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Description  |
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FIELD OF INVENTION
This invention relates to constructions for the erecting of, for example,
side and overhead portions of structures and more particularly to panels
provided with interlocking edges. The invention also relates to associated
methods.
PRIOR ART
Different structures formed of multiple panels are known and have been
shown in various U.S. Patents such as U.S. Pat. Nos. 2,682,938; 3,367,076;
3,479,784; 3,742,672; 3,760,548; 4,186,539; 4,373,312, and 4,769,963.
S. Meyerson discloses in U.S. Pat. No. 4,769,963 a building panel formed
from two sheets of thin metal bonded to a foamed core. One longitudinal
edge of the panel has a first pair of shaped interlocking elements with a
shaped-wedge portion of a core projecting outwardly between this first
pair of elements. A second and opposite edge of the panel has a second
pair of interlocking elements with a cup-like edge of the core conforming
to the wedge at the opposite side and associated with a second pair of
U-shaped interlocking elements. Adjacent panels are snapped together by
moving the same in relatively edge-to-edge direction such as to bring the
interlocking elements over the ramp and into the groove of the first pair
of interlocking elements to form an edge-to-edge seal. It will be
particularly noted that the cores are formed at their adjoining edges as
receptacles and as projections which are received in these receptacles.
In U.S. Pat. No. 2,682,938, A. MacDonald discloses a metal plank in which
installation of adjacent planks takes place as in the Meyerson
construction. At the edges of adjacent planks there are provided male and
female members which may be engaged by bringing the panels together in
edge-to-edge direction.
P. O'Brien discloses in U.S. Pat. No. 3,367,076 a complicated arrangement
of interlocking elements. These elements require the bringing of panels
together in edge-to-edge abutting relationship in a manner which is
subject to various disadvantages.
In U.S. Pat. No. 3,479,784, D. Massagli shows an arrangement which permits
installation by transverse relative displacement of adjacent panels. One
panel must be tilted into position relative to another which under various
circumstances is rather disadvantageous.
H. Schaeufele reveals a building panel in U.S. Pat. No. 3,742,672 which is
useful for modular construction. A plurality of such panels are assembled
in edgewise abutting relationship to form a structural barrier such as a
wall. The interlocking elements disclosed in this patent are subject to
various disadvantages which it is an object of the present invention to
avoid.
G. Sauer in U.S. Pat. No. 3,760,548 shows a modular panel relationship
unlike that to be disclosed below as does W. Harmon in U.S. Pat. No.
4,186,539.
In U.S. Pat. No. 4,373,312, K. Kim reveals a structure utilizing roof
panels including interior and exterior corrugated sheets disposed on
opposite faces of a foam core. Self drilling threaded fasteners are
employed requiring steps and hardware which are different from what is
contemplated within the scope of the present invention.
In British Patent 1,066,701 is shown cooperating panels having mating male
and female members at opposite extremities thereof. French Patent
2,444,762 reveals panels which are unlike those which will be sent forth
herein.
Various U.S. Patents disclose panels which are engaged by virtue of some
type of transverse motion. These patents include U.S. Pat. Nos. 2,783,507;
2,739,677; 2,838,144, and 4,091,588.
SUMMARY OF INVENTION
An object of the invention is to provide improved panel construction
systems relative to the prior art patents mentioned hereinabove.
A further object of the invention is to provide an improved interlocking
arrangement for panels employed in roofs, walls and the like.
Another object of the invention is to provide an improved interlocking or
interengagement system in which a series of panels may be aligned in
parallel and edgewise abutting relationship with one another.
Still another object of the invention is to provide an improved panel
arrangement having superior thermal insulation qualities.
It is yet another object of the invention to provide an improved panel
arrangement having novel arrangements for drainage.
In achieving the above and other objects of the invention in accordance
with one aspect thereof, there is provided a construction comprising at
least two adjacent panels including respective cores with skins being
provided on these cores. These panels have respective edge portions
proximate one another. Each portion includes a pair of longitudinal edges
in the shape of interlocking members which are interengageable to hold the
panels together. The core of one of the panels includes an extension and
the interlocking members of the other end of the panels are spaced from
one another and define a receptacle to receive and hold the extension
preferably short of penetration into the core of the other panel.
