Note: Descriptions are shown in the official language in which they were submitted.
CA 02873353 2014-12-05
[00011VENT1LATED STRUCTURAL PANELS AND METHOD OF CONSTRUCTION
WITH VENTILATED STRUCTURAL PANELS
[0002] PRIORITY
[0003] This Application claims priority from United States patent
application serial
no. 141099,100 filed December 6, 2013.
[0004] FIELD OF THE INVENTION
[0005] Residential and commercial sheathing for roofs, walls, floors, and
ceilings.
[0006] BACKGROUND OF THE INVENTION
[0007] Sheathing is an essential component of any residential or
commercial
structure and provides structural support for roofs, walls and floors, as well
as
providing a surface of sufficient thickness and strength for the attachment of
roofing
materials such as asphalt shingles and metal roofing, siding materials such as
wood
clapboards or vinyl siding and flooring finishes such as tile, wood, hardwood,
laminates, vinyls or carpets and the like.
[0008] Sheathing has traditionally been supplied in 4' x 8' sheets, made
of plywood
or OSB, which provide a desirable modular size that can be handled by one
worker.
The means of attachment depends on the function, thickness and strength
requirements of the application and may include mechanical fasteners such as
nails
or staples and/or adhesives. Roofs, walls, and flooring use sheets of similar
sizes,
though varied thickness.
[0009] Complex, costly, and non-commercially feasible systems have been
proposed
to incorporate in some manner ventilation systems into sheathing, but they
lack the
structural strength and other benefits of the present invention.
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[0010] SUMMARY OF THE INVENTION
[0011] Wherefore, it is an object of the present invention to overcome
the above
mentioned shortcomings and drawbacks associated with the prior art by
providing
a ventilated structural panel that allows for ventilation out of and
throughout a
structure, while simultaneously providing a panel of substantially increased
strength,
formed of readily available construction materials, for small additional cost.
[0012j Another object of the present invention is to provide a
ventilated structural
panel comprising a first sheet, having edges that define a horizontal axis
with a first
horizontal edge and a second horizontal edge, and vertical axis with a first
vertical
edge and a second vertical edge. The panel additionally comprises a second
sheet
being of substantially the same planar dimensions as the first sheet and
having
edges that define a horizontal axis and vertical axis, with a first horizontal
edge and
a second horizontal edge and a first vertical edge and a second vertical edge;
the
first and second sheet being parallel in plane and preferably matched in at
least one
of the vertical axis and the horizontal axis. A plurality of spacing
structural elements
fixedly attaches the first sheet to the second sheet, such that the strength
of the
combined panel is multiple times greater than the combined individual strength
of
the first and second sheet. The ventilated structural panel can be at least
semi-
permeable to the passage of gases and liquids and the first or bottom sheet of
the
panel could have one or more perforations.
[0013] The invention is an interlocking construction panel of the same
size and
approximate weight of conventional sheathing products that incorporates
integral
ventilation into the structure. The invention may be used as a conventional
sheathing
and is attached with the same mechanical methods of nailing and/or adhesives.
It
is cut and fitted in the same manner. It interlocks to provide continuity of
strength
and ventilation.
[0014] The panel is engineered such that it provides the same or
superior strength
of conventional methods of providing construction strength and ventilation,
with
fewer materials. The materials involved in the construction of the panel are
relatively
inexpensive and readily available.
[0015] The panels facilitate the use of a wide variety of insulation
possibilities without
the need for special consideration for ventilation, since the ventilation is
integral with
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the panels. This is useful for common fiberglass as well as blown products
such as
fiberglass, Rockwool, cellulose and other products. This is especially useful
for the
new high performance spray foam expanding insulations that are becoming
popular
because of their high energy efficient performance and ability to seal
infiltration, as
the foams can break, plug or destroy conventional foam, plastic, or cardboard
ventilation products, or intrude into the seams.
[0016] The panels could be combined with a multitude of construction
materials and
methods in the same way conventional sheathing is used today. The panels could
be used with conventional soffit and ridge vents by cutting the sheathing on
the
panels for access to the ventilation cavity. Drip edges would have to have an
extended leg to cover the side ventilation or it could be blocked with
conventional
trim.
[0017] The panel may be constructed sheets of commonly available 4' x 8'
sheathing
of a thickness determined by structural and roof fastening requirements, but
may
preferably vary from 1/4" to 1 Y2" in thickness, and more preferably vary from
3/8" to
3/4" in thickness. The top and bottom sheets may also vary in thickness.
[0018] The two sheets are attached to each other via the spacing structural
elements, with adhesive and/or mechanical means such as nailing, stapling,
screwing or machine impressed metal connections, so as to provide for the
transfer
of forces.
[0019] In essence, the two sheets function as the top and bottom chords of
a truss
or "1" beam providing superior strength, load carrying capacity, and
resistance to
deflection (stiffness). As a result, rafter or stud or purloin spacing may be
increased
where these panels are used, which would reduce material requirements,
allowing
the elimination of rafters and trusses with the greater spacing.
[0020] The spacing structural elements may protrude beyond two contiguous
edges
of the panel, and the spacing structural elements may be chamfered to enhance
interlocking with adjacent panels. The spacing structural elements would
likewise be
indented on the two opposite contiguous edges.
100211 Another embodiment of the invention is a panel comprised of two
sheets of
the same size (i.e., same area, but perhaps different thicknesses) connected
to each
other with a matrix of crossed spacing structural elements such that the
combined
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entity is one structural panel. Ideally, the panel is the same size as
conventional
building sheathing, generally 4' x 8', but can be of any size or thickness.
The sheets
are connected so as to be are parallel in plane and matched in the vertical
axis, one
on top of the other, such that they can be used in place of traditional
sheathing
materials currently used in building construction such as plywood sheathing,
05B
sheathing and other composite sheathing materials.
[0022] In one embodiment, the panel includes a first and a second 4' x
8' sheet of
plywood, Oriented Strand Board (05B), or a composite board of wood and/or
plastic, each sheet having a thickness of Yi" to 3/4" depending on the
application.
Roofs would usually consist of the two sheets measuring ''/1" to 5/8" in
thickness,
depending on strength and span requirements and shingle attachment
requirements,
and whether the shingles are attached by staples or nails. Wall sheathing
sheet
thickness would also be of 1/4" to 1/2" thickness depending on strength
requirements.
The top wear layer of the flooring panel will usually have a 1/2" to 3/4"
finish layer
depending on strength requirements and floor covering.
[0023] Blocks
may be used as the as the spacing structural elements, spacing the
sheets ideally 1W from each other. Blocks of a preferably of square or
rectangular
form, but the blocks could be of any shape or size, including circular, oval,
regular
polygons, and irregular shapes. The spacing can vary depending on the
application
and ventilation requirements ¨ more spacing not only enhances ventilation and
potentially increases the strength of the assembly, but would also require
closer
spacing of the blocks or spacers. While panels constructed with blocks would
not
have the degree of added strength as panels constructed of elongated members
(discussed below), panels constructed of blocks would potentially be less
expensive,
and provide sufficient increased strength for construction with conventional
16 or 24
inch spaced of stud, rafter, truss, or joist is used.
[0024] The
blocks are generally spaced from 1 to 12 times their own width apart
horizontally and vertically. The specific spacing would depend on the sheet
thickness and strength requirements. Blocks were found to only increase the
strength of the panel, over the combined individual strength of the separate
sheets
comprising the panel, by approximately one half the amount of increase as
panels
utilizing rectangular shaped elongated members. But, using blocks does offer
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additional construction possibilities over rectangular elongated members dye
to the
increased contagious space inside a panel offered by using blocks compared to
using a matrix of elongated members. The blocks can be oriented on the same
axis
of the sheets or arranged on an angle of preferably 45 ; but other
orientations, such
as 30' or 60 , are possible depending on the application. The angled
orientation
strengthens the plywood or OSB assembly.
[0025] Another embodiment of the invention uses spacing
structural elements
consisting of a matrix of rectangular shaped elongated members, preferably
comprised of wood members with a square cross section, arranged in layers,
each
layer oriented perpendicular to the next, and each layer interconnected to
each
adjacent layer or adjacent sheet with mechanical means and/or adhesives. The
individual elongated members would ideally be of 3/4" x 3/4", but could be
larger or
smaller. The individual elongated members would ideally be long enough to
stretch
from one edge of a sheet to another this required length varying depending on
the
orientation of the elongated member.
[0026] The individual elongated members would be aligned in layers and
spaced,
parallel, apart from one another preferably between Ito 18 times the thickness
of
the elongated member, or 3/4" to 13.5 inches for elongated members with cross
sections measuring 3/4" x 3/4", and more preferably between 5 and 16 times the
thickness of the elongated member, and most preferably between 8 and 12 times
= the thickness of the elongated member. In another embodiment, each
elongated
member preferably measures between 0.25 and 1.50 inches in height and between
0.25 and 1.50 inches in width, more preferably measures between 0.5 and 1.0
inches in height and between 0.5 and 1.0 inches in width, and most preferably
measures between 0.7 and 0.8 inches in height and between 0,7 and 0.8 inches
in
width. The matrix of elongated members could consist of two layers
perpendicular
to each other or of multiple successive perpendicular layers. The matrix can
be
attached to the sheets either parallel to the sheet axis or on an angle. If an
angular
orientation is used, the elongated members will be ideally oriented 45 to
each axis
of both sheets, but other orientations such as 30 or 60'i are possible
depending on
the application. The length of the elongated members would be of a length that
they
stretched from a first edge of a first sheet, to a second edge of the first
sheet.
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Chamfered elongated members would preferably measure the "edge to edge" length
of a sheet, but would be shifted in the direction of the chamfered end. This
would
allow for the terminal chamfered end of a given elongated member to extend
into a
mating indented end on an abutting panel, while simultaneously allowing room
for
a chamfered end on an opposing abutting panel to mate with the indented end of
the
given elongated member. For example, chamfered mating elongated members
would measure 48 inches and 96 inches in an orientation parallel to the sheet
axis,
and chamfered mating elongated members with a 45 orientation would measure
approximately 69 inches or 137 inches respectively at the greatest
measurements.
