 |
Description  |
|
|
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a prefabricated multicomponent panel
system.
A typical problem associated with existing prefabricated panel systems is
that when assembled at the building site they are not sufficiently
flexible to allow easy adaptation to various architectural plans.
Typically, panels are precut into pre-existing dimensions such as
4.times.8, 6.times.10, etc. If the architectural plans call for any
deviation from this, it is very difficult to adapt the panels to the
building specification. Furthermore, there is a problem associated with
creating windows and doorways from such prefabricated panel structures.
Still another problem associated with assembling prefabricated panels at
the job site is that it is difficult to level and/or square the
structures. For example, if the foundation is not level, the wall will be
inclined as the panels are put together such that at the juncture of two
intersecting walls there will be an improper fit. Additionally, panels
which are roughly cut will not always be level or square. Additionally,
the corners of the foundation are often times not perfectly square such
that two walls which are meant to be at ninety degrees with respect to one
another in fact extend out at something other than ninety degrees and
create a problem when the next corner wall is assembled.
The present invention solves these and other problems.
SUMMARY OF THE INVENTION
The present invention relates to a multicomponent panel system wherein the
interacting cooperating parts are closely machined (planed) so as to
ensure a proper alignment and fit between the individual components of the
system.
The present invention further relates to a method of assembling the
multicomponent panel system such that partitions formed by the
multicomponent system are square with one another and level.
The preferred embodiment of the present invention is machined (planed) to
tolerances typically associated with metal tolerances as opposed to the
large tolerances associated with wood. In a preferred embodiment, male
parts (inserters) are machined to within minus three thousandths of an
inch (-0.003), i.e., the desired size to the desired size -0.0003 inches,
whereas female parts (receptors) are machined to within plus three
thousandths of an inch (+0.003), i.e., the desired size to the desired
size +0.0003 inches. Most dimensions are machined to be within .+-. three
to five thousandths of an inch.
The present invention relates to a multicomponent panel system including a
machined, one-piece, generally T-shaped plate having a stepped-up portion
which is rectangular in cross-section and a base portion which is also
rectangular in cross-section, of greater width than the stepped-up
portion. The multicomponent system further includes a honeycomb panel
having two spaced-apart, parallel sheets separated by a honeycomb
structure intermediate thereof, the honeycomb structure defines a
plurality of openings extending perpendicular to the sheets, the sheets of
the honeycomb panel being machined along edge portions of the panel to
enable insertion of the stepped-up portion of the plate intermediate of
the sheets in a tight-fitting relationship. A machined panel corner
structure comprising two honeycomb panels secured to one another so as to
form a ninety degree angle is yet another component of the multicomponent
panel system. A further component is a spline being rectangular in
cross-section and comprising two spaced-apart, parallel sheets separated
by a honeycomb structure, the spline is machined to enable insertion of
the spline between the honeycomb panel sheets in a tight-fitting
relationship. The multicomponent panel system further includes a
one-piece, solid, generally U-shaped trim member having a base
intermediate of two parallel, spaced-apart sides, the sides being machined
to enable insertion of the spline between the sides of the trim member in
a tight-fitting relationship.
A preferred embodiment of the multicomponent panel system further includes
a conduit chase member positionable between two adjacent honeycomb panels
and defining a pathway for placement of wiring or the like.
In the preferred embodiment, the plate members are precisely pre-drilled as
well as the edge portions of the panels so as to facilitate leveling of
the plate members with the panels.
In the preferred embodiment, adhesive is placed on the male parts
(inserters) and the female parts (receptors) are pre-drilled for receipt
of screws used in attaching the components.
These and various other advantages and features of novelty which
characterize the invention are pointed out with particularity in the
claims annexed hereto and forming a part hereof. However, for a better
understanding of the invention, its advantages and objects obtained by its
use, reference should be made to the drawings which form a further part
hereof, and to the accompanying descriptive matter, in which there is
illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings wherein like reference numerals indicate
corresponding parts throughout the several views:
FIG. 1 illustrates problems associated with prior art paneling structures
which are not properly leveled;
FIG. 2 illustrates a multicomponent panel system in accordance with the
principles of the present invention wherein honeycomb panels are being
positioned on a bottom plate intermediate of two corner structures along
one side of a building structure;
FIG. 3 illustrates a multicomponent panel system as shown in FIG. 2 with
various ones of the components being illustrated separated from the other
components;
FIG. 4 illustrates the formation of doorways and windows with a
multicomponent panel system in accordance with the principles of the
present invention;
FIG. 5 illustrates the intersection of two bottom plates at a corner of the
building structure, the plates configured to receive an embodiment of a
corner plate structure in accordance with the principles of the present
invention;
FIG. 6 illustrates positioning of two corner panel structures along a first
side of a building structure;
FIG. 7 is a sectional view illustrating attachment of a ceiling panel
structure to a wall panel structure in accordance with the principles of
the present invention; and
FIG. 8 is a view illustrating panel structures having a covering material
thereon.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a typical problem associated with prior art
multicomponent panel system designs. FIG. 1 illustrates a prior art panel
system 20 wherein the individual panels 22 are being positioned on a
foundation 24 which is not perfectly level as is indicated by the level
line 26. As is illustrated by this diagram, as subsequent panels are
positioned this creates problems at the building site. Either the
individual panels 22 will be inclined to follow the curvature or slope of
the foundation or the building personnel will have to individually attempt
to level each and every panel as it is positioned, which creates numerous
problems. Similar problems are encountered when it comes to making sure
the wall partitions are square. It is very difficult to assure that
intersecting partitions will be square with one another because of the way
they are attached to each other, the foundation not being square, etc.
