Note: Descriptions are shown in the official language in which they were submitted.
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INTERLOCRING PANEL ~BUILDI~G CON~TRUCTION
FIELD OF THE INVEN~ION
This invention is directed to a novel interlock-
ing panel building construction. More particularly, this -
invention pertains to a novel structure building which is
formed of walls and doors formed of unique interlocking
modular panels which can be snap-locked together to form a
combined reinforcing frame and membrane construction.
BACKGROUND OF THE INV:E~NTION
Conventionally, when six-sided cube or rectangu-
lar-cube hollow structural buildings are constructed, a
~rame of ribs and joists are first constructed, and then an
external skin of metal, plastic or wood material sheet is ~-
nailed, screwed, riveted, or bolted to the ~rame. This
construction of cube or rectangular-cube envelope is
expensive and labour-intensive. Moreover, after a time,
particularly with structural building envelopes formed of ~- -
aluminum ribs and skin, the rivets or bolts move or loosen
over time, due to jostling, and the like, and accordingly ~-~
leaks develop, or the structure weakens. Structural cube ~ -
25 or rectangular-cube building envelopes are commonly used `
for truck bodies, trailers, mobile buildings and prefabri-
cated building structures.
To minimize assembly time, and to cut costs,
30 various designs of interlocking panels and modular struc- ~-
tural envelope constructions have been developed. The
following are patents which illustrates various interlock- -
ing panel constructions. ~ -
United States -~
Patent Number Inventor
3,085,367 De Ridder et al.
3,111,203 De Ridder ~ -
3,420,028 Barker
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An inherent disadvantage of structural building
envelopes formed of interlocking panels of the type dis-
closed in some of the above patents is that the panels can
shift longitudinally with respect to adjacent panels. To
prevent such shifting, a separate per:ipheral frame is
usually required, not only to provide dimensional stabil-
ity, but also to provide additional supporting strength.
U.S. Patent No. 4,099,358, Compaan, discloses a
design of interlocking pan~l which can be used to construct
structural envelopes. However, it has been found with the
interlocking panel design disclosed in Compaan that the
connections between adjacent panels do not hold permanently
under variable load conditions and accordingly, the panels
are prone to separating, particularly when stressed in
certain directions. A problem with the panels is that once
they are snapped together, and subsequently separated due
to various forces, they cannot be reliably snapped together
again. Also, the panels have a tendency to have a domino
effect, in that once one joint separates, adjacent joints
are also likely to separate.
Canadian Patent No. 1,089,172, granted November
11, 1980, which is a reissue of Canadian Patent No.
1,021,129, granted November 22, 1977, Compaan, is a coun-
terpart of U.S. Patent No. 4,099,358. That reissued patent
discloses an interlocking construction panel which is
subject to the limitations discussed above regarding the
U.S. patent. When interlocked with an identical panel, a
smooth flat surface is presented on one side, while a
plurality of longitudinal integral channels project from
the opposite face. There is no teaching in the patent of
bending the panels longitudinally in order to form corners.
Moreover, the interlocking panels are fastened over a frame
network. There is no disclosure of using the panels to
form single or double doors in the walls of the structural
envelope formed by the interlocking panels.
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SUMMARY OF THE INVENTION
The invention is directed to an interlocked
structure comprising: (a) at least two separate first and
second planar panelis each having at onf side thereof an
interlockable connection means, and at the opposite side
thereof, an interlockable engaging means adapted to mate
with a connection means of another panel; (b) at least one
panel constructed similarly to one of the panels (a) above,
but bent in the interior region thereof between the connec-
tion means and the engaging means, the bent panel being
interspersed between the first and second planar panels
(a), the interlockable connection means at one side of the
bent panel interlocking with a mating interlockable engag-
ing means of an adjacent first planar panel (a), and the
interlockable engaging means at the opposite side of the
bent panel interlocking with a mating interlockable connec-
tion means of an adjacent second planar panel (a).
The combination of the planar panels (a) and four
alternating bent panels (b) can be in sufficient number to
form an enclosed configuration. There may be at least two
adjoining planar panels (a) along each linear side of the
enclosure, the planar panels (a) being interconnected with
one another in pairs, and the planar panels (a) at the
corners of the four sides of the enclosure being intercon~
nected with the respective bent panels (b).