[0027] In another embodiment, the indented end of an elongated member
can have
a concave face that will accept all or a portion of the chamfered end of a
mating
elongated member. In such an embodiment, the total length of the elongated
member would preferably be extended by the length in which the chamfered end
recesses within the concave portion of the indented end. In the
manufacturing
of the panels, the elongated members may initially be secured to the sheets at
lengths greater then required, and then be trimmed to finished length at a
later point
in the manufacturing process.
[0028] The spacing structural elements can also be constructed of
elongated
members comprised of a plurality of plywood veneers, each veneer being
typically
1/8" thick. This plywood matrix would be built up by multiple layers of
veneered
elongated members, each veneered elongated member being ideally 1/2" to 3/4"
thick
and spaced from Yz" to 4" apart. The plywood matrix would consist of a first
layer of
similarly shaped and parallel aligned veneered elongated members, followed by
one
or more additional layers laid perpendicular to the first and/or immediately
preceding
layer, until a multi-layer plywood matrix of desired thickness is assembled.
The
veneered elongated members would be attached with adhesives. The resulting
plywood matrix can be attached to the sheets either parallel to the sheet axis
or on
an angle. If an angular orientation is used, the veneered elongated members
will be
ideally oriented 45' to each axis of both sheets, but other orientations such
as 30'
or 60 are possible. The length of the veneered elongated members would be
similar to that of the non- veneered elongated members above depending,
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depending on the angle of the orientation of the members to the axis of the
sheets,
and whether or not the veneered elongated members were chamfered.
[00291 in all cases, including spacing blocks and elongated members,
the spacing
structural elements can protrude on two contiguous edges and be chamfered to
enhance interlocking with adjacent panels. The spacing structural elements can
be
similarly mating ly indented on the two opposite contiguous edges. The
extension is
normally less than or equal to 1 inch and ideally between 1/2." to 3.4".
Additionally, the
elongation and indentation may be modified to provide for both contiguous
mating
of adjacent panels and a spacing gap between adjacent panels of between 0,0625
inches and 0.25 inches. For example, the elongated members length could be
increased by, for example, 1/8 inch, orthe indentation could be reduced by 1/8
inch,
or both, such that the elongated members may mating abut, but the neighboring
first
and second sheets would be spaced between 0.0625 inches and 0.25 inches apart.
[00301 The panels with all attributes herein described can also be
manufactured
similarly to plywood except that the two exterior sheets are instead separated
by a
plurality of elongated members that are spaced apart and, in layers, are laid
on to
one another perpendicular to each other to permit the passage of air and the
transfer
of forces. These elongated members function as the spacing structural
elements.
The number of elongated members can vary as can the thickness of the elongated
members, the width of the elongated members, the spacing of the elongated
members and the orientation of the elongated members, for instance, some may
be
oriented on an or arranged in the same axis of the sheets.
[0031] In all
cases where there are matrices of elongated members acting as the
spacing structural elements, there may be one, two, three, or four layers of
elongated members, and where veneer elongated members are used, up to twelve
layers may be used. Each additional layer potentially adds cost and weight,
but also
potentially adds strength.
[0032] The
apparatus may include three layers of elongated members, with two
layers perpendlcularto one another and diagonally oriented to the axis of the
sheets,
and one layer perpendicular to an axis of the sheets. The apparatus may
include
three layers of elongated members, with two layers perpendicular to one
another
and each perpendicular to an axis of the sheets, and one layer diagonally
oriented
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to the axes of the sheets. The apparatus may include four layers of elongated
members, with two layers perpendicular to one another and each perpendicular
to
an axis of the sheets, and two layers perpendicular to one another and
diagonally
oriented to the axes of the sheets. The apparatus may include three or four
layers
of elongated members, with each layer oriented perpendicular to the next, and
all
layers either perpendicular to an axes of the sheets, or all layers diagonally
oriented
to the axes of the sheets.
[0033] In one
embodiment, the individual sheets for each panel are spaced equally
apart from each other in parallel planes and in the same vertical axis,
ideally at a
distance of 1%2" from each other, with a matrix of spacing structural elements
or
members arranged in a cross hatch pattern between the two sheets. The matrix
of
members would ideally consist of a first layer of elongated members, each
parallel,
coplanar, and spaced equally from one another, the first layer being
perpendicular
to a second layer of elongated members, each parallel, coplanar, and spaced
equally from one another. Each elongated member would generally have a square
cross section and would extend in length from one side of the panel to
another. For
a perpendicular arrangement to the panels, where the panels are spaced at 1
1/2"
apart, this would require members of 3/4" square faces with lengths of 48" and
96",
or, if chamfered, longer, depending on the length of the chamfer.
[0034] A layer
of screening (e.g., fiberglass, aluminum, plastic) could be affixed
between the first and the second layers of elongated members. This would aid
in
adhesion and/or fastening of elongated members, and would facilitate the
running
of wires through the interior of the panels.
[0035] The
elongated members are generally spaced apart from a neighboring
elongated member in the same layer from 1 to 12 times their own width, more
preferably 3 to 9 times their own width, and most preferably 5 to 7 times
their own
width. The specific spacing would depend on the sheet thickness and strength
requirements.
[0035] For
roofing sheathing, the top layer would preferably be laid in the long
horizontal direction, and have a length of 96 inches, with a repeat of 5 5/8"
for
shingle attachment if using nails for shingles and the object is to nail into
the
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elongated member. The panel faces could be stamped, painted, or otherwise
visibly
marked with the orientation of the underlying matrix for ease of use by the
workman.
[0037] The elongated members would usually be oriented perpendicular to
one
another on the same axis of the sheets but other orientations are possible
depending on the application. Testing indicates that the perpendicular
orientation
significantly strengthens the plywood or OSB assembly more than any other
orientation, allowing the use of thinner exterior sheets. Tests have
demonstrated that
a strength increase in bending stiffness for an assembly of two 1/4 inch
sheets, with
a perpendicular matrix of two layers of 3/4" x 3/4" elongated members spaced 5
inches apart, has a bending strength approximately 10 times greater than a
single
sheet of 1/2" of plywood alone.
[00381 The elongated members of the matrix can consist of
square members made
= of wood, wood composite, plastic, or similar material, arranged
perpendicular or
close to perpendicular for an offset matrix, and interconnected to each other
with
mechanical means and/or adhesives.
[00391 The individual matrix members would ideally be 3/4" x
'A" square, and long
enough to extend beyond the panel edge. The size of the elongated members
could
be larger or smaller and long enough to complete the required matrix of the
sheets,
which depends on the orientation, and extend to or beyond one edge. Spacing
would
be 1 to 12 times the thickness of the elongated member or 3/4" to 9 inches.
The
matrix of "elongated members" could consist of two layers perpendicular to
each
other or multiple layers. The matrix can be attached to the sheets either
parallel to
the sheet axis or on an angle of 450, but other orientations are possible
depending
on the application. In all cases, a provision is made so that the panels
interconnect
structurally.
[0040] For the matrix of elongated members, the elongated members may
be
indented preferably between "A" and 518" and more preferably between 3/8" and
1/2"
on two contiguous sides, while the other two sides would be extended by
between
preferably %" and 5/8" and more preferably between 3/8" and 1/2" with an end
member. Additionally, the length of the elongated members could be between
1/4"
and 1/4" longer than the sheet on two contiguous sides to machine a tongue and
groove attachment.
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[0041]
In all embodiments, the spacing structural elements can protrude on two
contiguous edges and may be chamfered to enhance interlocking with adjacent
panels. The spacing structural elements would be similarly indented on the two
opposite contiguous edges. The extension would normally be no more than 1 inch
and would ideally be between 1/2" to 3/4".
[0042]
Additionally, the one or both sheets can be manufactured from plastic
materials. These plastic sheeted panels could be used for waterproof
applications
such as for roofing or basement wall applications, with one or both sheets
providing
a barrier to liquid water and/or water vapor. The joints would be waterproofed
with
an application of waterproof mastic or tape. The panels could be combined with
a
= multitude of construction materials and methods in the same way
conventional
sheathing is used today. Further, a top sheet of one panel may be extended in
length and attached such that it overlaps a top sheet of an abutting lower
adjacent
panel by approximately two to four inches.
[0043]
The panels could also be manufactured with a perforated bottom sheet to
facilitate ventilation into the panel matrix. The perforations would ideally
be round
in shape, sized iti" to 1" in diameter, and arranged in a matrix that is
ideally
staggered from the adjacent holes with a spacing of 4 to 12 diameters in
widths. A
layer of screening (e.g., fiberglass, aluminum, plastic) could be affixed
along the
interior or exterior surface of the perforated sheet. The perforations allow
for the
exhausting of heat, gases, and moisture in attics and non-living spaces. The
holes
should be such that the panel can still transfer necessary tensile and
compressive
forces. Both solid and perforated panels can be used together in building
assembly,
such as a roof.
[0044]
The panels can facilitate the use of a wide variety of insulation
possibilities
without requiring special consideration for ventilation since the ventilation
is integral
with the panels. This is useful for common fiberglass as well as blown
products such
as fiberglass, Rockwool, cellulose and other products. This is especially
useful for
the new high performance spray foam expanding insulations that are becoming
popular because of their high energy efficient performance and ability to seal
infiltration.
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[0045] The
panels can be used in both residential and commercial construction. The
panels can be used both for on site installation and for factory built modular
homes.
The panels would be useful for manufactured homes and trailers.
[0046] To
facilitate construction, the exterior of one or both sheets could be marked
with exterior lines showing the location of the interior elongated members.
The
exterior facing sheet could also be of waterproof construction and made of
waterproof material, such as some form of plastic, providing for the exposed
layer
of roofing or wall covering. The top sheet could be sized larger than the
bottom
sheet such that a top sheet of a first panel would extend to overlap a top
sheet of an
adjacent, and preferably vertically lower, panel.
