Note: Descriptions are shown in the official language in which they were submitted.
77~
1~ 1
n EXTRUDED STRUCTURA.L SYSTEMn l -
~g~ . .
lS 1. Field of the InYention :
~ The present invention relates .
generally to structural systems, and specifically
relates to extruded ~tructural systems which
include extruded structural panels and extruded
panel joining members for assembling a structural .
system ~ith a plurality of panels.
2 Descri tion of the P~ior ~rt
. ~ .
Extruded structural system components
are known in the art and have been fabricated for
such widely varying purposes such as window. .
mullions, doorst outer belt panels for buses, fluid
flumes, ducting, cable trays, and the likeO Hollow
extruded structural panels haYe been m~de for
upward-acting doors for refriyerated trucks to
replace bonded assemblies of metal or wood frames
with external s}ieet skins~ 5uch strllctllral panels
are usually constructed with tongue and ~roove
edges which allow relati~e motion between panels~
There have not heretofore been
~ .
.9~3
constructed extruded structural panel components
which rigidly fasten together in an interlocking
fashion so.to facilitate construction of immovable
structures such. as walls, floors, and the like~
Moreover, prior art extruded structural components,
although sometimes made with integral reinforcing
ribs, have not exhibited sufficient longitudinal
and transverse strengths to be seriously considered
for structural applications requiring load-bearing
capability.
Summary of the Inventlon
The present invention provides an
improved extruded s~ructural system which includes
a structural panel havi~g a pair of planar outer
walls, at least on~ reinforcing rib joining the
outer walls, a reinforcing shoulder formed at each
.. . .
intersection of a rib with the outer walls, and
panel connecting means on the outer edge of the
panel which allows joining the panel to an adjacent
panel in a rigid structure. A preferred Pmbodiment
of the pan~l connecting mean~ comprises a panel
connecting member which extends outwardly from the
walls along the longi~udinal edge in a head portion
and a neck portion. The head and neck portions
slidably engage and interlock with mating panel
joining members which allow assembly of several
panels into structures. Varisusly conf igured panel
joining members allow the panels to be assembled
edge-to-edge in co-planar, orthogonal, angular,
cross, and T-shaped intersectionsO
. . The structural system disclosed
herein is extremely versatile and possesses unusual
strength because of the unique features o the
structural panel. The structural panel
~9~773
_ demonstrates a remarkable resistance to compressive
and shear forces due to the uniq~e reinforcing ribs
which are integrally formed with the panel. The
unique interlocking panel connecting members, also
integrally formed along each longitudinal edye of
the panel, further contribu~e to the overall
strength and versatility of any structure built
using the system.
Structural assemblies made with the
preferred embodiment of the present invention may
be successfully employed in such diverse
applications as electrical utility cooling tower
- louvres, floating covers for oil and other
petroleum product storage tanks, anti-corrosive
~15 structures or use in harsh chemical plant
environments, computer room flooring,
self-supporting conduit for electrical and utility
cabling, energy efficient insulated building siding
for storage shelters and refrigerated enclosuresS
- 20 air intake housings and ducting, architectural room
dividers~ and beavy e~uipment hoods and enclosures.
A superior structural system can be
made if the preferred embodiment is extruded from
fiberglass reinforced plastic~ Such a system will
be lighter than aluminum yet nearly as rigid, and
will be a good insulator of both heat and
electricity~ Moreover; the system will not rust,
rot, corrode, or oxidize, and will be resistant to
most corrosive environments.
The preferred embodiment presents
hollow cross-section which may be filled with foam
or insulation in order to provide additional fire
resistance, thermal insulAtion, or floatability.
Moreover, a c~ble may be routed through the
cross-section and used to lash together several
~977;:~
panels. A sealing o-ring may be placed between the
panel and panel joining members so as to provide a
substantially water-tight structure.
Accordingly, it is an object of the
present invention to provide an improved structural
system which includes an improved structural pan~l
and means for assembling several panels into a
construction.
It is another object of the present
invention to provide an improved structural system
whose components are unitary and integrally formed.
It is another object of the present
invention to provide ~or use in a structural system
a~ improved structural panel having means affixed
to the outer longitudin~l edges of the panel for
connection of the panels to other like panels in a
variety of different configurations such as
corners, T-intersections, angled corners,
cross-intersections, and the like.
It is another object of the present
invention to provide for use in a structural system
an improved structural panel having panel
connecting members affixed to the ends of the
panels which are formed of a n~ck portion and a
head portion which allows interlocking the panel
with various different}y configured panel joining
members such as corner connectors, T-intersection
connectors, angled . corner connectors,
cross-intersection connectors, and the like.
It is another object of the present
invention to provide for use in a structural system
an improved structural panel having a pair of outer
walls separated by at least one reinforcing rib
joining th~ walls having reinf~rcing shoulders for
providing improved resistance to shear and
9773
_ compressive forces.
It is another object of the present
invention to provide an improved structural system
which includes means for slidably engaging a series
S of struc~ural panels in various configurations
including joining panels end to end, joining panels
in a corner and angular intersections, joining
panels in a T~shaped intersection, joining panels
in a cross intersection, and joining panels by
means of a bolted interlock when it is not feasible
to slidably engage a panel joining interlock
member.
