the edge of panel members, which facilitates openings for door jambs or windows.
In a preferred embodiment, the panels are substantially hollow or have channels within them and can accommodate a variety of purposes. By way of example, the channels can be utilized to run mechanical, electrical, or plumbing lines. Additionally, the channels may be utilized as ducting for air conditioning. Not only does this contribute to more efficient construction but conditioning the air within the panel will more efficiently heat or cool the structure. This is due in part to the fact that conduction of heat from one side of the panel to the other (and therefore heat loss or heat gain from one side of the panel to the other) can be tempered by conditioning the air within the panel. Such a structure can virtually eliminate the need for drop ceiling construction because of the space saving design. It will be appreciated that the channels can also store and/or act as conduits for a variety of future home technologies.
In yet another embodiment, the channels can be configured to collect, transport, and/or store rainwater. Where the inventive panels are used as roof members, apertures can be selectively created to facilitate introduction of rainwater into the channels. The channels of roof members can also be disposed in communication with channels of other panel members, such as walls or ceilings, to facilitate transportation and/or storage of collected rain water.
Another feature of the present invention is the ability to create buildings which are electromagnetically insulated due to the use of aluminum panels for all surfaces of the building. This can provide benefits in certain scenarios, such as where it may be desirable to prevent radio frequency transmissions from entering or leaving a building. On the other hand, the present invention may also block radio transmissions between various rooms in the same building. In this scenario a wired mesh network or similar may be desired to promote coverage of WiFi, cellular, and other signals throughout the building.
Yet another feature of the invention is the ability to utilize certain panels in an electrically conductive fashion. While using the panels to conduct main electrical voltage (e.g., in the range of 100-240 V) should be done with extreme caution, low voltage electrical transmission can be accomplished relatively easily, and with less safety concern. Therefore, a variety of low voltage electronic equipment can be powered merely through contact with the surface of the panel. This can facilitate placement of such household items as air conditioning thermostats, smoke detectors, security alarm panels and sensors, cameras, and other items, including, but certainly not limited to, internet connected and/or “Internet of Things” devices. Additionally, the aluminum panels themselves can be utilized as transducers to more accurately and more efficiently determine temperatures within the building. As is known, the resistivity of aluminum changes with temperature fluctuations. Therefore, each aluminum panel can be utilized as a temperature sensor if the fluctuations in low voltage current applied across the panel are monitored. Therefore, the temperature of each room in a building can be monitored with far more granularity than is currently possible. “Smart” air conditioning systems can then direct cooled or heated air where necessary, such as by opening or closing diffuser grills in certain rooms. It will be appreciated that the use of the panels as sensors and/or transducers is not strictly limited to use as a temperature sensor.
The panel members of the present invention are not limited to use in buildings or enclosures, and instead may be utilized as virtually any structural member. As such, bridges and other spans may be rapidly assembled from the system of the present invention. The present invention may find particular suitability where a temporary and/or reusable structural member is desired, such as pedestrian bridges, staging for event venues, or possibly even as a structural pool cover providing additional floor space to hotels.
Yet another advantage of the present invention is that building components may be sold by weight, instead of per piece. Given that all of the components of the system may be made from extruded aluminum, a total mass of aluminum required to assemble any structure can be calculated from the known quantities of components required for the structure. Therefore, the material cost to construct a particular structure can be estimated with ease.
The invention may also encompass a construction system in which panel members are connected with a variety of auxiliary components, such as track members and corner members. A track member in accordance with one embodiment of the present invention can include at least one flange dimensioned and configured to receive at least one edge of a panel member. In alternative embodiments, a track member may include a plurality of flanges, interconnected by webs, configured to form one or more open-ended channels, the channels being dimensioned and configured to receive a panel member. The channels on a track member may be arranged in any of a variety of configurations to connect and support panel members in a desired configuration, including, but certainly not limited to, an “L” shape for a 90 degree connection, a “T” shape for connecting three panel members, or a “V” shape for an angled connection (other than 90 degrees).
In one embodiment a track member includes two exterior flanges generally disposed in an “L” shape for an approximately 90 degree connection of two panel members. A central flange projects orthogonally from a first one of the exterior flanges, and is substantially parallel to a second of the exterior flanges, to create a first open-ended channel which can receive a second panel member. If desired, a third flange may project orthogonally from the central flange, being substantially parallel to the first exterior flange, to create a second open-ended channel which can receive a second panel member.
In certain embodiments, the length of the flanges may be altered to achieve different configurations of interconnection with panel members. In a basic configuration, all flanges May be of sufficient length to permit a fastener to pass through each flange flanking a channel, which results in a structurally secure connection. However, if such a level of structural security is not required, then certain flanges can be made shorter, only as long as is adequate to receive the panel. This configuration can offer substantial cost, material, and weight savings to a large-scale project.
The track members may include mounting apertures along their length, which are correspondingly dimensioned and configured with apertures in the panel members to receive fasteners. Additionally, or alternatively, self-drilling fasteners may be utilized to connect a panel to the track without the need for pre-configured apertures.
Another auxiliary component may include corner members as an additional component for interconnecting panel members. In a preferred embodiment, the corner member may be constructed as an enclosed channel with at least one of a ridge member or valley member on one face, and at least one of a ridge member or valley member on another face, with a predetermined included angle between the two ridge and/or valley members. The corner member may also include ornamental features, such as aesthetically pleasing curvature, in order to act as a finishing element or decorative cap where two panels meet and may be easily visible. In a preferred embodiment, the corner member includes a curved apex.
These and other objects, features and advantages of the present invention will become clearer when the drawings as well as the detailed description are taken into consideration.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:

