Note: Descriptions are shown in the official language in which they were submitted.
CA 02352556 2001-07-06
EXTRUDED PLASTIC WALL PANEL AND DOOR PANEL
CONSTRUCTION SYSTEM
BACKGROUND OF THE INVENTION
The present invention generally relates to a modular door and wall
panel system that is formed from extruded rigid PVC. More specifically, the
present invention relates to a modular door and wall system in which each of
the
components are formed from extruded rigid PVC such that the components can be
used to construct a door, a wall partition system and a shed.
In many situations, such as an agricultural environment, a need exists
for a door and wall system that is formed from a material that can be easily
washed
and sanitized. For example, in dairy, hog confinement, poultry and clean
rooms, it
is desirable to have a door and wall system that is formed from a material
that will
not stain, rot, peel or mildew and can be easily sanitized and cleaned.
Currently,
one such available material is stainless steel. Although stainless steel can
be easily
sanitized and cleaned, and is very durable, the cost of forming a door and
wall
system from stainless steel proves to be prohibitive. Further, the weight and
general inflexibility of the material makes stainless steel generally
unacceptable for
such an agricultural setting.
In addition to the desire for a door and wall system that can be easily
washed and sanitized, it is also desirable for a door and wall system that is
easily
expandable and configurable based on user requirements without requiring
specially manufactured parts. The use of modular components without requiring
specialized parts molded to a user requirement increases the flexibility of
the
system while dramatically reducing the cost.
As discussed above, it is desirable for a door and wall system that is
formed from a material that can be easily washed and sanitized. Although one
possible alternative is plastic, plastic doors and wall panels having widths
up to 36
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inches have presented a formidable challenge in the extruding and molding
process.
As the above comments indicate, a need clearly exists for a modular
door and wall system that is durable, inexpensive and can be sanitized.
Further, a
need exists for a modular door and wall system that is inexpensive, infinitely
expandable and configurable, and easy to maintain and assemble.
SUMMARY OF THE INVENTION
The present invention is a modular door, wall and shed construction
system that is formed entirely from extruded rigid PVC. The door, wall and
shed
construction system of the present invention are all centered around an
extruded
wall panel. The extruded wall panel includes a first face surface and a second
face
surface that are separated from each other by a plurality of center ribs. The
center
ribs space the first face surface and the second face surface to define a
generally
hollow interior for the extruded wall panel.
The extruded wall panel includes a first side and a second side that
define the width of the panel. In the preferred embodiment of the invention,
the
wall panel has a width of 36 inches. Both the first side and the second side
of the
wall panel include a recessed connector channel extending from the top of the
wall
panel to the bottom of the wall panel. The recess connector channel is formed
during the extrusion of the wall panel.
The recessed connector channel preferably defines the shape of a
dovetail mortise and can receive a dovetail end formed on other components of
the
construction system of the present invention. For example, an end cap can be
attached to either side of the wall panel to cover the recessed connector
channel.
In the door construction system of the present invention, the wall
panel is used as the actual door. The wall panel is mounted between a door
frame
formed from a pair of side door jamb members and a top door jamb member. In
accordance with the present invention, each of the door jamb members is formed
from extruded rigid PVC. Each door jamb member includes an extended stopping
section that contacts the door when the door is in the closed position. Each
of the
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door jamb members includes a pair of snap grooves that allow various other
components to be attached to the door jamb. For example, a door jamb extension
and a decorative molding can be attached to the opposite snap grooves as
desired.
The door system further includes a end cap that can be attached to the
recessed
connector channels formed in each side of the door to provide a clean
appearance
for the door.
In addition to allowing for the formation of a door system, the
extruded wall panels can be connected to each other to form various partitions
and
wall assemblies. Specifically, an extended panel adapter having a pair of
connectors can be used to securely join a pair of wall panels. The panel
adapter
can be configured to allow the wall panels to be connected parallel to each
other, or
the panel adapter can be configured such that the wall panels are connected at
any
desired angle. Thus, the extruded wall panels of the invention can be used to
form
a wall partition system by simply joining the panels in an end-to-end
configuration.