[0047] In
addition to wall and roof sheathing, a flooring system of the ventilated
structural panels as described would have many benefits. Increased structural
strength, spanning capability and reduced deflection, all of which would
result in less
materials needed for supports (joists or trusses or composite joists) and
better
performance in terms of strength and stiffness. A properly engineered panel
could
be usea for flooring providing a plenum for air distribution providing warmed
and
cooled air to be distributed within the floor. The warmed air would be a
desirable
characteristic in bathrooms.
[0048] A
properly engineered panel could be used for flooring providing a plenum for
electrical distribution where wires and data communication cables could be
easily
run. A properly engineered panel could be used for flooring to provide a
plenum for
radiant heat or forced hot air heat. In this case, one interior surface would
generally
receive a layer of reflecting material and the spacers would have to be
mechanically
connected. A properly engineered panel could be used for flooring providing a
plenum for plumbing distribution where pipes, tubes and conduits of proper
size
could be run. Finally, a flooring system with this panel construction is
naturally
quieter than one sheet of sheathing, providing a nose buffer. This noise
buffering
benefit would also apply to walls and roofing.
[0049] This
panel offers three main simultaneous advantages of ventilation, ease of
use, and significantly increased strength. First, these panels offer
ventilation both
through the panel sheets and between the panel sheets. In this way, the panels
may
remove moisture and gasses passing through an interior facing sheet, and
exhaust
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= them via the continuous air channel created between the sheets by the
spacing
structural elements. This air channel will be approximately the width and
height of
the combined width and height of any contiguous surface formed by the
ventilated
structural panels being attached contiguous with one another. Such a large air
channel can provide for dramatically increased air flow over the interior
facing sheet,
and thus dramatically increased ventilation between the interior and exterior
even
if only passively. A particular advantage this offers is for roofing
situations in colder
climates to assist in avoiding ice darns.
[0050] A ventilated structural paneled roof provides for
ventilation of moisture and
gasses from the house, and allows a flow of cold air along the entire roof
surface,
in the interior of the panels, to prevent the formation of ice dams. A
ventilated
structural paneled roof allows for the entire roof to remain cold in the
winter,
preventing snow from melting and ice dams from forming. Any heat that migrates
into the ventilation plenum is exhausted to the outdoors and does not melt the
snow
on the roof. Similarly, ventilation of a wall surface provides the same
benefits noted
above. Ventilation in warm climates orduring warm months can exhaust hot air
from
the attic space, extending the life of roofing materials and reducing cooling
costs.
Also, the inventive panels can typically achieve ventilation of at least 1/50,
when
compared to free, unobstructed end area, greatly exceeding many code
requirements.
[00511 Second, the structural connection between the two
sheets of material
interconnected with spacing structural elements with adhesive and or
mechanical
means to transfer shear forces provides that the entire entity becomes a
synergistic
structural panel with characteristics that exceed the strength of the
individual parts.
The top and bottom sheets act like the flanges on a beam or truss and provide
better
load carrying strength, increased span capability and less deflection than the
individual sheets together. Preliminary tests indicate that an assembly of two
'A inch
sheets of plywood spaced with 3/4 inch blocks is 4 times stronger than just
one sheet
of 1/2 inch plywood alone, and two 3/4 inch sheets of plywood spaced with a
matrix of
two 3/4" by 3/4" members can be 10 times stronger than just one sheet of 1/2
inch
plywood alone.
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[0052] This
extra strength can be used advantageously to increase the load capacity
or the length of the unsupported span of the panel, which reduces the required
number of underlying supporting rafters, studs, joists, trusses or purloins,
and thus
cost of building.
[0053] The spacing structural elements material, size, arrangement,
thickness,
shape and orientation can vary with the application and be adapted to the
specific
need of the application.
[0054) The plurality spacing structural elements may be arranged such
that a
number of linear pathways are created. Each pathway's dimensions are limited
by
the dimensions and arrangements of the spacing structural elements. Utilizing
blocks, the pathways may measure in height the full distance separating the
first and
the second sheet; the width measurement is dependent on how far apart the
blocks
are spaced from one another. Utilizing two layers of elongated members, the
height
of the pathways will measure approximately one half of the distance that
separates
the two sheets. Like the blocks, the width of the pathways formed with
elongated
members will be equal to the distance separating two neighboring elongated
members in the same layer. When the two layers of elongated members are
arranged perpendicular to each other, the pathways will also be orthogonal.'
Each
pathway allows air to move along each pathway unobstructed from at least one
edge
of the panel to at least one opposite edge of the panel.
[0055] The spacing structural elements can protrude on two contiguous
sides with
chamfered edges. The extent of the protrusion could be matched by an indention
of
the spacing structural elements on the opposite contiguous two edges which
would
provide for interlocking of panels. This interlocking of panels would provide
structural
continuity, increasing structural integrity and minimizing discontinuous
deflection and
buckling.
[0056] Third,
the panel offers significant advantages as to ease of use. Since the
panel is assembled from readily available building materials, it is familiar
to the
designers, suppliers and trades in terms of size and weight. it can be cut,
sized and
attached in the same manner of conventional sheathing. No special tools or
skills are
needed. No special orientation is needed to ensure the continuity of
ventilation,
except that the interlocks should be maintained for increased structural
integrity.
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Ventilation is maintained without any special considerations or the use of any
special
additional materials, except insect and moisture blocking at the exposed
edges.
[0057] in another embodiment, the panels can also be constructed as two
sheets
separated by a single layer matrix as described in paragraph 28. The matrix
=
members can consist of wood, plywood, OSB, medium-density fiberboard (MDF),
other wood composites, plastic or other materials and shaped in a rectangular
or
most likely square profile and extending either the length in the longitudinal
direction
or the width in the perpendicular direction. Said matrix can be extended on
two
contiguous edges and chamfered and indented on the opposite two edges to
facilitate interlocking as previously described.
[0058] The members would be placed parallel to each other and fastened
to both the
top and bottom panels with adhesives and/or mechanical means. The spacing
between members would be from 2 times the thickness an individual matrix
member
to 16 times the thickness, but ideally from 4 times to 12 times.
[0059] The single layer panels could also have perforations as
previously described.
The perforations would ideally be round but could also be other shapes such as
oblong, oval; square or rectangular or a combination of geometric shapes such
as
square with rounded corners.
[0060] The single layer panels would be useful for wall sheathing
applications where
the strength of the perpendicular matrix may not be as important or for some
flooring
applications. The panels may be used for decorating concrete formwork. The
orientation of the single layer matrix may be either longitudinal, lateral, or
diagonal
depending on the specific application,
[0061]
In an additional embodiment, the panel may be comprised of simply one
sheet of panel with a matrix of members, without a second sheet. It could be
constructed of plywood, OSB, MDF or other materials such as plastic or other
composite wood material. In a further additional embodiment, the matrix of
structural spacing elements can also be manufactured integrally with the
panels in
either OSB or Plywood or other materials such as MDF, plastics or other wood
composites.
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CA 02873353 2014-12-05
[0062]
Manufacturing integral structural spacing elements, including the matrix of
elongated members, would eliminate the need to separately attach the elongated
members to each sheet.
[0063] Integral raised members would serve as the matrix of elongated
members.
Two similar sheets may have integral elongated members formed longitudinally
in
a first sheet and laterally in a second sheet. The two sheets would then be
joined
together by adhesives and/or mechanical means, with the matrix members in
contact with one another. The finished flat panel surface would be exposed on
the
top and bottom. An alternative arrangement would provide for the integral
raised
members to be formed at angles to the edges of each respective sheet.
Preferably
the integral raised members on the first sheet would be formed such that, when
they
are mated with the integral raised members on the second sheet, the integral
raised
members of the first sheet will be perpendicular to the integral raised
members of
the second sheet,
[0064] The same
characteristics regarding the size, shape and spacing, and ranges
therein, of the individual integral elongated members would be as the
elongated
members previously described.
[0065] In
producing panels utilizing integral raised elongated members, plywood
sheets, for example, could be manufactured with a plurality of raised ridges
or strips.
The raised ridges or strips would function as the integral elongated members.
Two
sheets would then be attached to each other with adhesives and/or mechanical
means via the plurality of integral elongated members, preferably with the
integral
elongated members of each sheet in perpendicular orientation to the other
respective sheet. These panels could also be manufactured from OSB, medium
density fiberboard, or other wood composite materials or plastics. These
panels and
the sheets and integral elongated members could be manufactured in multiple
steps,
or in a single step. The integral members could be added during the panel
production, or material could be removed after production to leave the
plurality of
elongated members, or the sheet and members could be formed substantially
simultaneously, including with a mold,
[0066] The
integral raised elongated members could be made during the panel
manufacturing process with special tools, equipment, rollers, molds and other
such
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.
CA 02873353 2014-12-05
means as necessary. The shape of the integral raised member could take many
shapes depending on the tooling, rollers, presses, machinery and other
factors,
including flat or round tops, sharp or rounded edges, and flattened or rounded
sides.
They could have rounded chamfered corners with or without a flat top, they
could
have angled chamfered corners, they could be rectangular or square in shape.
[0067] The integral raised members could be either manufactured
simultaneously
with the sheets or could be shaped by removing material after manufacturing a
sheet
of extra thickness, to accommodate the finished thickness and integral raised
member. Applications of the panels utilizing integral structural spacing
elements
would include roofing, flooring, and siding for residential and commercial
construction.
[0068] The panels with integral matrices' could be manufactured out of
Plywood,
OSB, MDF or other similar material, including plastics.
[0069] The panels with integral matrices' could also have perforations as
previously
described_ The perforations would ideally be round but could also be other
shapes
such as oblong, oval, square or rectangular or a combination of geometric
shapes
such as square with rounded corners.
[0070] A further embodiment utilizing integral structural spacing elements
would
utilize the first sheet utilizing structural spacing elements, and a second
sheet
without integral structural spacing elements. In this embodiment non-integral
structural spacing elements can also be used to attach the second sheet to the
integral structural spacing elements of the first sheet to the second sheet.
[0071] A still further embodiment utilizing integral structural spacing
elements would
utilize both the first and the second sheet, each with integral structural
spacing
elements, being connected to one another via non-integral structural spacing
elements.