FIG. 1 is a perspective view of a panel member in accordance with one embodiment of the present invention.

FIG. 2 is a front isometric view of the panel member depicted in FIG. 1 .

FIG. 3 is a perspective view of a corner member according to one embodiment of the present invention.

FIG. 4 is a front isometric view of the corner member depicted in FIG. 3 .

FIG. 5 is a perspective view of a corner member according to another embodiment of the present invention.

FIG. 6 is a front isometric view of the corner member depicted in FIG. 6 .

FIG. 7 is a perspective view of a track according to one embodiment of the present invention.

FIG. 8 is a perspective view of a frame according to one embodiment of the present invention.

FIG. 9 is a perspective view of a pair of ridge plates in accordance with one embodiment of the present invention.

FIG. 10 is a perspective view of a reinforcement insert according to one embodiment of the present invention.

FIG. 11 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 12 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 13 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 14 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 15 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 16 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 17 is a detail partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 18 is a detail cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 19 is a detail partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 20 is a detail partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 21 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 21A is an exploded view of FIG. 20 .

FIG. 22 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 23 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 24 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 25 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 26 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 27 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 28 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 29 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 30 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 31 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 32 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 33 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 34 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 35 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 35A is a detail view of the embodiment presented in FIG. 35 .

FIG. 35B is a detail view of the embodiment presented in FIG. 35 .

FIG. 35C is a detail view of the embodiment presented in FIG. 35 .

FIG. 35D is a detail view of the embodiment presented in FIG. 35 .

FIG. 36 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 37 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 38 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 39 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 40 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 41 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 42 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 43 is a perspective view of several components according to one embodiment of the present invention.

FIG. 44 is a partial cutaway perspective view showing various components assembled according to a system of the present invention.

FIG. 45 is a section view of two panel members according to another embodiment of the presentation invention.

FIG. 46 is a perspective view of a panel member according to the embodiment of FIG. 45 .

FIG. 47 is a perspective view of a track according to another embodiment of the present invention.

FIG. 48 is a section view of a track according to FIG. 47 .

FIG. 49 is a perspective view of a track according to yet another embodiment of the present invention.

FIG. 50 is a section view of a track according to FIG. 49 .

FIG. 51 is a partially constructed structure utilizing panel members according to one embodiment of the present invention.

FIG. 52 is a perspective view of a gusset plate according to one embodiment of the present invention.

FIG. 53 is a perspective detail view showing the use of a gusset plate adjoining two panel members according to one embodiment of the present invention.

FIG. 54 is a perspective view of an insert plate according to one embodiment of the present invention.

FIG. 55 is a section view of the insert plate according to FIG. 54 .

FIG. 56 is a perspective view showing an insert plate disposed within a channel of a panel member according to one embodiment of the present invention, where the panel member is depicted as partially transparent to aid disclosure.

