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Description  |
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FIELD OF THE INVENTION
The present invention generally relates to the field of building
construction and, more particularly, to a wall assembly of a building
structure which is assembled from a plurality of panels having preformed
grooves thereon and from a plurality of supports which are installed in
these grooves and are appropriately interconnected.
BACKGROUND OF THE INVENTION
Conventional residential construction techniques are based upon a frame
substructure. That is, the initial task in the construction of the walls
is framing. More specifically, a series of vertically extending studs
(e.g., two-by-fours) are spaced between and nailed to top and bottom
horizontally extending studs (e.g. two-by-fours) to form a frame for a
given wall. This frame structure is typically nailed together on the
ground and is thereafter raised and anchored to the building structure's
floor and interconnected with adjacent walls. This aspect of the
construction is relatively labor intensive and typically two or more
laborers are utilized when standing and interconnecting the frames of each
wall.
Once all of the walls of the building are constructed in the above-noted
manner, typically four-by-eight sheets of plywood are nailed to the frame
on its exterior surface. Insulation may be positioned between the
vertically extending studs on the inside of the frame and/or sheets of
insulation may be positioned over the plywood exterior. Nonetheless,
siding and dry wall are installed on the exterior and interior surfaces,
respectively, of the frame. Insulating, siding, and hanging dry wall are
each separate steps and thus this aspect of the construction is also
relatively labor intensive. Moreover, due to the size and/or weight of the
plywood, siding, and dry wall, typically two or more laborers are used in
this aspect of the construction as well.
Based upon the foregoing, it can be appreciated that conventional
residential construction techniques are both material and labor intensive.
As the costs of materials and labor increases, so to then does the cost of
the residential building structures. Considering that there is an
ever-increasing need for low income housing, there is a corresponding need
for an alternative to conventional residential construction techniques
which will allow for the desired cost reduction.
SUMMARY OF THE INVENTION
The present invention generally relates to the construction of a building
structure and, more specifically, to the construction of the walls forming
the building structure. In this regard, the present invention utilizes a
plurality of panels (e.g. rectangular sheets having front and back
surfaces, two laterally displaced side surfaces, and two longitudinally
displaced end surfaces). These panels each have a plurality of grooves
formed thereon such that a wall may be assembled by installing support
members on the panels using these grooves. The supports associated with
the various panels are appropriately interconnected, directly or
indirectly, to provide a desired degree of structural integrity for the
wall.
In one embodiment, each panel has at least two longitudinal grooves which
are laterally displaced (e.g. supports installed thereon are vertically
extending). A method in accordance with principles of the present
invention includes standing one of the panels on its lowermost end surface
and positioning at least part of a support in one of its longitudinal
grooves, and positioning another of the panels on its lowermost end
surface and positioning at least part of another support in one of its
longitudinal grooves. When the panels are positioned substantially
adjacent to each other (e.g., such that adjacent side surfaces are in
abutting engagement) and the noted supports are interconnected, directly
or indirectly, at least a portion of a wall assembly is formed. This
methodology may be repeated any number of times to form a wall assembly
for a building structure of a desired length.
The noted longitudinal grooves may assume a variety of positions on the
panels. For instance, one longitudinal groove may be positioned on each of
the two side surfaces of the panels (those surfaces which abut the side
surface of an adjacent panel). In this case, the supports may be generally
U-shaped such that one part of the support will fit in the associated
longitudinal groove, another part of the support will be in substantial
abutting engagement with part of the corresponding side surface, and the
remaining part of the support will be in substantial abutting relationship
with the front or back surface of the panel (those surfaces which form the
interior and exterior surfaces of the wall). Consequently and in this
case, two supports of adjacent panels may be positioned in substantial
abutting engagement and directly connected to each other by, for instance,
one or more appropriate fasteners (e.g., screws, bolts, rivets). In order
to directly connect the abutting portions of the supports to each other in
this case, the connection should be established prior to positioning the
supports in the longitudinal grooves of both of the panels. That is, one
support may be installed on one panel and another support may be attached
thereto prior to this other support being installed on its associated
panel.