FIG. 2 illustrates a panel system in accordance with the principles of the
present invention, the panel system generally being referenced by the
reference numeral 30. The components of the system are machined (planed)
to very narrow tolerances. Referring now to FIGS. 2-8, the preferred
embodiment of the multicomponent panel system 30 is illustrated as
including a prefabricated, machined, one-piece, wooden plate 32, generally
T-shaped in cross-section, which serves as a bottom plate 32a along the
foundation and a top plate 32b proximate the ceiling. The plate 32 has a
stepped-up portion 34 which is rectangular in cross-section and a base
portion 36 of greater width than the stepped-up portion which is also
rectangular in cross-section. In the preferred embodiment, the plate 32 is
pre-drilled at precise locations 27 for receipt of a screw or the like.
A prefabricated honeycomb panel 40 is provided having two spaced-apart,
parallel sheets 42 separated by a honeycomb structure 44 intermediate
thereof. In the embodiment shown, the honeycomb structure 44 defines a
plurality of openings roughly a half inch in diameter or so extending
perpendicular of the sheets 42. The inside surfaces of the sheets 42 of
the honeycomb panel 40 are machined along edge portions 41 about the
periphery of the panel 40 to enable insertion of the stepped-up portion 34
of the plate intermediate of the sheets 42 in a tight-fitting
relationship. In the embodiment shown, the inside surfaces along the edge
portions 41 of the panels 40 are machined so as to provide roughly a
two-inch, U-shaped receptor (cavity) 43. Accordingly, two of the panels 40
abutting at their side edge portions 41 will provide roughly a four-inch
cavity. In particular, the walls and edges of the honeycomb sheets 42 and
the plate 32 are closely machined such that the fit provided therebetween
is a snug, tight fit which will retain the panel 40 on the plate 32 and
yet enable the panel 40 to be slid into and out of position on the plate
32 by hand. In addition to the inside surface of the edge portions 41
being closely machined, the edges 39 of the panel 40 are also machined to
assure a level and square interconnection of the panels 40 to one another
and the plate 32. Preferably, the panels 40 are made of a wood material.
It will be appreciated that the specific material and sizing of the sheets
42 as well as the specific honeycomb structure are immaterial to the
invention. In the preferred embodiment, the panels 40 are pre-drilled at
precise locations 45 to align with the pre-drilled holes in the plate
thereby facilitating leveling of the system.
The multicomponent panel system 30 further includes a prefabricated,
machined corner panel structure 50 comprising two honeycomb panels 40
secured to one another so as to form a ninety degree angle. A vertically
extending support member 47 is positioned in the edge portion 41 of the
panel 40a in an abutting relationship to the inner sheet 42 of the panel
40b. In the preferred embodiment shown in FIG. 5, one of the plates 32
interconnecting at the corner has a stepped-up portion 34a which extends
over a base portion 36a of the other intersecting plate 32. A groove 35 is
provided between the stepped-up portion 34a and the stepped-up portion 34
of the intersecting plate 32 so as to provide for insertion of a sheet 42
of the panel structure 40. The two intersecting plates 32 are preferably
interconnected to one another by suitable adhesive and/or fasteners.
The multicomponent panel system further includes a prefabricated, machined
spline 60 having sheets 62 and a honeycomb core 64 structured similar to
the panel 40 but having machined outer surfaces so as to have a width such
that the spline 60 snugly slides into place between opposing surfaces
along the edge portion 41 of the panel structure 40. Accordingly, the
spline 60 is used to interconnect two adjacent panels as is illustrated in
FIG. 3. The width of the spline 60 might be such so as to fill the entire
four-inch channel created by abutting edge portions 41 of the panels 40.
In alternative embodiments, the spline might have a lesser width such as
three inches so as to form a pathway for electrical wires or the like.
Such a smaller spline is illustrated as 60a in FIG. 3, a pathway 59 being
formed between the spline 60a and the panel honeycomb core 44. The spline
60 may be attached along the edge portion 41 of a panel 40 at the factory
so as to provide a panel having a female receptor or recess along a first
edge portion and a male receptor or projection along an opposite second
edge portion. The splines 60 may also be separately shipped to the
construction site. In the preferred embodiment, adhesive is applied to the
spline 60 to facilitate attachment of the spline 60 to the panels 40.
The multicomponent panel system 30 further includes a one-piece, solid,
generally U-shaped trim member 70 having a base portion 72 intermediate of
two spaced-apart, parallel sides 74. The sides 74 of the trim member 70
are machined to tightly fit over the sides 62 of a spline member 60. The
top of the base portion 72 provides a ledge 76 for resting of a header
panel structure 78 thereon. The header 78 is similar to the panels 40.