It is another object of the present
invention to provide an impr.oved structural system
having a flush exterior appearance at the joints
between structural panels and the interlocking
panel joining members which are used to join the
outer edges of the panels~
It is another object of the present
invention to provide an improved structural system
which includes a plurality of structural panels
having channels formed in the outer edges for
receiving reinforcing cable along the length of the
panel~
It is another object of the present
invention to provide an improved structural system
which includes sealing means between structural
panels and interlocking panel joinin~ members so as
to facilitate assembly of a structure which is
substantially water- or fluid-tight.
It is another objert of the present
invention to provide an improved structural system
which includes structural panels joined by
interlockin~ panel joining members which slidably
engage and interlock with the stru~tural panels so
73
_ as to form an extremely strong structural joint~
It is another object of the present
invention to provide an improved structural system
which presents a hollow cross-section which may
either be filled with foam, insulatior!, or the like
so that the structural system possesses fire
resistance, high electrical insulation properties,
floatability, thermal insulation, or may
alternatively be used hollow as conduit for
electrical cabling or other utilities.
It is another object of the present
invention to provide ~n Lmproved structural system
which possesses extremely high tensile strength,
compressive strength, flexural strength, bearing
stress resistance, interlaminar shear resistance,
and punch shear resistance by virtue of its unitary
and reinforced cross-section.
It is another object of the present
invention to provide an extruded structural system
which possesses extremely high strengths in both
longitudinal and transverse directions~ and thus
may advantageously be used to construct
load-bearing floors, walls, or ceilings.
It is another object of the present
invention to provide an improved extruded
fiberglass-reinforced plastic structural system
which is extremely strong, light-weight, and
substantially impervious to corrosive environments.
It is another object of the present
invention to provide an improved structural system
in which heatin~ means may be employed so as to
maintain the entire structural system at a
predetermined temperature for heating or cooling a
structure in which the structural system is
~mployed
~:ag9'~3
6a
In accordanc~ with the principal object, the invention
contemplates a structural panel having a thickness of a first
dimension which co~prises a pair of parallel planar outer wall
members whose oute~ surfaces are separated by the first dimension,
and at least one r~inforcing rib of generally I-shape joining the
pair of wall members. A reinforcing shoulder means is formed
at each intersecti~n of a surface of the rib with a surface
of one of the pair of wall members for imparting rigidity to
the panel. A flange means formed along the longitudinal edges
of the wall ~ember~ extends inwardly from each of the wall
members toward the opposite wall member. At least one panel
connecting member ~oins the panel to an adjacent panel, and
extends outwardly ~rom the flange means orming an outer longi-
tudinal edge of thè panel and includes a neck portion extending
outwardly from the flange means and between the wall members.
A head portion i~ attached to the neck portion and has a
thickness of a sec~nd dimension less than the first dimension.
The head portion i~ludes on the interior surface of the head
portion opposite t~e wall members an inwardly extending tab.
The tab and the in~r surface of the head portion define a pair
of opposed channels for receiving therein elongate reinforcing
cable means.
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773
These and other objects, features,
and advantages of the present invention may be more
clearly understood and appreciated from a review of
the following de~ailed description of the disclosed
embodiments and by reference to the appended
drawings and claims.
Brief Description of the Drawin~s
Fig. 1 shows a perspective view of a
preferred embodiment of the improved structural
system of the present invention, which includes an
- impr~ved structural panelO
Fig. 2 is a detailed cross-sectional view
of the system shown in ~ig. 1.
FigO 3 is a cross-sectional view of a
panel end trim member which may be used with the
panel shown in Fig. 1.
Figr 4 is a cross-sectional view of a
square corner interlocking panel joining member~
Fig. 5 is a cross-sectional view of a~
angled interlocking panel joininy member.
Fig~ 6 is a cross-sectional view of a
T-intersection interlocking panel joining member~
~ig. 7 is a cross sectional view of an
interlocking panel joining member which may be used
to join four panels in a cross-intersection.
Fig. 8 is a cross-sectional view of a
bolted interlocking panel joining member.
Fig. 9 is a cross-sectional view of an
interlocking panel end tri~:member whi~h includes a
moun~ing lip ana further shows how reinfor~ing
cables may be used in the present invention~
Fig~ 10 shows how several panels may be
lashed together with cables.
Fig. 11 is a cross-sectional view of an
1~L99~3
_ edge trim insert member for the transverse or cut
longitudinal edge of a panel. -
Fig. 12 is a cross-sectional v~ew of an
edge interlocking insert member for the transverse
or cut longitudinal edge of a panel.
Fig. 13 is a cross-sectional view of a
C-shaped edge panel end insert member for the
transverse or cut longitudinal edge of a panel.
Fig~ 14 is a cross-sectional view of a
rounded corner edge panel end insert member~
Fig, 15 is a cross-sectional view of an
angled corner edge panel end insert member~
Fig. 16 is a cross-sectional view of a
rounded angled corner edge panel end insert
member. ,
Fig~ 17 is a cross-sectional view of an
edge panel insert member which may be used to join
in a cross-intersection the edges of four panelsO
Fig. 18 is a cross-sectional view of an
edge panel insert member which may be used to jo;n
in a T-inter~ection the edges three panels.
