Note: Descriptions are shown in the official language in which they were submitted.
CA 02505640 2005-04-28
PATIO ENCLOSURE
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001 ] This application is a completion application of co-pending United
States
Provisional Patent Application Serial No. 60/566,673, filed April 30, 2004,
the entire
disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention:
[0002] This invention relates to an enclosed structure that may be attached to
the
exterior wall of an existing or new building, such structure typically being
referred to as a
patio enclosure, sunroom, or solarium. More particularly, the invention
relates to a patio
enclosure having a high proportion of windows and a roof and constructed from
a framework
of composite members and insulating wall panels. Even more particularly, this
invention
relates to composite plastic members extruded from material having improved
thermal
characteristics and stability.
2. ~ Description of Prior Art:
[0003] Patio enclosures and sunrooms are not new to the building industry.
When
adding onto or remodeling an existing home or other structure, many people
turn to the patio
enclosure or sunroom. Such rooms are relatively easy for trained technicians
to construct and
are inexpensive when compared to other improvements that can be made to a
home, such as
remodeled bathrooms or kitchens. These enclosures have traditionally been
constructed of an
aluminum frame with windows or glass sections. Aluminum sunrooms are shaped
with
vertical walls that have a curved transition to the roof, although most may
have a marquee
roof or gable type roof.
[0004] The following United States Patents and Patent Publication illustrate
various
CA 02505640 2005-04-28
enclosures, non-metallic structural elements used in constructing these
enclosures, and the
materials used in forming the non-metallic structural elements: 5,497,594 to
Guiseppe et al.;
5,848,512 to Corm; 6,003,279 to Schneider; 6,015,611 to Deaner et al.;
6,117,924 to Brandt;
6,248,813 to Zehner; 6,412,227 to DeZen; 6,337,138 and 6,344,504 to Zehner et
al.;
6,460,309 to Schneider; and 2002/0066248 to Buhrts et al.
[0005] As discussed in Schneider US-6,003,279 and US-6,460,309, aluminum
framed
enclosures have several disadvantages. The main problem is poor thermal
efficiency. Due to
the high rate at which aluminum conducts heat, a room constructed from
aluminum cannot
stay comfortably cool in the summer, without air conditioning, or warm in the
winter, without
supplemental heating. This drawback results in dramatically increased cooling
and heating
costs. Further, a high rate of heat transfer can lead to condensation on the
interior surfaces of
the aluminum structures. Moreover, many of the windows in aluminum frame type
sunrooms
are generally installed in such a way that the windows cannot be opened and no
screens are
present.
[0006] Another disadvantage is high maintenance. Aluminum must be painted if
chipped and is easily dented. Construction of aluminum rooms is a major
disadvantage as
well. Because of the nature of the metal, the aluminum pieces must be
assembled with
external fasteners. External fasteners increase the time of assembly and
degrade the overall
aesthetics of the room.
[0007] In light of these various deficiencies, Schneider US-6,003,279
discloses
various structural members, which include reinforced and non-reinforced
polyvinyl chloride
extrusions, which are joined together at joints using hardware which cannot be
seen from
inside or outside the enclosure, thereby enhancing the aesthetic appeal of the
enclosure.
Further, Conn US-5,848,512 and Schneider US-6,460,309 disclose an I-beam that
is extruded
from plastic and configured such that the vertical spacer wall defines a
central passageway
2
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that extends between the opposite ends of the beam. Schneider US-6,460,309 is
directed to a
vinyl roofing system utilizing the channel beam to interconnect roof panels
with a roof cap.
[0008] In obviating certain of the problems associated with unwanted
condensation
and thermal conductivity, many framing enclosure designs have used a "sleeve"
approach
wherein the aluminum elements and sections are enclosed within PVC frames. A
drawback
to this approach is that the aluminum reinforcing still has to be properly
insulated from the
rest of the vinyl profile. This approach results in massive, bulky sections
with high material
costs.
[0009) A need continues for a low maintenance sunroom/patio enclosure that is
economical, has improved thermal efficiency and minimizes thermal condensation
arising
from thermal transmittance, provides sliding or double hung windows and/or
doorway, has an
aesthetic appearance, conceals connecting fasteners, and employs fastening
components that
are easy to use when erecting the enclosure.