As an alternative to the above, each of the noted panel side surfaces may
have two longitudinal grooves formed thereon such that the noted generally
U-shaped supports are totally contained within the extent of the side
surface. That is, a portion of an installed support is in abutting
relation with part of the associated side surface. In this case and in
order to directly connect the abutting portions of the supports of
adjacent and abutting panels, it is necessary to establish this direct
connection prior to positioning the subsequently installed panel adjacent
to the initially installed panel, and thus prior to positioning its
associated support in the longitudinal grooves of the subsequently
installed panel. That is, one support will be installed on one panel and
another support will be attached thereto prior to this other support being
installed on its associated panel.
A further alternative is to have a pair of longitudinal grooves on the
front and/or back surface of each panel with these grooves being
substantially proximate opposite side surfaces. In this case, a part of a
generally U-shaped support fits in one of these longitudinal grooves, part
is in substantial abutting relationship with the front or back surface on
which the longitudinal grooves are formed, and part is in substantial
abutting relationship with at least part of one of the respective panel's
side surfaces. Consequently, parts of the supports of adjacent panels
would be in substantial abutting relationship and could be appropriately
interconnected.
Each of the noted panels may also have at least one lateral groove on at
least one of its two end surfaces (e.g., supports installed thereon being
horizontally extending in the assembled position). In this case, the noted
method may include the steps of positioning one or more linearly aligned
supports on the main support surface (e.g., the floor of the building
structure) and positioning at least part of this support in the lateral
groove on the lowermost of the end surfaces of each panel. Moreover, the
method may include the step of positioning one or more linearly aligned
supports at least partially within the lateral groove of the uppermost end
surface of each panel. When supports are positioned in lateral grooves on
the lowermost and/or uppermost end surfaces of the panels, the laterally
extending supports may interconnect the various longitudinally extending
supports. That is, each of the supports installed on the longitudinal
grooves of the various panels may be directly connected to the support(s)
installed on the lateral grooves on the uppermost and/or lowermost end
surfaces of the various panels. For instance, the laterally extending
support(s) may be placed in overlapping relation with the corresponding
upper or lower portion of the vertically extending supports. Preferably,
adjacent supports installed in the longitudinal grooves of adjacent panels
are also directly connected to each other and are also connected to the
supports installed on the lateral grooves on the uppermost and/or
lowermost end surfaces of the various panels to further increase the
structural integrity of the formed wall.
In order to enhance the cost effectiveness of the present invention, the
panels may be formed from styrofoam which is both light in weight (e.g.,
easy for handling by one laborer) and has insulating qualities. Moreover
and in this case, grooves may be formed about the entire perimeter area of
such panel such that the panel has support members about its entire
perimeter. Further, generally U-shaped metal supports of a certain
rigidity may be used to provide for a desired degree of structural
integrity. Consequently, the assembly of a given wall in accordance with
principles of the present invention is cost effective in that the
materials are relative inexpensive and in that a wall may be assembled
relatively expeditiously.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of a panel which may be used
in accordance with principles of the present invention;
FIG. 1A is a cross-sectional view of the panel of FIG. 1 taken along line
A--A;
FIG. 1B is a cross-sectional view of the panel of FIG. 1 taken along line
B--B;
FIG. 2 is a perspective view of one embodiment of a support which may be
used in accordance with principles of the present invention;
FIG. 3 is an exploded, perspective view of a wall assembly in accordance
with principles of the present invention which uses the panels of FIG. 1
and the channels of FIG. 2;
FIG. 3A is front view of the wall assembly of FIG. 3 in the assembled
position;
FIG. 3B is a partial cutaway front view of the two panels of FIG. 3