FIG. 57 is a front isometric view of a panel according to another embodiment of the present invention.

FIG. 58 is a front perspective view of a panel according to the embodiment of FIG. 57 .

FIG. 59 is a front isometric view of a track according to another embodiment of the present invention.

FIG. 60 is a front isometric view of a track according to yet another embodiment of the present invention.

FIG. 61A is a front isometric view of a track according to yet another embodiment of the present invention.

FIG. 61B is a perspective view of the track according to the embodiment of FIG. 61A.

FIG. 61C is a front isometric view of the track according to the embodiment of FIG. 61A interconnected to panel members.

FIG. 62A is a front isometric view of a track according to yet another embodiment of the present invention.

FIG. 62B is a perspective view of the track according to the embodiment of FIG. 62A.

FIG. 62C is a front isometric view of the track according to the embodiment of FIG. 62A interconnected to panel members.

FIG. 63A is a front isometric view of a corner member according to yet another embodiment of the present invention.

FIG. 63B is a perspective view of the corner member according to the embodiment of FIG. 63A.

FIG. 63C is a front isometric view of the corner member according to the embodiment of FIG. 63A interconnected to panel members.

FIG. 64A is a front isometric view of a corner member according to yet another embodiment of the present invention.

FIG. 64B is a perspective view of the corner member according to the embodiment of FIG. 64A.

FIG. 64C is a front isometric view of the corner member according to the embodiment of FIG. 64A interconnected to panel members.

FIG. 65A is a front isometric view of a corner member according to yet another embodiment of the present invention.

FIG. 65B is a perspective view of the corner member according to the embodiment of FIG. 65A.

FIG. 65C is a front isometric view of the corner member according to the embodiment of FIG. 65A interconnected to panel members.

FIG. 66A is a front isometric view of a corner member according to yet another embodiment of the present invention.

FIG. 66B is a perspective view of the corner member according to the embodiment of FIG. 66A.

FIG. 66C is a front isometric view of the corner member according to the embodiment of FIG. 66A interconnected to panel members.

