WO1997012099A1 - Joint connector device and method for assembling prefabricated building panels - Google Patents
Joint connector device and method for assembling prefabricated building panels Download PDFInfo
- Publication number
- WO1997012099A1 WO1997012099A1 PCT/CA1996/000640 CA9600640W WO9712099A1 WO 1997012099 A1 WO1997012099 A1 WO 1997012099A1 CA 9600640 W CA9600640 W CA 9600640W WO 9712099 A1 WO9712099 A1 WO 9712099A1
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- WO
- WIPO (PCT)
- Prior art keywords
- channelled
- joint connector
- wall
- cove
- wall panel
- Prior art date
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Classifications
-
- 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
- E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
- E04B1/34315—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts
- E04B1/34321—Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts mainly constituted by panels
Definitions
- This invention relates to a new and improved panel joint connector device and a method for assembling the prefabricated panels For wail panels each faced with external finished siding applied, which connect in a manner that the assembly may be rapidly completed at the building site in a water and air tight manner
- the concept also includes the unique potential of building a portable or permanent building
- Prefabricated wall panels of many types are well known in the art where panels are assembled at a factory and delivered to a job site are known, where they are erected These wall panels are butted together, then fastened to adjacent framing stud members The exterior vapour barrier and exterior siding or finish are then applied Electrical wi ⁇ ng, if required, is installed in the wall panel Finally, the insulation, interior vapour barrier and interior wall boards are installed
- This known art requires extensive labour and time to complete the wall sections at the job site The wall sections are virtually impossible to disassemble without damaging the building It is therefore the principle object of the current invention to provide a weather tight joint connector and a method of assembly that allows for less labour, less labour skills and less time at the job site to complete the wall sections
- the present invention, the L-shaped cove channelled joint connector and method of assembly eliminates the infiltration of water and air between the join in adjacent panels, creating an advantageous situation in the sense that the structure can be either portable or of a permanent building
- the prefabricated wall sections are constructed to a standardized height and of various lengths. All wall sections include an L-shaped cove channelled joint connector device on the extreme left and extreme right side of the wall panel.
- the L-shaped cove channelled joint connector device is cove channelled to receive an acoustical caulking or a backer rod.
- the L-shaped cove channelled joint connector devices completely eliminate water and air infiltration between the adjacent panels. This L-shaped cove channelled joint connector device will have necessary holes for the passage of screws on the lap side, which is the interior side of the device. This enables the building to be erected by unskilled people who simply screw the wall panels together.
- Standard intermediate wall sections include a rectangular frame made up of two L-shaped cove channelled joint connector devices.
- the first L-shaped cove channelled joint connector device is located on the extreme left side of the wall panel with the lap positioned to the exterior side of the wall panel.
- the second L-shaped cove channelled joint connector device is located on the extreme right side of the wall panel with the lap positioned to the interior side of the wall panel.
- Vertical timber frame studs are positioned and spaced between the L-shaped cove channelled joint connector devices.
- Horizontal top and bottom timber frame members are then assembled in a conventional manner
- the L- shaped cove channelled joint connector devices, the vertical and horizontal timber frame members are of the same width i.e. 38mm x 64mm or 38mm x 89mm timber.
- Rectangular sheets of plywood or exterior panel boards are fastened to the exterior side of the framing members enclosing the space between the L-shaped cove channelled joint connector devices, the vertical and top and bottom timber framing members. These spaces are then filled with a thermal insulation material ; ie polystyrene foam board or fiberglass type insulation.
- Interior vapour barrier and panel board is attached to the interior side of the wall panel.
- the vapour barrier and interior panel board can be attached to the wall panel at the factory or at the job site.
- the exterior sheathing plywood or exterior panel board may be flush to the bottom timber frame member of the wall or may overlap bottom timber frame member.
- the adjoining panels are fastened together with framing screws.
- acoustical caulking is applied to the cove channel of each L-shaped cove channelled joint connector device. If the building is to be portable and relocated in the future then a backer rod is more suitable as the joint sealer.
- the adjoining panels are then joined and then fastened to the subfloor or subfloor framing members either by toe nailing or bolting the bottom member of wall to the subfloor or subfloor framing members.
- the upper end of the wall member slides over top of the connector lap device and is fastened to the lap part of the adjoining connector device.
- the two L-shaped cove channelled joint connector devises are then fastened together from the interior side of the wall panel using framing screws in the predrilled holes.
- a tie plate a board the same width as the upper timber frame member, is fastened to the upper timber frame member for the full perimeter of the assembled wall sections overlapping the joints between the adjacent wall panels.
- Two types of wall panel sections are required for each outside corner of the building; a left hand outside corner wall panel and a right hand outside corner wall panel.
- An outside corner wall panel is built in the same manner as the first noted wall panel except that in the case of the right hand L-shaped cove channelled joint connector device, the lap side of the connector device faces the exterior side of the wall panel. Both laps for a right hand outside corner wall panel face the exterior side of the wall panel.
- Upper and lower framing members are cut short by the width of the framing members plus the thickness of the exterior plywood wall sheathing or exterior wall panel board .
- the exterior wall sheathing or wall panel board extends beyond the right hand L-shaped cove channelled joint connector device to intersect and connect with said first wall panel section.
- the other wall panel required to build an outside corner is a left hand outside corner wall panel.
- This wall panel is built in the same manner as the first noted wall panel except that in the case of the left hand L-shaped cove channelled joint connector device, the stud part of the L-shaped cove channelled joint connector device faces the exterior side of the wall panel, the cleat lap part of the L-shaped cove channelled joint connector device faces the interior side of the wall panel.
- the other wall panel required is an inside corner wall panel.
- the L-shaped cove channelled joint connector device has a vertical timber stud attached to it being of the same width as the L-shaped cove channelled joint connector device.