The wall panels of the present invention can also be connected end-
to-end to form an enclosed shed or storage building. The enclosed shed can
include the door assembly of the present invention to allow access to the
interior of
the enclosed area.
The shed assembly constructed in accordance with the present
invention includes an eave connector mounted to the top end of each wall panel
that forms the opposite sidewalls of the shed. The eave connector includes a
sloped panel support surface that receives one of the wall panels used to form
the
roof of the shed. An eave end cap secures the outer end of the wall panel to
the
eave connector such that the wall panel is secured to the sidewalk to form the
roof
of the shed.
A peak connector is positioned between the ends of the wall panels
that form the roof to define the peak of the roof. Preferably, the peak
connector
includes a pair of panel receptacles that are each sized to receive an end of
the wall
panels used to form the roof. In this manner, the roof connector defines the
peak of
the roof and secures the wall panels that form the roof.
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In a proposed embodiment of the invention, the peak connector
defines a hollow central opening positioned between the pair of the wall panel
receptacles. The hollow, central opening is sized to receive an aluminum
stiffener
such that the aluminum stiffener acts to support the weight of the roof.
Various other features, objects and advantages of the invention will
be made apparent from the following description taken together with the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings illustrate the best mode presently contemplated of
carrying out the invention.
In the drawings:
Fig. 1 is a partial perspective view illustrating a door formed from an
extruded wall panel and extruded door jamb members constructed in accordance
with the present invention;
Fig. 2 is a section view taken along line 2-2 of Fig. 1 illustrating the
specific configuration of the door and the extruded door jamb and trim
components
formed in accordance with the present invention;
Fig. 3 is a section view taken along line 3-3 of Fig. 1 illustrating the
hinge, door knob and wall panel used to form the door of Fig. l;
Fig. 4 is a magnified view illustrating the end configuration of the
wall panel used to form the door of Fig. 1;
Fig. 5 is a magnified view of the hinge and mounting arrangement for
the door of the present invention;
Fig. 6 is a top view of an extruded wall panel that forms a basis of the
present invention;
Fig. 7 is a top view illustrating a door jamb extension;
Fig. 8 is a top view of an extruded panel adapter used to join adjacent
wall panels;
Fig. 9 is a top view of a door jamb including a smooth trim section;
Fig. 10 is a side view illustrating a molded door sill used in
connection with one of the doors;
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Fig. 11 is an exploded view taken a long line 11-11 of Fig. 10;
Fig. 12 is a front view and partial section view illustrating a storage
shed formed from the wall panels and door assembly of the present invention;
Fig. 13 is a section view taken along line 13-13 of Fig. 12;
Fig. 14 is a section view taken along line 14-14 of Fig. 12 illustrating
the peak connector used in forming the roof of the shed;
Fig. 15 is a section view taken along line 15-15 of Fig. 12 illustrating
the eave connector used to secure the wall panels that form the roof of the
shed
illustrated in Fig. 12; and
Fig. 16 is a section view illustrating one corner of the shed of the
present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to Fig. 1, thereshown is a door assembly 10 that is
formed exclusively from extruded plastic components that form the present
invention. In Fig. 1, the door assembly 10 is shown mounted between a pair of
conventional walls 12 that are formed from any one of numerous currently
available materials, such as conventional wood support beams and drywall. The
door assembly 10 of the present invention includes an extruded wall panel
mounted
to a door frame 15 formed from a pair of side door jamb sections 16 and a top
section 17. In the preferred embodiment of the invention, both the wall panel
14
and the door jambs 16 and 17 are extruded from rigid PVC. The rigid PVC that
forms the entire door assembly 16 provides the required durability and can be
easily washed and sanitized.
Referring now to Figs. 2 and 3, thereshown are detailed section views
of the door assembly of the present invention. As can be seen in Fig. 3, the
door
itself is formed from a wall panel 14 that has a width extending between a
first side
18 and a second side 20. In the preferred embodiment of the invention, the
wall
panel 14 has an overall width of approximately 36 inches, although other
widths
for the wall panel are contemplated.
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As can be seen in Fig. 3, the wall panel 14 is a monolithic structure
and includes a first face surface 22 and a second face surface 24 that create
a
generally open interior 25 and define the thickness of the wall panel 14. In
the
preferred embodiment of the invention, the wall panel 14 has a thickness of
1.75
inches, although it is contemplated that other thicknesses of the wall panel
are
possible.