illustrating one type of connection of the abutting supports;
FIG. 4 is a perspective view of another embodiment of a panel which may be
used in accordance with principles of the present invention;
FIG. 4A is a cross-sectional view of the panel of FIG. 4 taken along line
A--A;
FIG. 4B is a cross-sectional view of the panel of FIG. 4 taken along line
B--B;
FIG. 5 is an exploded, perspective view of a wall assembly in accordance
with principles of the present invention which uses the panels of FIG. 4
and the channels of FIG. 2;
FIG. 5A is front view of the wall assembly of FIG. 5 illustrating one type
of connection of the abutting supports;
FIG. 5B is a perspective view of the wall assembly of FIG. 5 illustrating
another type of connection of the abutting supports;
FIG. 6 is a perspective view of another embodiment of a panel which may be
used in accordance with principles of the present invention;
FIG. 6A is a cross-sectional view of the panel of FIG. 6 taken along line
A--A;
FIG. 6B is a cross-sectional view of the panel of FIG. 6 taken along line
B--B;
FIG. 7 is an exploded, perspective view of a wall assembly in accordance
with principles of the present invention which uses the panels of FIG. 6
and the channels of FIG. 2;
FIG. 8A is a perspective view of a corner panel for interconnecting
adjacent wall assemblies;
FIG. 8B is a top view of the corner panel of FIG. 8A;
FIG. 9 is a perspective view of a corner support member;
FIG. 10 is a top view of two adjacent wall assemblies, without a top
support thereon, in accordance with principles of the present invention
and with the corner panel of FIGS. 8A-B and corner support member of FIG.
9 providing for an interconnection therebetween;
FIG. 11A is a perspective view of a portion of a wall assembly in
accordance with principles of the present invention with a rim joist and
interfacing floor joists for supporting a floor and/or ceiling; and
FIG. 11B is a top view of the wall assembly, rim joist, and I-shaped floor
joists illustrated in FIG. 11A.
DETAILED DESCRIPTION
The present invention will be described in relation to the accompanying
drawings which assist in illustrating its various features. In this regard
and as noted, the present invention is generally directed toward a wall
assembly of a building structure. More specifically, the present invention
is directed toward a wall assembly which is formed from a plurality of
panels having a plurality of preformed grooves thereon and support members
which are installed in these grooves and appropriately interconnected.
One type of panel in accordance with principles of the present invention is
illustrated in FIGS. 1, 1A, and 1B. Initially, the panel 10 is
substantially rectangular and has two main surfaces 14 which define the
interior and exterior surfaces, respectively, of the wall assembly, two
laterally displaced side surfaces 18, and two longitudinally displaced end
surfaces 22. Moreover, the panel 10 has a longitudinally or vertically
extending left groove 26 on one of the side surfaces 18, and a
longitudinally or vertically extending right groove 30 on the other of the
side surfaces 18. Furthermore, the panel 10 has a laterally or
horizontally extending top groove 34 positioned on one of the end surfaces
22, and a laterally or horizontally extending bottom groove 38 on the
other of the end surfaces 22.
The panel 10 may be formed from a variety of materials. However, a
preferred material is styrofoam or more particularly, EPS (expanded
polystyrene). Styrofoam is lightweight such that the panels 10 are easy to
handle in the assembly procedure to be discussed below. Moreover,
styrofoam also has good insulating qualities such that the need for a
separate insulation installation procedure may be alleviated when forming
a wall assembly in accordance with principles of the present invention. In
this regard, panels 10 formed from styrofoam may have an R value of about
R-32 (for a panel 10 having a thickness of about 8 inches). Although the
present invention is not limited to panels 10 of a specific size,
generally the height of the panels 10 (the distance between the two
longitudinally displaced end surfaces 22) will range from about eight feet
to about twenty-four feet, and will typically be about ten feet, the width
of the panels 10 (the distance between the two laterally displaced side
surfaces 18) will range from about two feet to about four feet, and will
typically be about four feet, and the thickness of the panels 10 (the
distance between the two main surfaces 14) will typically range from about
four inches to about twelve inches, and will typically be about eight
inches.