- the exterior plywood wall sheathing or finished exterior panel wall board is cut short by the width of the framing member plus the thickness of the exterior plywood wall sheathing or the finished exterior panel wall board. The wall panel then connects easily to the said first wall panel.
- a range of different wall panel sizes can be produced to satisfy the type of building proposed and the thermal transmittance value/insulation of the wall may be adjusted to suit individual and statutory requirements.
- the exterior facing material of the wall panels can be applied at the factory, reducing on site labour. Still another aspect of the invention is that the interlocking wall panels can be easily disassembled and the building can be reassembled at a different location It is a further object of the invention to provide windows and doors installed in the wall panel sections
- Fig. 1 is a common structural timber framing stud cove channelled exactly in the middle of the width of the timber stud.
- FiG 2 shows the fastening cleat, lap part of the wall panel connector device with predrilled holes for the framing screws used in joining the mated wall panel connector devices together
- Fig 3 is the end view of the L-shaped cove channelled joint connector device assembled with cleat lap attached to timber frame stud
- Fig 4 is an assembled L-shape cove channelled joint connector device in a vertical position before top and bottom timber framing members are attached to the interlocking L-shaped cove channelled joint connector device
- Fig 5 is a top view of a single standard intermediate wall panel used in the system of the present invention
- Fig 6 is a top view of a right hand corner wall panel, one of the two required to build an outside corner
- Fig. 7 is an elevation view of an assembled single standard intermediate wall panel of Fig. 5
- Fig 8 is an elevation view of an assembled right hand corner wall panel of Fig 6
- Fig 9 is a top view of a left hand outside corner wall panel, the second wall panel required to build an outside corner with the panel of Fig 6
- Fig 10 is a top view of an inside corner wall panel of Fig 9
- Fig.11 is an elevation view of an assembled left hand outside corner wall panel.
- Fig. 12 is an elevation view of an assembled inside corner wall panel of Fig. 10..
- Fig. 13 is a top view showing a plurality of wall panels joined together with exterior panel board applied, interior panelling applied, with insulation material installed into the interior wall cavity.
- Fig. 14 is a top view of the wall panels joined in plurality, which include an inside corner wall panel, an exterior standard intermediate wall panel and the two types of wall panel sections required to build an outside corner.
- Fig. 15 is a sectional view showing an alternative wall panel configuration comprising standard intermediate wall panels to build an outside wall corner.
- Fig. 16 is a perspective view of a typical structure embodying the concepts of the present invention.
- Figs. 1- 4 illustrate a prefabricated wall panel L-shaped cove channelled joint connector device 7 comprising a standard timber stud 2 38mm x 89mm cove channeled 4 exactly in the middle of timber stud 2 between 2D and 2C the width of cove channel 4 being 12.7mm in width and 3.175mm in depth at the center of the coved channel 4.
- the coved channel extends the total length of the timber stud 2, which is sized in length for an 2438mm high wall.
- the width of the timber stud 2, 2A - 2B may be either 64mm or 89mm in width and the thickness of timber stud 2, 2A - 2D is 38mm in thickness.
- the cleat lap part 6 of the wall panel L-shaped cove channelled joint connector device 7 is exactly half the width of timber stud 2, 2A - 2B and the same thickness as timber stud 2, 2A - 2D - 38mm thick.
- the cleat lap 6 is attached flush to the coved channel side of the timber stud 2.
- the width of 6A - 6B of cleat lap 6 is equal to exactly half the width of timber stud 2. 2A - 2B.
- the cleat lap 6 is attached to timber stud 2 with glue and 64mm nails 8.
- the nails 8 are located 51 mm from the ends of cleat lap 6 and thereafter at 153mm intervals.
- the cleat lap 6 of assembled wall panel L-shaped cove channelled joint connector device 7 is predrilled 10 for the framing screws used for fastening adjacent panels together.
- the assembled L-shaped cove channelled joint connector devices 7 are standard in length for 2438 mm high walls, but may vary in length for other wall heights.
- Figs 5 and 7 refer to a standard rectangular shaped prefabricated building wall panel usually 2438mm in height and can be of various widths up to 2438mm in length.
- This standard intermediate wall panel is comprised of two L-shaped cove channelled joint connector devices 7, one of which is located on the extreme left side of the wall panel, with the cleat lap 6 of the L-shaped cove channelled joint connector device facing the exterior side of the wall panel .
- the other L- shaped cove channelled joint connector device 7 is located to the extreme right side of the wall panel, with the cleat lap 6 of the L-shaped cove channelled joint connector device facing the interior side of the wall panel.
- the cleat lap 6 on the right side of the wall panel is predrilled for the framing screws required to attach it to the adjoining wall panel.
- Top and bottom 18 horizontal timber framing members are attached to the L-shaped cove channelled joint connector devices 7 with 76mm framing nails.
- Vertical timber stud framing members 14 are attached to timber framing members 18 which can be spaced 406mm, 455mm, or 610mm on center and which can vary in number depending on the length of the prefabricated wall panel.
- Exterior plywood sheathing or finished exterior panel board 12 is fastened to the timber framing members 14, 18, and L-shaped cove channelled joint connector devices 7.
- the L-shaped cove channelled joint connector devices 7 are coved channelled 4 to receive acoustical caulking for a permanent building, or a backer rod if the building is to be a portable type.
- the acoustical caulking or backer rod completely eliminates air or water infiltration between the two mating L-shaped joint connector devices.
- a window or door may be placed in the wall panels where required.
- the windows and doors are framed in the same traditional ways common to standard methods used in conventional framing.
- This wall panel Fig. 6 and 8 is known as the right hand outside corner wall panel.
- This wall panel is comprised of two L-shaped cove channelled joint connector devices 7, one located on the extreme left side of the wall panel with the cleat lap 6 of the L-shaped cove channelled joint connector device facing the exterior side of the wall panel.
- the other L-shaped cove channelled joint connector device 7 is located to the extreme right side of the wall panel with the cleat lap 6 of the L-shaped joint connector device 7 facing the exterior side of the wall panel.