In the aforesaid arrangement, the panels are elongated parallel members and
the extension and receptacle extend longitudinally relative thereto.
According to one embodiment, the locking members of the other panels each
define a receptacle with flat parallel sides, the extensions each having
flat parallel sides for sliding insertion into the receptacles. The
penetration of each extension into the core of the associated panel is
prevented by engagement of the interlocking members such that the
extension is held in spaced relationship to the core of said other panel.
It should be noted that the panels include flat faces parallel to the
aforementioned sides.
In accordance with other embodiments, the extensions have chamfered edges,
enabling the panels to be brought together in angularly related positions
whereafter the panels can be brought to a common planar relationship.
In accordance with another aspect of the invention, a construction is
provided which comprises first and second adjacent panels including
proximate edge portions. The panels include respective cores with skins
being provided on these cores as aforesaid. The skins include a first
arrangement at the edge portion to hold adjacent panels together and a
second arrangement is associated with the cores to enhance the fire
resistant qualities thereof.
In the aforesaid arrangement, the item which enhances the fire resistant
qualities of the cores includes sheets of fire resistant material
sandwiching the cores. The fire resistant item may also be constituted by
sheets of fire resistant material which are embedded in the cores. The
sheets of fire resistant material may be arranged in such a manner as to
constitute interlocking arrangements themselves.
In accordance with yet another aspect of the invention there is provided a
construction consisting of first and second panels having first and second
faces and including facing edge portions with pairs of interengaged
locking arrangements being provided on the panels at the edge portions and
at respective of the faces. One of the interengaged locking arrangements
of each pair may include a first section extending along the corresponding
edge portion of the associated panel and a second section extending from
the first section in cantilever relationship thereto. A sloped cantilever
arm section may be provided extending angularly from the cantilever
section and a lip may be provided which extends from the cantilever arm in
substantially spaced parallel relationship with the first mentioned
section. The other of the engaged interlocking arrangements of each pair
include a first part aligned in parallel with the cantilever section, a
second part extending orthogonally from the first part in parallel to the
first section mentioned above and a third part extending orthogonally from
the second part in spaced parallel relationship to the first part. The
first, second and third parts constitute a first J-shaped structure. A lip
extends therefrom in spaced parallel relationship with the aforementioned
second part. This lip and the second part as well as the third part
constitute a further J-shaped structure. A sealing arrangement such as a
silicone sealant may be arranged, for example, between the first section
and second part to seal the interengaged locking arrangement
hydraulically.
Another manner in which to view the invention is as a structure including
as aforesaid a plurality of parallel panels connected in series with
locking means extending along edge portions of these panels and connecting
the panels together. In this arrangement, the locking arrangements define
channels for fluid evacuation and a gutter is mounted on adjacent ends of
the panels by means of flanges. The gutter defines a passage at the ends
to receive fluid evacuated by the aforementioned channels. At least one of
the flanges connecting the gutter to the ends is provided with openings
for the removal of fluid found in the passage.
In general, the invention may be regarded as providing a structure which
includes a plurality of panels preferably defining a common plane and
including coplanar cores and pairs of skins thereon including interlocking
elements. One of the pairs of interlocking elements on each of the panels
defines a receptacle for receiving the core on the next adjacent of the
panels as will all be explained hereinafter.
According to still other aspects of the invention, provision is made for
bringing panels together with edge-to-edge displacements either directly
or angularly or with relative longitudinal displacement. As will be shown,
C-shaped receptacles or the like can be employed to hold the panels
against a supporting structure into which the panels may be slid as a unit
or individually.
As a feature of the invention, the cores with their extensions can be
fabricated monolithically or the extensions can be fabricated separately
and then affixed to the cores. The latter technique is advantageously
economical and convenient.
The above and other objects, features and advantages of the invention will
be apparent from the following detailed description of some preferred
embodiments as illustrated in the accompanying drawing.