As noted, supports are positioned within the grooves of the various panels
to be discussed herein to provide a frame structure for a wall assembly in
accordance with principles of the present invention. One embodiment of a
suitable support is illustrated in FIG. 2. The support 42 is generally
U-shaped, having first and second legs 46, 50, respectively, with a center
leg 54 positioned therebetween. Since the supports 42 effectively define
the frame structure of a wall assembly in accordance with principles of
the present invention, the supports 42 should be of sufficient rigidity
and thus structural integrity. In this regard, the supports 42 may be
formed from materials such as steel or other suitable metals/materials,
and in one embodiment the supports 42 are formed from light gauge steel
(e.g. gauges twelve to twenty-five).
In order to enhance the performance of a wall assembly in accordance with
principles of the present invention and/or the assembly procedure itself,
the dimensions of the supports 42 and the size and positioning of the
various grooves on the various panels disclosed herein (e.g, panel 10, as
well as panels 66 and 110 to be discussed below) may be jointly selected.
For instance, the thickness of the first and second legs 46, 50,
respectively, of the support 42 and the width of the various grooves on
the panels may be jointly selected such that the portion of the support 42
which interfaces with a given groove is effectively press-fit therein.
Moreover, the length of the first and second legs 46, 50, respectively, of
the support 42 should be substantially equal to, and preferably slightly
less than, the depth of the various grooves on the panels such that the
center leg 54 will abut a portion of the panel when a portion of the
support 42 is positioned within one of the grooves. Furthermore, the
distance between the first and second legs 46, 50, respectively, is
preferably selected to be substantially the same as the distance between
the various grooves on the panel and one of its other surfaces such that
when one of the legs 46, 50 is positioned within one of the grooves, the
other of the legs 46, 50 will be in substantial abutting engagement with
one of the main surfaces of the panel or one of its side surfaces.
A plurality of the panels 10 and support members 42 may be assembled to
form the wall assembly 58 illustrated in FIGS. 3, 3A, and 3B. Although
only two panels 10 are illustrated therein, it will be appreciated that
the number of panels 10 may be selected to accommodate for a plurality of
factors, such as the desired length of the wall assembly 58. That is, any
number of panels 10 may be assembled in the manner described herein to
form a wall assembly 58 of desired length.
Initially, one or more of the supports 42a (only one shown) are linearly
aligned and positioned upon the floor (not shown) of the building
structure with the first and second legs 46, 50, respectively, projecting
upwardly. The support(s) 42a may then be secured to the floor (not shown)
with suitable fasteners 62 (e.g., screws, bolts, rivets, and/or
adhesives), such as by passing these fasteners 62 through the center leg
54 at a plurality of spaced locations along the support(s) 42a (not
shown). This defines a bottom runner for the wall assembly 58 and extends
substantially the entire length thereof.
The panels 10 which form the wall assembly 58 interface with the support(s)
42a. In this regard, the panel 10a is stood on one of its end surfaces 22a
with the first leg 46a of the support 42a being positioned within the
bottom groove 38a on the panel 10a. Once again, it is desirable for the
first leg 46a to be totally contained within the bottom groove 38a and to
be snugly received therein. Moreover, preferably the width of the support
42a is such that the second leg 50a is in substantial abutting engagement
with one of the main surfaces 14a of the panel 10a. However, there may be
a slight gap to accommodate for the positioning of the supports 42b and
42c between the support 42a and main surface 14a. That is, the support 42b
is positioned on one of the side surfaces 18a of the panel 10a with its
first leg 46b being positioned within the left groove 26a of the panel
10a, with its center leg 54b being in substantial abutting engagement with
the corresponding side surface 18a, and with its second leg 50b being in
substantial abutting engagement with one of the main surfaces 14a. In this
case, it will be appreciated that the support 42b may be slid downwardly
in the left groove 26a until the lower portion thereof is substantially
contained within the support 42a. When in this position, a portion of the
support 42a is also in overlapping relation with the lower portion of the
support 42b such that the overlapping portions of the supports 42a and 42b
may be directly connected together by one or more fasteners 62. In the
case where screws and/or rivets are used as fasteners 62, no preexisting
holes are required on the supports 42. Notwithstanding the order presented
in this aspect of the assembly procedure, it will be appreciated that the
support 42b may actually be installed on the panel 10a prior to installing
the panel 10a on the support 42a, and such is within the scope of the
present invention.