[0072] Yet another embodiment utilizing integral structural spacing
elements involves
manufacturing the panel such at that the location where the integral members
of the
first sheet contact the integral members of the second sheet, there is
provided that
at least one first integral member of the first sheet may enter into a recess
of at least
one second integral member of the second sheet. The recess in the at least one
second integral member functioning as a notch for the at least one first
integral
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CA 02873353 2014-12-05
member to be received into. The at least one first and at least one second
integral
member could also be adhesively and/or mechanically joined. Additionally the
least
one first integral member may also be provided with a recess in which the at
least
one second integral member may enter. It is envisioned that the notched
recesses
may be provided only on the integrated members of one sheet, could be provided
on the integrated members on both sheets. The notches could be provided
uniformly
on every elongated member one or both sheets, or could be staggeredly provided
= at alternating locations and/or on alternating integrated members on one
or both
sheets. It is also envisioned that this notch/recess arrangement could
similarly be
employed with non-integrated member embodiments.
[0073] This notch like interface between members of multiple layers of
members
may also be utilized for panels including non-integral structural spacing
elements,
such as those discussed above.
[0074] It should be noted, that the edges of the sheets on any panels
in this
application may be shaped with tongues on two contiguous edges and
corresponding groves on the remaining two contiguous edges for interlocking of
multiple panels, and/or interlocked with the indented and overlapped spacing
structural elements arrangement described in paragraphs above.
[0075] It should also be noted a number of different arrangements are
contemplated
in which spacing structural elements create unobstructed pathways for air to
move
through the panel, from at least one edge of the panel to at least one of an
opposite
and an adjacent edge of the panel. The height of the unobstructed pathways
will
normally be equal to the height of the members. The width of the pathways will
normally be equal to the spacing between adjacent members of a common layer.
The number of parallel unobstructed pathways created in the panel for air to
move
in any one direction will preferably range from between 1 and 30, more
preferably
between 2 and 25, even more preferably between 4 and 20, yet even more
preferably between 5 and 19, and most preferably between 6 and 12. If the
elongated members were spaced at approximately 16 inches on center, the
pathways could be approximately 15 inches in width. Similarly, if the
elongated
members were spaced at approximately 24 inches on center, the pathways could
be approximately 23 inches in width. In such a way it is achievable to have at
least
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CA 02873353 2014-12-05
between two to three unobstructed pathways in a first direction, and between
four
and six unobstructed pathways in a second, preferably perpendicular direction,
each
measuring approximately 3/4" in height and 15" to 23" in width. It is also
achievable
to have at least between four and ten unobstructed pathways in a first
direction, and
between eight and twenty unobstructed pathways in a second, preferably
perpendicular direction, each measuring approximately 3/4" in height and 4" to
12"
in width.
[0076] It should also be noted that the structural spacing elements, and in
particular
the elongated members, can be formed in specialized shapes to convey
additional
qualities to the structural spacing elements, and thus the panels. Some
specialized
shapes include non-perforated and perforated I-beam, truss, skip truss,
honeycomb,
and corrugated shaped engineered matrix members.
[0077] It should further be noted that the invention will preferably be
configured in
one of the four ways following ways. First, a panel could be configured as a
single
sheet with a single layer of elongated members attached to the sheet, the
elongated
members arranged parallel with one another, and parallel with one axis of the
panel
and perpendicular to the other axis. That is, the elongate members could be
arranged parallel to a long axis or a short axis of the sheet. In a second
panel
configuration, a single layer of members, as described in the first
alternative, may
be arranged between and connected to two sheets. Third, a panel could be
configured as at least a double layer of elongate members attached to a single
sheet, with each layer of elongate members arranged perpendicular to each
adjacent layer of elongate members, at least one layer arranged parallel to
one of
a long or a short axis of the single sheet, and the elongate members being
attached
to one another where the multiple layers of elongate members intersect.
Fourth, an
at least double layer of elongate members, as described in the third
alternative, may
be arranged between and connected to two sheets.
[0078] To reiterate, the panels, and their constituent sheets and
structural spacing
elements, can be constructed or made from porous or non- porous wood,
cellulose
or other organic material, composite, ferrous, metallic, plastic, or any other
material
that can be shaped into a flat sheets and/or the structural spacing elements.
The
top and bottom sheets and the structural spacing elements can each be of
different
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CA 02873353 2014-12-05
materials and thicknesses. The top sheet can be waterproof and the bottom
sheet
can be perforated to facilitate ventilation.
[0079] It should further also be noted that the panel typically has an
empty volume
of approximately 70%, but can range from 40% to 90%, or preferably from 50% to
80%, or more preferably from 65% to 75%, depending on sheet thickness and
structural spacing element size, shape, and placement.
[0080] The panels may have a clear, unobstructed airflow of approximately
30% of
the area of the end of any panel assembly, but can range from 10% to 60%, or
preferably frorn20% to 50%, or more preferably from 25% to 40%. With the use
of
special engineered matrix members, discussed in further detail below, the
clear,
unobstructed airflow can be up to around 75%, but can range from 65% to 85%,
or
more preferably from 70% to 80% of the end area of the panel assembly.
[0081] The clear unobstructed airflow on a panel with solid matrix members
of a
range from approximately 1/50 to 1/70when comparing free, unobstructed end
area
with panel coverage. This depends on roof slope, matrix member size and
spacing.
Some building codes require ventilation of 1/300, and some codes are
contemplating requiring or recommending ventilation of 1/150. The inventive
panels
could provide 6 to 12 times greater ventilation performance.
[0082] A further object of the present invention is to provide a multi-
plenum structural
panel comprising a top sheet, a middle sheet, and a bottom sheet, each sheet
having a first horizontal edge and a second horizontal edge, and a first
vertical edge
and a second vertical edge, all three sheets being parallel in plane, and all
three
sheets having at least one of both vertical edges and both horizontal edges
aligned
along a same plane; a first plurality of spacing structural elements, fixedly
attaching
the top sheet to the middle sheet, and a second plurality of spacing
structural
elements fixedly attaching the middle sheet to the bottom sheet, such that the
yield
strength of the combined multi-plenum structural panel is greater than the
combined
individual yield strengths of the top, the middle, and the bottom sheets; an
upper
plenum defined by a spacing between the first sheet and the second sheet; a
lower
plenum defined by a spacing between the second sheet and the third sheet; the
plurality of spacing structural elements being formed such that a plurality of
unobstructed pathways are created in each plenum for air to move from at least
one
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CA 02873353 2014-12-05
edge of the multi-plenum structural panel to at least one of an opposite and
an
adjacent edge of the multi-plenum structural panel.
[0083] A yet further object of the present invention is to provide a
method of
constructing a building including one or more multi-plenum structural panels
comprising a top sheet, a middle sheet, and a bottom sheet, each sheet having
a
first horizontal edge and a second horizontal edge, and a first vertical edge
and a
second vertical edge, all three sheets being parallel in plane, and all three
sheets
having at least one of both vertical edges and both horizontal edges aligned
along
a same plane; a first plurality of spacing structural elements, fixedly
attaching the top
sheet to the middle sheet, and a second plurality of spacing structural
elements
fixedly attaching the middle sheet to the bottom sheet, such that the yield
strength
of the combined multi-plenum structural panel is greater than the combined
individual yield strengths of the top, the middle, and the bottom sheets; an
upper
plenum defined by a spacing between the first sheet and the second sheet; a
lower
plenum defined by a spacing between the second sheet and the third sheet; the
plurality of spacing structural elements being formed such that a plurality of
unobstructed pathways are created in each plenum for air to move from at least
one
edge of the multi-plenum structural panel to at least one of an opposite and
an
adjacent edge of the multi-plenum structural panel, the method comprising the
steps
of supporting the mass of one of an interior and exterior wall with the multi-
plenum
structural panel; and connecting one of an air heater and an air conditioner
in a fluid
tight connection with the at least one of the upper and the lovver plenums.
[0084] An additional embodiment of the ventilated structural panels can
consist of
a multi-layered or multi-plenum panel consisting of two plenums, constructed
out of
three sheets of material separated by structural spacing elements of
preferably
blocks. One plenum would supply treated, heated, cooled, humidified,
dehumidified,
or otherwise conditioned air while the other plenum would provide the return
air to
be conditioned. The original design of the multi-plenum panels provides at
least two
distinct and significant benefits ¨ inexpensive multi-location air supply and
return,
and much greater strength and structural integrity for subflooring.
[0085] Floor sheathing in residential homes is usually a 5/8 or % inch
thick plywood
or OSB panel supported on joists or engineered lumber joists which are usually
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CA 02873353 2014-12-05
spaced at 12 inches on center or 16 inches on center. By contrast, multi-
plenum
panels are much stronger than regular floor sheathing because its multi-layer
design
acts like a specialized "I" beam and can provide for long spans with better
performance than standard sheathing.
[0086] The two cavities or plenums could allow for the distribution of
conditioned air
to the home or building. In the winter, warm air could be pushed into the
upper
plenum and tapped with vents in each room, as required, with a standard
commercially available metal or plastic register placed into the upper plenum.
[0087] Return air would be tapped into the lower plenum by a special
"plenum tap"
system made of metal or plastic that penetrates the top and middle sheets and
is
fixed into the top and middle sheets with mechanical means and/or adhesives.
The
"plenum tap" is now ready to accept a standard, commercially available
register.
=
[0088] The same procedure is used for providing cool air
distribution, however, to
prevent cold floors, the cool supply could be directed to the lower plenum
while the
return warmer air is directed through the upper plenum.
[0089] In one embodiment an extruded or deposited glob of uncured semi-
liquid or
foam substance is used as the structural spacing element. The glob would
preferably be dispensed at various locations on the surface of the bottom or
middle
sheet, analogous to various placements of the structural spacing elements
described
above, but compositions with greater strength could be spaced farther apart.