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A door can be formed in at least one side there-
of. The door can be constructed of planar panels which can
be arranged in parallel, or at an angle, or in an orienta-
tion perpendicular to the orientation of the panels forming
the surface adjacent the door. The door can have a door
frame surrounding the panels of the door and a door opening
frame can be formed in` the panels forming a wall of the
structure, the door opening frame receiving the door frame.
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The interlockable engaging means on one side of
the panel can form a reinforcing rib and can be adapted to
engage with the reinforcing rib on the opposite side of an
adjacent panel. Tlle reinforcing rib can have a channel
formed therein, one side of the channel being formed to
have a first fish-hook type connection, and the opposite
side of the channel being formed to have therein a cylin-
drical groove and overhanging lip which is adapted to
receive a rounded rail with a protrusion along one side
thereof.
The interlockable engaging means on the opposite
side of the panel can have formed therein a protrusion
which has formed in the end thereof a second fish-hook type
connection adapted to mate with the first fish-hook type
connection of the channel reinforcing rib, and in congruent
configuration therewith, a rounded rail with a square-
shaped protrusion at the side thereof, the rounded rail and
square-sided protrusion being adapted to interlock and
engage with a channel-like groove, and overhanging lip of
the reinforcing rib of an adjacent panel.
The planar panels and the bent panels can have a
longitudinal construction, and the interlockable means can
be formed along the elongated sides of the panel. The
planar and bent panels forming the enclosure can be inter-
locked in adjacent relationship with one another in a
vertically or horizontally extending configuration, while
the panels forming the door in a wall of the envelope can
be arranged adjacent to one another in a horizontal,
vertical or angled configuration.
An elongated paneI for interlockable connection
with an adjacent panel of similar configuration comprising:
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(a) An elongated planar member having an interl-
ockable connection means and a first linear side along one
longitudinal side thereof, and an interlockable engaging
means and a second linear side along a second longitudinal
side thereof;
(b) The interlockable connection means compris-
ing an elongated channel with a bottom, an interior wall
adjacent the planar member and an exterior wall removed
from the planar member formed in the planar member along
and adjacent to the first longitudinal linear side of the
planar member, the top of the exterior wall of the channel
being formed to have a first longitudinal fish-hook type
connection, extending into the interior of the channel,
with a connecting under-edge which is parallel to the plane
of the planar member, and a groove on the underside of the
under-edge of the first fish-hook type connection, and the
interior wall of the channel opposite the exterior wall
being formed to have therein a longitudinal partial cylin-
2~ drical cross-section groove extending along at least part
of the interior wall and parallel with the longitudinal
side of the main body of the planar member, and a rounded
edge lip extending from the top of the interior wall into
~he interior of the channel and partially above and over
the partial cylindrical groove, the partial cylindrical
groove and edge lip being adapted to receive a partially
circular cross-section rail with a blunt square-shaped
cross-section protrusion from an adjacent panel;
(c) The interlockable engaging means being
formed in the second linear side of the planar member and
extending along the longitudinal side of the panel member
parallel with and opposite to the channel, the in~erlockab-
le engaging means comprising at a distance from the edge of
the second linear side commensurate with the width of the
channel and a protrusion which extends from the planar
member on the same side and in the same direction as the
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channel, which protrusion has formed in the end thereof a
second longitudinal fish-hook type connection with a
connecting under-edge which is parallel to the plane of the
planar member and the corresponding under-edge of the first
fish-hook type connection, adapted to abut with the under-
edge of the first fish-hook type connection of an adjacent
panel, and at the second linear side of the planar member,
a partially circular cross-section thick-necked longitudi-
nal rail with a squara cross-section shaped protrusion
lo extending from the second linear side thereof parallel to
the planar ~ember and away from the channel, the rail
extending from the planar member on the same side and in
the same direction as the channel and the second fish-hook
type connection, the rail and square cross-section shaped
protrusion being adapted to interlock and engage with a
corresponding partial cylindrical cross-section groove, and
the rounded overhanging edge lip of an adjacent panel.
The overhanging lip can have a bevelled edge,
the groove can be connected to the inner interior wall of
the channel by a pivot stem, and the square-sided protru-
sion can extend longitudinally along the rounded rail on
the side of the rail opposite to the second fish hook
connection.