Fig. 19 is a cross-sectional view of a
double edge panel end insert member.
Fig. 20 is a cross-sectional view of a
s~uare corner e~ge panel end insert member.
FigO 21 is a cross-sectional view of a
double lip edge panel end insert member.
Fig. 22 is a cross-sectional view of a
bolted edge panel joining member~
Fig. 23 is a cross-sectional view of a
double pane window mullion member which may be used
to support panes of glass in a construckion~
Fig. 24 is a cross-sectional view o a
3S
hinge edge panel end insert member.
Fig. 25 is a hinge interlocking panel end
member.
S Detailed Descri tion of the Preferred Embodiment
_ . P _ ~ :
Referring now to the drawings, in which
like numerals indic~te like elements throughout the
several views, Fig. 1 shows a preferred embodiment
of an extruded structural system 10 according to
1~ the present invention in cross-section. The
preferred embodiment includes a unitary, integrally
formed structural panel 12 which is ~oined to a
- similar panel 12' by means of an integrally formed
interlocking coplanar panel joining member 14. A
panel connecting member 15 is integrally formed at
: each end of panel 12 and runs along an outer
longitudinal edge 16 of the panel. The preferred
embodiment of panel connecting member 15 comprises
a double keyway interlocking portion and prsvides
2~ means for attaching panel 12 to adjacent panels via
an interlock in a variety of configurations and
shapes. As disclosed herein, a variety of
interlQcking extruded panel joining members having
different shapes are a part of the present
invention and allow assembly of the panels 12 and
12' in a variety of configurations, includiny
corner-intersections, T-intersections, cross
intersections, and the like.
In the preferred embodimentl panel 12 and
the various interlocking panel joining members such
as coplanar panel joining member 14 are
manufactured by extruding fiberylass-reinforced
plastic in a ~pultrusion~ process which is known in
the art. The "pultruded" panels and interlocking
members produced by pultrusion provide an extremely
73
10
_ light-weight and strong structural system which is
also impervious to many types of corrosive
substances. Consequently, pultruded fiberglass
reinforced plastic panels manufactured in
accordance with the present invention provide
structural systems superior to extruded from
materials such as aluminum and the like. However,
it will be appreciated that the present invention
may be manufactured by extruding aluminum or other
materials and the advantages a~d features disclosed
herein will be similarly achie~ed.
Turning now to Fig. 2, a more detailed
partial cross-section of panel 12 and interlocking
panel joining member 14 may be seen. Panel 12
includes a pai~ of parallel planar out~r walls 20,
-21 which are joined by at least one reinforcing rib
22 which extends across the thickness of the panel
between the walls. In the preferred embodiment,
rib 22 is of generally I-shape and connects the
walls at right angles. Reinforcing shoulders ~3
are intë'grally formed at each intersection of rib
22 with walls 20~ 21. Shoulders 23 provide an
enlarged cross-section to walls 20, 21 in the
vicinity of the ~ntersèction with rib 22. The
~5 shoulders contribute significantly to the unusual
structural strength of the panel and allow use of
the structural system in applications requiring an
extremely high strength-to-weight ratio.
In the preferred embodiment t as shown
3~ more clearly in Fig. l, there are three reinforcing
ribs spaced equally along the width of panel 12.
preferred embodiment of panel 12~ pultruded from
fiberglass reinforced plastic, is about 24 inches
wide and about l l/2 inches thick, having ribs
spaced at about 5-6 inches apart. The wall
773 ~ i1
_ thickness of the preferred embodiment is about 1/8
inch along the non-reinforced portions and about
5/32 inch at the reinforcing shoulders 23. A
fiberglass reinforced plastic panel manufactured .in
accordance with the present invention has been
found to exhibit in the longitudinal direction a
tensile strength in excess of 30,000 pounds per
square inch, a compressive strength in excess of
20,000 pounds per square inchJ a flexural strength
in excess of 30, oob pounds per s~uare inch, and has
demonstrated abilities to withstand bearing
stresses in excess of 35,000 pounds per square
inchy interlaminar shears in excess of 3,700 pounds
per square inch, and punch shears in excess of
15,000 pounds per squar,e inch.
; In the transverse direction along the
width, a 24 inch wide fiberglass reinforced plastic
pultruded pa~el has exhibited a tensile strength in
excess o 12,500 pounds per square inch, a
compressive strength in excess of 15,009 pounds per
square inch, and a flexural strength in excess of
17,S00 pounds per square inch. The panel of the
preferred embodiment of the present invention has
additionally demonstrated a longitudinal deflection
of but 0.750 inch in the center of an 11 foot long
span when loaded with 2~0 pounds in the center of
the span. Consequently, it may be seen and
appreciated that the present invention provides
unique structural properties heretofore
unattainable with similar materials and
configurations.