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

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

While the overall construction system of the present invention will be disclosed in detail, it is worthwhile to first discuss the various individual components of the system. With reference to FIGS. 1 and 2 , a preferred embodiment of a panel member or panel 10 is depicted. The panel 10 is preferably formed monolithically, such as by extrusion, but assembly of a panel 10 from a plurality of components may be possible. The panel 10 includes two oppositely disposed faces 12 supported by a plurality of webs 15. The faces 12 also define a long edge 1 of the profile of the panel 10. The panel 10 also includes a ridge member 13 and a valley member 14 defining a short edge 2 of the profile of the panel 10. The ridge member 13 and valley member 14 also serve to facilitate a mating relationship between consecutive, adjoining panel members 10 when utilized for construction of a wall, floor, or ceiling, for example. It will be understood that the precise shape of the ridge member 13 and valley member 14 are not critical, so long as they can facilitate a mating relationship. In the Figures, they are represented as simple shapes. The webs 15 at least partially define a plurality of channels 11 that run lengthwise along the panel 10 and terminate in open ends 16 at each end of the panel 10. The panels 10 may also include a plurality of mounting apertures 17 located where desired, and as discussed further below, may be placed to coordinate with other mounting apertures on the various components of the system of the present invention.
Turning to FIGS. 3 through 6 , two corner members 20, 20′ are presented which may be employed with one embodiment of the present invention, though they are not required or necessary. As can be seen the corner member 20, 20′ is essentially an enclosed channel 21, 21′ with a ridge member 23, 23′ and valley member 24, 24′ disposed on faces to facilitate the adjoining of panels 10 at angles other than zero (i.e., not in a straight line). A relatively standard corner angle in building construction is ninety degrees, which is represented in FIGS. 3 and 4 . As can be seen, the ridge member 23 and valley member 24 are orthogonal to each other, which facilitates the adjoining of consecutive panel member 10 at ninety degree angles. However, virtually any adjoinment angle may be accommodated as represented by FIGS. 5 and 6 .
FIG. 7 represents a track 30 according to a preferred embodiment of the present invention. The track includes a channel 33 at least partially defined by two webs 31, as well as an external flange 32. Panel members 10 may be inserted into the channel 33 to facilitate alignment and fastening when construction walls, floors, or ceilings. In that regard, the mounting apertures 35 may be aligned with the mounting apertures 17 of the panel members (as depicted in FIG. 1 ) in order to facilitate fastening of a panel 10 to the track 30.
Turning now to FIG. 8 , a frame 40 in accordance with a preferred embodiment of the present invention is depicted. The frame 40 may serve as an end cap when required, such as when framing window openings with panels 10. As such it includes a channel 42 at least partially defined by webs 41, and is distinguished from the track by the lack of an external flange. The frame 40 may also include a plurality of mounting apertures 43 in order to facilitate fastening to a panel 10.
FIG. 9 depicts a ridge plate 50 to facilitate adjoinment of panel members along the ridge of a gabled roof. FIG. 10 depicts an insert 60, essentially an enclosed channel or box beam, which may be inserted into a channel 11 of a panel 10 in order to provide structural reinforcement for the panel 10, e.g., when used as a support beam or girder. The insert 60 may also be used to increase the safety margin for a free-standing span or cantilevered configuration of panels 10.
Now that several of the individual components have been described, the interconnectivity of the components can be discussed. With reference to FIGS. 11 through 16 , several partial, detail views of assemblies created with the foregoing components can be seen. In each of the views, a plurality of panels 10, tracks 30, and frames 40 are disposed in various configurations on top of a foundation 500 for a structure such as a home or building. As can be seen, the panels are used to form the various external and internal walls, ceilings, upper story floors, and the roof of the building. The tracks 30 are utilized to secure the panels 10 to the foundation 500 and to each other when two panels are joined to form a ceiling/floor or roof connection with a wall. The frames 40 serve as an “end cap” when framing a window, otherwise the interior opening of the window would not be a uniform, flat surface given the existence of the valleys 14 and ridges 13 on the panels 10.
In FIG. 11 , a plurality of tracks 30 are fastened to a foundation 500 and are being utilized to support a plurality of panel members 10 in a vertical orientation to be utilized as wall members. In FIG. 12 , two panel members can be seen in a “T” configuration to show that the panel members may also be used as columns and support beams. Also, in FIG. 12 , the panels 10 have been arranged to form a window by suspending a panel 10 as a lintel across two other panels 10 acting as columns. It may also be seen that frames 40 are fastened to the interior of the window in order to prepare a flat surface for installation of the window and/or window jamb.