BRIEF DESCRIPTION OF THE_DRAWINGS
In drawings which illustrate various embodiments
of the invention, but which should not be regarded as
restricting the spirit or scope of the invention in any
way:
Figure l illustrates an isometric view of a
structural envelope formed of interlocking wall and corner
- 35 panels.
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Figure 2 illustrates an enlarged isometric view
of a section taken from the upper right corner of the
structural envelope illustrated in Figure 1.
Figure 3 illustrates an isometric view of a cube
van truck body formed o~ interlocking corner and side
panels.
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Figure 4 illustrates an isometric view of the
10 reverse side of the cube van truck body, as illustrated in ~-~
Figure 3.
Figure 5 illustrates a front view of a single
door formed of interlocking panels and a door frame.
Figure 6 illustrates a front view of a double
door formed of interlocking panels and a door frame.
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Figure 7 illustrates an end view of an interlock-
ing panel.
Figure 8 illustrates an enlarged end view of the
right side of the interlocking panel as illustrated in
Figure 7.
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Figure 9 illustrates an enlarged view of the left
side o~ the interlocking panel illustrated in Figure 7. ~
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Figure 10 illustrates an end view of the right -
side of the panel illustrated in Figure 9, snapped into
place with the left side of a similar adjacent panel formed
according to the configuration illustrated in Figure 9.
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DETAILED DESCRIPTION OF A SPECIFIC
EMBODIMENT OF THE INVENTION
Referring to Figure 1, which illustrates an
isometric view of an interlocked structural envelope 2, the
planar walls of the envelope 2 are constructed of a series
of longitudinal interlocking panels 4, which are connected
at the corners by 90 bent interlocking panels 6. When the
interlocking panels 4 and 6 are interconnected, adjacent to
one another, in the form illustrated in Figure 1, a strong
self-reinforced structural envelope i5 providedO As can be
seen in Figure 1, the interior of the structural envelope
2 consists of a parallel series of vertically extending
reinforcing frames 16, with a planar membrane 14 extending
between each of the reinforcing frames 16. This construc-
tion is sufficiently strong that no separate reinforcing
network, or construction frame, is required.
As shown in Figure 1, the longitudinal side of
the structural envelope 2 has built therein a side door 8
which is constructed of horizontally disposed interlocking
panels 4. It is preferable that the panels 4, which form
the door, are horizontally disposed in order to provide
additional structural strength, particularly diagonal, to
the overall structural envelope construction. The horizon-
tal interlocking panels 4, comprising the door 8, are
enclosed in a reinforcing frame 34. This frame is prefer-
ably formed of extruded aluminum, but it can be *ormed of
steel, wood or some other material as required~ in ordPr
to comply with accepted construction standards, or to
:: provide the required dimensional strength to the overall
structural envelope construction 2. A door opening frame
38 is built into an opening formed in the interconnecting
vertically disposed panels 4, forming the body of the side
wall of the structural envelope 2. The door opening frame
~ 38 can al~so be preferably formed of extruded aluminum, but
; steel or wood, or the like, can be used as required to meet
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structural requirements. The door 8 is connected to the
door opening frame 38 by commercially available hinges 36,
the number and type being determined by door size and
weight~
Figure 1 also illustrates a double rear door 12,
built into the end of the structural envelope 2. The
douhle rear door 12 is formed of horizontally disposed
interlocking panels ~, each of the double doors having
10 rectangular door frames 34 around the exterior thereo~. -
It will be r~cognized that the door panels can be arranged
vertically, or even at an angle, if desired. The pair of
doors 12, and the door frames 34, are hingedly connected to
a rectangular door opening frame 38 built into the encl of
the structural envelope 2. Interlocking panels 4 and 6 can
be constructed of various lengths, and cut ko slze, in
order to form structural envelopes 2 of various heights.
Likewise, the horizontal panels 4, making up the doors 8
and 12, can be cut to length in order to form doors of
20 prescribed widths. ~
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Figure 2 illustrates an enlarged isometric view -
of the top right corner of the structural envelope 2
illustrated in Figure 1. As illustrated in Figure 2, the
interlocking corner panel 6 is formed by bending a planar
interlocking panel 4 into a curved corner interlocking
panel 6 utilizing hydraulic presses, dies, and the like.
As can be seen also in Figure 2, there are a pair of
reinforcing ribs 16 adjacent to and parallel with the
corner. These reinforcing ribs 16 provide structural
strength to the corner panel 6.