[00010] Accordingly, a primary object of this invention is the provision of a
sunroom/patio enclosure that obtains the benefits of framing elements and
sections of
polymeric and like material, and achieves the above noted needs.
[00011 ] Another object of this invention is the provision of a sunroom/patio
enclosure
using frame elements formed of composite PVC to allow parts to have smaller
cross-sections
without a great degree of internal reinforcing.
[00012] As is known, steel has much lower conductivity to thermal loss than
aluminum, and has higher strength properties with lower cost.
[00013] Accordingly, another object of this invention is the elimination of
most if not
all aluminum components from the enclosure product, such as by replacing some
frame
connecting elements with galvanized steel.
[00014] Another object of this invention is the provision of an enclosure
structure that
3
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shows no screw heads on the inside or the outside of the enclosure room.
[0001 SJ A further object of this invention is the provision of an enclosure
structure
comprised of composite PVC to combine the properties of wood with the
maintenance free
advantages of vinyl.
SUMMARY OF THE INVENTION
[00016] Briefly described the objects of the present invention are achieved,
in a room
structure for attachment to the exterior wall of a building mounted on a
foundation adjacent
to said exterior wall, said room structure comprising an upright frame
assembly having an
upper end and formed by at least one enclosure wall and a roof structure
extending between
said exterior wall and the upper end of said frame assembly, said frame
assembly including at
least one vertically disposed support member, the improvement wherein
said support member comprises an assembly of an H-beam and a closure
member,
each said support member and H-beam being comprised of a single piece of
composite and having a like vertical height,
said H-beam being formed by a spacer wall and a pair of webs, the spacer wall
extending between the webs and disposed inwardly and between the outer edges
of the webs
wherein to form a pair of outwardly open squared-C channels, and
said closure member being formed by a pair of sidewalls and a base wall, the
sidewalls extending from opposite edges of the base wall wherein to form a
squared-C cross-
section, the closure member being snap-fittable in a friction fit into one of
the squared-C
channels of the H-beam to substantially close said channel and in a manner
that the exterior
base wall of the closure member and the edges of webs of the squared-C channel
into which
interfitted are substantially coplanar.
[00017] According to an important aspect, the H-shaped beam and C-shaped
closure
4
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member are extruded from a composite PVC plastic.
[00018] A preferred embodiment according to this invention is the provision of
a beam
structure for a patio enclosure, the beam structure comprising
a support member and a filler member, said members extending longitudinally
and each of a generally constant cross-sectional shape,
said support member having a base wall, first and second walls disposed
generally perpendicularly to the plane of said base wall, and outer end faces
disposed parallel
to the plane of said base wall, the first and second walls cooperating to
define an outwardly
open longitudinally extending channel sized to receive said filler member, and
said filler member having a base member and a pair of upstanding sidewalls
adapted to frictionally engage and form a snug snap-fit engagement with a
respective of said
first and second walls, the base member and the outer end faces forming a
generally
continuous surface following said interfitment.
[00019] According to an aspect of this embodiment, the support member
comprises a
generally H-shaped beam member and the channel thereof has a squared-C cross-
section, the
filler member has a squared-C cross-section, and the H-shaped beam member and
filler
member are extruded, or injection molded from a synthetic wood composition.
[00020] According to another aspect of this invention, the H-shaped beam
member has
a pair of flange members, each forming a respective of said outer end faces,
and the exterior
surfaces of the outer end faces and the exterior surface of the filler member
are clad with
vinyl cap stock.