FIG. 13 depicts a plurality of tracks 30 that have been fastened to the top of a plurality of vertically oriented panel members 10. In this regard, the structure is being prepared for the addition of a second story or flat roof. FIG. 14 shows a panel member 10 in a horizontal orientation employed as a first story ceiling and second story floor. As will be disclosed in further detail below, the horizontal panel member 10 is secured to the tracks 30 by fasteners, such as self-drilling screws, bolts, or rivets inserted through the external flange 32. In FIG. 15 it can be seen that another vertically oriented panel member 10′ has been installed in the track 30 to create a second story wall. It may also be seen that the horizontally oriented panel member 10 is cantilevered outside of the structure, and may act as an awning or balcony. Finally, in FIG. 16 , it can be seen that yet another panel member 10 has been mounted in an angled configuration in order to create a peak or gabled roof. It is secured to the vertically oriented panel member 10 via a track 30.
FIGS. 17 and 18 show detail views of a corner configuration according to one embodiment of the present invention. FIG. 17 depicts the interconnection between two adjoining panels 10 via a ninety degree corner member 20, along with the associated mating interface between the panel 10 ridge and valley members 13, 14 and the ridge and valley members 23, 24, of the corner member 10. FIG. 18 shows a plurality of tracks 30 fastened to a foundation 500 via fasteners 600 through the external flange 32. In certain scenarios, it may be desirable to use steel fasteners to penetrate a concrete foundation. However, when the track 30 is made of aluminum, galvanic corrosion may occur over time. Therefore, a neoprene gasket or washer may be used to insulate the fastener 600 from the track 30 to avoid electrical contact between the fastener 600 and the track 30. Additionally, a plurality of fasteners 600 are disposed through the corresponding mounting apertures in each of the tracks 30 and panels 10 in order to secure the panels 10 to the tracks 30.
FIGS. 19 and 20 provide a detail view of the system of the present invention utilized to construct a multi-story building. As such a plurality of panels 10 are utilized to construct the walls as well as the ceiling of the first floor and floor of the second floor. The panel 10 serving as a ceiling/floor is sandwiched between two tracks 30 disposed on the panels 10 serving as walls. In this scenario, fasteners 600 are disposed through the external flanges 32 of the tracks and into the panel 10 serving as a floor. Therefore, the panel serving as a floor can be securely retained in place. In certain embodiments, it may be desirable to use self-tapping screws, bolts, or rivets for this purpose as the panels 10 may not have mounting apertures appropriately placed.
FIGS. 21 and 21A show a partially completed structure in both constructed and exploded form for further exemplification. As can also be seen, several panel members 10 are adjoined together to create a gabled roof. Thus, two ridge plates 50 are employed to facilitate the connection of each panel 10 at the ridge of the roof.
FIG. 22 depicts a partially completed structure utilizing a membrane 100 between consecutive panels 10. In a preferred embodiment, the membrane 100 is self-adhering and water resistant. Therefore, particularly with regard to roof construction, the system of the present invention can be employed where resistance to water intrusion is a concern. As can be seen, the membrane 100 may be applied at the intersection of any two consecutive panels 10 in order to ensure that water does not weep between the crevice formed therein. The Figure also shows that panel members 10 may be employed in a cantilevered configuration to create awnings and balconies. Caulking may be employed in addition to, or in lieu of, the membrane 100, particularly between adjoining panels 10.
FIGS. 23 through 28 show how traditional interior and exterior finishes can be used in conjunction with the system by applying them on top of the panel members 10. By way of non-limiting example, the exterior finishes may include sheathing, housewrap/mesh, and stucco (FIG. 23 ), rigid insulation, fiberglass mesh, and stucco (FIG. 24 ), or sheathing, high-density polyethylene paper, and siding (FIG. 25 ). Non-limiting examples for interior finish include drywall and paint (FIG. 26 ), cement board and stucco (FIG. 27 ), and furring strips, cement board, and wall tiles (FIG. 28 ).
FIGS. 29 through 34 show how traditional roof and floor finishes may be used in conjunction with the system. By way of non-limiting example, such roof finishes may include rigid insulation, sheathing, and TPO (FIG. 29 ), rigid insulation, a moisture barrier, and metal tiles (FIG. 30 ), or rigid insulation, plywood, and asphalt shingles (FIG. 31 ). Flooring finishes May include, by way of non-limiting example building paper/mesh and tile flooring (FIG. 32 ), plastic barrier, foam pad, and laminate wood (FIG. 33 ), or furring strips, foam padding, and hard wood (FIG. 34 ).
FIGS. 35 through 35D depict how traditional mechanical, electrical, and plumbing lines may be integrated with the present invention. In particular, water lines 1000 and electrical conduits 2000 may be simply routed through the channels 11 within the panels 10. Additionally, the channels 11 may be used as air conditioning ducts 300 as shown in FIG. 35B.
FIGS. 36 through 41 show various insulation options that may be applied to the surface of a panel or disposed within the channel 11 of a panel 10. FIG. 36 is a depiction of pre-formed or pre-cut insulation 3000, such as foam, that may be slid into the channels 11 during construction. FIG. 37 depicts a spray insulation 4000 that may be applied to the face 12 of a panel 10. FIG. 38 depicts an injection foam insulation 5000 that can be utilized in channels 11 where electrical or plumbing lines are utilized. FIGS. 40 and 41 show that the insulation may be added in-situ due to the open ends 16 of the panels 10.