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The manner in which the inner "fish-hook" connec-
tion 18 and outer "fish-hook" connection 46 connect to
gether on one side of reinforcing rib 16, and the rounded
rail and socket groove connection 20 connect at the oppo- --
site side, is clearly illustrated in Figure 2.
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Figure 3 illustrates an isometric view of a cube
van truck body formed of interlocking corner and side
panels. The van illustrated in Figure 3 has a cube trucX
body formed by an interlocking series of vertically dis-
posed interlocking panels 4, with int~erlocking corner
panels 6 at each of the corners. The side and end walls
formed thereby, are covered on the top surface by a flat
roof panel 28, which can be constructed of aluminum sheet-
ing, with reinforcing bows or ribs underneath. If necess-
ary, the roof 28 can be constructed of a series of inter-
locking panels 4. The roof 28 is peripherally connected
around the four sides to the side and rear walls by a roof
rail 24 which aIso can be formed of extruded aluminum or
steel, as required. Normally, the roof 28 is formed of
aluminum sheeting, since interlocking panels 4 and the
inherent strength therein, is not required for the roof.
If need be, the interlocking panels 4 can be
reversed from that shown in Figure 3, so that the reinforc-
ing ribs 16, which normally are on the interior of the
structural envelope 2, are on the exterior. The advantage
of this reversed construction is that the walls in the
interior of the structural envelope 2 are smooth. This
type of construction may be required for moving vans,
cattle liners, grain boxes, and the like, where smooth
interior walls are advantageous when loading and unloading
cargo in the interior of the structural envelope 2. The
exterior reinforcing rib is not unattractive and need not
be covered over by exterior aluminum sheeting. Howeverl
this can be done if required. The exterior aluminum or
steel sheeting can be riveted or bolted to the exterior
reinforcing ribs 16. The cube van illustrated in Figure 3
has a sliding window 22 built into the side wall. A rub
rail 26 is also fastened to or built into the lower periph-
ery of the interlocking panels 4 and corner panels 6.
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Figure 4 illustrates an isometric view of the
reverse side of a cube van truck body, as illustrated in
Figure 3. Figure 4 illustates a double rear door 30, built
into the rear wall of the structural envelope 2. The
construction of the doors will be discussed in more detail
below. Figure 4 illustrates also a pair of small single
rear doors 32, built into the rear wall on either side of
the double rear door 30. A pair of smaller double doors 32
are also built into the side wall of the envelope 2.
Figure 5 illustrates a front view of a single
rear or side door 32. The central body of the door is
formed of a series of adjacent interlocked horizontally
disposed panels 4. If desired, the panels 4 could be
vertically disposed, or even at an angle. However, as a
general rule, it is preferable to dispose the interlocking
panels 4 horizontally in order to provide lateral strength
to the door, while the vertical disposed panels 4 of the
end or side walls of ~he envelope 2 provide vertical
20 strength. The combination provides diagonal strength. The ~ ;
series of horizontally disposed panels 4 are framed by a
door frame extrusion 34. This door frame e~trusion is
preferably formed of aluminum, but steel, wood or any other
suitable construction material, can be used as required.
A door opening frame 38 is built into the wall of the
envelope 2. The door frame 34 is connected to the door
opening frame 38 by hinges 36. The door 8 can be con-
structed according to virtually any size, but normally the
door is sized according to accepted building or construc- i -
tion requirements.
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Figure 6 illustrates a front view of a double
door formed of interlocking panels and a door frame.
Fiyure 6 illustrates a doub~e door comprising a bu~per door
42, and a swing door 44. Both the bumper door 42 and the
swing door 44 are ~ramed independently with rectangular
door frames 34. The bumper door 42 and swing door 44 are
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mounted in a rectangular door opening frame 38, which is
connected to the end or side wall of the structural envel-
ope. Again, the dimensions of the bumper door 42 and swing
door 44 can be of virtually any size, but in most cases,
the size of the doors will be according to standardized
building or vehicle requirements.