[00021] Another preferred embodiment according to this invention is the
provision of
modular wall for a patio enclosure formed as an add-on extension to an
existing structure
supported on the ground and having framing structure for at least one of a
window or door,
the modular wall comprising:
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a longitudinally extending upper and lower track beam, the lower track beam
being supported on the ground,
a pair of vertically extending corner posts, each post having an upper and
lower end portion and forming at least one outwardly open channel,
at least one vertically extending H-beam disposed between the posts and
defining a pair of separated wall sections, the H-beam having an upper and
lower end portion
and forming a pair of opposed outwardly open channels,
[00022] said wall section including a lower and an upper C-shaped cross-beam,
a
lower and an upper wall panel, and the framing structure sandwiched between
said wall
panels, said cross-beam having opposite longitudinal ends, a base having an
outer surface,
and an outwardly open channel, said lower and upper wall panel having,
respectively, upper
and lower edges engaged with the outer surface of a respective cross-beam,
lower and upper
edges interfitted within the channel of said lower and upper track beam, and
vertically
disposed side edges interfitted within the channels of said corner posts and H-
beam,
[00023) first means for positioning and securing the lower end portions to the
lower
track beam and the upper end portions to the upper track beam, wherein said
track beams are
disposed in generally parallel horizontal relation, said corner posts are
secured and positioned
at the opposite longitudinal ends of the lower track beam, and the channels of
said H-beam
and said corner posts are facing one another,
[00024] second means for enclosing the outwardly open channels of said corner
posts
and said H-beam wherein to cover said first means, at least in part, and
[00025] third means for positioning and securing the opposite ends of the
cross-beams
to said corner post and H-beam.
[00026) According this embodiment of the invention, the second means comprises
a
filler beam of predetermined cross-section, which filler beam is frictionally
interfit in a snug-
6
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fit into the respective channel to form an exterior surface that appears to be
unitary.
[00027] Further, and according to an important aspect of this embodiment, the
upper
and lower track beams, the corner posts, the H-beam, the cross-beams, and the
filler beam are
extruded or injection molded from a synthetic wood PVC composition and have
exterior
surfaces selectively clad with vinyl cap stock.
[00028] Another preferred embodiment according to this invention is the
provision of a
wall joint for a patio enclosure, which enclosure is formed as an add-on
extension to an
existing structure, supported on the ground, and has framing structure for at
least one of a
window or door, the wall joint comprising:
a first pair of longitudinally extending upper and lower track beams and a
second pair of longitudinally extending upper and lower track beams, the first
pair of track
beams being disposed at a right angle to the second pair of track beams and
each said lower
track beam being supported on the ground,
a vertically extending corner post, said post having a lower and upper end
portion and forming outwardly open first and second channels, the channels
being disposed at
right angles to one another,
a vertically extending first and second wall section, each said wall section
including upper and lower end portions that are juxtaposable with and extend
along a
respective pair of said lower and upper track beams, said first wall section
having a first
vertical edge that is juxtaposable with the first channel of said corner post
and at least one
framing structure, and said second wall section having a second vertical edge
that is
juxtaposable with the second channel of said corner post and at least one
framing structure,
first means for securing and positioning the lower end portion of said corner
post and said lower track beams to said support wherein the first and second
channels are
juxtaposed with the ends of the lower track beams,
7
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second means for securing and positioning the upper end portion of said
corner post to said upper track beams,
third means for enclosing the outwardly open first and second channels of said
corner post wherein to cover each said first and second means, at least in
part, and
fourth means for connecting the wall sections to the track beams and said
corner post.
[00029] Another preferred embodiment according to this invention is the
provision of a
new and improved extruded article, said article produced by extruding a
cellulosic inorganic
filled plastic composite, the composite consisting of a bound together mixture
of polyvinyl
chloride, a cellulosic material, selected from sawdust, finely pulverized
dried wood, and
wood flour, baking flour, and a binder.
[00030] A further preferred embodiment according to this invention comprises a
kit for
constructing an enclosure to the exterior wall of an existing structure, said
kit comprising:
a plurality of wall panels of predetermined height, width, and thickness,
framing structure, such as for providing at least one window or door, as
required,
a plurality of elongated track beams, the track beams forming upper and lower
end caps of front and side walls formed by the kit and each having a central
track,
a plurality of vertical uprights of H-shaped cross section, the H-beam forming
two opposed outwardly opening C-shaped channels,
a plurality of C-shaped cross-beams, the cross-beam having an outwardly open
C-shaped channel,
a plurality of corner posts of generally square cross section and forming two
outwardly opening channels of squared-C cross-section,
means for positioning and securing the wall panels, framing structure, track
8
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beams, H-beams, C-shaped cross-beams, and corner posts to one another and the
support
structure, and
a plurality of closure members of squared-C cross-section, the closure
members being snap-fittable into a respective C-shaped channel provided in the
H-beam and
corner post, wherein to close the channel and form a unitary appearing
exterior
[00031 ] Preferably, and according to this embodiment of the invention the
track
beams, H-beam, corner-post, C-shaped cross-beam, and closure members of the
kit are
extruded or injection molded of a composite PVC, with predetermined exterior
surfaces of
each clad with a protective surface of vinyl.