The support 42c interfaces with the panel 10a in a manner similar to that
of the support 42b, but on the opposite side surface 18a of the panel 10a.
That is, the support 42c is installed on the opposite side surface 18a of
the panel 10a with its first leg 46c being positioned within the right
groove 30a of the panel 10a, with its center leg 54c being in substantial
abutting engagement with the corresponding side surface 18a, and with its
second leg 50c being in substantial abutting engagement with the noted
main surface 14a. Consequently, the lower portion of the support 42c is
also substantially retained within the support 42a. Therefore, a portion
of the support 42a is in overlapping relation with the lower portion of
the support 42c such that the overlapping portions of the supports 42a and
42c may be directly connected together by one or more fasteners 62.
The panel 10b may be installed similarly to the panel 10a. Although the
panels 10a and 10b may be interconnected solely by the support 42a and/or
support 42f (discussed below), the panels 10a and 10b may be
interconnected in a manner which further enhances the structural integrity
of the wall assembly 58. In this regard, the supports 42 on the side
surfaces 18 of adjacent panels 10 may be placed in partial abutting
relationship and directly connected to each other. More specifically and
referring to panels 10a and 10b, prior to installing the support 42d on
the panel 10b, the support 42d may be directly connected to the support
42c on the panel 10a via the center legs 54c and 54d. That is, the center
leg 54d of the support 42d is positioned in abutting engagement with the
center leg 54c of the support 42c. The overlapping portions of the center
legs 54c, 54d may then be directly connected to each other by one or more
of the fasteners 62 which are preferably spaced along substantially the
entirety of the respective lengths of the supports 42c and 42d. As will be
appreciated, it may be desirable to connect the supports 42c and 42d
together before being installed on any panel 10. Moreover, the connection
of the supports 42c and 42d may be established prior to installing the
support 42d on the panel 10b and/or prior to installing the panel 10a on
the support 42a in the above-noted manner.
Once the supports 42c and 42d are joined together in the above-noted
manner, the panel 10b is stood on one of its end surfaces 22b with the
first leg 46a of the support 42a being installed within the bottom groove
38b on the panel 10b. Moreover, the support 42d is installed on one of the
side surfaces 18b of the panel 10b with its first leg 46d being positioned
within the left groove 26b of the panel 10b, with its center leg 54d being
in substantial abutting engagement with the corresponding side surface
18b, and with its second leg 50d being in substantial abutting engagement
with one of the main surfaces 14b. Consequently, the support 42a also
substantially retains the lower portion of the support 42d. Therefore, a
portion of the support 42a is in overlapping relation with the lower
portion of the support 42d such that these overlapping portions may thus
be directly connected together by one or more fasteners 62. In order to
further enhance the structural integrity of the wall assembly 58, an
appropriate adhesive (e.g., styrene adhesives) may be positioned on the
abutting side surfaces 18 of the panels 10.
The support 42e is installed on the panel 10b in the manner noted above
with regard to the support 42c on the panel 10a such that the lower
portion of the support 42d is retained within the support 42a. Therefore,
a portion of the support 42a is in overlapping relation with the lower
portion of the support 42e such that these overlapping portions may be
directly connected together by one or more fasteners 62.
The above-described assembly procedure may be repeated a plurality of times
with more than two of the panels 10 until the desired length of the wall
assembly 58 is achieved. In order to further improve upon the structural
integrity of the wall assembly 58, however, another support 42f may be
installed in the top grooves 34 of the panels 10 in a manner similar to
that in which the support 42a is installed on the bottom grooves 38 of the
panels 10 and as discussed above. That is, one or more linearly aligned
supports 42f may be installed to run substantially the entire length of
the wall assembly 58. Specifically, the first leg 46f of the support(s)
42f is positioned within the top groove 34 of each of the panels 10 of the
wall assembly 58 (e.g. panels 10a, 10b), such that the center leg(s) 54f
of the support(s) 42f is positioned in substantial abutting relation with
the corresponding end surface 22 of each panel 10 of the wall assembly 58
(e.g., panels 10a, 10b), and such that the second leg 50f of the
support(s) 42f is in substantial abutting relationship with one of the
main surfaces 14 of each of the panels 10 of the wall assembly 58 (e.g,
panels 10a, 10b), although there may be a slight gap as noted above.