- Top and bottom 18 horizontal timber framing members are cut short in length by the width of framing member 18.
- the framing members 18 are attached with 76mm framing nails to L- shaped cove channelled joint connector device 7. Note: the framing members 18 are attached flush less the width of the framing member 18 to the timber stud 2 of right hand L-shaped cove channelled joint connector device 7.
- the cleat lap 6 extends beyond framing members 18.
- Vertical timber stud framing members 14 which can be spaced 406mm, 455mm, or 610mm on center and which can vary in number depending on the length of the prefabricated wall panel are attached to the top and bottom framing members 18 with 76mm framing nails.
- Exterior plywood sheathing or finished exterior panel board 12 extends past the framing member 18 equal to the width of framing member 18 plus the thickness of the panel board 12.
- the exterior plywood sheathing or finished exterior panel board 12 is fastened to timber framing members 14, 18 and L- shaped cove channelled joint connector devices 7.
- the L-shaped cove channelled joint connector devices 7 are cove channelled 4 to receive acoustical caulking for a permanent building, or backer rod if the building is to be a portable type.
- a window or door may be placed in the wall panel if required.
- Framing member 16 Fig. 8 may be added for additional support to wall panel or for backing for fastening interior panel board.
- the second wall panel Fig. 7 and Fig. 9 otherwise known as the outside left hand corner wall panel required to build the outside corner of the present invention is comprised of and assembled in the following manner.
- the cleat lap 6 faces to the interior of the wall panel.
- Timber stud 16 is fastened to the L-shaped cove channelled joint connector device 7 for extra support and as a backing for interior panel board.
- the other joint connector device 7 is located to the extreme right of the wall panel with the cleat lap 6 facing the interior of the wall panel.
- Top and bottom 18 horizontal timber framing members are attached to the L-shaped cove channelled joint connector device 7 with 76mm framing nails.
- Vertical timber stud framing members 14 can be spaced 406mm, 455mm, or 610mm on center and can vary in number depending on the length of the prefabricated wall panel. These vertical timber stud framing members 14 are attached to the top and bottom 18 horizontal timber framing members with 76mm framing nails.
- Exterior plywood sheathing or finished exterior panel board 12 is fastened to timber framing members 14 , 18 and L-shaped cove channelled joint connector devices 7.
- the L-shaped cove channelled joint connector devices 7 are cove channelled 4 to receive acoustical caulking for a permanent building, or backer rod if the building is to be a portable type.
- a window or door may be placed in the wall panel if required.
- the fourth type of wall panel required to build a building according to the present invention is an inside corner wall panel Fig 10 and 12. It is comprised of two L-shaped cove channelled joint connector devices 7, one located to the extreme left side of the wall panel and the other located to the extreme right side of the wall panel. Both cleat laps 6 of the L-shaped cove channelled joint connector devices 7 face to the interior side of the wall panel. Each of the cleat laps 6 is predrilled 10 for framing screws required to attach the adjoining walls together. Top and bottom 18 horizontal timber framing members are attached with 76mm framing nails to timber stud 2 of L-shaped cove channelled joint connector device 7. The cleat laps 6 extend beyond the top and bottom framing members 18.
- Timber framing member 16 is attached to L-shaped cove channelled joint connector device 7 and timber framing members 18. The extra timber framing member 16 is required for fastening exterior panel board, location 12B.
- Vertical framing members 14 can be spaced 406mm, 455mm, or 610mm on center and can vary in number depending on the length of the prefabricated wall panel. These vertical framing members 14 are attached to top and bottom timber framing members 18 with 76mm framing nails.
- Exterior plywood sheathing or finished exterior panel board 12 is fastened to timber framing members 18, 16,14 and L-shaped cove channelled joint connector device 7. Exterior finish wall board 12 is cut short in width by the thickness of the exterior wall board. Standard wall panel Fig.
- the L-shaped cove channelled joint connector devices 7 are cove channeled to receive acoustical caulking for a permanent building, or backer rod if the building is to be a portable type.
- a window or door may be placed in the wall panel if required.
- Figure 13 shows a top view of standard intermediate prefabricated wall panels in plurality connected and assembled together as mentioned in Figures 5 and 7. Also comprising a wall thermal insulation 20 and showing interior panel board 22. Prefabricated wall sections units of four different configurations Fig 14 are shown in plurality and designated Fig 5, Fig 6, Fig 9 and Fig 10.
- the panel configurations are so designed that standardized prefabricated panels extend around the periphery of the building.
- the present invention provides a timber frame wall system comprising a plurality of prefabricated wall panels all of the same height and thickness with two L-shaped cove channelled joint wall connector devices 7; cove channel 4 to receive acoustical caulking for a permanent building, or backer rod if the structure is to be of a portable type.
- Inside and outside corner wall panels Fig 10, Fig 6 and Fig 9 respectively and standard intermediate wall panel Fig 5 are used in plurality to construct buildings of various sizes and shapes. Permanent buildings or buildings of a portable type may be built using this method of assembly.
- Fig. 15 shows an optional method of assembling an outside corner for a building constructed according to the present invention.
- Two standard intermediate wall panels are attached at 90 degree angles, an L-shaped timber stud post or filler blocks are used to fill the cavity. Corner trim boards are then applied to finish the exterior of the corner. This method of assembly allows the structure to be built by using only standard intermediate style wall panels. It also offers the choice and flexibility of placing the standard intermediate wall panels in different locations.
- FIG. 16 This view represents a typical structure and the end result of the practiced invention. Standard intermediate wall panels with doors and windows installed, exterior trim boards, insulation and interior finish wall board are shown. A typical wood floor joist system and truss or rafter roof system completes the structure.
- a sequence of steps are required to erect the wail system as disclosed in the present invention.