BRIEF DESCRIPTION OF THE DRAWINGS
[00032] These and other objects, advantages and features of the invention will
become
apparent from the following description taken in conjunction with the
accompanying
drawings, which illustrate specific embodiments of the invention. In the
drawings:
[00033] FIG. 1 is an exploded perspective view of a patio enclosure positioned
for
assembly using a variety of frame members and structural elements according to
this
invention;
[00034] FIGS lA - lE are cross-sectional views of structural elements used in
assembling the enclosure of FIG. 1;
[00035] FIG. 2 is an elevation view showing the front side of the patio
enclosure of
FIG. l, following assembly to an exterior wall of a house;
[00036] FIG. 3 is an elevation view showing the left side of the patio
encloswe of FIG.
2;
[00037] FIG. 4 is an elevation view showing the right side of the patio
enclosure of
FIG. 2;
[00038] FIG. S is a section view of the front wall taken along line 5-5 of
FIG. 2
9
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showing an H-beam disposed vertically, C-shaped upper and lower track members
disposed
horizontally, L-shaped flanges securing the opposite ends of the beam to the
track members,
and connections that extend along the top and bottom ends of the front wall of
the enclosure
and connect the upper track member to the lower front end of the roof
structure and the lower
track member to the ground structure;
[00039] FIG. 6 is a section view of the front wall taken along line 6-6 of
FIG. 2
showing a C-shaped channel member disposed horizontally, the bottom edge of a
window
channel supported on the channel member, the upper and lower edges of a front
wall panel
received in the channel member and lower track member, and a connection, which
extends
along and connects the front wall of the enclosure to the ground structure;
[00040) FIG. 7 is a section view of the front wall taken along line 7-7 of
FIG. 2
showing the upper track member, the top edge of the window channel supporting
a channel
member, the upper and lower edges of a the front wall panel received in the
upper track
member and the channel member, and a the connection between the upper track
member and
the roof structure;
[00041 ] FIG. 8 is a section view of the right side wall taken along line 8-8
of FIG. 4
showing a channel member, the top edge of a window channel supporting the
channel
member, the upper and lower edges of a right side wall panel received in the
upper and
channel members, and a connection between the upper track member and the roof
structure,
which extends along and between the lower front and upper rearward end of the
roof
structure of the enclosure;
[00042] FIG. 9 is a section view of the front wall taken along line 9-9 of
FIG. 2
showing two window channels separated by an H-beam, and a pair of L-shaped
flanges and a
pair of E-shaped filler channels interfitted into oppositely facing outwardly
open channels of
the H-beam, the flanges for connecting the H-beam to the a track member, and
thus to the
CA 02505640 2005-04-28
ground structure;
[00043) FIG. 10 is a section view of the front wall taken along line 10-10 of
FIG. 2
showing opposite edges of front wall panels and an L-shaped flange for
connecting the beam
to the ground structure interfitted into oppositely facing outwardly open
channels of the H-
beam;
[00044] FIG. 11 is a section view of the right side wall taken along line 11-1
I of FIG 4
showing a C-shaped track member connected to the exterior wall, a window
channel, and an
E-shaped filler and an L-shaped flange interfitted into an outwardly open
channel of the track
member;
[00045) FIG. 12 is a section view of the right side wall taken along line 12-
12 of FIG.
4 showing a track member disposed vertically and connected to the exterior
wall and a
vertical edge portion of an enclosure panel interfitted into the track member;
[00046] FICi. 13 is a section view of the left side wall taken along line 13-
13 of FIG. 3
showing a C-shaped track member disposed vertically and connected to the
exterior wall, a
C-shaped track disposed vertically and connected by an L-shaped flange to the
lower track,
and thus to the ground structure, and a wall panel having opposite vertical
edges interfitted
into opposed channels of the track members; and
[00047] FIG. 14 is a section view taken along line 14-14 of FIG. 3 showing a
box-
shaped corner post having opposed channels for connecting the left and front
wall panels to
one another, and L-shaped flanges for connecting the corner post to a track
member of the
enclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[00048] Referring to FIGS I and 2 - 4 there is shown an exemplary patio
enclosure,
generally indicated at 10, constructed according to the present invention. The
enclosure 10 is
supported from below by a load-bearing substrate 12 and laterally by the
exterior wall 14 of
II
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an existing structure, such as a house (not shown). The load bearing substrate
12 may be a
concrete slab, wood decking, or the like.