Consequently, the support 42f substantially retains the upper ends of the
vertically extending supports 42 (e.g., supports 42b, 42c, 42d, and 42e).
Therefore, a portion of the second leg 50f of the support 42f is in
overlapping relation with the upper portions of the supports 42 in both
the left and right grooves 26, 30, respectively, of each of the panels 10
and such overlapping portions may be directly connected to each other by
fasteners 62. Although the support 42f has been described as the last step
in the installation, it could be installed after the panel 10a is stood on
its noted end surface 22. However, the installation of additional panels
10 may be more cumbersome than the noted procedure if this sequence is in
fact used.
Based upon the foregoing, it will be appreciated that adjacent vertically
extending supports 42 are interconnected in a variety of manners.
Initially, these supports 42 are directly connected to each other (e.g.,
supports 42c and 42d). Moreover, the horizontally extending supports 42
(e.g., support 42a and support 42f) are each connected to each of the
vertically extending supports 42 (e.g., support 42b, 42c, 42d, 42e).
Although this provides for a desired structural integrity of the wall
assembly 58, it will be appreciated various other manners of
interconnecting the various supports 42 are within the scope of the
present invention. For instance, adjacent and vertically extending
supports 42 (e.g., support 42c and support 42d) need not be directly
connected to each other, but instead may be interconnected by being
connected to a common horizontally extending support (e.g., via connection
to support 42a and/or support 42f). In this case, the vertically extending
supports 42 could be interfaced with the associated panel 10 prior to
positioning the panels 10 in abutting engagement. That is, the support 42d
may be positioned within the left groove 26b of the panel 10b prior to
positioning the panel 10b adjacent the panel 10a. Notwithstanding these
potential variations, the noted procedure is preferred for the structural
integrity achieved for the wall assembly 58.
Another type of panel which may be used in accordance with principles of
the present invention is illustrated in FIGS. 4, 4A, and 4B. Initially,
the panel 66 is similar to the panel 10 except for the positioning of its
grooves. In this regard, the panel 66 is substantially rectangular and has
two main surfaces 70 which define the interior and exterior surfaces,
respectively, of the wall assembly, two laterally displaced side surfaces
74, and two longitudinally displaced end surfaces 78. Moreover, the panel
66 has a longitudinally or vertically extending left groove 82 on one of
the main surfaces 70 proximate one of the side surfaces 74 (e.g., slightly
displaced therefrom), and a longitudinally or vertically extending right
groove 86 on the main surface 70 proximate the other side surface 74
(e.g., slightly displaced therefrom). Furthermore, the panel 66 has a
laterally or horizontally extending top groove 90 positioned on one of the
end surfaces 78, and a laterally or horizontally extending bottom groove
94 on the other of the end surfaces 78.
A plurality of the panels 66 and support members 42 may be assembled to
form the wall assembly 98 illustrated in FIGS. 5, 5A, and 5B. Although
three panels 66 are illustrated in FIG. 5, it will be appreciated that the
number of panels 66 may be selected to accommodate for a plurality of
factors, such as the desired length of the wall assembly 98. That is, any
number of panels 66 may be assembled in the manner described herein to
form a wall assembly 98 of desired length.
Initially, one or more of the supports 42g (only one shown) are linearly
aligned and positioned upon the floor (not shown) of the building
structure with the first and second legs 46g, 50g, respectively,
projecting upwardly. The support(s) 42g are then secured to the floor (not
shown) with fasteners 102, such as by passing these fasteners 102 through
the center leg 54g at a plurality of spaced locations along the support(s)
42g. This defines a bottom runner for the wall assembly 98 and extends
substantially the entire length thereof.