[00901 The globs may be extruded alone, or may be used in conjunction
with one or
more inserts. The inserts can be shaped as spheres, boxes, rods, spikes,
barricade
shapes, barred, flanged, or spindle shaped, for example. The inserts can be
three-
dimensional shapes as in a sphere or a box, and can be hollow or solid. The
inserts
can have smooth outer surfaces, or can have protrusions lining their surface.
The
inserts serve multiple functions. First, they add structural integrity to the
glob.
Second, they can perform as spacers to prevent the two sheets on either side
of the
glob from pressing too close together. That is, they can mechanically define a
minimum clearance between the two adjacent sheets. Also, protrusions or spikes
on the surface of the inserts can aid in mechanical connection between two
adjacent
sheets to one another. The inserts can additionally be used without the globs,
and
function as the structural spacing elements themselves.
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CA 02873353 2014-12-05
[0091] Though
preferably 4x8 feet in measurement, as mentioned above, the sheets
can be a variety of sizes. For example, larger sheets could be used and make
larger
panels in a first step, that could be cut down to 4x8 foot or 1x2 meter panels
in a
second step.
[0092] Depending on the different situations, the sheets used in the
single or multi-
plenum panels, that is the top, middle, or bottom sheets, could be made of be
made
of many and a variety of materials, including but not limited to: wood and
wood
fibrous materials; wood fiber panels; wood plywood panels; wood masonite
material;
plastic materials; fiberglass materials; carbon fiber materials, drywall, or
some
combination of thereof.
[0093]
Composite sheets composed of a combination of materials could be made of
fibers and some binding agent. Said fibers could be wood, cellulose, hemp and
other plant materials such as cotton, man-made materials such as glass,
plastics,
metal, carbon, etc. The binding agent can be made of a variety of materials
that
have the qualities to bind fibers and cure with or without heat or other
agents to a
usable structural material with compressive and tensile strength capabilities.
[0094] The
sheets can be layers of different materials. For example, the sheets can
be composed of metal or have a metal layer. As another example, the bottom
sheet
can be drywall or a composite drywall panel where the bottom sheet is composed
of the gypsum material placed on a wood or other substrate with tensile
strength.
[0095] The sheets can be a variety of shapes depending on the use. For
example,
the sheets can be flat or corrugated or shaped for additional strength with
geometric
patterns. Also, for sheets of composite construction, corrugated materials can
also
be used to face the sheet.
[0096] The
sheets can also have insulating properties beyond that of normal plywood
or OSB sheets. The sheets can be made of insulating material, or be a
composite
sheet of an insulating material with one or more layers of surface materials
(like
metal or plastic) capable of providing the needed strength and performance.
Additionally, any or all of the sheets may have a reflective radiant barrier
applied to
any surface to further aid in insulation.
[0097] To aid
in microbial, rot, mold, mildew, and pest prevention, any or all sheets
may have an anti-fungal, anti-mold, or other effective preventative treatment
applied
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CA 02873353 2014-12-05
to any or all surfaces, including surfaces of structural spacing elements. Any
wood
sheet could be made of pressure treated lumber if condensation or an
application
against concrete is anticipated. Similarly, any or all sheets can have a
painted or
protective coating applied to any surface, depending on the need.
[0098] In one production embodiment, the single or multi plenum panels
may be
constructed with a 3D printing process, using a variety of available materials
including fibrous compounds, plastics, carbon fiber, metal compounds, and
other
materials suitable for 3D printing applications. 3D printing can be utilized
for the
entire panel construction or for portions of the panels such as a sheet and
the
structural spacing elements, or any combination thereof.
[0099] The structural spacing elements can be made of a variety of
materials and
shapes and may include the following but not limited to: wood blocks in any
shape
and thickness; wood composite blocks in any shape and thickness; wood blocks
cut
from existing OSB and plywood products; solid plastic materials; adhesives of
any
type; foams, both closed and open cell; plastics, permeable materials
including
plastics and foams and adhesives; metal, and composites.
[0100] The structural spacing elements may be extruded, molded, cut,
welded,
pressed, glued, or punched, or otherwise formed.
[0101] The structural spacing elements may be spaced at various
positions, in
addition to those shown, as required for strength for various applications.
[0102] The structural spacing elements may be made of various shapes,
including
square, round, rectangular, triangular, elongate, tubular, truss like,
honeycomb,
corrugated shapes, and of various thicknesses. These include tubes of round,
square or rectangular shapes, and hollow extrusions.
[0103] Where
the shape of the structural spacing element has an orientation, like
tubes, it can be oriented with the shape (e.g. tube) axis perpendicular to the
sheet,
or with the shape axis parallel to the sheet. For elongate structural spacing
elements or sticks in a matrix, the matrix may be oriented perpendicular to
each
other. Structural spacing elements with openings may be arranged in a grid
type
matrix, with structural spacing elements perpendicular to one another, to
allow air
flow.
[0104] Further description will be provided with reference to the Figures
below.
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CA 02873353 2014-12-05
[0105] BRIEF DESCRIPTION OF THE DRAWINGS
[0106] Below is a brief description of the drawings of the
inventive panel, in which:
[0107] Fig, 1 is an exploded depiction of an embodiment of
the panel;
[0108] Fig. 2 is plan view of an embodiment of the panel;
[0109] Fig, 3 is a plan view of an embodiment of the panel
depicting the indented
space and protruding segments;
[01101 Fig. 4 is a close-up iso view of an embodiment of the panel,
depicting the
indented space, protruding segments, and chamfered edges;
[0111] Fig. 5 is an iso view of the panel mounted on mounting
elements;
[0112] Fig. 6 is an iso view of an embodiment of the panel
utilizing plywood veneer
as spacing structural elements, without showing the top sheet;
[0113] Fig. 7 is an iso view of an embodiment of the panel where the
spacing
structural elements are aligned diagonally, without showing the top sheet;
[0114] Fig. 8 is an iso view of an embodiment of the panel utilizing
rectangular blocks
as spacing structural elements, without showing the top sheet;
[01151 Fig. 9 is an iso view of an embodiment of the panel utilizing
circular blocks as
spacing structural elements, without showing the top sheet;
[0116] Fig. 10 is an iso view of an embodiment of the panel
utilizing square blocks
= as spacing structural elements, without showing the top sheet;
[0117] Fig. 11 is a close-up iso view of an embodiment of the panel,
depicting the
indented space, protruding segments, and chamfered edges;
[01181 Fig. 12 is an iso view of an embodiment of the panel with
perforations in one
sheet, viewed from the underside;
[0119] Figs. 13A and 136 are side views of two roof arrangements
constructed with
the panels;
[0120] Fig. 14 is a sectional view of a roof arrangement constructed
with the panels
for an unoccupied attic;
[0121] Fig. 15A is a sectional view of a roof arrangement constructed
with the panels
for an occupied attic;
[0122] Fig. 158 is a sectional view of a roof arrangement constructed
with the panels
for an unoccupied attic space, where some of the panels are perforated;
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CA 02873353 2014-12-05
[0123] Fig. 16
is an iso view of a roof arrangement constructed using perforated and
non-perforated panels;
[0124] Fig. 17 is a sectional view of a portion of a roof arrangement
constructed
using perforated and non-perforated panels;
[0125] Fig. 18 is a sectional view of a house showing a wall, floor,
and roof
constructed using the panels;
[0126] Fig. 19 is a sectional view of an insulated house showing a
wall, floor, and
roof constructed using the panels;
[0127] Fig. 20
is an exploded view of the portion indicated as portion A in Fig. 19;
[0128] Figs.
20A and 20B are iso-views of panels with a single layer of spacing
structural elements, each having a portion of the top sheet cutaway to show
detail;
[0129] Fig. 21 is an iso-view of a panel with a sheet having integrated
spacing
structural elements;
[0130] Fig. 22
is an iso-view of a panel with two sheets, each having integrated
elongated members, with a portion of the top sheet cutaway to show detail;
[0131] Fig. 23
is an iso-view of a panel with two sheet, each having integrated
=
elongated members with rectangular profiles;
[0132] Fig. 24 is an iso-view of a panel with two sheets, each having
integrated
elongated members with curved profiles:
[0133] Fig. 25 is an iso view of a sheet having integrated elongated
members and
the plurality of perforations;
[0134] Figs. 26A-26D are profile views of multiple examples of
potential profiles of
integrated elongated members;
[0135] Fig. 27 is an iso views of a panel comprised of a single layer
of nesting
elongated members.
[0136] Fig. 28 is an up close iso view of two elongated members with a
notched
attachment;
[0137] Figs. 29-31 are an up close perceptive views of panels using
three different
embodiments of specialized shaped engineered matrix members, where the top
sheet in each panel is not shown;
[0138] Figs. 32-33 are close up perspective views of two additional
embodiments of
specialized shaped engineered matrix members;
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CA 02873353 2014-12-05
[0139] Fig. 34 is a iso perspective view of a multi-plenum
embodiment of the panel
according to the present invention;
[0140] Fig. 35 is an exploded iso perspective view of the
panel of Fig. 34;
[0141] Fig. 36 is a close up partial side view of the panel
of Fig. 34;
[0142] Fig. 37 is a side view along the long edge of the
panel of Fig. 34;
[0143] Fig. 38 is a close up side view of an end edge of a
panel of Fig. 34 that forms
a plenum boundary,
[0144] Fig. 39 is a cut-away close up iso perspective view of the panel
of Fig. 34 with
a register in exploded view to show detail;
[0145] Figs. 40 and 41 are iso perspective views of the panel of Fig.
34 including a
plenum tap, with a register in exploded view to show detail, and the blocks
omitted;
[0146] Fig. 42 is a sectional side view of the panel of Fig.