- Brace wall panel with temporary brace supports. Apply a bead of caulking compound or backer rod in cove channel 4 extending through the total height of the wall panel. Apply caulking compound or backer rod in cove channel 4 to the mating side of left hand corner wall panel Fig 9. Abut the wall panels together.
- the mating corner wall panels Fig 6 and Fig 9 are then fastened together with 89mm nails or framing screws. It is of the utmost importance that the first two corner wall panels be located in their right location, plumbed and squared. It is recommended that the wall panels be erected in a clockwise method.
- the next wall panel, Fig 5, a standard intermediate panel, and mating side of wall panel Fig 9 require caulking compound or backer rod to be applied to cove channel 4.
- the two wall panels, Fig 9 and Fig 5 are abutted together. Wall panel 5 is toe-nailed to subfloor or floor plate.
- Top plate 18 is fastened to L-shaped cove channelled joint connector device 7.
- the L-shaped cove channelled wall panel joint connector devices and prefabricated wall framing members are made of wood although without departing from the embodiments shown or the scope of the present invention, the L-shaped cove channelled wall panel joint connector device and prefabricated wall framing members may be made from light gauge 1.65mm tubular steel of the same size and shape and having the same structural integrity as the wood framing members.
- the steel framing components are welded together instead of being nailed together.
- the exterior and interior wall panels are secured to wall framing components with steel screws or pneumatic air gun applied nails.
- the adjoining wall panels are fastened to each other with steel screws.
- the acoustical caulking compound or backer rod is installed in the cove channel in the steel framing stud.
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Abstract
The present invention relates to an L-shaped cove channelled joint connector device for joining prefabricated structural building panels and method for the assembly of the prefabricated structural building panels, wherein the assembly is accomplished at a factory from wood framing components and the use of other traditional building materials. It is desirable to have a method of connecting prefabricated structural building panels which have the unique connecting feature suited to either a portable or permanent structure and being capable of disassembling if required. The L-shaped cove channelled joint connector device and method of construction is particularly suited to the assembly of wall panels, floor panels, and roof panels. The connector building system disclosed comprises a plurality of prefabricated structural building panels being of the same height and of various widths. Disposed in a side to side relation the panels are joined in a lap fashion. The L-shaped cove channelled joint connector is cove channelled on the mating side to receive acoustical caulking for a permanent building, or a backer rod in the case of a portable or relocatable building. With a lap extending the edge of one panel and being received by the adjacent panel, the adjacent panels are fastened together from the interior side of the structure with framing screws. This connector and system of construction allow for the exterior finish to be applied to the wall panel before the wall is set in place.
Description
JOINT CONNECTOR DEVICE AND METHOD FOR ASSEMBLING PREFABRICATED
BUILDING PANELS
BACKGROUND OF THE INVENTION
This invention relates to a new and improved panel joint connector device and a method for assembling the prefabricated panels For wail panels each faced with external finished siding applied, which connect in a manner that the assembly may be rapidly completed at the building site in a water and air tight manner The concept also includes the unique potential of building a portable or permanent building
Prefabricated wall panels of many types are well known in the art where panels are assembled at a factory and delivered to a job site are known, where they are erected These wall panels are butted together, then fastened to adjacent framing stud members The exterior vapour barrier and exterior siding or finish are then applied Electrical wiπng, if required, is installed in the wall panel Finally, the insulation, interior vapour barrier and interior wall boards are installed This known art requires extensive labour and time to complete the wall sections at the job site The wall sections are virtually impossible to disassemble without damaging the building It is therefore the principle object of the current invention to provide a weather tight joint connector and a method of assembly that allows for less labour, less labour skills and less time at the job site to complete the wall sections The present invention, the L-shaped cove channelled joint connector and method of assembly eliminates the infiltration of water and air between the join in adjacent panels, creating an advantageous situation in the sense that the structure can be either portable or of a permanent building These and other objects will become more apparent to those skilled in the art upon reviewing the summary of the invention and upon undertaking a study of the description of its preferred embodiment, in view of the drawings
SUMMARY OF THE INVENTION
It is the object of the present invention to provide an improved panel joint connector device and a method of assembling the prefabricated panels. The prefabricated wall sections are constructed to a standardized height and of various lengths. All wall sections include an L-shaped cove channelled joint connector device on the extreme left and extreme right side of the wall panel. The L-shaped cove channelled joint connector device is cove channelled to receive an acoustical caulking or a backer rod. The L-shaped cove channelled joint connector devices completely eliminate water and air infiltration between the adjacent panels. This L-shaped cove channelled joint connector device will have necessary holes for the passage of screws on the lap side, which is the interior side of the device. This enables the building to be erected by unskilled people who simply screw the wall panels together. Standard intermediate wall sections include a rectangular frame made up of two L-shaped cove channelled joint connector devices. The first L-shaped cove channelled joint connector device is located on the extreme left side of the wall panel with the lap positioned to the exterior side of the wall panel. The second L-shaped cove channelled joint connector device is located on the extreme right side of the wall panel with the lap positioned to the interior side of the wall panel. Vertical timber frame studs are positioned and spaced between the L-shaped cove channelled joint connector devices. Horizontal top and bottom timber frame members are then assembled in a conventional manner The L- shaped cove channelled joint connector devices, the vertical and horizontal timber frame members are of the same width i.e. 38mm x 64mm or 38mm x 89mm timber. Rectangular sheets of plywood or exterior panel boards are fastened to the exterior side of the framing members enclosing the space between the L-shaped cove channelled joint connector devices, the vertical and top and bottom timber framing members. These spaces are then filled with a thermal insulation material ; ie polystyrene foam board or fiberglass type insulation. Interior vapour barrier and panel board is attached to the interior side of the wall panel. The vapour barrier and interior panel board can be attached to the wall panel at the factory or at the job site. The exterior sheathing plywood or exterior panel board may be flush to the bottom timber frame member of the wall or may overlap bottom timber frame member. The adjoining panels are fastened together with framing screws. If the building is to be permanent, acoustical caulking is applied to the cove channel of each L-shaped cove channelled joint connector device. If the building is to be portable and relocated in the future then a backer rod is more suitable as the joint sealer. The adjoining panels are then joined and then fastened to the subfloor or subfloor framing members either by toe nailing or bolting the bottom