Referring again to Fig. 2, panel 12
defines along its outer longitudinal edge 16 a
panel connecting member 15 which provides the means
for attaching the:longitudina1 edge of the panel to
7~3
12
_ other portions of a struc~ure in which the panel is
assembled. In the preferred embodiment, panel
connecting member 15 is a double keyway
interlocking portion. Panel connecting member 15
includes a head portion 30 which extends ~utwardly
from walls 20, 21 and forms an outer longitudinal
edge 16 of the panel 12. A neck portion 31 of
connecting member 15 joins'head portion 30 to walls
20, 21 and thereby defines a pair of keyways 32~ 33
which matin~ly interfit with interlocking lips on
various panel joining members. Flange means 34, 35
- extend inwardly from each of walls 20, 21 toward
the opposite wall and join with neck portion 31 of
connecting member 15.
lS ~ead portion,30 of connecting member 15
- includes on its interior surface a tab 40 which
extends inwardly toward walls 20, 21. Tab 40 has a
thickness in the direction of panel thickness less
than the interior thickness of the head portion 30
and thus divides the interior of the head portio~
30 a~d defines with the in~erior surface of head
portion 30 a pair of opposed channels 41, 42 for
receiving a reinforcing cable ~See Fi~s. 9, 13)~
Preferably, ta~ 40 should extend sufficiently into
~5 the interior of head portion 30 so that channels
4i, 42 have suff icient circum~erential surface area
to frictionally grip a reinforcing cable which has
been inserted iongitudinally through the channels.
In the preferred embodiment, channels 41, 42 are of
a size suff icient to allow the insertion
~herethrough of a 1/4 inch steel cable.
Advantayeously, tab 40 provides a
thickene'd portion of the outer edge of connecting
member 15 w~ich permits attachment or affixation of
other structural system components such as screws,
77~
13
_ bolts and the like~ In the preferred embodiment,
tab 4n is of suficient thickness to allow drilling
and tapping for a 1/4-20 threaded screw or bolt.
The panel of the preferred embodiment has
demonstrated that a 1/4-20 bolt drilled and tapped
into tab 40 can withstand a pulling torque of up to
about 1,250 pounds.
Formed along the outer longitudinal edge
16 of connecting member 15 disposed away from walls
20, 21 is an indentation 43 or receiving a sealing
member 44 when panel 12 is assembled in a
structure. Sealing member 44 in the preferred
embodiment is an elastic or rubber O-ring gasket
which seats itself firmly in indentation 43 when
compressed. It will be appreciated that a
structural system which includes sealing members 44
at each iunction between panel 12 and an
interlocking panel joining member such as member 14
will he substantially water- or fluid-tight.
On the interior surface of walls 20, 21,
at the point of intersection between flanges 34, 35
with the interior surfaces of the walls, are formed
additional rein~orcing shoulders 37, 38. Shoulders
37, 38 provide addi~ional resistance to -1
interlaminar shear and compressive forces and ,,
further provide a solid base along walls 20, 21.
upon which flanges 34, 35 may be affixed. '
Also shown in ~ig. 2 is an H-snaped
coplanar interlocking panel joining member 14 which
is used to join two panels 12 and 12' in an
end-to~end conf iguration in the same plane. The
preferred embodiment of coplanar joining member 14
has a pair of parallel planar outer side members
50l 51 which are connected by a bar member 52 whieh
joins~ side members 50, 51 orthogonally and
~9~3
14
_ intermediate the outer ends of the side members.
Each of side members 50, 51 includes on its outer
opposite ends an inwardly extending interlocking
lip 53 having a dimension A slightly smal?er than
the length of neck portion 31 of panel 12~ It will
be appreciated that the interlocking lips 53 of
coplanar joining member 14 matingly interfit with
keyways 32, 33 of a panel 12, and allow slidable
engagement there between.
19 I~ may be observed in Fig. 2 that the
thickness (dimension B~ of the longitudinal edge 16
of head portion 30 of pan~l 12 i5 less than the
overall thickness (dimension C) of pa~el 12 between
walls 20,21. Thus, when panels 12 and 12' are
joined by coplanar joi~ing member 14, the outer
sur~ace of panel 12 between longitudinal edges is
flush with the outer surface of side members 50, 51
of coplanar joining member 14. It will be
appreciated that the flush outer surfaces present
an aesthetically pleasing structural assembly and
contribute o the unique features of the structural
system of the present inventionO
As stated above, the structural system of
the present invention includes several structural
components which may be used to assemble the
structural panels 12 into a variety of
configurations. AIso, certain applications of the
system may cali for the use of decorative trim in
order to improve the appearance of the functional
portions of the system. FigO 3 shows C-shaped
integrally formed interlocking panel end trim
member 60 which ~atingly interfits with panel
connecting member 15 of panel 12 and provides an
attractive cov2rin~ for the panel connecting
member. The panel end trim member 60 covers the
:1199773
head portion 30 and neck portion 31 and includes a .
pair of parallel planar outer side members 61, 62
which extend orthogonally from the ends o.f wall
member 63. The ends of side members 61, 62 each
include an inwardly extending interlocking lip 64, .
65 which interfits within keyways 32, 33 of panel
12. .
An interlocking panel joining corner .
member 70 is shown in Fig. 4 and may be used for
10joining the outer edge of a panel 12 to the outer .
- edge of an orthogonally adjacent panel 1~' in a
struct.ural system. Corner member 70 generally
comprises a square tubular member 68 which has a
pair of C-shaped members 60a, 60b extending at
15right angles from adjacent sides. In the preferred
: embodiment, C-shaped members 60a, 6Qb include the .
elements of panel end tr;m member 60 (Fig. 3) and
are integrally extruded or pultruded together with
tubular member 68.