FIGS. 42 and 44 provides a schematic depiction of how the present invention may be utilized to route cooled air more efficiently from an air conditioning unit via the channels 11 of the panels 10. FIG. 43 depicts additional components to facilitate this aim. As can be seen, connectors 330 and elbows 320 may be used to route the cooled air from the air conditioning unit 6000 into one or more channels 11 and between channels 11 in consecutive panels. While it May be possible to simply provide apertures in the tracks 30 (and ends of panels 10) to facilitate air flow between successive panels 10 and tracks 30, that may hinder construction of the overall structure. The elbows 320 and connectors 330 allow for implementation of this benefit after construction. Diffuser grills 310 can also be employed to introduce cooled air into the room via the wall panels 10 or ceiling panels 10.
Turning to FIGS. 45 and 46 another embodiment of a panel 10′ is depicted therein. This embodiment finds particular suitability for utilizing the panel 10′ as a roof member. As can be seen, the panel member 10′ contains the same structure as in previous embodiments, including opposite faces 12′ spaced by a plurality of webs 15′, which at least partially define channels 11′ traversing the open ends 16′ of the panel 10′. The panel 10′ also includes a ridge member 13′ and a valley member 14′. The additional structure of the present embodiment is a flanged extension 19 traversing the length of the panel 10. Each flanged extension 19 includes a flange which extends inwardly toward the panel 10′. As can be seen in FIG. 45 , when two panels 10′ are adjoined next to one another, the flanged extension 19 abut one another. A cap 200 which encompasses the flange portion of the flanged extension can then be disposed about both flanged extensions 19, thereby locking the two panels 10′ together and creating a water-resistant seal. In this fashion, the assembly approximates the typical crimped construction of existing metal roofs. Utilizing this embodiment of the present invention avoids the need for additional waterproofing steps, such as membranes and caulking, when the panels 10′ are employed as roof members.
FIGS. 47 and 48 depict an alternative embodiment of a track 30′ that may be utilized to facilitate construction of a gabled roof. As can be seen the webs 31′ are angled relative to the external flange 32′. Therefore, when a panel member 10 or 10′ is positioned at an angle to be used for a gabled roof, it may sit flush against the external flange 32′, which facilitates better fastening.
FIGS. 49 and 50 depict yet another embodiment of a track 30″ which includes two external flanges 32″, each projecting perpendicularly from the two webs 31″. This embodiment of a track 30″ is suitable for certain installation scenarios, such as when an interior wall is used to support a ceiling. The wall can be inserted into the channel between the two webs 31″, while the ceiling panels can be secured to each of the two flanges 32″.
FIG. 51 depicts a partially completed structure wherein the panels 10 are used in a vertically oriented configuration to support longer spans between panels acting as columns. For purposes of aiding disclosure in the context of FIG. 51 , the vertically oriented panels are denoted as 10′, while horizontally oriented panels are denoted as 10″. The vertically oriented panels 10′ can also be referred to as those supporting loads in the plane of the panel, while the horizontally oriented panels 10″ can be referred to as those supporting loads out of the plan of the panel. It will be appreciated that the bending strength of the panel is much greater around its short edge than its long edge. Thus, the vertically oriented panels 10′ are capable of withstanding much greater loads when cantilevered, suspended between two or more points, or otherwise not continuously supported, as compared to the horizontally oriented panels 10″. The panels 10 acting as columns are configured to support axial loading.
FIG. 51 also depicts a configuration to support a peaked roof using panel members 10′ disposed in vertical orientation. With additionally reference to FIGS. 52 and 53 , a gusset plate 70 can be used to facilitate the angled and vertically oriented connection between panel members 10 and 10′. The gusset plate 70 may include mounting apertures 71 to support the use of bolts or other fasteners.
FIGS. 54 and 55 depict an insert plate 80 in accordance with one embodiment of the invention. The insert plate includes two webs 81 at least partially defining an interior channel 83. Two flanges 82 project exteriorly of the insert plate 80. As depicted, the flanges 82 are orthogonal to the webs 81, but they may be disposed at any angle that is desired. Turning now to FIG. 56 , it can be seen that the insert plate 80 is to be inserted within a channel 11 of a panel member 10. Therefore, the length of the insert plate 80 distance between the two webs 81 should be correspondingly configured and dimensioned with the channel 11. In a most preferred embodiment, this is approximately a 4 inch square (as disclosed above). Accordingly, as can now be seen, the insert plate 80 can be used in a similar fashion to the track 30, 30′, and 30″ in any scenario where it is more desirable to have the webs disposed within the panel 10. This can be for aesthetic purposes, for water proofing, or other reasons. Additionally, the insert plate 80 can also be useful for installations where a full length track member may not be suitable, such as when some of the channels 11 of a panel member 10, are used for mechanical, electrical, or plumbing conduits, or a variety of other purposes. Using a plurality of single channel-sized insert plates 80 may be preferable to cutting a track 30 to the desired size.