Figure 7 illustrates an end view of an interlock-
ing panel. The construction of interlocking panel 4 has
been carefully designed and improved over time to ensure
ease of interlocking and to ensure that once interlocked,
the panels will not separate. The design illustrated in
Figure 7 is typically formed by extruding aluminum through
a high precision die. The design incorporates a number of
very subtle but important features which enable adjacent
panels 4 to be easily snapped together, while at the same
time, ensuring that once snapped together, the panels will
not separate, even when exposed to severe disruptive
forces. As seen in Figure 7, the panel 4 has a flat,
planar membrane 14, which has formed at each side thereof
a specific construction. At the right side, inset from the
end, there is formed an inner fish-hook connection 18,
projecting downwardly as seen in Figure 7. At the extreme
right side, as seen in Figure 7, there is formed a rounded
rail connection 50, which has a sguare shaped snap rim 54
formed on the right side of rail connection 50.
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At khe left side of the membrane 14 of panel 4,
there is ~ormed a channel shaped reinforcing rib 16. As
seen in Figure 7, the left side of the channel shaped
rein~orcing rib 16 is formed so that it ends with an
upwardly projecting outer fish-hook connection 46. In the
interior of the reinforcing rib 16 at the riyht side
thereof, as seen in Figure 7, there is formed a socket
groove 48. Formed in the panel above the socket groo~e 48
is a leftwardly projecting snap lip 52. - -~
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Figure 8 illustrates an enlarged end view of the
right side of the interlocking panel as illustrated in
Figure 7. The right side of the panel 4, as seen in Figure
8l illustrates in detail the cylindrical lower face of
rounded rail connection 50O At the riqht side of rail
connection 50, the square shaped positive locking tab 54 is
formed. The design of rounded rail connection 50 and
positive locking rib 54 is carefully fashioned so that the
combination can readily rotate into socket groove 48, with
locking tab 54 locking into place underneath locking lip
52, of an adjacent panel. Similarly, downwardly extending
inner fish-hook connection 18 is carefully designed to mate
with outer fish-hook connection 46 of an adjacent panel.
Inner fish hook 18 is formed at the end of inner fish-hook -
stem 60, which is designed to enable fish-hook 18 to move
laterally a slight extent in order to facilitate its
snapping into place in association with outer fish-hook
connection 46.
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20The whole assembly comprising rounded rail ;-~
connection 50 and positive locking tab 54 acts as a "ball
and socket union" with locking lip 52, socket groove 48 and
pivot stem 56. It is designed to allow the panel 4 to
rotate into position for assembly purposes while locking
the unit together after assembly. At the same time, the
various angles and extrusions act as lateral stiffeners to
the rib assembly.
Figure 9 illustrates an enlarged view of the left
~ide of the interlocking panel illustrated in Figure 7.
Socket groove 48 is formed to have pivot stem 56 connecting
it with the right wall of reinforcing frame 16. Pivot stem
56 is carefully designed to enable socket groove 48 to move -
upwardly or downwardly a slight extent, in order to ~acili-
tate engagement with rounded rail zonnection 50, and to
enable square-shaped locking tab 54 to lock into place
underneath locking lip 5~ of an adjacent panel. At the
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left side of reinforcing rib 16, outer fish-hook connec-
tion 46 has formed immediately below it: on the interior
face, inner fish-hook receiving notch 58. Inner fish-hook
connection 18 and upwardly extending outer fish-hook
connection 46 of adjacent panels 4 are designed to snap
together readily, under construction conditions, but once
snapped together, do not separate even when the adjoining
panels 4 are exposed to considerable shaking and disruptive
forces.
Figure 10 illustrates the configuration that is
obtained when rounded rail connection 50 is rotated into
place in socket groove 48 of an adjacent panel 4 while
inner fish-hook connection 18 is snapped in place in
receiving notch 58, underlying outer fish-hook connection
~6 of the adjacent panel. As can be seen, an extremely
snug, dimensionally stable, readily assembled construction
is obtained. Groove 48 is rounded so as to minimize
friction bending, which can be severe for extruded aluminum
and to facilitate sliding engagement with rounded rail
connection 50. Square-shaped locking tab 54 fits securely
under the flat face of locking lip 52, thereby retarding
separation. If locking tab 54 was rounded, then the
reliability of the connection between locking tab 54 and
locking lip 52 would be reduced.
As will be apparent to those skilled in the art
in the light of the foregoing disclosure, many alterations
and modifications are possible in the practice of this
invention without departing from the spirit or scope
thereof. Accordingly, the scope of the invention is to be
construed in accordance with the substance defined by the
following claims.
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