20More particularly described, corner
member 70 includes a first wall member 71 which has
an interlocking lip 72 which interfits with keyway .
3~ of panel 12~. A second wall member 73 is formed
at the end of wall member 71 opposite lip 72 and
25extends at right angles to form together with first
wall member 71 the outer surface of a structure
which includes panels 12 and 12'. Second wall
member 73 also includes an interlocking lip 74. A
third wall member 75 parallel to the first wall
30member 71 extends at right angles from and
intermediate the ends of second wall member 73 and
intersects with a fourth wall member 76 which
extends at riyht angles from irst wall memb~r 71
intermediate the ends thereofO ~all members 75, 76
35meet at an orthogonal intersection 77. A ifth ~ '
~9~'~73 -
_ wall member 78 is formed parallel and opposite to
the first wall member 71 and includes an
interlocking lip 79 for matingly interfitting with
panel 12. Finally, a sixth wall member 80 parallel
to and opposite the second wall member 73 extends
at right angles from wall members 7S and 78 and
includes an interlocking lip 81 for interfitting
with panel 12'.
Fig. 5 shows an interlocking angular
panel joining member 90 which may be used to join a
pair of panels 12, l~' at an angle other than 90
degrees. Angular panel joining member 90 generally
comprises a pair of C-shaped members 6~c, 60d
which are connected at one corner at an angular
intersection 95. Si~e member 61c of C-shaped
member 60c includes an extension 104 which extends
at right angles to wall member 63c of C-shaped
member 60c opposite intersection 960 Side member
61d of C-shaped member 60d likewise include~ an
extension 93 which extends at ri~ht angles to wall
member 63d o~ C-shaped member 60d, opposite
intersection 96, and intersects with extension 104
at an obtuse intersection 106~
More particularly descr.ibed, angular
~5 panel joining member 90 includes a first wall
member 91 which includes on one end an interlocking
1 ip 92 for interf itting with a panel 12. A second
wall member 93 is formed at the end of the first
wall member opposite lip 92 at an obtuse angle lQÇ
and together with first wall member 91 forms an
outer surface for the panel structure. Second wall
.member 93 also includes an inwardly extendin~
interlocking lip 94 for interfitting with a se ond
panel 12' in the panel assembly~ A third wall
member 9 5 extends inwardly at right angles fr~m
1~9~7~73
_ intermediate the ends of first wall member 91 and
intersects at 96 in an acute angle with a fourth
wall membe~ 97 which extends at riyht angles from
intermediate the ends of the second wall member 93.
A fifth wall member 100 opposite and parallel to
the first wall member 91 extends at right angles
from the third wall member 95 and includes on the ¦
end opposite the intersection 96 an interlocking
lip 101. Finally, angular panel joining member gO
includes a sixth wall member 102 opposite and
parallel to the second wall member 93 which extends
at right angles from the fourth wall member 97 and
includes an inwardly extending lip 103. Although ,
~ig. 5 shows an angular panel joining member which
allows joining two panel6 at an angle of 45
degrees, it will be understood that the present
invention contemplates that panels may be joined at
any angle.
Fig. 6 discloses an interlocking
2U integrally formed T-intersection panel joining
member 110 which may be used in a structural system
for joining three panels 12, 12`, 12'' in an
essentially T-shaped intersection. The
T-intersection panel joining member 110 generally
comprises an H-shaped member 14a which includes the
eIements of panel joining member 14 (Fig. 2), with
a C-shaped member 60e formed at a right angle on
one side member of H-shaped member 14a~ .
~ore p a r t i c u 1 a r 1 y d e s c r i ~ ed ,
T-intersection member 110 comprises a ~irst wall
member 11~ which includes on opposite ~nds inwardly
extending in~erlocking lips 113, 114 or
interfitting within the keyways of panels 12 an~
12'. A second wall member 115 joins the first wall
member 112 at a right angle intermediate the ends
9~773
18
_ thereof to a third wall member 120 which is
parallel to the first wall member. At each end of
the third wall member 1~0 is formed ourth wall
member 121 and a fifth wall member 122,
respectively, of generally L-shape which are
parallel to the second wall member 115. The fourth
and fifth wall members ~21, 122 include inwardly
extending interlocking lips 123, 124 opposite lips
113, 114 for interlocking with panels 12 and 12~
respectively, L-shaped fourth and fifth wall
members 121, 122 further include inwardly extending
interlocking lips 125, 126 opposite to each other
which mat~ with the third structural panel 12' ' .
Fig. 7 shows an interlocking integrally
formed panel cross joining member 130 which may be
.~ used in a structural system to join four panel s in
a cross intersection. The panel cross join.ing
member 130 incl~des~a irst member 131 of generally
~-shape having a pair of parallel opposite side
walls 132,133 joined by a cross wall 134
intermediate the ends of the side walls. At the
ends of each of side walls 132~133 are formed
L-shaped members 135, 136, 137, and 13B. Each of
the L-shaped members includes a first leg 140, 141,
142, 143 parallel to the cross wall 134, and a
second leg 144, 145, 146, 147 parallel to the side
walls 132,133 of the first member 131. The second
legs 144--147 extend inwardly parallel to side
walls 132, 133 and form interloc~ing lips which
interfit with panels 12' and 12'l~ Each leg of
L-shaped members 135~-138 has a thickness which
permits interfitting within the keyways of panel
connecting member 15 of the panels to which the
cross joining member is assembled. At the ends of
L-shaped me~bers 135--138 opposite the second leg,
773
i9
_ the first legs 140--143 extend inwardly beyond the
point of attachment with the fi~st member 131 so to
form an interlocking lips 150, 151, 152, 153 which
interfit with the keyways of panels 12 and 12'''.