34 including a plenum tap;
[0147] Fig. 43 is an iso perspective view of a plenum tap
with selector doors and
levers;
[0148] Figs. 44 and 45 are a sectional side view of buildings with
panels of Fig, 34
used for structural support and conditioned air delivery and return;
[0149] Fig, 46 is an upward looking sectional view along the sectional
line marked
"Fig. 46" in Fig. 44;
[0150] Fig. 47 is a side sectional view along the sectional line marked
"Fig. 47" in
Fig. 46;
[0151] Fig. 48 is an iso perspective view of the panel of
Fig. 34 arranged on joists;
[0152] Fig. 49 is an side sectional perspective view panel of
Fig. 34 installed
adjacent to the exterior wall of a building;
[0153] Figs. 50 to 52 are close up partial side views of edges of
sheets of joined
adjacent panels of Fig. 34, separated to show detail;
[0154] Fig. 53 is an exploded perspective view of the panel of Fig. 34
using glob
spacing structural elements, before compression;
[0155] Fig. 54 is a side sectional view of a possible multi-
plenum panel configuration;
[0156] Fig. 55 is a close up view of a glob of Fig. 53, with
an embedded insert;
[0157] Fig. 56 is a perspective view of a spacer;
[0158] Fig. 57 is a perspective view of a caged insert with
spikes;
= [0159] Fig. 58 is a perspective view of a barricade
shaped insert;
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CA 02873353 2014-12-05
[0160] Fig. 59 is a perspective view of a spacer with an elongate mid-
section;
[0161] Fig. 60 is a perspective view of three through inserts in a middle
sheet;
[0162] Fig. 61 is a close up side sectional view of a multi-plenum panel
where two
through inserts pass through a middle sheet and two globs;
[0163] Fig. 62 is a close up side sectional view of an integrated through
insert;
[0164] Figs. 63 and 64 show multiple side sectional views of panels with
nail shaped
through inserts;
[0165] Figs. 65 and 66 are perspective views of an orthogonal frame used in
the
panel;
[0166] Figs. 67 and 68 are perspective views of unitary or bonded
orthogonal frame;
[0167] Fig 69 shows a production schematic for scaled up production of the
panels;
[0168] Fig. 70 shows a perspective view of a orthogonal matt;
[0169] Fig. 71 shows a close up pan view of a belt of the orthogonal matt;
[0170] Fig. 72 shows a side view of a block connected to the orthogonal
matt and a
sheet;
[0171] Fig. 73 shows a close up side sectional view of an interlocking
mechanism
to attach adjacent panels;
[0172] Fig_ 74 is an partial perspective view of space truss;
[0173] Fig. 75 is a partial perspective view of a truss matrix viewed from
a first
direction;
[0174] Fig. 76 is a side view of the truss matrix of Fig. 75;
[0175] Fig 77 is a partial perspective view of the truss matrix of Fig. 75
viewed from
a second direction;
[0176] Fig. 78 is a partial plan view of the truss matrix of Fig. 75;
[0177] Fig. 79 is a partial perspective view of the truss matrix of Fig. 75
viewed from
a third direction;
[0178] Fig. BO is a close up perspective view of an apex area of the truss
matrix of
Fig. 75;
[0179] Figs. 81¨ 83 is a partial perspective views of engineered perforated
members
used in multi-plenum panels;
[0180] Figs. 84 and 85 are a perspective view and up close perspective view
of a
molded middle sheet from above;
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[01811 Fig. 86 is a close up sectional view of the molded middle sheet of
Fig. 84;
[0182] Figs. 87 and 88 are a perspective view and up close perspective
view of the
molded middle sheet of Fig. 84 from below;
[01831 Figs. 89 and 90 are a perspective view and up close perspective
view of a
molded middle sheet with blocks extending in two directions;
[0184] Fig. 91 is a close up sectional view of the molded middle sheet of
Fig. 89;
[01851 Fig. 92 is a perspective view the molded middle sheet of Fig.89
from below;
[0186] Fig. 93 is a close up sectional view of the two mirror molded
sheets;
[0187] Figs. 94 ¨ 97 are perspective views of a single plenum panel in
multiple
stages of assembly;
[0188] Fig. 98 is a close up perspective view of a wire frame pyramid
shaped insert
embedded into a glob; and
[0189] Fig. 99 is a close up perspective view of a solid pyramid shaped
insert
embedded into a glob.
[0190] DETAILED DESCRIPTION OF THE DRAWINGS
[0191] As seen in Figs. 1 and 2, the panel 2 is comprised of a first sheet
4 and a
second sheet 6 fixedly mated together via spacing structural elements 8. In
one
embodiment the spacing structural elements 8 are comprised of a first layer 10
and
a second layer 12 of rectangular shaped elongated members 14, spaced apart
from
each other a predetermined spacing distance 16. The arrangement of elongated
members 14 in the first layer 10 is perpendicular to the arrangement of
elongated
members 14 in the second layer 12, forming a matrix 17 of elongated members
14.
[01921 As shown in Fig, 1; a first horizontal edge 18 and a second
horizontal edge
20 of the first sheet 4 substantially align with a first horizontal edge 22
and a second
horizontal edge 24 of the second sheet 6, respectfully. Similarly, a first
vertical edge
26 and a second vertical edge 28 of the first sheet substantially align with a
first
vertical edge 30 and a second vertical edge 32 of the second sheet 6,
respectfully.
For sake of clarity, the second sheet 5, though present each embodiment
depicted,
is not shown in Figs. 2, 3 and 6-10 below.
[0193] As shown in Fig. 3, the first 10 and the second layer 12 of
elongated
members 14 are indented a certain first distance 34 inward from the first
horizontal
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edges 18, 22 of the first and the second sheet 4, 6. The first 10 and the
second layer
12 of elongated members 14 correspondingly overlap the second horizontal edges
20, 24 of the first and the second sheet 4, 6 by the same first distance 34,
creating
first protruding segments 35. Similarly, the first 10 and the second layer 12
of
elongated members 14 are indented a certain second distance 36 inward from the
first vertical edges 26, 30 of the first and the second sheet 4, 6. Likewise,
the first 10
and the second layer 12 of elongated members 14 correspondingly overlap the
second vertical edges 28, 32 of the first and the second sheet 4, 6 by the
same
second distance 36, creating second protruding segments 37.
[0194] These matching indents and overlaps aid in fittingly mating a first
panel 2 to
a neighboring second panel 2 in a secure "tongue in grove" fashion. By
providing
corresponding indent and overlap on all four edges, a surface formed of
multiple
panels may be assembled faster, have increased strength and rigidity as a
unit, and
helps ensure a continued smooth panel surface. As in the embodiment shown, the
first distance 34 of indent and overlap with respect to the horizontal edges
can be
of the same value as the second distance 36 of indent and overlap in the
horizontal
direction. it is to be noted that the indent and overlap have been exaggerated
in Fig.
3, to show detail.
[01951 As shown in Fig. 4, a portion of the first protruding segments 35
that overlap
the second horizontal edges 20, 24 of the first and the second sheet 4, 6,
have a
chamfered edge 38. These chamfered edges facilitate inserting the first
protruding
segments 35 of the first 10 and the second layer 12 of a first panel 2 into a
second
adjacent panel 2, and specifically into a space provided by the inward indent
of the
elongated members 14 the first distance 34 from first horizontal edges 18, 22
of the
first 10 and the second layer12 of the adjacent panel. The chamfer on the
chamfered
edge 38 would terminate between 1/8" and 3/8" from the second horizontal edges
20, 24 of the first and the second sheet 4, 6, and preferably would terminate
approximately 1/4" from the second horizontal edges 20, 24 of the first and
the
second sheet 4, 6.
[01961 in a like manner a portion of the second protruding segments 37
that overlap
the second vertical edges 28, 32 of the first and the second sheet 4, 6, have
a
chamfered edge 38 (not shown). These chamfered edges similarly facilitate
inserting
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the second protruding segments 37 of the first 10 and the second layer 12 of a
first
panel 2 into a second adjacent panel 2, and specifically into the space
provided by
the inward indent of the elongated members 14 the second distance 36 from the
first
vertical edges 26, 30 of the first 10 and the second layer 12 of the adjacent
panel.
The chamfer on the chamfered edge 38 would terminate between 1/8" and 3/8"
from
the second vertical edges 28, 32 of the first and the second sheet 4, 6, and
preferably would terminate approximately 1/4" from the second vertical edges
28,
32 of the first and the second sheet 4, 6.
[0197] As shown in Fig. 5, the panel 2 may be mounted onto mounting
elements 40
such as roofing rafters or trusses, flooring joists, or wall studs, just as
normal
plywood or OSB board would be mounted ¨twelve inches on center. Because of the
panels' increased strength, they may be mounted to mounting elements 40 spaced
father apart than a plywood or OSB board of the same thickness as the sum of
the
thickness of the first and second sheet of the panel would require under
similar
conditions ¨ including allowing the panels to be mounted on mounting elements
40
spaced sixteen, twenty four, thirty six, forty two, forty eight, and ninety
six inches
apart on center.
[01981 Turning to Fig. 6, a plurality of plywood veneer strips 42 may also
function as
the elongated members 14. In such an embodiment, each elongated structural
element 14 may be made up of a plurality of plywood veneer strips 42, ranging
from
two to ten 1/8 inch plywood veneer strips 42 per elongated structural element
14,
and preferably six 1/8 inch plywood veneer strips 42 per elongated structural
element 14.
[01991 As shown in Fig. 7, the matrix 17 of elongated members 14 may be
arranged
diagonally with respect to the horizontal 18, 20, 22, 24 and vertical 26, 28,
30, 32
edges of the first and the second sheet 4, 6. In this embodiment, the
elongated
members 14 of the first layer 10 may be arranged at an angle of between 30
and
60" with respect to the first horizontal edge 18 of the first sheet 4, and
preferably at
an angle of 45'with respect to the first horizontal edge 18 of the first sheet
4. The
elongated members 14 of the second layer 12 may also be arranged at an angle
of
between 30 and 60' with respect to the first horizontal edge 18 of the first
sheet 4,
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and preferably at an angle of 45 with respect to the first horizontal edge 18
of the
first sheet 4.
[0200] As shown
in Figs. 8 through 10, the spacing structural elements 8 may also
be comprised of blocks 44 being preferably rectangular 46, circular 48, or
square 50
in shape. Though according to tests, panels 2 utilizing blocks 44 as the
spacing
structural elements 8 increased the strength of a comparable plywood board by
only
half as much as panels 2 utilizing elongated members 14 as the spacing
structural
elements 8, panels utilizing blocks 44 as the spacing structural elements 8
offer an
increased assortment of paths that a pipe, tube, wire, or other insert 52 may
be run
through the panel 2, especially if the insert has dimensions approaching one
half the
spacing between the first and second sheet 4,6.