member of wall to the subfloor or subfloor framing members. The upper end of the wall member slides over top of the connector lap device and is fastened to the lap part of the adjoining connector device. The two L-shaped cove channelled joint connector devises are then fastened together from the interior side of the wall panel using framing screws in the predrilled holes. A tie plate, a board the same width as the upper timber frame member, is fastened to the upper timber frame member for the full perimeter of the assembled wall sections overlapping the joints between the adjacent wall panels. Two types of wall panel sections are required for each outside corner of the building; a left hand outside corner wall panel and a right hand outside corner wall panel. An outside corner wall panel is built in the same manner as the first noted wall panel except that in the case of the right hand L-shaped cove channelled joint connector device, the lap side of the connector device faces the exterior side of the wall panel. Both laps for a right hand outside corner wall panel face the exterior side of the wall panel. Upper and lower framing members are cut short by the width of the framing members plus the thickness of the exterior plywood wall sheathing or exterior wall panel board . The exterior wall sheathing or wall panel board extends beyond the right hand L-shaped cove channelled joint connector device to intersect and connect with said first wall panel section. The other wall panel required to build an outside corner is a left hand outside corner wall panel. This wall panel is built in the same manner as the first noted wall panel except that in the case of the left hand L-shaped cove channelled joint connector device, the stud part of the L-shaped cove channelled joint connector device faces the exterior side of the wall panel, the cleat lap part of the L-shaped cove channelled joint connector device faces the interior side of the wall panel. The other wall panel required is an inside corner wall panel. It is built in the same manner as the first noted wall panel except that in the case of the left hand L-shaped cove channelled joint connector device the lap side of the connector faces the interior of the wall panel. Both laps for the inside corner wall panel face the inside of the wall panel. The L-shaped cove channelled joint connector device has a vertical timber stud attached to it being of the same width as the L-shaped cove channelled joint connector device. The exterior plywood wall sheathing or finished exterior panel wall board is cut short by the width of the framing member plus the thickness of the exterior plywood wall sheathing or the finished exterior panel wall board. The wall panel then connects easily to the said first wall panel.
A range of different wall panel sizes can be produced to satisfy the type of building proposed and the thermal transmittance value/insulation of the wall may be adjusted to suit individual and statutory requirements. The exterior facing material of the wall panels can be applied at the factory, reducing on site labour. Still another aspect of the invention is that the interlocking wall panels can be easily disassembled and the
building can be reassembled at a different location It is a further object of the invention to provide windows and doors installed in the wall panel sections
DESCRIPTION OF THE DRAWINGS
The invention, as exemplified by a preferred embodiment, is described with reference to the drawings in which
Fig. 1 is a common structural timber framing stud cove channelled exactly in the middle of the width of the timber stud.
FiG 2 shows the fastening cleat, lap part of the wall panel connector device with predrilled holes for the framing screws used in joining the mated wall panel connector devices together
Fig 3 is the end view of the L-shaped cove channelled joint connector device assembled with cleat lap attached to timber frame stud
Fig 4 is an assembled L-shape cove channelled joint connector device in a vertical position before top and bottom timber framing members are attached to the interlocking L-shaped cove channelled joint connector device
Fig 5 is a top view of a single standard intermediate wall panel used in the system of the present invention
Fig 6 is a top view of a right hand corner wall panel, one of the two required to build an outside corner
Fig. 7 is an elevation view of an assembled single standard intermediate wall panel of Fig. 5
Fig 8 is an elevation view of an assembled right hand corner wall panel of Fig 6
Fig 9 is a top view of a left hand outside corner wall panel, the second wall panel required to build an outside corner with the panel of Fig 6
Fig 10 is a top view of an inside corner wall panel of Fig 9
Fig.11 is an elevation view of an assembled left hand outside corner wall panel.
Fig. 12 is an elevation view of an assembled inside corner wall panel of Fig. 10..
Fig. 13 is a top view showing a plurality of wall panels joined together with exterior panel board applied, interior panelling applied, with insulation material installed into the interior wall cavity.
Fig. 14 is a top view of the wall panels joined in plurality, which include an inside corner wall panel, an exterior standard intermediate wall panel and the two types of wall panel sections required to build an outside corner.
Fig. 15 is a sectional view showing an alternative wall panel configuration comprising standard intermediate wall panels to build an outside wall corner.
Fig. 16 is a perspective view of a typical structure embodying the concepts of the present invention.
Referring to the drawings and the embodiment of the invention disclosed Figs. 1- 4 illustrate a prefabricated wall panel L-shaped cove channelled joint connector device 7 comprising a standard timber stud 2 38mm x 89mm cove channeled 4 exactly in the middle of timber stud 2 between 2D and 2C the width of cove channel 4 being 12.7mm in width and 3.175mm in depth at the center of the coved channel 4. The coved channel extends the total length of the timber stud 2, which is sized in length for an 2438mm high wall. The width of the timber stud 2, 2A - 2B may be either 64mm or 89mm in width and the thickness of timber stud 2, 2A - 2D is 38mm in thickness. The cleat lap part 6 of the wall panel L-shaped cove channelled joint connector device 7 is exactly half the width of timber stud 2, 2A - 2B and the same thickness as timber stud 2, 2A - 2D - 38mm thick. The cleat lap 6 is attached flush to the coved channel side of the timber stud 2. The width of 6A - 6B of cleat lap 6 is equal to exactly half the width of timber stud 2. 2A - 2B. The cleat lap 6 is attached to timber stud 2 with glue and 64mm nails 8. The nails 8 are located 51 mm from the ends of cleat lap 6 and thereafter at 153mm intervals. The cleat lap 6 of assembled wall panel L-shaped cove channelled joint connector device 7 is predrilled 10 for the framing screws used for fastening adjacent panels together. The assembled L-shaped cove channelled joint connector devices 7 are standard in length for 2438 mm high walls, but may vary in length for other wall heights.