BRIEF DESCRIPTION OF DRAWING
In the drawing:
FIG. 1 is a diagrammatical plan view illustrating a plurality of panels
connected in parallel to form a structure such as a roof or wall or the
like;
FIG. 2 is a fragmentary view of adjoining panels including an interlocking
structure provided in accordance with the invention;
FIG. 3 is a view corresponding to FIG. 2 illustrating adjacent cores or
panels in connected relationship;
FIG. 4 is a view corresponding to FIG. 3 illustrating a further embodiment
of the invention;
FIG. 5 is a view corresponding to FIG. 4 illustrating still a further
embodiment of the invention;
FIG. 6 is a partially sectional partially diagrammatical view illustrating
a gutter arrangement for the evacuation of fluid;
FIG. 7 illustrates adjoining edges of adjacent panels according to a
further embodiment of the invention;
FIG. 8 illustrates the angular relationship of the panels of FIG. 7 upon
being brought together;
FIG. 9 illustrates the engagement of the panels of FIGS. 7 & 8;
FIG. 10 illustrates the panels of FIGS. 7-9 in engaged and caulked
relation;
FIG. 11 illustrates a modification of FIG. 10;
FIG. 12 is a partially broken away view, partly in section, illustrating
the attachment of panels to a vertical support; and
FIG. 13 is a perspective, diagrammatic view further illustrating a
multiple-panel assembly technique of the invention.
DETAILED DESCRIPTION
In accordance with the invention, a roof or wall panel assembly or the like
is provided that can support irregular roof or wall loads on adjoining
panels without having the panels assume a misaligned relationship or
becoming deformed. If, for example, distortion might result from the fact
that heavier loads are placed on one panel than on the next adjacent
panel, arrangements of the invention are useful for supporting the panels
by a plurality of bearing arrangements which are effective from the use of
interlocking elements which are provided in accordance with the invention.
This, as will be seen, provides a multiple zone support of the outer metal
skin of the cores and this, in turn, provides for avoiding the result that
silicone caulk seals which are employed might be broken.
According to another aspect of the invention, a panel assembly is provided
which can be caulked for purposes of providing a water-proof seal and
which provides for water removal while avoiding leakage or water damage to
the interior core. A silicone seal may be provided on select surfaces, as
will be indicated below, joining the panels together. Once joined, the
outer metal skins of the various cores provide water drainage passages or
cavities which carry away any seepage or condensation to the ends of the
panels while keeping the water from damaging the inner core or the bonding
agent holding the inner core and the metal skins together. This prevents
delamination of the panels.
In yet another aspect of the invention, there is provided a panel assembly
with improved double-spring action characteristics providing improved
interlocking ability. This in turn provides for maximum interlocking
engagement with minimum effort beings needed to engage or join the panels
together. This double-spring action is achieved by inward deflection of
various of the elements and outward deflection of various other of the
elements as the panels are joined together upon full engagement. As will
be shown, after initial deflection, certain of the interlocking elements
spring back to their original positions and become seated in pockets
forming a deep interlock which resists being pulled apart.
As will be described below, there is further provided a panel assembly with
a triple engagement for maximum strength, stability and weather proofing
as well as air infiltration protection. The various elements which engage
with one another will be described in greater detail below.
According to still another aspect of the invention, a panel assembly system
is provided that is easy to fabricate and which lends itself to a
moisture-protected multi-layered core arrangement in which fire-rated
sheetrock layers may be utilized in order to meet fire-rating requirements
for various building codes. The sheetrock is prevented from being damaged
by moisture by the utilization of the drainage passages mentioned
hereinabove which completely contain the moisture in metal skins and which
drain off the moisture at the ends of the panels. According to one
particular embodiment, as will be shown hereinafter, the protruding edge
of each sheetrock element is protected from damage by the related metal
channels which, at the same time, provide a means for further
interengaging the panels.
Referring next to FIG. 1, there is illustrated therein a construction
element 10 which may be part or all of, for example, a roof or wall
structure. This constructional element consists of multiple elongated
parallel panels, preferably flat, such as indicated by way of example at
12, 14, 16, 18, 20 and 22. The illustrated panels have, for example,
abutting edges at which interlocking takes place. These abutting edges are
illustrated by way of example at 24, 26, 28, 30 and 32. The details of
this interlocking arrangement are discussed in greater detail below with
reference to FIGS. 2 and 3.