S It will be appreciated and understood
that the structural systems shown in Fig. 1 through
Fig. 7 contemplate a slidable engagement between
the panels and the panel joining members along the
outer longitudinal edges of the panels. In some.
applications, however, it may be impractical or
infeasible to slidably engage the panels to the
panel joining members in order to assemble a
structure. Consequently, Fig. 8 shows a bolted
interlocking coplanar joining member 160 which may
be used to join a pair of panels 12, 12' in a
~: coplanar end~to-end configuration, similar to that
accomplished by panel joining member 14 described
above, without having a slidable engagement. The
bolted jo;ning member 160 includes a first outer
side member 161 which has a generally GreeX letter
~pin~shape. The first outer side member 161 has an
outer wall 162, at the ends of which are formed
interlocking lips 163, 164 for interfitting with
the keyways of panels 12 and 12'. A pair of
~5 parallel bar members 165, 166 extend at right
angles from the outer ~all 162 on the same side as~
lips 163, 164, intermediate the ends of the outer
wall 162.
Bolked joining member 160 further
includes a separate second outer side member 170
which is mounted parallel to the first outer side
.member 161 and includes on each opposite end
thereof interlockin~ lips 171; 172 for interfitking
with t~e keyways of panels 12 and 12' opposite the
keyways which receive lips 163l 1640 Coaxial
773
_ apertures 173, 174 for receiving fastening means
175l such as a bolt, rivet, screw, or the like, are
formed intermediate the ends of outer side members
161, 170. Thus, it will.be appreciated that bolted
joining member 160 may be used in applications in
which it is desirable to assemble a structural
system without slidably engaging the panel with the
panel joining member.
Fig. g shows a panel end trim member 180
substantially similar to the panel end trim member
60 ~shown in Fig. 3) except that bar member 63'
. includes in extension 185 which extends beyond the
end of wall member 61' and the~eby provides a
surface to which accessor~es may be bolted,
screwed, or otherwise ~ttached. Fig. 9 also shows
a pair of rein~orcing ~able members 181, 182 which
are received in channels 41, 42 of panel 12. Cables
181 r 182 may be steel or other suitable reinforcing
cable, or alternatively may be electrical cables
for carrying electrical current.
Fig. 10 shows how a plurality of panels
12a--12f may be joined together by reinforcing
cables in a stacking fashion. Panels 12a--12c are
joined longitudinal edye-to-edge by panel joining
members 14a and 14b. Panels 12d~ f are similarly
joined longitudinal edge-to-edge by panel joining
members 14c and 14d. The panel ~ssemblies of
12a--12c and 12d--12f are then stacked by aligning
the assemblies on the transverse edges of the
panels along the width of the panels (not shown~.
Cables 181, 182 are then serpentined through the
.opposed channeis 41, 42 ~not shown in Fig. 1~), and
joined at a pair of 'curnbuckles 183~ 184 which may
be used to tighten the cablesO
Fig. 11 shows an edge insert 190 which is
~9~i73
_ formed of an outer wall 191 and a pair o~ inner
ledges 192, 193 which are inwardly offset from the
outer surfaces so as to interfit with the
transverse edge of a panel or with an edge of a
S panel 1~ which has been longitudinally cut so as to
remove a portion thereof. The edge insert 190 may
be placed along the width of a panel, i~
appropriate notches are cut to receive the ribs of
the panel. Also shown in Fig. 11 is a pair of
flat heater strips 194, 195 which may be attached
to the interior walls of a panel so as to provide
temperature control of a structure made with the
system. The heater strips may be attached to run
. longitudinally along any wall of the panel. It will
also be understood that,cooling coils (not shown)
~ may be placed within the hollow portions of the
panel so as to provide cooling capability.
Fig. 12 shows an interlocking edge insert
200 having essentially the same outer shape as the
panel connecting member 15' of a panel~ The
interlocking edge insert 200 includes a head
portion 3~' and a neck portion 31' (together
forming a panel connecting member 15'), a pair of
keyways 32', 33', an inw~rdly extending tab 40',
and a pair.of opposed channels 41', 42', all of the
same dimensions as in panel 12. A pair of recessed.
extending ledges 201, 202 extend outwardly away
from the panel connecting member lS' and interf it
with the edge 203 of a panel 12. Thus, it will be
appreciated that the interlocking cut edge insert
200 may be used to attach a panel connecting member
15' to the longit~dinal edge of a panel 12 which
has had a portion cu'c away so as to prov ide a
transverse ~idth less than the width of a complete
panel. It will also be appreciated that insert 200
~99~'~3
22
_ may be used along the transverse width of a panel
if appropriate notches are cut to receive the ribs
of the panel.