[00049) As shown in FIG. 1, the enclosure 10 comprises a front wall 16, a pair
of
lateral side walls 18 and 20, and a sloping roof 22. The walls 16, 18 and 20
project upwardly
from the substrate 12 where they are joined to the roof 22. The sidewalls 18
and 20 have
opposite lateral ends connected, respectively, to the house and a respective
lateral end of the
front wall 16.
[00050] The walls and roof of the enclosure 10 are formed by a framework of
joined
horizontal and vertical structwal members, such as structural filler wall
panels 24 and roof
panels 26, multiple pairs of sliding glass windows 28, framed screens 30 for
each pair of
windows (one shown), and an optional conventional door assembly 32.
[00051 ] Each wall panel 24 is generally rectangularly shaped and has a
central body
24a of polymeric material, such as foam, and outer layers 24b and 24c wherein
to provide a
wall panel element of generally uniform thickness. The thickness of the wall
panel 24 is such
that the lateral edges thereof may be interFtted into the squared-C channel of
a structural
element according to this invention (described in detail below). Preferably,
both of the layers
24b and 24c are clad with vinyl.
[00052] Preferably and according to this invention, certain of the structural
elements
used in this assembly are shown and identified on FIGS. IA - lE. These
structural elements
include a corner post 34, a post or H-beam 36, a base track 38, a cross-beam
channel 40, and
a filler 44. As will be discussed below, nails, screws and like threaded
fasteners, flanges and
like connecting elements are used to connect the structural elements together
and form
modular wall portions and the patio enclosure 10.
[00053] Preferably and according to this invention, each of these structural
elements
are comprised of a composite PVC material and extruded into the desired cross-
section and
12
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length. Subsequent to extrusion, a vinyl surface is clad to the exterior
surfaces of the
structural elements. The resulting element is sometimes referred to a
composite PVC
element. The structural elements made from the composite PVC material are
generally
stronger than wood, metal, or vinyl, has no adverse heat conduction, and has
the durability of
vinyl. Although extrusion is a preferable method, these elements may be
injection molded.
[00054] According to one aspect, the composite material is comprised of a
bound
together mixture of cellulosic material (esp. sawdust or like finely
pulverized dried wood,
such as wood flour) and baking flour (e.g., the fine powdery foodstuff
obtained by grinding
and sifting the meal of a grain, especially wheat, used chiefly in baking).
Suitable woods for
sawdust are resin-free softwoods such as pine, fir and spruce, and to a lesser
extent,
hardwoods. The percentage of sawdust to baking flour, measured by weight or
volume, and a
binder and/or mixer ingredient used to hold the composition together is
determined, in part,
on a cross-section property of the structural element that is desired (i.e.,
thickness and area
moment of inertia of the cross-section).
[00055] Referring to FIG. IA, the corner post 34 is box-like, in cross-
section, axially
elongated, and formed by walls 46, 48, 50 and 52. The walls intersect with one
another to
form a square central opening 54 and outwardly open squared-C shaped channels
56 and 58
for receiving the lateral edge of a wall panel 24. The walls 46 and 52 form an
exterior corner
with the outwardly facing surfaces 46a and 52a thereof clad with vinyl.
[00056] Refernng to FIG. 1 B, the post or H-beam 36 is axially elongated and
includes
a central body 60 and a pair of transverse flanges 62 and 64, which define
oppositely facing
squared-C shaped channels 63 and 65. The exterior surfaces 62a and 64a of the
flanges 62
and 64 are clad with vinyl and the central body 60 is hollow and defines a
central rectanguIar-
shaped passageway 66.