In FIG. 2 is illustrated, by way of example, the abutting edges of panels
12 and 14 before these panels have been brought together. As mentioned
hereinabove, the panels are flat elongated panels. They are, in the
preferred arrangement, coplanar and cooperatively define a plane of
symmetry indicated at 34. The panel 12 is, for example, fabricated of a
core 36 having bonded thereto skins 38 and 40. The core 36 is of
rectangular cross section and is bonded to the skins 38 and 40 at
contacting surfaces 42 and 44. The core 36, as are the other cores of the
assembly, is preferably formed of a foamed material such as, for example,
polyurethane or the like. Core 36 has, moreover, a flat end or edge face
indicated at 46. The skins 38 and 40 may be fabricated preferably of metal
such as, for example, rolled steel or aluminum of any thickness and
strength.
The ends of the skins at the lateral edges of the panel form, in protruding
beyond the edges of the core 36, interlocking elements 50 and 52. Elements
50 and 52 are spaced from one another and are intended to engage with
interlocking elements of the next adjoining panel as will be described
hereinafter. It will be noted that interlocking elements 50 and 52 have
flat parallel surfaces 54 and 56 which confine therebetween a receptacle,
the purpose of which will become apparent hereinbelow.
Panel 14 includes a core 60 of the same material as employed for the core
36. The end or edge portion 62 of this core is flat and parallel and
proximate to the end surface 46 of core 38. The upper and lower
extremities of the edge portion 62 are recessed as indicated at 64 and 66.
This provides shoulders 68 and 70 which cooperatively define a projection
or tongue 72. The upper and lower edges of the tongue 72 are chamfered as
seen at 74 and 76.
The skins of the core 60 are indicated at 80 and 82. These skins are formed
of metal, preferably the same as is used for skins 38 and 40. The skins
extend beyond the shoulders 68 and 70 to form interengageable or
interlocking elements 84 and 86. Moreover, the extremities 88 and 90
extend beyond surface 62 of tongue or projection 72 in order that the
interlocking elements should afford a protection against contact with and
damage to the tongue 72. It should be noted at this point that the
interlocking elements 50 and 52 as well as the interlocking elements 84
and 86 preferably extend along the entire longitudinal extent (i.e.,
perpendicular to the plane of the drawing) of the corresponding edges of
the associated panels and cores.
Referring now by way of example to interengageable or interlocking element
50, it will be seen that such interlocking element includes a first part
or section 100 which extends perpendicularly to the plane 34 and
furthermore extends along the face 46 of the core 36. To section 100 is
connected a cantilever section or part 102 to the extremity of which is
connected a sloped cantilever arm 104 having a lip 106. The lip 106 is
parallel to and spaced from the first section 100. The angle which the
cantilever arm 104 makes with the cantilever 102 is in the range of
25.degree. to 40.degree. which angular relationship is mentioned by way of
preferred example only. Between these two sections results a hinge 110
which enables the ramp 104 to be depressed and to spring back into its
illustrated position.
The interlocking or interengageable element 84 which is next described by
way of example includes a first section 114 which extends beyond the
shoulder 68. A second section 116 is connected orthogonally to section 114
and a lip 118 is connected at right angles to the section 120. Sections
114, 116 and 120 constitute a first J-shaped part extending inwardly of
the outer skin of the associated panel. Sections 116, 120 and 118
constitute a second J-shaped section which is hook-shaped. By reason of
its length and connection to the remainder of the panel, section 114 is a
resilient cantilever member which supports the first J-shaped section to
ride up the cantilever arm 104 and to snap into the receptacle 122 of
interlocking element 50 as will be discussed hereinbelow. At the same
time, the similar cantilever arm in interlocking element 52 as well as the
J-shaped section of interlocking element 86 cooperate in the same manner.
It will be noted that the tongue 72 is intended to slip into the
receptacle or cavity defined between surfaces 54 and 56 and that the
adjoining panels are intended to be interconnected by a movement indicated
by the double-headed arrow 130.
Referring next to FIG. 3, it is seen that panels 12 and 14 are intended to
be brought into the interengaged relationship discussed hereinabove.