Figs 5 and 7 refer to a standard rectangular shaped prefabricated building wall panel usually 2438mm in height and can be of various widths up to 2438mm in length. This standard intermediate wall panel is comprised of two L-shaped cove channelled joint connector devices 7, one of which is located on the extreme left side of the wall panel, with the cleat lap 6 of the L-shaped cove channelled joint connector device facing the exterior side of the wall panel . The other L- shaped cove channelled joint connector device 7 is located to the extreme right side of the wall panel, with the cleat lap 6 of the L-shaped cove channelled joint connector device facing the interior side of the wall panel. The cleat lap 6 on the right side of the wall panel is predrilled for the framing screws required to attach it to the adjoining wall panel. Top and bottom 18 horizontal timber framing members are attached to the L-shaped cove channelled joint connector devices 7 with 76mm framing nails. Vertical timber stud framing members 14 are attached to timber framing members 18 which can be spaced 406mm, 455mm, or 610mm on center and which can vary in number depending on the length of the prefabricated wall panel. Exterior plywood sheathing or finished exterior panel board 12 is fastened to the timber framing members 14, 18, and L-shaped cove channelled joint connector devices 7. The L-shaped cove channelled joint connector devices 7 are coved channelled 4 to receive acoustical caulking for a permanent building, or a backer rod if the building is to be a portable type. The acoustical caulking or backer rod completely eliminates air or water infiltration between the two mating L-shaped joint connector devices. A window or door may be placed in the wall panels where required. The windows and doors are framed in the same traditional ways common to standard methods used in conventional framing.
One of the two exterior wall panels Fig 6 and 8 to build an outside corner of the present invention. This wall panel Fig. 6 and 8 is known as the right hand outside corner wall panel. This wall panel is comprised of two L-shaped cove channelled joint connector devices 7, one located on the extreme left side of the wall panel with the cleat lap 6 of the L-shaped cove channelled joint connector device facing the exterior side of the wall panel. The other L-shaped cove channelled joint connector device 7 is located to the extreme right side of the wall panel with the cleat lap 6 of the L-shaped joint connector device 7 facing the exterior side of the wall panel. Top and bottom 18 horizontal timber framing members are cut short in length by the width of framing member 18. The framing members 18 are attached with 76mm framing nails to L- shaped cove channelled joint connector device 7. Note: the framing members 18 are attached flush less the width of the framing member 18 to the timber stud 2 of right hand L-shaped cove channelled joint connector device 7. The cleat lap 6 extends beyond
framing members 18. Vertical timber stud framing members 14 which can be spaced 406mm, 455mm, or 610mm on center and which can vary in number depending on the length of the prefabricated wall panel are attached to the top and bottom framing members 18 with 76mm framing nails. Exterior plywood sheathing or finished exterior panel board 12 extends past the framing member 18 equal to the width of framing member 18 plus the thickness of the panel board 12. The exterior plywood sheathing or finished exterior panel board 12 is fastened to timber framing members 14, 18 and L- shaped cove channelled joint connector devices 7. The L-shaped cove channelled joint connector devices 7 are cove channelled 4 to receive acoustical caulking for a permanent building, or backer rod if the building is to be a portable type. A window or door may be placed in the wall panel if required. Framing member 16 Fig. 8 may be added for additional support to wall panel or for backing for fastening interior panel board.
The second wall panel Fig. 7 and Fig. 9 otherwise known as the outside left hand corner wall panel required to build the outside corner of the present invention is comprised of and assembled in the following manner. With two L-shaped cove channelled joint connector devices 7, one located on the extreme left side of the wall panel with the timber stud 2 part of the L-shaped cove channelled joint connector device 7 facing the exterior side of the wall panel. The cleat lap 6 faces to the interior of the wall panel. Timber stud 16 is fastened to the L-shaped cove channelled joint connector device 7 for extra support and as a backing for interior panel board. The other joint connector device 7 is located to the extreme right of the wall panel with the cleat lap 6 facing the interior of the wall panel. It is predrilled 10 for the framing screws required to attach the adjoining mating wall panels. Top and bottom 18 horizontal timber framing members are attached to the L-shaped cove channelled joint connector device 7 with 76mm framing nails. Vertical timber stud framing members 14 can be spaced 406mm, 455mm, or 610mm on center and can vary in number depending on the length of the prefabricated wall panel. These vertical timber stud framing members 14 are attached to the top and bottom 18 horizontal timber framing members with 76mm framing nails. Exterior plywood sheathing or finished exterior panel board 12 is fastened to timber framing members 14 , 18 and L-shaped cove channelled joint connector devices 7. The L-shaped cove channelled joint connector devices 7 are cove channelled 4 to receive acoustical caulking for a permanent building, or backer rod if the building is to be a portable type. A window or door may be placed in the wall panel if required.