Turning to FIGS. 57 and 58 , yet another embodiment of a panel 10″″ is depicted which includes protrusions or bosses 3 along the inner faces of the panel. The bosses 3 provide additional material for a fastener to grip, which can reduce the total number of fasteners per panel necessary to securely retain the panels 10″″. The bosses 3 can take on virtually and size, dimension, or placement that is desired for the purpose. In the depicted embodiment, the bosses 3 are arranged approximately ½ inch from the side of each panel 10″″ and are approximately ¼ inch in thickness. The bosses 3 may run the entire length of the panel or may be truncated to the desired length. With specific reference to FIG. 58 , a visual marker 4 can be provided on the outer surface to assist users with accurate placement of fasteners.
Turning to FIGS. 59 and 60 , further embodiments of tracks 30′″ and 30″″ are depicted, respectively. Each track 30′″, 30″″ contains additional flanges 32′″, 32″″ relative to previously disclosed embodiments to provide a more structurally secure fitment of panels within the channels 33″″, 33″″ of the tracks 30′″, 30″″. This is due to the fact that fasteners can be driven into both flanges 32′″, 32″″ instead of relying on a single flange as previously disclosed. FIG. 59 shows a “T” shaped track 30′″ which can accommodate three panels at each of the three channels 33″ FIG. 60 shows an “L” shaped track 30′″ which accommodates two panels. The tracks 30′″, 30′″ may be dimensioned and configured to suit any orientation or load capacity. For example, the flanges 32′″, 32″″ may be lengthened to provide additional support.
FIG. 61A-62C represent different track members 30 a, 30 b configurations according to one embodiment of the present invention. The track members 30 a, 30 b include two channels 33 a, 33 b as well as a plurality of external flanges 32 a, 32 b. Panel members 10 may be inserted into the channels 33 a, 33 b to facilitate alignment and fastening when construction walls, floors, or ceilings. In that regard, mounting apertures may be aligned along the flanges 32 a, 32 b in order to facilitate fastening of a panel 10 to the tracks 30 a, 30 b. With regard to the differences between the depicted embodiments, as can be seen best in FIGS. 61A and 62A, the embodiment of FIG. 61A has a short flange 36, while the embodiment of FIG. 62A has a long flange 37. As can be seen in FIGS. 61C and 62C, the differing lengths of flanges permits different fastening configurations. In certain embodiments, as shown in FIG. 61C, it may only be necessary to fasten the panel 10 through the central flange 38. However, if additional support is desired, as shown in FIG. 62C, the fastener 600 may also be secured through both the central flange 38 and the long flange 37.
The track members 30 a, 30 b may also be described as including two exterior flanges, a first exterior flange 310 and a second exterior flange 311, generally disposed in an “L” shape for an approximately 90 degree connection of two panel members 10. A central flange 380 projects orthogonally from the first exterior flange 310, and is substantially parallel to the second exterior flange 311, to create a first open-ended channel 33 a, 33 b which can receive a panel member 10. Additionally, a third flange 312 may project orthogonally from the central flange 38, being substantial parallel to the first exterior flange 310, to create a second open-ended channel 33 a, 33 b which can receive a panel member 10.
FIGS. 63A-66C depict corner members 20 according to various embodiments of the invention, and having different included angles. For reference, corner member 20 shown on FIG. 66A has a 90 degree included angle; corner member 20 a shown on FIG. 63A has a 30 degree included angle; corner member 20 b shown on FIG. 64A has a 45 degree included angle; and corner member 20 c shown on FIG. 65A has a 60 degree included angle. It should be appreciated that the corner members of the present invention can be configured in virtually any included angle desired, from 0 to 180. It may be necessary to reduce the thickness of the panel members for smaller angles, such as those below 30 degrees, in order to avoid overly elongating the corner member. With general reference to FIGS. 63A-66C, the corner member 20, 20 a, 20 b, and 20 c, is essentially an enclosed channel 21, 21 a, 21 b, and 21 c, with a ridge member 23, 23 a, 23 b, and 23 c, and valley member 24, 24 a, 24 b, 24 c disposed on faces to facilitate the adjoining of panels 10 at angles other than zero (i.e., not in a straight line). The corner member 20, 20 a, 20 b, and 20 c should include ridge 23, 23 a, 23 b, and 23 c and valley members 24, 24 a, 24 b, 24 c that are dimensioned to accommodate the desired panel 10 size. Thus, for a panel of 4 inches thickness, the ridge 23, 23 a, 23 b, and 23 c and valley members 24, 24 a, 24 b, 24 c should each span the 4 inch thickness of the panel 10 for optimum fitment, though other configurations may also work. It should also be appreciated the one each of the ridge and valley members is not required. Depending upon the type of construction and desired configuration, the corner member may employ two ridge members or two valley members, alternately.
Since many modifications, variations and changes in detail can be made to the described embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents.