First, it will be noted that cantilever arm 104 has accommodated the
insertion of section 116 as well as the sections connected thereto into
the passage or pocket 122 (FIG. 2) by accommodation due to the resilient
nature of section 114 and by the slope of cantilever arm 104. Before this
interengagement takes place, there is applied to the outer surface of
section 100, a silicone sealing caulk indicated at 132. This intervenes
between the facing surfaces of sections 116 and 100 (FIG. 2) and provides
for a sealed relationship thereat. This in turn seals off the passage 134
which constitutes a hydraulic or fluid drainage passage extending the
length of the associated panel for a purpose to become more apparent
hereinbelow. It should be noted, however, that this passage is intended
for the removal of condensation or leakage or other fluids which might
otherwise accumulate and do damage to the respective cores 36 and 60.
Contact or bearing areas are indicated in FIG. 3 at 140 and 142. A further
bearing area is indicated at 144 and 146. While the surfaces adjoining
bearing areas 140 and 146 are shown in somewhat spaced relationship, this
is for purposes of illustration only. In practice, the facing surfaces
will ordinarily be in contacting relationship.
It will be noted that the tongue 72, while penetrating between sections 54
and 56, does not penetrate sufficiently to engage with core 36. In fact,
there is a space 150 between the tongue and core such that the tongue does
not penetrate into the core or, in other words, is short of the same. The
interlocking elements therefore define for receiving the tongue, a
receptacle which extends the length of the associated panel. Engagement of
the tongue, which is a substantially rectilinear rib, is by virtue of the
motion indicated in FIG. 2 by arrow 130.
In FIG. 4 are illustrated panels 160 and 162, the parts of which are
essentially what has been described above relative to FIGS. 2 and 3. In
this embodiment of the invention, however, there are embedded, in the
respective cores 164 and 166, sheets 168 and 170 of sheetrock. In this
arrangement, sheet 168 extends beyond the edge of core 164 to provide a
projecting section 172. Sheet 170 is, however, withdrawn from the edge of
core 166 in order to define a slot 174. Projection 172 extends into the
slot 174 thereby to provide a further interlocking between the panels.
This arrangement of sheetrock is moreover intended to facilitate meeting
fire-rating requirements for various building codes. In such arrangement,
the cores 164 and 166 can be provided in separate sections to accommodate
the embedding of the sheets 168 and 170. It is possible, however, to make
the sheets 168 and 170 of lesser longitudinal extent than cores 164 and
166 so that separate sections for the respective cores will not be
necessary.
In FIG. 5 are illustrated panels 180 and 182 which are of a construction
similar to that indicated above. In this embodiment of the invention,
however, the cores 184 and 186 are sandwiched between sheets 190, 192, 194
and 196. These sheets are of sheetrock having the requisite fire-rating
requirements for the reasons mentioned hereinabove.
FIG. 6 illustrates a further feature of the invention wherein a gutter 200
consisting of sides 202 and 204 connected by bottom 206 is employed for
the evacuation of fluid such as water. The gutter 200 is provided with
flanges 208 and 210 which are intended to embrace the ends 212 of a series
of panels such as has been mentioned hereinabove. These panels are
provided with drainage channels shown diagrammatically by way of example
at 214 and 216. As a result of these channels, there may be a seepage of
water such as indicated at 218. Caulking may be provided between the
flanges and the panels. Such caulking is shown by way of example at 220.
The flanges may be provided with openings 222 to enable the escape of
fluid as shown at 224. These holes constitute means to drain any water
accumulated in the drainage channel as illustrated. It will be noted that,
in the illustration of this feature, the panel assembly constitute a roof
generally indicated at 230 supported on a wall indicated generally at 232.
It should be noted that the gutter 200 can readily be fabricated of a
plastic having suitable strength or of a sheet metal as preferred.
FIGS. 7-10 illustrate a further embodiment of the invention. Therein appear
panels 250 and 252 including cores 254 and 256 respectively. Panel 250 is
provided with skins 258 and 260 whereas panel 252 is provided with skins
262 and 264. As described hereinabove, these skins are formed as
interlocking elements 266, 268, 270 and 272. Interlocking elements 266 and
268 are provided in spaced relationship so as to define a receptacle 274.
The edge of core 256 is provided with tongue 276. This tongue is provided
with chamfered edges 278 and 280. Tongue 276 is adapted for accommodation
within receptacle 274 between interlocking elements 266 and 268. As in the
previously described embodiment, this accommodation of tongue 276 is
preferably such as to avoid contact between tongue 276 and the core 254.