Fig. 13 shows a C-shaped edge panel end
insert member 210 which may be used to attach an
interlocking C-shaped portion to the transverse
edge of a panel or to the edge of a panel which has
been longitudinally cut. The C-shaped insert
member 210 generally comprises a C-shaped member
60f substantially similar to the shape shown in
Fig. 3, which is integrally connected to an edge
insert portion l9Oa similar to edge insert 190
shown in Fig~ 11. The C-shaped insert member 210
further comprises a pair of inner ledges 212, 213
lS which are inwardly offset from the outer surfaces
~of C-shaped portion 60f so as to interfi~ with an
edge 214 of a panel 12.
Fig. 14 shows a rounded orner edge panel
end-insert member 220 which may be used to join the
edge of a panel 12 to the edge of an orthogonally
adjacent panel 12'. Rounded corner insert member
220 comprises a quarter-section tubular member 221
which has a pair of edge insert members l90b, l90c
extending at right angles from adjacent sides of
t~bular member 221. Edge insert members l90b, l90c
include the elements of edge insert member 190
shown in Fig. 11 and are integrally extruded or
pultruded together with quarter-section tubular
member 221. It will be appreciated that a lower
edge insert member such as shown in ~ig. 14 may be
used to form an upper surface or ceiling for a
construction by placing the insert member/ notched
to receive the panel ribs~ along the transverse
width of the panels in the construction~
More particularly describPd~ rounded edge
, ~9~773 ~.~
_ panel insert member 220 includes a first wall
member 222 which has ledges 223, 224 which are
inwardly offset so as to interfit with edges 225,
226 of panel 12. A second wall member 227 is
formed at a right angle to first wall member 222 at
an intersection 233 and also includes a pair of
ledges 228t 229 which are inwardly offset so as to
interfit with edges 230, 231 of panel 12'. A
rounded wall member 232 joins first wall member 2~2
and second waIl member 227 opposite intersection
~33 where first wall member 222 and second wall
member 227 meetO
Fig. lS shows an angled corner edge panel
end insert member 240 which may be used to join at
an angle other than 90' a pair of pa~els 12, 12l.
; Angled corner insert member 240 generally comprises
a pair of edge inserts l90d, l90e which include all
the elements of edye insert 190 shown in Fig. 11.
Edge inserts l90d, ~9Oe are joined at an angled
intersection~ 241. Edge insert member l90d includes
an extension 242 which extends ~t right angles to
edge insert member l90d opposite intersectior. 241a
Edge insert member l9Oe likewise includes an
extension 243 which extends at right angles
opposite intersection 241 and intersects with
extension 242 at an obtuse angled intersection 244.
~dge insert member l9Od includes a pair of inner
ledges 245, 246 which are .inwardly offset so as to
interfit with the edge of a panel 12~ Similarly,
edge insert member l9ne includes a pair of ledges
247, 248 which are inwardly offset so a5 to
interfit with the edges of a panel 12'.
Fig. 16 shows a rounded angled corner
edge pan~l end insert member 250 substantially
similar to the angled corner edge panel end insert
~.~L95~t7~3
24
member shown in Fig. 15, except that the edge
insert portions are joined by a rounded edge as
opposed to an angled edge-. The rounded angled
panel end insert member 250 cornprises a pair of
edge insert members l90f, 1909 which inciude all
the elements of edge insert 190 shown in Fig~ 11
and which are joined at an angled intersectiorl 251.
A rounded wall member 252 joins edge insert members
l90f, l90g opposite intersection 251 and forms a
rounded outer w 11 surface. Cut edge insert member
l90f includes a pair of inner ledges 253, 254 which
interfit with an edge of a panel 12~ and edge
insert member 190g likewise includes a pair of
ledges 255~ 256 which interfit with the edge of a
panel 12~. Although Figs. 15 and 16 show angled
corner edge panel insert members which allow
joining two panels at an angle of 45 degrees, it
will be understood-that the present invention
contemplates that panels may be joined at any
angleO
Fig~ 17 shows an edge panel insert cross
~oining member 260 which may be used to join the
edges of four panels 12, 12', 12' ', 12' ' ' in a
cross intersection. The edge cross joining member
260 includes an H-mémber 261 having a pair of
parallel opposite side walls 262, 263 joined by a
cross wall 264 intermediate the ends of the side
walls. An edge insert member l90h having a pair of
ledges 265, 266 for interfitting with an edge of a
panel 12 is formed on the outer surface of side
wall 262. Similarly, a edge insert member 19 0 i
having a pair of ledges 267, 268 is formed on the
outer surface vf side wall 263 for interfitting
with the edge of a panel 12'~l~ Edge insert
members l90h, l90i include all the elements of
773
edge insert 190 shown in Fig. 11. The edges of
panels 12' and 12'' overlap-and interfit with
opposite ends, respectively, of side walls 262,
263.