[0201] As shown
in Figs. 8 and 9 the blocks 44 would also preferably be indented
a first and second distance 34, 36, and similarly have first and second
protruding
segments 35, 37, correspondingly overlapping their respective edges the same
first
and second distances 34, 36.
[0202] As shown
in Fig. 8, the blocks 44 could also be aligned diagonally with
respect to the horizontal 18, 20, 22, 24 and vertical 26, 28, 30, 32 edges of
the first
and the second sheet 4, 6, In this embodiment, the blocks 44 may be arranged
at
an angle of between 30' and 60 with respect to the first horizontal edge 18
of the
first sheet 4, and preferably at an angle of 45 with respect to the first
horizontal edge
18 of the first sheet 4.
[0203) As shown
in Fig. 11, the protruding segments 35, 37 of the blocks 44 would
similarly be provided with a chamfered edge 38, to assist in inserting the
protruding
segments 35, 37 of the blocks of a first panel 2 into the space provided by
the blocks
44 of an adjacent second panel 2 indented at least as much as the distance the
protruding segments 35, 37 protrude past the edge of the first and the second
sheet
4, 6,
[0204] Turning
to Fig. 12, a perforated panel 2' with a perforated first sheet 4' is
shown. The perforations 46 are arranged in a matrix type arrangement and
facilitate
the passage of air from the outside of the perforated panel 2', through the
perforated
first sheet 4', via the plurality of perforations 46 into the interior of the
perforated
panel 2'. The perforations 46 are through holes of between 1/16 inches and
11/2
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inches in diameter, and preferably between 1/4 inches and 1 inch in diameter,
and
most preferably between 3/8 inches and 5/8 inches in diameter. The matrix
arrangement may be staggered, with each hole spaced between 4 arid 12
diameters
from adjacent holes. Additionally, a layer of screening 80 (not shown) may be
attached to the inner surface of the perforated first sheet 4'. The perforated
panel
2' is constructed in a similar manner to the non-perforated panel 2, with the
exception of perforating or using a perforated first sheet 4', and the
perforated panel
2' may be used in the same manner as the non-perforated panel 2.
[0205] Turning to Figs. 13A and 13B, two panel roofing arrangements are
shown.
Fig. 13A shows a panel arrangement suited for unfinished attics and non-living
spaces. The panels 2, 2' are arranged so that neither the first nor the second
sheets
4, 4', 6 of the panels 2, 2' opposite the ridge meet, leaving an interior
ridge gap 48
and an exterior ridge gap. The ridge will be capped with a ridge vent 52. The
bottommost terminal edges 56 of the panels 2, 2' will be include a screen 54,
insect
block 58, or other permeable occlusion, arranged to allow air passage into the
interior of the panels 2, 2', but hinder insect entry.
[0206] Fig. 1313 shows a panel arrangement suited for finished attics and
living
spaces. The panels 2, 2' are arranged so that the first sheets 4, 4' of the
panels 2,
2' opposite the ridge meet, forming a solid interior ridge 50, but the second
sheets
6 of the panels 2, 2' opposite the ridge meet do not meet, leaving an exterior
ridge
gap. The ridge will be capped with a ridge vent 52, and the bottommost
terminal
edges 56 of the panels 2, 2' will be likewise permeably occluded.
[0207] As shown in Fig. 14, a panel arrangement for an unoccupied attic is
demonstrated. Panels 2, 2' are arranged on trusses and rafters 60 so as to
leave
an interior ridge gap 48 and an exterior ridge gap, as described in Fig. 13A.
The
ridge is capped by a ridge vent 52, Warm, moist air 62 from the interior of
the house
is exhausted through the ridge vent, via the interior ridge gap 48 and
exterior ridge
gap. The panels are installed with the permeably occluded 54, 58 terminal
edges
56 adjacent to openings in soffits or lower fascia (not shown). Cooler air 64
enters
through the permeably occluded 54, 58 terminal edges 56, travels through the
interior of the panels 2, 2', absorbing heat from the first and the second
sheets 4, 4',
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6 and mixing with warm moist air entering through perforations 46, and exits
through
the ridge vent 52, via the exterior ridge gap.
=
{02081 As shown in Fig. 15A, a panel arrangement for an occupied attic
or directly
roofed living space is demonstrated. Panels 2, 2' are arranged on trusses and
rafters
60 so as to leave an only an exterior ridge gap, as described in Fig. 138. The
ridge
is capped by a ridge vent 52. Warm, moist air 62 progresses from the interior
of the
house through insulation 65 and transfers its heat and moisture to the
insulation 65
and first sheets 4,4' of the panels 2, 2'. The panels are installed with the
permeably
occluded 54, 58 terminal edges 56 adjacent to openings in soffits or lower
fascia (not
shown). Cooler air 64 enters through the permeably occluded 54, 58 terminal
edges
56, travels through the interior of the panels 2, 2', absorbing heat from the
first and
the second sheets 4, 4', 6 and exits warm air 62 through the ridge vent 52,
via the
exterior ridge gap. The upper terminal edges 56 forming the upper ridge gaps
in
each embodiment may also be permeably occluded 54, 58.
[0209] As shown in Fig. 158 a panel arrangement for an unoccupied attic
space,
using perforated panels is demonstrated. The perforated panels 2' are arranged
such that the perforated first sheet faces the interior of the building,
allowing warm
air 62 to directly enter into the interior of the panel matrix through the
perforations
46, from multiple locations in the attic space. Because of the increased
ventilation
due to the perforations 46 in the perforated panels 2', the panels may be
arranged
either with or without an interior ridge gap 48. It is envisioned that a ridge
vent 52
will be used to cap an exterior ridge gap (not shown) to allow the exhaust of
warm
air 64 out of the panel matrix, and in combination may be used with one or
more
gabled vents (not shown).
[02101 As shown in Figs. 16 and 17, the perforated panels 2' and non-
perforated
panels 2 may be used in conjunction in a roofing construction arrangement. In
one
embodiment, the perforated panels 2' are arranged in the top one or more rows
of
the roof sheathing and the non-perforated panels 2 are arranged in the bottom
one
or more rows of roof sheathing. The inner first sheets 4' of the upper rows of
panels
2' normally lack abutting insulation 65, allowing warm moist air to more
freely enter
perforations 46. The inner first sheets 4 of the lower rows of panels 2
normally have
abutting insulation 65, diminishing air transfer rates through perforations
46, and
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CA 02873353 2014-12-05
therefore would normally have non-perforated first sheets 4. It is to be
appreciated
that sheeting arrangements of all perforated panels 2', all non-perforated
panels 2,
or any combination of perforated and non-perforated panels 2' 2, would still
fall in the
scope of this invention.
[0211] Turning now to Figs. 18 and 19, the panels may be
likewise used in wall
= sheathing and flooring. As shown in Fig. 18, a panel 2, 2' may be
attached to a wall
joist/wall stud 66 and floor joist 68, in a similar manner as traditional
sheeting
materials. As with roofing embodiments, the terminal edges 56 will include
permeable occlusions 54, 58. In one embodiment, a terminal gap 74, facilitated
by
joist spacing elements 72, here proximate to the ceiling joists 70, provides a
passageway for air to inter and exit the interior of the panels 2, 2'.
[0212] In the embodiment shown in Fig. 19, a panel 2, 2' is
attached to an insulated
65 wall joist/wall stud and a floor joist 68, with siding 76 attached to the
exterior
sheet of the panels 2, 2'. The flooring panel 2, 2' contains a layer of
screening 80
between the first layer 10 and the second layer 12 of elongated members 14.
Cool
air 64 enters the panel 2, 2' interior by passing through a lower terminal gap
74,
facilitated by joist spacing elements 72, then through the permeably occluded
54, 58
lower terminal edge 56, moves up through the interior of the panel 2, 2'
absorbing
heat and moisture from the first and the second sheets 4, 4', 6, and exits
warm air
62 through the permeably occluded 54, 58 upper terminal edge 56, and out an
upper
terminal gap 74. The air flow may be channeled by one or more first channeling
component 78, and as shown in Fig. 20, one ore more second channeling
components 82. The first and the second channeling components may be
decorative as well as functional, and serve additionally as housing trim.
[0213] Fig. 20 shows a close up of the upper section of Fig.
19, indicated as portion
A, showing in detail the upper terminal gap, and the first and the second
channeling
components 78, 82.
[0214] Turning to Figs. 21 and 22. A first sheet 4A of a panel 2A with
integrated
spacing structural elements 8A is shown. The spacing structural elements 8A
may
take the form of, for example, integrated blocks 44A (not shown) or integrated
elongated members 14A. In panels 2A employing integrated elongated members
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CA 02873353 2014-12-05
14A, the integrated elongated members 14A generally run horizontally on a
first
sheet 4A and will generally run vertically on a second sheet 6A.
[0215] Turning to Figs. 23, 24, and 26A-D, the profiles of the integrated
elongated
members are generally either rectangular 100, square 101, or curved 102, or
some
combination of each, depending upon the application requirements, each
providing
a plurality of parallel, unobstructed, contiguous pathways 5. As shown in Fig.
26, for
example, the integrated elongated members may have flat tops 104, flat sides
106,
and angled edges 108, and/or curved tops 110, curved sides 112, and rounded
edges 114 or chamfered edges 116. Additionally the sides maybe perpendicular
where they intersect the top and/or the interior surface of the sheet 4A, 6A,
or at a
non-perpendicular angle.
[0216] As shown in Fig. 25, similar to panels 2' described above, a first
sheet 4A'
and/or second sheet 6A' of panels 2A'with integrated elongated members 14A may
also possess perforations 46A, and may be used in similar embodiments as those
described in paragraphs above.