13
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[00057] Referring to FIG. 1C, the base track 38 is axially extending and
includes a flat
base member 68 having opposite lateral edges 68a and 68b and a pair of opposed
L-shaped
arms 70 and 72, the arms being spaced apart and defining a track 73
therebetween. The L-
shaped arms 70 and 72 are generally perpendicular to the plane of the base
member 68 and
define opposed squared-C shaped channels 70a and 72a that are in faced
relation and
communicate with the central track 73. The arm 70 extends along and upstands
from the
lateral edge 68a of the base member 68. The arm 72 extends along and upstands
from the
base member 68 at a location inwardly of the lateral edge 68b of the base
member 68 wherein
to define an offset base portion 69. The exterior surfaces 70b, 72b, and 69a,
respectively, of
the upstanding arms 70 and 72 and the offset base portion 69 are clad with
vinyl.
[00058] Referring to FIG. I D, the cross-beam channel 40 is axially extending
and
forms a generally squared-C shape in cross-section. The channel 40 includes a
base member
76 and a pair of opposed upstanding legs 78 wherein to define a squared-C
shaped channel 80
having a width adapted to receive the lateral edge of a wall panel 24
interfitted therewithin.
The base member 76 is hollow and defines a central rectangular shaped
passageway 77. The
exterior surface 76a and 78a, respectively, of the base member 76 and the legs
78 are clad
with vinyl.
[00059] Refernng to FIG. 1 E, the filler 44 is axially extending and generally
E-shaped
in cross-section. The filler 44 includes a flat base 82 and three upstanding
legs 84, 86, and
88, the legs 84 and 88 being outer legs and upstanding from the opposite
respective lateral
edges of the filler, and the leg 86 being a central leg upstanding from a
central location of the
base 82. The legs 84 and 86, and the legs 86 and 88, respectively, cooperate
to form two
squared-C shaped channels 85 and 87. The exterior surface 82a of the central
base member
80 is clad with vinyl.
14
CA 02505640 2005-04-28
[00060] As shown in FIGS. l and 2-4, the front, left, and right walls 16, 18
and 20 of
the enclosure 10 are assembled by he formed by various of the structural
elements 36, 38, 40,
42, and 44 and wall panels 24. As shown in FIG. 2, the front wall 16 is
defined by and
extends between two box-beams 34 and includes two H-beams 36 wherein to define
three
modular wall portions, each portion including a window framing 28 and wall
panels 16. As
shown in FIGS. 3 and 4, the left and right side walls 18 and 20 are defined by
and extend
between a box beam 34 and a base track 38. The right side wall 20 includes an
H-beam 36
and defines two modular wall portions and the left side wall 18 includes
optional door
framing 32.
[00061 ] As shown in FIG. 5, the modular wall portion of the front wall 16
includes
elongated lower and upper base tracks 38, denoted as 38a and 38b and disposed
horizontally,
and an H-beam 36 disposed vertically. L-shaped flanges 90 are secured at
predetermined
locations along the lower and upper base tracks 38a and 38b and serve to
properly space and
position the H-beams 36 and the corner box-beams 34 in a manner to receive
wall panels 24,
or door or window framing 28 and 32.
[00062] The lower base track 38a is positioned atop the substrate 12 and
secured
thereto by an L-shaped flange 90 and at least one threaded fastener 92. The
flange 90 has
opposite legs 90a and 90b and is nested in the track 73 formed between the
opposed L-shaped
arms 70 and 72 of the base member 68 with the flange leg 90a seated atop the
base member
68 of the base track 38a and the flange leg 90b extending vertically upwardly
from the base
track. Fasteners 92 extend through the flange leg 90a, the base member 68, and
into the
substrate 12.
[00063] The upper track 38b forms the upward vertical extension of the front
wall 24
and is secured, at least in part, to the upward vertical extension of the H-
beam 36. As with
the track 38a, the upper track 38b is provided with positioning flanges 90.
CA 02505640 2005-04-28
[00064] The lower and upper ends 36a and 36b of the H-beam 36 are nested into
a
respective track 73 formed between the opposed L-shaped arms of each
respective track 38a
and 38b. So positioned by the flanges 90 secured to the lower and upper tracks
38a and 38b,
the flange leg 90b extending upwardly from the lower track 38a is threadably
secured to the
lower end portion of the H-beam, and the flange leg 90b extending downwardly
from the
upper track 38b is threadably secured to the upper end portion of the H-beam.