The purpose of providing the chamfers on core tongue 276 appears more
clearly in FIG. 8. It enables the panels 250 and 252 to be brought
together in an angular relationship wherein the interlocking elements 266
and 270 can be brought together initially followed by a coupling of the
interlocking elements 268 and 272. The latter connection is illustrated
more specifically in FIG. 9 wherein the tongue 276 is inserted to nearly
full extent in the receptacle 274 with all of the interlocking elements
engaged with one another. Thereafter, as appears in FIG. 10, a caulking is
inserted as appears at 290 and 292 thereby to seal in drainage channels
294 and 296. Although some spacing is shown between the tongue 276 and the
interlocking elements, this is for illustration purposes only as it is
preferred that interlocking elements be brought to bear against the tongue
thereby to enable the panels to be held in aligned,relationship with one
another.
In the embodiment of the invention illustrated in FIGS. 7-10, the tongue is
shown as being integral with the associated core. In a preferred
relationship, the tongue is fabricated separately of the associated core
as appears in FIG. 11. In FIG. 11 appears core 300 and tongue 302. The
tongue 302 is fabricated separately from the core 300 but is cemented
thereto prior to the assembling of the panels. The core and its tongue are
fabricated of a sponge-like material such as a polyurethane ether such as
fabricated by HO Products Corp. of Wynsted, Conn. The tongue 302 is
provided with chamfered edges 304 and 306 to enable the panels to be
assembled as has been described hereinabove. It will be noted that the
tongue 302 is illustrated as being connected by cement or other such
adhesive to the core 300. It is equally possible for the core 302 to be
cemented instead to the core 308. For purposes of illustration, there is
shown a space at 318. Preferably however, the interlocking elements bottom
out against one another and against the associated tongue to provide for
the most advantageous relationship.
FIG. 12 illustrates a wall 320 and a front structure 322 spaced therefrom.
A plurality of panels 324 are connected with one another and provided with
a drain 326 such as has been described hereinabove. The panels may be
supported by the wall 320 by the utilization of a C channel 328. Screws
such as, for example, shown at 330 and 332 may be inserted into the panels
through appropriate holes provided in the C channel 328 in order to retain
the panels in aligned relationship firmly affixed to the support 320.
Additional screws may be utilized such as illustrated at 334 and 336.
FIG. 13 illustrates support wall 350 with front wall 352 spaced therefrom.
A plurality of panels are illustrated, for example, at 354 and 356, these
being accommodated in the C channel 358. In the illustrated embodiment, a
further panel 360 is illustrated as being coupled with the panel 356 in
edge-to-edge relationship by relative longitudinal displacement between
the same as a consequence of which the interlocking elements are engaged
with each other. The relative longitudinal displacement is indicated by
the arrow 362.
According to the method of the invention, there are comprised the steps of
sandwiching each of a plurality of cores between respective pairs of
skins, while extending said skins beyond the cores and forming
interlocking elements thereat. The elements are interlocked together to
connect the cores. Selected interlocking elements are spaced from each
other to form a receptacle. A tongue is formed on one of the cores to be
received in the receptacle. It will noted hereinabove that the tongue can
be separate from but cemented to the associated core. It will also be
noted that the tongue is preferably chamfered to permit the interlocking
of said elements by tilting said cores relative to one another. The cores
may also, as has been noted hereinabove, be brought together directly in
edge to edge direction.
According to still another embodiment of the invention as has been
discussed above, the interlocking elements can be brought together by
relative longitudinal displacement. The interlocking elements themselves
are brought together by camming displacement such as has been noted
hereinabove relative, for example, to the sloped section 104 (see FIG. 3).
In addition to the foregoing, it has been noted that the method comprises
interlocking elements in such a manner as to constitute drainage channels.
A further step in the method of the invention involves inserting caulking
between selected of the interlocking elements.
There will now be obvious to those skilled in the art many modifications
and variations of the structures and methods set forth hereinabove. These
modifications and variations will not depart from the scope of the
invention if defined by the following claims or the functional equivalents
of what is defined.
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