The panels 66 which form the wall assembly 98 each interface with the
support(s) 42g. In this regard, the panel 66a is stood on one of its end
surfaces 78a with the first leg 46g of the support 42g being positioned
within the bottom groove 94a on the panel 66a and the second leg 50g in
substantial abutting engagement with the main surface 70a of the panel
66a. The support 42h is positioned on one of the main surfaces 70a of the
panel 66a with its second leg 50h being positioned in substantial abutting
engagement with one of the side surfaces 74a, with its center leg 54h
being in substantial abutting engagement with the main surface 70a, and
with its first leg 46h being positioned within the left groove 82a on the
panel 66a. In this case, it will be appreciated that the support 42h may
be slid into and downwardly in the left groove 82a until the lower portion
thereof is substantially retained within the support 42g. When in this
position, a portion of the support 42g is in overlapping relation with the
lower portion of the support 42h such that these overlapping portions may
be directly connected together by one or more fasteners 102.
Notwithstanding the order presented in this portion of the assembly
procedure, it will be appreciated that the support 42h may be installed on
the panel 66a prior to installing the panel 66a on the support 42g, and
such is within the scope of the present invention.
The support 42i interfaces with the panel 66a in a manner similar to that
of the support 42h, but on the opposite side of the panel 66a. That is,
the support 42i is installed with its first leg 46i being positioned
within the right groove 86a of the panel 66a, with its center leg 54i
being in substantial abutting engagement with the main surface 70a, and
with its second leg 50i being in substantial abutting engagement with one
of the side surfaces 74a. Consequently, the lower portion of the support
42i is substantially retained within the support 42g. Therefore, a portion
of the support 42g is in overlapping relation with the lower portion of
the support 42i and these overlapping portions may be directly connected
together by one or more fasteners 102.
The panel 66b may be installed similarly to the panel 66a by installing the
supports 42j and 42k on the panel 66b in its left and right grooves 82b,
86b, respectively. Although the panels 66a, 66b may be interconnected
solely by the support 42g and/or 42n (discussed below), the panels 66a,
66b may be further interconnected in a manner which enhances the
structural integrity of the wall assembly 98. More specifically and with
the supports 42j and 42k in the noted position, the panel 66b is stood on
one of its end surfaces 78b with the first leg 46g of the support 42g
being positioned within the bottom groove 94b on the panel 66b. As a
result, the lower portions of each of the supports 42j and 42k are
retained within the support 42g and a portion of the support 42g is in
overlapping relation with each of these lower portions. The panel 66b is
thereafter positioned adjacent the panel 66a such that the second leg 50i
of the support 42i and the second leg 50j of the support 42j are in
substantial abutting relation. In this position, the portion of the
support 42g in overlapping relation with the support 42j may be directly
connected thereto by one or more fasteners 102, and the portion of the
support 42g in overlapping relation with the support 42k may be similarly
directly connected thereto by one or more fasteners 102. Moreover, the
supports 42i and 42j may be directly connected to each other, such as by
welding the supports 42i and 42j together at a plurality of locations 106.
Alternatively, a connector piece (not shown) could be directly connected
to the center leg 54i of the support 42i via one or more fasteners 102 and
to the center leg 54j of the support 42j by one or more fasteners 102.
Instead of installing the support 42j in the above-noted manner, it could
alternatively be directly connected to the support 42i prior to being
installed on the panel 66b (and/or prior to installing the support 42i on
the panel 66a) as illustrated in FIG. 5A. That is, the second leg 50j of
the support 42j could be placed in the noted abutting relationship with
the second leg 50i of the support 42i and directly connected thereto by
one or more fasteners 102. However, establishing this type of
interconnection may be more difficult than the above-noted procedure. In
any case, once the supports 42i and 42j were connected to each other, the
panel 66b may be installed on the support 42j in the above-noted manner
and installed on the support 42g in the above-noted manner. As with the
panels 10 noted above, it may be desirable to use the noted adhesives on
the side surfaces 74 of the panels 66 to further enhance the structural
integrity of the wall assembly 98.