[00065] A wall panel 24 is inserted downwardly into the opposed squared-C
channels
of successive H-beams 36 or corner post 34 and H-beam 36. As can be seen in
FIG. 5, the
protective outer layers 24b and 24c of the panel 24 are generally coextensive
(i.e., flush) with
the outward extension of the flanges 62 and 64 of the H-beam 36.
[00066] The upper track 38b forms a closure cap and support for a forward
lower front
end of the roof structure 22. To provide support and sealing, an axially
elongated, generally
cylindrical strand 94 of elastomeric material is supported atop the upper
track 38b, on the
extended base portion 74 thereof, and supports and moisture seals the roof
structure 22 of the
enclosure 10.
[00067] As shown in FIG. 6, a cross-beam channel 40 is interfitted onto and
supported
atop the upper lateral horizontally extending edge of the wall panel 24.
Further, window
framing 28 is thereafter supported atop the cross-beam channel 40.
[00068] As shown in FIG. 7, a cross-beam channel 40 is inte~tted onto the
lower
lateral horizontally extending edge of the wall panel 24. Further, window
framing 28 is
thereafter abutted against the cross-beam channel 40. In a manner described in
connection
with FIG. 5, the upper track 38b and strand 94 are shown in relation to the
roof structure 22.
[00069] As shown in FIG. 8, the upper track 38b of the right wall 20 is shown
supporting the roof structure 22_ The right wall 22 includes an upper track
38b, a wall panel
24, and window framing 28. Because the upper end of the right wall 20 angles
upwardly and
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CA 02505640 2005-04-28
is supporting relation with the bottom surface of the roof structure 22, the
support strand 94 is
not needed. Further, the base portion 74 extends in a direction outwardly of
the enclosure 10.
[00070] As shown in FIG. 9, an H-beam 36 is shown separating two window
framing
sections 28, and L-shaped flanges 90 are connected to opposite sides of the
central body 60
extending between the flanges 62 and 64 of the H-beam. Importantly, an E-
shaped filler 44 is
inserted into each of the two opposed squared-C channels 63 and 65 of the H-
beam.
[00071 ] According to this invention, the cross-sections of the filler 44 and
the squared-
C channels 63 and 65 of the H-beam are such that the filler 44 forms, with the
flanges and
channels of the H-beam, a closure that makes the beam and filler elements
appear as one
unitary structure. That is, the base surface 82a of the filler 44 and the
surfaces formed by the
lateral edges of the respective flanges 62 and 64 are substantially
coextensive with one
another. The interfitment between the outer legs 84 and 88 of the filler 44
and the interior
facing walls of the flanges 62 and 64 results in a snug frictional snap-fit
interengegement.
[00072] As shown in FIG. 10, the opposed squared-C channels 63 and 65 of an H-
beam 36 are shown receiving opposite respective lateral vertical edges of a
respective pair of
panels 24, and a flange 90 positioning the H-beam 36.
[00073] As shown in FIG. 11, a track 38 is disposed vertically and connected
to the
existing structure 14, and window framing 28 of the left side wall 18 is shown
relative to the
track.
[00074] Further and according to this invention, the cross-sections of a
filler 44 and the
central track 73 of a base track 38 are such that the filler 44 forms, with
the central track 73, a
closure that makes the two elements appear as one unitary structure. The
interfitment
between the outer legs 84 and 88 of the filler 44 and the interior facing ends
of the L-shaped
arms 70 and 72 of the base track 38 results in a snug snap-fit frictional
interengagement.
17
CA 02505640 2005-04-28
[00075] As shown in FIG. 12, a base track 38 is threadably fastened to the
exterior
wall 14 and the vertical lateral edge of a wall panel 24 is interfitted within
the track 73
formed between the opposed L-shaped arms 70 and 72 of the base track 38.
[00076] As shown in FIG. 13, a base track 38, a wall panel 24, and -a cross-
beam
channel 40 extend vertically upwardly from their connection to a horizontally
extending
lower base track (not shown). The opposite lateral vertically disposed edges
of the wall panel
24 are interfitted within the central track 73 and squared-C channel 80 formed
by the
vertically disposed base track 38 and cross-beam channel 40. A flange 90
positions and
secures the lower end of the cross-beam channel 40 relative to the lower base
track. Further,
the cross-beam channel 40 positions associated window framing 28.