As illustrated in Fig. 3, the first face surface 22 and the second face
surface 24 are joined by a series of center ribs 26 that extend across the
open
interior 25 and provide the required rigidity for the wall panel 14. Several
of the
center ribs 26 include an integrally formed extruded screw boss 28 that
extends
along the entire length of the wall panel 14. The screw boss 28 provides for a
point
of attachment for various end caps and other components, such that these
components can be secured to the top and bottom ends of a length of wall panel
14.
The wall panel 14 further includes a series of standoff ribs 30 that
extend along the entire length of the extruded wall panel 14. The standoff
ribs 30
are used to support a stiffening device, such as the wood stiffener 32
illustrated in
Fig. 3. The standoff ribs 30 space the wood stiffener 32 away from both the
first
face surface 22 and the second race surface 24 as illustrated.
Referring now to Figs. 3 and 6, both the first side 18 and the second
side 20 of the wall panel 14 include a recessed connector channel 34 having a
shape corresponding to a dovetail mortise. The connector channel 34 is defined
by
a pair of inwardly angled sidewalls 36 and a back wall 38. The connector
channel
34 extends along the entire length of the wall panel 14, which allows various
components to be slid down the length of the wall panel 14, the significance
of
which will be discussed in greater detail to follow.
Refernng back to Fig. 3, the wall panel 14 used to form the door is
mounted between a pair of vertical door jamb members 40, each of which are
positioned in contact with a support stud 42. Each of the door jamb members 40
is
formed from extruded rigid PVC and can be formed in any length desired. The
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extruded door jamb member 40 provides the required mounting and contact points
for opening and closing the door formed from the wall panel 14.
Referring now to Fig. 9, thereshown is a detailed view of the door
jamb 40. The door jamb 40 generally includes an exterior wall 44 and an inner
wall 46. The exterior wall 44 and the inner wall 46 are joined by a series of
center
ribs 48, several of which include extruded screw bosses 50. The screw bosses
50
allow various components to be selectively attached to the top and bottom ends
of
each door jamb 40.
The door jamb 40 further includes a protruding stopping section 52
that includes a stop surface 54. The stopping section 52 includes a pair of
angled
weather-strip grooves 56 that receive a portion of a rubberized weather-strip
58.
The weather-strip 58 contacts the door to provide a seal when the door is in
its
closed position.
As illustrated in Fig. 9, the inner end 60 of the door jamb member 40
includes at least one snap groove 62. The snap groove 62 is sized to receive a
mating snap 64 formed on an accessory piece, such as the door jamb extension
66
shown in Fig. 9. Door jamb extension 66 allows the width of the door jamb 40
to
be extended in situations where the support stud 42 is wider than the door j
amb
member 40, such as is shown in Fig. 3.
Referring back to Fig. 9, the outer end 68 of the door jamb member
40 also includes a snap groove 70 that receives a snap 72 formed on an
exterior
trim piece 74. The exterior trim piece provides for a smooth appearance of the
door jamb when viewed from the front. As can be seen in Fig. 4, a decorative
door
jamb mold 76 including the snap 72 can be attached to the outer end 68 of the
door
jamb member 40. The decorative door jamb molding 76 includes a tacking strip
78
that allows the molding 76 to be secured to the wall formed from the support
stud
42.
Referring back to Fig. 9, the connector channel 34 of the wall panel
14 can receive the protruding connector 80 of an end cap 82. As illustrated,
the
connector 80 has the shape of a dovetail such that the connector 80 mates with
the
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dovetail mortise shape of the connector channel 34. The end cap 82 includes a
generally flat trim portion 84 attached to the dovetail connector 80 such that
the
end cap provides a smooth, finished appearance for the side of the door when
the
end cap 82 is inserted into the connector channel 34.