The fourth type of wall panel required to build a building according to the present invention is an inside corner wall panel Fig 10 and 12. It is comprised of two L-shaped
cove channelled joint connector devices 7, one located to the extreme left side of the wall panel and the other located to the extreme right side of the wall panel. Both cleat laps 6 of the L-shaped cove channelled joint connector devices 7 face to the interior side of the wall panel. Each of the cleat laps 6 is predrilled 10 for framing screws required to attach the adjoining walls together. Top and bottom 18 horizontal timber framing members are attached with 76mm framing nails to timber stud 2 of L-shaped cove channelled joint connector device 7. The cleat laps 6 extend beyond the top and bottom framing members 18. Timber framing member 16 is attached to L-shaped cove channelled joint connector device 7 and timber framing members 18. The extra timber framing member 16 is required for fastening exterior panel board, location 12B. Vertical framing members 14 can be spaced 406mm, 455mm, or 610mm on center and can vary in number depending on the length of the prefabricated wall panel. These vertical framing members 14 are attached to top and bottom timber framing members 18 with 76mm framing nails. Exterior plywood sheathing or finished exterior panel board 12 is fastened to timber framing members 18, 16,14 and L-shaped cove channelled joint connector device 7. Exterior finish wall board 12 is cut short in width by the thickness of the exterior wall board. Standard wall panel Fig. 5 and 7 connects to the left hand side of wall panel inside corner Fig 10 and 12. The L-shaped cove channelled joint connector devices 7 are cove channeled to receive acoustical caulking for a permanent building, or backer rod if the building is to be a portable type. A window or door may be placed in the wall panel if required.
Figure 13 shows a top view of standard intermediate prefabricated wall panels in plurality connected and assembled together as mentioned in Figures 5 and 7. Also comprising a wall thermal insulation 20 and showing interior panel board 22. Prefabricated wall sections units of four different configurations Fig 14 are shown in plurality and designated Fig 5, Fig 6, Fig 9 and Fig 10.
The panel configurations are so designed that standardized prefabricated panels extend around the periphery of the building. The present invention provides a timber frame wall system comprising a plurality of prefabricated wall panels all of the same height and thickness with two L-shaped cove channelled joint wall connector devices 7; cove channel 4 to receive acoustical caulking for a permanent building, or backer rod if the structure is to be of a portable type. Inside and outside corner wall panels Fig 10, Fig 6 and Fig 9 respectively and standard intermediate wall panel Fig 5 are used in plurality to construct buildings of various sizes and shapes. Permanent buildings or buildings of a portable type may be built using this method of assembly.
Fig. 15 shows an optional method of assembling an outside corner for a building constructed according to the present invention. Two standard intermediate wall panels are attached at 90 degree angles, an L-shaped timber stud post or filler blocks are used to fill the cavity. Corner trim boards are then applied to finish the exterior of the corner. This method of assembly allows the structure to be built by using only standard intermediate style wall panels. It also offers the choice and flexibility of placing the standard intermediate wall panels in different locations.
Referring to Fig. 16. This view represents a typical structure and the end result of the practiced invention. Standard intermediate wall panels with doors and windows installed, exterior trim boards, insulation and interior finish wall board are shown. A typical wood floor joist system and truss or rafter roof system completes the structure.
A sequence of steps are required to erect the wail system as disclosed in the present invention. First locate the two mating left and right hand corner wall panels Fig 6 and Fig 9. Place right hand corner wall panel Fig 6 in the location in which you want to start erecting the wall panels. Toe-nail corner wall panel Fig 6 to the subfloor or floor plate. Brace wall panel with temporary brace supports. Apply a bead of caulking compound or backer rod in cove channel 4 extending through the total height of the wall panel. Apply caulking compound or backer rod in cove channel 4 to the mating side of left hand corner wall panel Fig 9. Abut the wall panels together. Toe-nail the second wall panel to the subfloor or floor plate. Nail or screw top plate 18 to adjoining L-shaped cove channelled joint connector device 7. The mating corner wall panels Fig 6 and Fig 9 are then fastened together with 89mm nails or framing screws. It is of the utmost importance that the first two corner wall panels be located in their right location, plumbed and squared. It is recommended that the wall panels be erected in a clockwise method. The next wall panel, Fig 5, a standard intermediate panel, and mating side of wall panel Fig 9 require caulking compound or backer rod to be applied to cove channel 4. The two wall panels, Fig 9 and Fig 5 are abutted together. Wall panel 5 is toe-nailed to subfloor or floor plate. Top plate 18 is fastened to L-shaped cove channelled joint connector device 7. The adjoining panels are then fastened together with 76mm framing screws in the cleat lap 6. Erection of the wall proceeds simply by adding prenumbered wall panel units in end to end relationship with the previous erected panels until the wall is completed. When an inside wall corner Fig 10 is required, the same sequence applies. A top plate timber framing member the same width as top plate 18 is fastened to the top plate 18 of the completed walls. Second floor joists if required are set on the walls if the building is to be more than one story. If the building is to be one story then ceiling joists/rafters or roof trusses are set on the walls.
The L-shaped cove channelled wall panel joint connector devices and prefabricated wall framing members are made of wood although without departing from the embodiments shown or the scope of the present invention, the L-shaped cove channelled wall panel joint connector device and prefabricated wall framing members may be made from light gauge 1.65mm tubular steel of the same size and shape and having the same structural integrity as the wood framing members. The steel framing components are welded together instead of being nailed together. The exterior and interior wall panels are secured to wall framing components with steel screws or pneumatic air gun applied nails. The adjoining wall panels are fastened to each other with steel screws. The acoustical caulking compound or backer rod is installed in the cove channel in the steel framing stud.
In the preferred embodiment four types of wall panels are disclosed making it possible to build many styles and shapes of buildings.
Various changes may be made to the embodiments shown herein without departing from the scope of the present invention which is limited only by the following claims.
Claims
1. A wall panel L-shaped cove channelled joint connector device and the assembly of prefabricated wall panels for a permanent or portable building comprising a plurality of prefabricated rectangular shaped standard intermediate wall panels all having the same height and thickness including a plurality of right hand outside comer wall panels, a plurality of left hand outside comer wall panels, a plurality of inside comer wall panels, a plurality of standard intermediate wall panels joined together to form a continuous wall; each of said wall panel members having an extemal surface and two selectively positioned engaging means; an L-shaped cove channelled joint connector device positioned to the extreme left side of the wall panel and an L-shaped cove channelled joint connector device positioned to the extreme right side of the said wall panel; comprising a selectively sized and shaped timber frame stud continuously cove channeled; a cleat lap laminated to cove channel timber stud; including horizontally extending top and bottom timber frame members, a plurality of horizontally spaced vertical timber frame members, said spaced vertical timber frame members and said L- shaped cove channelled joint connector devices secured to top and bottom timber frame members, said L-shaped cove channelled joint connector devices, said spaced vertical timber frame members and said top and bottom horizontal framing members combining to define an intemal wall frame; outer face panels, plywood sheathing or finished panel board is secured to said intemal wall frame members.