[00077] As shown in FIG. 14, a corner post 34 connects the vertical edges of
the left
and front walls 18 and 20. The corner post 34 extends vertically upwardly from
the substrate
12 and is connected to two base tracks 38a, the base tracks extending
horizontally along the
substrate and at right angles to one another. The two base tracks 38a are
connected to the
substrate 12 by L-shaped flanges 90 in a manner described above. One L-shaped
flange 90 is
disposed in one base track 38a and has a vertical leg 90a received in the
squared-C channel
56 and threadably fastened to the wall 48 of the corner post beam. The other L-
shaped flange
90 is disposed in the other base track 38a and has a vertical leg 90a received
in the squared-C
channel 58 and threadably fastened to the wall SO of the corner post beam.
[00078] An E-shaped filler beam 44 is snugly interfitted within the squared-C
channels
56 and 58 wherein to provide the corner post 34 with a clean aesthetic
appearance.
[00079] As shown in FIG. I, the roof 22 is generally rectangularly shaped,
angles
downwardly from the exterior wall 14, and is generally coextensive with the
front and side
walls 16, 18 and 20 of the enclosure 10. The roof structure includes severally
generally
rectangularly shaped roof panels 26, a rearward channel bracket 98, a forward
channel
18
CA 02505640 2005-04-28
bracket 100, left and right end brackets 102 and 104, and a plurality of H-
beams 36. The roof
panels 26 are as described for the wall panels 24. Further, the channels 98
and 100 and end
brackets 102 and 104 are comprised of a composite PVC, as described herein
above.
[00080] The rearward channel bracket 98 is mounted to the exterior wall 14 and
has an
outwardly open channel 98a adapted to receive rearward lateral edges of the
roof panels 26
and rearward end portions of the H-beams 36.
[00081 ] The forward channel bracket I 00 has an outwardly open channel 100a
adapted
to receive forward lateral edges of the roof panels 26 and forward end
portions of the H-
beams 36. Further, the channel bracket 100 includes an upwardly open channel
100b which
forms a gutter or trough for directing water from the roof.
[00082] The left and right end brackets 102 ands 104 have outwardly open
channels
102a and 104a, respectively, for receiving the lateral edge of a roof panel
26.
[00083] As assembled, the rear channel 98 is connected to the exterior wall
14. The
rectangular roof panels 26 have their opposite longitudinal edge portions
interfitted within the
channel 63 and 65 of a respective H-beam 36, or left and right end bracket 100
and 102, and
their opposite lateral edges ends interfitted within a channel 98a and I OOa
in the rearward and
forward channel brackets 98 and 100. The opposite ends of the channel brackets
98 and 100
are connected to the opposite ends of the left and right end brackets 102 and
104.
[00084] As contemplated herein, the patio enclosure 10 may be advantageously
supplied to the user in kit form, ready to go and for assembly to an existing
structure. The kit
for constructing an enclosure to the exterior wall of an existing structure
would generally
comprise the various structural elements as described in detail herein above.
[00085] In particular, the kit would comprise a plurality of wall panels 24 of
predetermined height, width, and thickness, framing structure 28 and 32 for at
least one
window or door, a plurality of elongated track beams 38, the track beams
forming upper and
19
CA 02505640 2005-04-28
lower end caps of front and side walls 16, 18 and 20 formed by the kit, a
plurality of vertical
uprights 36 of H-shaped cross section, a plurality of corner posts 34, a
plurality of C-shaped
cross-beams 40, a plurality of closure members 44 of squared-C cross-section,
the closure
members being snap-fittable into a respective C-shaped channel provided in the
H-beam and
corner post, and fasteners 90 and 92 for positioning and securing the wall
panels, framing
structure, track beams, H-beams, corner posts, C-shaped cross-beams, and
closure members
to one another and the support structure.
[00086] Preferably, and according to this embodiment of the invention, the
track
beams, H-beam, corner-post, C-shaped cross-beam, and closure members of the
kit are
extruded or injection molded of a composite PVC, with predetermined exterior
surfaces clad
with a vinyl.