In addition to receiving the end cap 82, the connector channel 34 can
receive either of the dovetail connectors 86 of the extruded panel adapter 88
shown
in Fig. 8. As can be understood in Figs. 6 and 8, when the dovetail connector
86a
of the panel adapter 88 is inserted into the connector channel 34 of the wall
panel
14, another wall panel 14 can be connected to the opposite dovetail connector
86b
of the panel adapter 88 such that successive wall panels can be attached to
one
another to form a wall structure. In addition to the panel adapter 88 shown in
Fig.
8, it is also contemplated by the inventor that various panel adapters can be
configured in accordance with the present invention. For example, a panel
adapter
in which the dovetail connectors 86 are 90° apart from each other would
form a
corner adapter, while an adapter having four dovetail connectors 86 would
allow
four panel sections 14 to be connected to each other at a common junction
point.
Additionally, it is contemplated by the inventor that numerous other angle
configurations between the dovetail connectors 86 are possible while operating
within the scope of the present invention.
Referring back to Figs. 3 and 5, the wall panel 14 that forms the door
is connected to the wood support stud 42 by a conventional hinge 90. The first
plate 91 of the hinge 90 is connected to the wall panel 14 by an extended
screw 92
that is received within the wood stiffener 32. A second screw 94 extends
through
the plate 91 and is received solely in the end cap 82 and the second side 20
of the
wall panel 14.
The opposite plate 96 of the hinge 90 is connected to the wood stud
42 by a second extended screw 98 that passes through the door jamb member 40.
A second screw 100 also passes through the door jamb member 40 and is secured
solely to the door jamb member 40.
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In the embodiment of the invention illustrated in Fig. 5, the door
j amb member 40 includes an extruded aluminum stiffener 102 extending through
the hollow interior between a pair of center ribs 48. The extruded aluminum
stiffener 102 provides additional stability for the door jamb member 40,
especially
when the door formed from the wall panel 14 is a significant height, which
increases the weight of the door.
Refernng now to Fig. 3, thereshown is a proposed configuration for a
door handle 104 used in connection with the door of the present invention. The
door handle 104 includes a pair of knobs 106 that are connected to an
activation
rod 108 including the movable plunger 110. The plunger 110 is received within
a
recess 112 formed in a latch plate 114. The latch plate 114 is mounted to the
door
jamb member 40 in a conventional manner.
As can be seen in Fig. 3, the activation rod 108 passes through an
internal bore 116 formed in the wood stiffener 118. Further, the activation
rod 10$
passes through the connector channel of the wall panel 14 and the end plate
attached to the connector channel.
Referring now to Fig. 2, thereshown is a lengthwise section view of
the door assembly and illustrates the top end 120 and the bottom end 122 of
the
wall panel 14 used to form the door illustrated in Fig. 1. The wall panel 14
can be
extruded to almost any length, depending upon the length requirement for the
door
formed from the wall panel 14.
As shown in Fig. 2, both the top end 120 and the bottom end 122 of
the wall panel 14 include a weather-strip cap 124 that closes off the open
hollow
interior of the wall panel 14. As illustrated in Fig. 2, a series of screws
126 are
received within the corresponding screw bosses 28 that are molded within the
wall
panel 14 and extend along the entire length of the wall panel 14.
As shown in Fig. 2, the extruded weather-strip cap 124 includes a
pair of channels 128 that extend along the width of the wall panel 14 and each
receive a resilient weather-strip 130. The weather-strip 130 provides a seal
between the top end 120 of the wall panel 14 and the inner wall 46 of the door
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jamb member 40. In addition to the pair of weather-strips 130, the top door
jamb
40 also includes a similar weather-strip 58 to further seal the door upon
closure.
As illustrated in Fig. 2, the bottom end 122 of the wall panel 14 that
forms the door also includes a pair of lower weather-strips 130 that engage an
extended door sill 132. Referring to Figs. 10 and 11, the door sill 132
includes a
pair of sloped, serrated surfaces 134 that angle upward to a flat top surface
136.
The flat top surface 136 includes a protruding bead 138 that defines the
center of
the door sill 132. In the preferred embodiment of the invention, the entire
door sill
132 is an extruded element formed from rigid PVC material.