~ig~ 18 shows a T-intersection edge panel
insert member 270 which may be used for joining the
edges of three panels 12, 12', 12'l in an
essentially T-shaped intersection. The
T-intersection edge insert member 270 generally
comprises an H-shaped member 271 having a pair of
parallel opposite side walls 272, 273 joined by a
cross wall ~74 intermediate the ends of the side
walls. An edge pane~ end insert member l90j having
the elements of edge insert 190 shown in Fig. 11
is formed along the outer surface of side wall 273
and includes a pair of ledges 275, 276 which are
inwardly offset so as to interfit with the edge of
a panel 12'. Ledges ~77, 278 are formed on
opposite ends of side wall member 272 so as to
interfit with the edge of panels 12 and 12'
respectively.
~ig. 19 shows a double edge panel end
insert member which may be used to join the edges
of two panels 12, 12~ în a coplanar end-to-end
~onfiguration. The double edge insert member 280
has a pair of parallel planar outer side members
281, 282 which are connected by a bar member-283
which joins side members 2~1, 282 orthogonally and
intermediate the outer ends of the side members.
Side members 281, ~82 include offset ledges 284,
285 which interfit with the edge of panel 12, and
ledges 2B6, 287 which interfit with the edge of a
panel 12~o
FigO 2~ ~hows a square corner edge panel
end insert member 290 which may be used for joining
9773
- the edge of a panel 12 to the edge of an
orthogonally adjacent panel 12'. Square corner
edge panel end insert member 290 generally :~
comprises a square tubular member 291 which has a ~
pair of edge panel end insert members l9Ok, 1901 ~,.
extending at right angles from adjacent sides. ~
Edge panel end insert members l90k, 1901 include .Y~,.
the elements of edge panel end insert 190 shown in
Fig. 11. Panel end insert member ~9Ok interfits
with the edge of a panel 12' while panel end insert
member 1901 interfits with an edge of a panel 12. 3
. . Fig 0 21 shows a double lip edge panel end
insert member 300 ~hich may be used to interfit
with the cut edge of a panel 12 so as to provide a
surface to which ac.cessories may be bolted,
: screwed, or otherwise attached. Double lip insert
member 300 comprises a planar wall member 301 and a
pair of orthogonally extending ledges 302, 303
which interfit with the edge of panel 12.
. Fig. 22 shows a bolted edge panel ~oining
member 310 which may be used to join in a coplanar
end-to-end configuration a pair of panels 12, 12'.
The function accomplished by bolted cut edge
joining member 310 is similar to that accomplished
by interlocking coplanar member 160 shown in Fig.
80 The bolted edge joining member 31Q includes a
irst outer side member 312 which has a generally
Greek letter "pin-shape. The first outer side.
member 312 has an outer wall 313 and a pair of
parallel bar members 314~ 315 which e~tend at right
angles from one side of outer wall 313 intermediate
the ends of the outer wall. Bolted edge joining
member 310 further includes a separate second outer
side member 316 which has a insert portion 317
which înterfits between parallel bar members 314,
27
315. Coaxial apertures 318, 319 for receiving
fastening means 320 such as a bolt, rivet, screw,
or the like, are formed intermediate the ends of
outer side members 312, 316. Thus, it will be
appreciated that bolted edge joining member 310 may
be used in applications in which it is desirable to
assemble a structural system without slidably
engaging the panel with any panel joining members.
Fig. 23 shows a double panel window
mullion member 330 which may be used to mount a
pair of planes of glass 331, 332 in a structural
system by mounting atop a panel or along a
longitudinal edge of a panel. Window mullion
member 330 includes a pair of opposite side walls
333, 334 which are separated by a distance greater
than the thickness of a panel 12 so that the window
mullion member 330 may straddle the overall
thickness of a panel such as shown by dimension C
in Fig. 2. It will be appreciated that window
mullion member 330 may be used as either a mullion,
a header, or a sill for supporting panes of glass
or other panels in a construction by simply placing
the window mullion member across the overall
thickness of a panel or across a cut edge of a
panel.
Fig. 24 shows a hinge edge panel end
insert member 340 which may be used to attach a
hinge to the cut edge of a panel 12. Hinge edge
panel end insert member 340 generally comprises an
edge panel end insert member 190m having the
elements of edge panel end insert 190 shown in Fig.
11, which interfits with the edge of a panel 12.
The hinge edge member 340 further includes hinge
means 341 formed integrally with edge panel end
insert member 190m.
28
_ It will be understood and appreciated
that the panel accessory members shown in Figs.
11--24 may be used along the transverse width of
panels, if notches are cut for th~ ribs of the
S panels, or along the longitudinal edges of panels
which have had a portion cut away so as to provide
a transverse width less than the width of a
complete panel. It will be further understood and
appreciated that the panel accessory members may be
1~ combined as desired to create structural assemblies
of many different shapes, configurations, and
sizes. For example, entire enclosed structures
having walls, floors, ceilings, a roof, doors, and'
windows may be assembled by combin;ng the various ¦'.
disclosed accessories with the disclosed structural
panel.
Fig. 2~ shows a hinge interlocking panel
end member 350 which includes'an interlocking panel
end member 60g having' all'the elements of panel end
trim member-60 shown in Fig. 3 and further includes
hinge means 351 which may be used to attach a panel
connecting member 15' of a panel 12 to a pivoting
hinge mechanism so that a door may be formed in a
structure.
~5 The preferred embodiment of the present
invent;on has been disclosed by way of example and
it will be understood that other modifications may
occur to those skilled in the art without departing
from the scope and the spirit of the appended
claims.