2. A wall panel L-shaped cove channelled joint connector device and the assembly of prefabricated wall panels for a permanent or portable building according to claim 1 , wherein the left and right side wall panel L-shaped cove channelled joint connector devices are continuously coved channelled to accommodate acoustical caulking or backer rod.
3. A wall panel L-shaped cove channelled joint connector device and the assembly of prefabricated wall panels for a permanent or portable building according to claim 1 , wherein the installation of doors and windows may be installed in the wall sections.
4. A wall panel L-shaped cove channelled joint connector device and the assembly of prefabricated wall panels for a permanent or portable building according to claim 1 , wherein thermal insulating material may be positioned between the horizontally spaced vertical timber frame members.
5. A wall panel L-shaped cove channelled joint connector device and the assembly of prefabricated wall panels for a permanent or portable building according to claim 1 , wherein the wall panel L-shaped joint connector device and the prefabricated wall framing members are made from wood or light gauge tubular steel of the same size and shape and having the same structural integrity as the wood framing members.
6. A wall panel L-shaped cove channelled joint connector device and the assembly of prefabricated wall panels for a permanent or portable building according to claim 1 , wherein the securing means of joining the prefabricated wall panels with the L-shaped cove channelled joint connector devices to allow disassembly and reassembly of a building.
7. A wall panel L-shaped cove channelled joint connector device and the assembly of prefabricated wall panels for a permanent or portable building according to claim 1 , wherein a plurality of prefabricated wall panel sections which define substantially the entire extemal wall of a permanent or portable building erected from the assembly.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU69821/96A AU6982196A (en) | 1995-09-26 | 1996-09-24 | Joint connector device and method for assembling prefabricated building panels |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA2,159,126 | 1995-09-26 | ||
CA 2159126 CA2159126A1 (en) | 1995-09-26 | 1995-09-26 | Joint connector device and method for assembling prefabricated building panels |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1997012099A1 true WO1997012099A1 (en) | 1997-04-03 |
Family
ID=4156656
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/CA1996/000640 WO1997012099A1 (en) | 1995-09-26 | 1996-09-24 | Joint connector device and method for assembling prefabricated building panels |
Country Status (3)
Country | Link |
---|---|
AU (1) | AU6982196A (en) |
CA (1) | CA2159126A1 (en) |
WO (1) | WO1997012099A1 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO1998032935A1 (en) * | 1997-01-23 | 1998-07-30 | The Molloy Group Pty. Ltd. | Dwelling assembly |
CN103821229A (en) * | 2014-02-26 | 2014-05-28 | 山东大学 | Rapid assembly type integrated house and installation method |
US11447944B2 (en) | 2017-12-12 | 2022-09-20 | Oikos Concept Inc. | Exterior wall panel and exterior wall panel assembly |
Citations (6)
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DE804131C (en) * | 1950-02-05 | 1951-04-16 | Willy Sinzig | Dismountable, transportable lounge |
DE1937353A1 (en) * | 1969-07-23 | 1971-02-04 | Misawa Homes Co | Prefabricated house |
CA1133674A (en) * | 1981-04-21 | 1982-10-19 | Noel Girard | Prefab building panel structures |
FR2586729A1 (en) * | 1985-09-02 | 1987-03-06 | Boyard Guy | Method for constructing timber framework buildings using insulating load-bearing composite panels |
DE8712398U1 (en) * | 1987-09-12 | 1987-10-22 | Karb, Horst, 4800 Bielefeld | Kit consisting of prefabricated concrete parts for the construction of buildings |
FR2610967A1 (en) * | 1987-02-18 | 1988-08-19 | Silve Jean | Method for producing prefabricated box-panels and box-panels obtained |
-
1995
- 1995-09-26 CA CA 2159126 patent/CA2159126A1/en not_active Abandoned
-
1996
- 1996-09-24 WO PCT/CA1996/000640 patent/WO1997012099A1/en unknown
- 1996-09-24 AU AU69821/96A patent/AU6982196A/en not_active Abandoned
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE804131C (en) * | 1950-02-05 | 1951-04-16 | Willy Sinzig | Dismountable, transportable lounge |
DE1937353A1 (en) * | 1969-07-23 | 1971-02-04 | Misawa Homes Co | Prefabricated house |
CA1133674A (en) * | 1981-04-21 | 1982-10-19 | Noel Girard | Prefab building panel structures |
FR2586729A1 (en) * | 1985-09-02 | 1987-03-06 | Boyard Guy | Method for constructing timber framework buildings using insulating load-bearing composite panels |
FR2610967A1 (en) * | 1987-02-18 | 1988-08-19 | Silve Jean | Method for producing prefabricated box-panels and box-panels obtained |
DE8712398U1 (en) * | 1987-09-12 | 1987-10-22 | Karb, Horst, 4800 Bielefeld | Kit consisting of prefabricated concrete parts for the construction of buildings |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO1998032935A1 (en) * | 1997-01-23 | 1998-07-30 | The Molloy Group Pty. Ltd. | Dwelling assembly |
CN103821229A (en) * | 2014-02-26 | 2014-05-28 | 山东大学 | Rapid assembly type integrated house and installation method |
US11447944B2 (en) | 2017-12-12 | 2022-09-20 | Oikos Concept Inc. | Exterior wall panel and exterior wall panel assembly |
Also Published As
Publication number | Publication date |
---|---|
AU6982196A (en) | 1997-04-17 |
CA2159126A1 (en) | 1997-03-27 |
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