The above-described assembly procedure may be repeated a plurality of times
with a plurality of the panels 66 until the desired length of the wall
assembly 98 is achieved. For instance, a third panel 66c may be installed
in a manner similar to the panel 66b noted above. Nonetheless, when the
desired length of the wall assembly 98 is achieved and in order to further
improve upon the structural integrity of the wall assembly 98, another
support 42n may be installed on the top grooves 90 of the various panels
66 in a manner similar to that in which the support 42g is installed on
the bottom grooves 94 of the panels 66 and as discussed above. That is,
one or more linearly aligned supports 42n may be installed such that its
first leg 46n of the support(s) 42n is positioned within the top groove 90
of each of the panels 66 (e.g. panels 66a, 66b, 66c), such that its center
leg(s) 54n of the support 42n is positioned in substantial abutting
relation with the corresponding end surface 78 of each panel 66, and such
that its second leg 50n is in substantial abutting relation with one of
the main surfaces 70 of each of the panels 66. Consequently, the support
42n substantially retains the upper ends of the vertically extending
supports 42 (e.g, supports 42h, 42i, 42j, 42k, 42l, 42m). Therefore, a
portion of the first leg 46n is in overlapping relation with the upper
portions of the supports 42 in both the left and right grooves 82, 86,
respectively, of each of the panels 66 and these overlapping portions may
be directly connected to each other by fasteners 102. Although the support
42n has been described as the last step in the installation, it could be
installed after the panel 66a is stood on its end surface 74a. However,
the installation of additional panels 66 thereafter may be more cumbersome
than the noted procedure.
Based upon the foregoing, it will be appreciated that adjacent vertically
extending supports 42 may be interconnected in a variety of manners.
Initially, these supports 42 are directly connected to each other (e.g.,
supports 42i and 42j are directly connected; supports 42k and 42l are
directly connected). Moreover, the horizontally extending supports 42
(e.g., support 42g and support 42n) are each connected to each of the
vertically extending supports 42 (e.g., support 42h, 42i, 42j, 42k, 42l,
and 42m). Although this provides for a desired structural integrity of the
wall assembly 58, it will be appreciated various other manners of
interconnecting the various supports 42 are within the scope of the
present invention. For instance, adjacent and vertically extending
supports 42 (e.g., support 42i and support 42j) need not be directly
connected to each other, but instead may be interconnected by being
connected to a common horizontally extending support (e.g., via connection
to support 42g and/or support 42n). Notwithstanding the potential
variations for interconnection of supports 42, the noted procedure is
preferred for the structural integrity achieved for the wall assembly 98.
Another type of panel which may be used in accordance with principles of
the present invention is illustrated in FIGS. 6, 6A, and 6B. Initially,
the panel 110 is similar to the panel 10 except for the positioning of its
grooves. In this regard, the panel 110 is substantially rectangular and
has two main surfaces 114 which define the interior and exterior surfaces,
respectively, of the wall, two laterally displaced side surfaces 118, and
two longitudinally displaced end surfaces 122. Moreover, the panel 110 has
two longitudinally or vertically extending left grooves 126 on one of its
side surfaces 118, and two longitudinally or vertically extending right
grooves 130 on the other of its side surfaces 118. Furthermore, the panel
110 has two laterally or horizontally extending top grooves 134 positioned
on one of the end surfaces 122, and two laterally or horizontally
extending bottom grooves 138 on the other of the end surfaces 122.
A plurality of the panels 110 and support members 42 may be assembled to
form the wall assembly 142 illustrated in FIG. 7. Although three panels
110 are illustrated in FIG. 7, it will be appreciated that the number of
panels 110 may be selected to accommodate for a plurality of factors, such
as the desired length of the wall assembly 142. That is, any number of
panels 110 may be assembled in the manner described herein to form a wall
assembly 142 of desired length.
Initially, one or more of the supports 42o (only one shown) are linearly
aligned and positioned upon the floor (not shown) of the building
structure with the first and second legs 46o, 50o, respectively,
projecting upwardly. The support(s) 42o may then be secured to the floor
(not shown) with suitable fasteners 146 (e.g., screws, bolts, rivets),
such as | | |