Such a header structure is used over doorways and windows. The header
structure 78 in turn includes a support member 79 secured along a lower
edge portion of the header 78 between the sheets 42 of the header panel 40
such as a 2.times.4, 2.times.6, etc. which rests on the ledge 76. In the
preferred embodiment, the trim member is predrilled at locations 71.
A preferred embodiment of the present invention further includes a conduit
chase member 80 machined to fit between the opposing facing sides 42 of a
panel and defining a pathway for positioning of electrical wiring or the
like therethrough. In one embodiment, the interior sheets 42 are cut along
the edge portion 41 to provide an opening from the room into the pathway
when the exterior sheets 42 are in abutting relationship behind the
conduit chase member 80.
The components of the multicomponent panel system are prefabricated at the
factory. The various components are closely machined such that interacting
surfaces between the various ones of the components provide a very close,
tight fit so as to enable the various components to be slid into place and
yet provide a solid structure and retain their connection. In the
preferred embodiment, male parts (inserters) are machined (planed) to
within minus three thousandths of an inch (-0.003), i.e., the desired size
to the desired size -0.0003 inches, whereas female parts (receptors) are
machined to within plus three thousandths of an inch (+0.003), i.e., the
desired size to the desired size +0.0003 inches. Most dimensions are
machined to be within .+-. three to five thousandths of an inch.
Additionally, this arrangement provides for a self-leveling and squaring
system. Adhesive and/or threaded fasteners are preferably used to further
interconnect various ones of the components. In particular, screws 82,
such as drywall screws or self-tapping screws, are utilized to attach the
panel structures 40 to the bottom and top plates 32a,b and for
interconnecting the panels 40 to the splines 60. In addition to machining
the major opposing facing surfaces of the components, the edges are also
very closely machined to assure that they are level. Because of this, the
prefabricated multicomponents can be readily assembled at the job site.
Moreover, as they are assembled they will properly align and level
themselves.
In the preferred embodiment, when first erecting a building structure 90,
the bottom plate 32a is positioned about the foundation (see FIG. 4) with
plates 32a intersecting in a corner as shown in FIG. 5. Typically, each
side of a partition has only one plate. Anchor bolts 91 or the like are
used to loosely fasten the plate 32 in place. Next, two corner panel
structures 50a, 50b are positioned along a first side 92 of the building
structure. The corner members 50a,b are tightly secured to the plate 32a
such that a bottom edge 37 of the corner members 50a,b rests on a top
surface 33 of the base portion 36. In addition, the sheets 42 are abutted
against machined sides 31 of the stepped-up portion 34. This will square
the corner. Panel structures are then placed between the two corner
sections 50a,b onto the base plate 32a. The panel structures 40 are then
securedly fastened into place by the use of the screws 82 or the like. As
the panel structures 40 are fastened, they will pull the loosely mounted
plate 32 into a parallel and aligned orientation. Shims 29 or the like are
then used to support the plate 32 where any gaps occur between the plates
32 and the foundation 24. The anchor bolts 91 can then be tightened. Next,
a third corner structure is placed opposite one of the first two corner
structures 50a,b. Panel structures 40 are then positioned onto the base
plate 32a and securedly fastened into place. It will be appreciated that
by building the walls of the building structure 90 in this fashion, it
will be assured that the walls are perfectly level and square relative to
one another. In yet other approaches, only one corner structure need be
positioned before positioning the panels 40.
Illustrated in FIG. 7 is an embodiment of a top plate structure 32b which
is inclined so as to provide the desired incline or slope for a ceiling
panel which is also formed by one of the panel structures 40. The panel
structure 40 is suitably secured to the top plate 32b by a threaded,
elongated member 94 having an enlarged washer or plate 95 suitably mounted
thereon so as to prevent any damage to the sheet 42 of the panel 40. A
spline 60 and a trim member 70 are used to form an overhang.
As illustrated in FIGS. 5 and 6, doorways and windows 96 are formed by
cooperation of the spline 60 and the trim member 70 so as to provide the
ledge 76 for supporting the support member 79 of a doorway or window
header 78. As shown in FIG. 6, the bottom frame of the window is formed by
the cooperating spline member 60 and the trim member 70.
In some embodiments, the panels 40 might have a material covering 98, e.g.,
wallpaper, applied at the factory. The covering 98 preferably will have a
release layer along its edges so that the edges of the covering 98 can be
pulled back to allow the panels to be threadedly fastened via pre-drilled
holes 45 to the splines 60, plates 32, etc. and then attached along the
edges to the panels 40.
It is to be understood, however, that even though numerous characteristics
and advantages of the present invention have been set forth in the
foregoing description, together with details of the structure and function
of the invention, the disclosure is illustrative only, and changes may be
made in detail, especially in matters of shape, size and arrangement of
parts within the principles of the invention to the full extent indicated
by the broad general meaning of the terms in which the appended claims are
expressed.
* * * * *
|
|
 |
|
 |
Description |
|