Referring now to Fig. 12, thereshown is a shed 140 formed utilizing
the extruded wall panels of the present invention. The shed 140 generally
includes
a pair of sidewalls 142 and 144, a front wall 146, and a back wall (not
shown). As
illustrated in Fig. 12, the walls of the shed 140 support a roof assembly 148
inlcuding a right roof panel 149 and a left roof panel 150. The right roof
panel 149
and the left roof panel 150 are each formed from a series of wall panels 14
that are
joined together side-to-side. As shown in Fig. 12, the right and left roof
panels are
joined to define a peak 151. The opposite sides of each roof panel 149 and 150
are
supported on the spaced sidewalls 142 and 144 in a manner to be discussed in
greater detail below.
As can be seen in Fig. 12, a door assembly 10 can be formed in the
shed 140. The door assembly 10 includes a wall panel 14 that functions as the
door, which supported between the door frame formed from extruded door jamb
members. The door assembly 10 is generally identical to that shown in Figs. 1-
11.
Referring now to Fig. 13, the outer perimeter of the shed 140 is
defined by a shed base 152 that is secured to the ground. The shed base 152 is
preferably formed from extruded aluminum and includes a pair of sidewalk 154
and 156. The sidewalls 154 and 156 are spaced to receive one of the wall
panels
14 that forms the walls of the shed 140.
Refernng now to Fig. 16, each of the sidewalls is formed from a
series of wall panels 14 joined to each other by panel adapters 145. As can be
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understood in Fig. 16, the length of each wall can be selected by joining
together
the desired number of wall panels.
As can be seen in Fig. 16, a corner adapter 158 is used to join a pair
of walls at a 90° angle to define one of the corners of the shed. As
discussed
previously, the corner adapter 158 is formed from extruded rigid PVC and
includes
a pair of end connectors 160 that are received in the connector channels
formed in
each of the wall panels. In the embodiment of the invention illustrated in
Fig. 16,
an extruded aluminum stiffener 161 is positioned within the corner adapter 158
to
provide the required rigidity for the shed 140.
Refernng now to Fig. 15, thereshown is an eave connector 160 used
to support the roof on either of the sidewalk 142 or 144. As shown in Fig. 15,
the
wall panel of the sidewall 142 is received within the lower portion of the
eave
connector 160. Specifically, a pair of spaced eave sidewalls 162 and 164
receive
the sidewall~ 142.
The eave connector 160 includes a sloped panel support surface 166
that receives and supports the wall panel 14 used to construct the roof
assembly
148. The panel support surface 166 terminates with an extended lip 168 that
contacts an outer end 170 of the end portion 171 attached to the wall panel
14. The
lip 168 prevents the panel 14 from sliding off of the roof.
In addition to the eave connector 160, the roof assembly includes an
eave cover cap 172 that surrounds the combination of the eave connector 160
and
the end portion 171 to provide a smooth, decorative trim and aid in holding
the
wall panel along the eave connector 160. The eave cover cap 172 includes a top
panel 174 and an end panel 176 that combine to entrap the end 170 of the end
portion 171 in contact with the sloped panel support surface 166. A bottom
panel
178 of the eave cover cap 172 contacts the sidewall 164 of the eave connector
160
to further support the wall panel.
In addition to being supported along each of the sidewalls of the
shed, each of the wall panels that form the roof are supported at their
opposite end
180 by a peak connector 182, as illustrated in Fig. 14. The peak connector 182
is
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formed from extruded rigid PVC and generally defines a first panel receptacle
184
and a second panel receptacle 186 sized to receive the wall panels 14. The
first
and second panel receptacles 184 and 186 thus support the ends 180 of the pair
of
opposed wall panels used to form the roof assembly 148.
The peak connector further defines a hollow central opening 188 that
is positioned between the pair of panel receptacles 184 and 186. The central
opening 188 is sized to receive an aluminum stiffener 190, such as shown in
Fig.
14. The aluminum stiffener 190 provides additional rigidity for the peak of
the
roof formed in accordance with the present invention.
Although not shown in Fig. 14, the peak connector 182 is supported
on each of its ends by a support column 192, such as shown in Fig. 12. The
support column 192 aids in supporting the weight of the roof along each of the
front and back walls of the shed 140.
Various alternatives and embodiments are contemplated as being
within the scope of the following claims particularly pointing out and
distinctly
claiming the subject matter regarded as the invention.
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