Claims

What is claimed is:

1. A system for constructing structures using multi-purpose, monolithic, and identical panel members, the system comprising:

a monolithic, extruded aluminum panel member utilized for all surfaces and support beams within the structure; and

a track member including a channel for receiving one end of the panel member, the track member further including at least one exterior flange.

2. The system of claim 1, wherein the panel member comprises a first longitudinal end and a second longitudinal end, and wherein the track member is configured to retain the first longitudinal end.

3. The system of claim 2, wherein the channel of the track member comprises opposing walls that engage both sides of the panel member.

4. The system of claim 3, wherein at least one wall of the channel includes an inwardly projecting rib configured to engage a recessed portion of the panel member.

5. The system of claim 1, wherein the exterior flange of the track member is adapted to receive fasteners for anchoring the track member to a substructure.

6. The system of claim 1, further comprising a second track member configured to receive an opposite end of the panel member.

7. The system of claim 1, wherein the panel member is vertically aligned and the track member is horizontally mounted to a floor or ceiling.

8. The system of claim 1, wherein the panel member includes an integral foot portion extending into the track channel to limit lateral movement.

9. The system of claim 1, wherein the track member includes a drainage pathway configured to direct moisture away from the panel member.

10. The system of claim 1, further comprising a compressible sealing element disposed within the channel of the track member and positioned to abut a surface of the panel member.

11. The system of claim 1, wherein the panel member comprises a plurality of internal webs and the lower-most web is seated within the track channel.

12. The system of claim 1, further comprising an alignment rib in the track channel configured to engage a groove on the bottom edge of the panel member for rotational constraint.

13. A system for constructing structures using multi-purpose, monolithic, and identical panel members, the system comprising:

a monolithic, extruded aluminum panel member having first and second opposed faces and a plurality of internal structural webs;

a track assembly comprising a channel with first and second opposing vertical walls and a horizontal base; wherein

a lower portion of the panel member is received within the channel; and wherein

at least one of the vertical walls includes a retention flange that limits vertical movement of the panel member within the channel.

14. The system of claim 13, further comprising a compressible gasket interposed between the panel member and an interior surface of the track channel.

15. The system of claim 13, wherein the retention flange is formed as a continuous lip along the upper edge of the vertical wall.

16. The system of claim 13, wherein the channel includes a central drain aperture in the horizontal base.

17. The system of claim 13, wherein the panel member comprises a recessed notch at its lower edge configured to interlock with a protrusion in the channel.

18. A system for constructing structures using multi-purpose, monolithic, and identical panel members, the system comprising:

a monolithic, extruded aluminum panel member having first and second ends;

a track member configured to receive the first end of the panel member; and

a corner extrusion configured to receive the second end of the panel member and at least one additional panel member at an angular orientation; wherein

the corner extrusion includes a plurality of panel-receiving grooves, each groove defined by parallel walls and configured to engage a corresponding edge of the panel member.

19. The system of claim 18, wherein the corner extrusion is formed as an L-shaped or T-shaped member with panel-receiving grooves on each leg.

20. The system of claim 18, wherein at least one panel-receiving groove of the corner extrusion includes a longitudinal seal configured to form a weather-resistant connection with the panel member.