[0217] Turning to Fig. 27, a panel 2A comprised of a first and a second
sheet 4A, 6A,
each having integrated elongated members14A. In this embodiment, the
integrated
members 14A on the first sheet 4A are arranged parallel to the integrated
members
14A on the second sheet 6A. This arrangement allows the integrated members 14A
on the first sheet 4A to be nested within the spacing distance 16 separating
the
integrated members 14A on the second sheet 6A from one another, when the first
and the second sheet 4A, 6A are brought together to form the panel 2A. In the
same
way, this allows the integrated members 14A on the second sheet 6A to be
nested
within the spacing distance 16 separating the integrated members 14A on the
first
sheet 4A from one another. The integrated members 14 A on the first sheet 4A
would attach directly to the interior surface of the second sheet 6A in this
embodiment. The parallel unobstructed continuous pathways 5 for air would be
defined by the interior surface of the first and second sheets 4A, 6A and
their
respective integrated members 14A, similar to a other single layer
embodiments, as
compared to being defined by the interior surface of one of the first sheet
and
second sheet 4A, 6A, and at least three separate elongated members 14, 14A, as
in multiple layer embodiments.
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CA 02873353 2014-12-05
[0218] In a related embodiment, integrated elongated members 14A of a
first and
second sheet 4A, 6A could be arranged parallel such that, instead of nesting
within
respective spacing distances 16 in the posing sheets 4A, 6A, as shown in Fig.
27,
the parallel elongated members 14A of each sheet 4A, 6A could stack
substantially
directly on top of one another along the full length of the elongated members
14 A
not shown). This would create parallel unobstructed continuous pathways 5 for
air
that would be two elongated members 14A high, and defined by for elongated
members 14A, two from each of the first and the second sheet 4A, 6A, and the
interior surface of both the first sheet 4A and the second sheet, 6A.
[0219] Turning to Fig. 28, a panel 2 is shown wherein the respective
elongated
members 14 of the first and the second sheets 4A, 6A interacts with one
another at
their point of attachment in a notch/recess fashion. At the point where a
first
elongated member 14 contacts a second elongated member 14, one or both of the
first and the second elongated member 14 is provided with a notch 118. In the
case
where only one of the first nor the second elongated member is provided with a
notch 118 at their point of interaction, this allows either the first or
second elongated
member 14 to recess into the notch 118 on the opposed elongated member 14. Or,
in the case that both the first and second elongated members 14 are provided
with
opposing notches 118 at the point of interaction, this allows each elongated
member
to recess into the notches 118 provided on the opposed elongated member 14.
While this notch/recess arrangement creates a potentially stronger bond
amongst
the elongated members 14 and therefore the panel 2 as a whole, at the same
time
this decreases the size of the parallel, contiguous, unobstructed pathways 5
for air
within the panel 2.
[0220] Additional embodiments of the elongated matrix members 14 are
envisioned.
In their simplest form, an elongated matrix member 14 is a stick or extrusion
with a
square or rectangular cross section and a length equal to a parallel axis of
the sheet
4, 6 to which it is attached. The elongated matrix members 14 are ideally/4" x
'A"
in cross section, but, as mentioned above, can be larger (2" or greater) or
smaller
(1/4" or smaller) as required for the application. The elongated matrix
members 14
are preferably attached to at least one sheet 4, 6 and to one another where
multiple
layers of elongated matrix members 14 intersect, in order to transfer shear
stresses,
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though the elongated matrix members 14 may have one or more locations where
they intersect that they are not attached, in order to increase flexibility of
the overall
panel, as may be required in certain situations.
[0221] Additionally, engineered matrix members 120 can be utilized and
manufactured from a variety of materials, like organic, wood, cellulose or
other
fibrous materials, plastics, metals or other materials that can be shaped or
extruded,
and can be formed into the square or rectangular cross sectional shapes
discussed
previously, or formed into one of many specialized shapes.
[0222] Specialized shaped engineered matrix members 120 will preferably
have a
first flat section 122 with a rectangular outer face, an opposed second flat
section
124 with a rectangular outer face, and transverse section 126 connecting an
inner
face of the first flat section 122 to an inner face of the second flat section
124. The
outer face of at least one of the first and the second flat section 122, 124
will
preferably be attached to at least one of a sheet 4, 6 and an outer face of a
first or
a second flat section 122, 124 of an additional specialized shaped engineered
matrix
member 120 disposed in an adjacent layer. The range of shapes and structures
of
the specialized shaped engineered matrix members 120 will vary mainly based
upon
the design of the transverse section 126.
[0223] In a first embodiment of specialized shaped engineered matrix
members 120,
"I" beam shaped members 125 are formed by the first and second flat sections
122,
124 of engineered matrix members 120 being joined by a relatively thin and
elongate
transverse section 126. The thin elongate transverse section 126 and the inner
faces of the first and the second flat sections 122, 124 define two narrow
channels,
one on each side of the thin elongate transverse section. These narrow
channels
act to increase the size of parallel, contiguous, unobstructed pathways 5 for
air to
pass between two adjacent "I" beam shaped members 125 of a common layer, as
compared to similarly spaced elongated members 14 with a square or rectangular
cross section.
[0224] Additionally, the thin elongate transverse sections 126 in the "1"
beam shaped
members 125 may be solid or perforated. The perforated "I" beam shaped members
125 offer the benefit of enhanced cross ventilation performance and increase
the
interior cabling options of the panels, as the perforations 128 provide
additional
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CA 02873353 2014-12-05
pathways 129 for air and/or cables to pass through the panel 2, and through
the very
"I" beam shaped members 125. Either perforated or solid, the "I" beam shaped
members 125 offer the benefit of being easily extruded and utilized in a panel
2.
[0225] Turning to Fig. 30, in a second embodiment of specialized shaped
engineered
matrix members 120, "truss" shaped members 130 are constructed by the first
and
second flat sections 122, 124 of engineered matrix members 120 being joined by
a
truss web 132 transverse section 126. The truss web 132 is formed of a
plurality of
truss web supports 134 that can be both diagonal supports of the same or
varying
angles, and vertical supports. The truss web supports 134 will normally be of
approximately an equal width as that of the first and the second flat sections
122,
124.
[02261 In a first embodiment of truss shaped members 130, the truss web 126
is
comprised of a plurality of diagonal truss web supports 134 that form a
continuous
series of triangles down the length of the truss shaped member 130. That is,
except
for terminal ends of the truss shaped members, at each intersection of a
diagonal
truss web support 134 with the inner face of the first and the second flat
sections
122, 124, another diagonal truss will also intersect the same inner face of
the first
and the second fiat sections 122, 124 at an adjacent location. Such adjacent
intersections form a triangulated parallel chord truss. The truss web supports
134
can be comprised of folded or formed material, and similar to the perforated
"I" beam
shaped members 125, the truss shaped members 130 to facilitate additional air
flow
and additional pathways for running cables and pipes through the panels 2,
especially with the additional pathways diagonally and orthogonally through
the
specialized shaped engineered matrix members 120.
[0227] Turning to Fig. 31, in a second embodiment of truss shaped members
130,
the intersection of the diagonal truss web supports 134 with the inner face of
the first
and the second flat sections 122, 124 can be spaced either a fixed or varying
distance from one another. These "skip truss" shaped members 136 are similar
to
the truss shaped members 130, but because they have less truss web supports
134,
they are less costly to manufacture and fabricate and offer increased size and
angles of pathways through the panels 2 and the specialized shaped engineered
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= CA 02873353 2014-12-05
matrix members 120, while still retaining much of the superior strength
qualities of
the truss shaped members 130.
= [0228] Turning to Fig. 32, in a third embodiment of specialized
shaped engineered
matrix members 120, honeycomb shaped members 138 are constructed by the first
and second fiat sections 122, 124 of engineered matrix members 120 being
joined
by a honeycomb web 140 transverse section 126. The honeycomb web 140 is
formed by a plurality of honeycomb or other repeating open geometric shapes
connected to one another, and arranged such that an axis of opening B-B is
disposed perpendicular to a long axis A-A. Similar to the perforated "1" beam
shaped members 125 and the truss shaped members 130, the honeycomb web 140
of the honeycomb shaped members 138 facilitates additional air flow and
additional
pathways 129 for running cables and pipes through the panels 2, especially
with the
additional pathways diagonally and orthogonally through the specialized shaped
engineered matrix members 120.
[0229j Turning to Fig. 33, in a fourth embodiment of specialized shaped
engineered
matrix members 120, corrugated shaped members 142 are constructed by the first
and second flat sections 122, 124 of engineered matrix members 120 being
joined
by a corrugated or sinusoidal type curved web 144 transverse section 126. The
peaks and the troughs of the corrugated web 144 attach to the inner faces of
the first
and second flat sections 122, and curving a path in-between. The curved shape
of
the corrugated web 144 provides a different profile and potentially wider
pathways
129 for air flow and running cables, as compared to the truss shaped members
130.
[0230]
The specialized shaped engineered matrix members 120 may be used in all
situations as the rectangular shaped elongate members 14. The specialized
shaped
engineered matrix members 120 may be formed in a separate process and later
attached to the sheets 4,6, or, similar to the integrated elongated members
'14A, the
specialized shaped engineered matrix members 120 may be formed, in whole OF
part, together with the sheets 4A, 6A. Panels 2 may be constructed out of all
non-
engineered spacing structural elements 8, all engineered matrix members 120,
or
some combination of each.
[0231]
Turning now to Figs. 34 - 37 a further additional embodiment of the
invention
disclosed herein is disclosed. As can be seen, in this multi-plenum panel 202
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CA 02873353 2014-12-05
embodiment an additional top third sheet 204, parallel in plane with both the
first
(now middle) sheet 206, and the second (now bottom) sheet 208, has been
affixed
to the now multi-plenum panel 202 with blocks 210, to create two separate
plenums
¨ a upper plenum 212 and a lower plenum 214. The plenums 212, 214 extend from
one multi-plenum panel 202 to adjacent multi-plenum panels 202 such that the
top
and the lower plenums 212, 214 can extend the length and width of an entire
floor
of a building. The three sheets 204, 206, 208 are ideally joined by regularly
spaced
blocks 210, which provide excellent strength characteristics and superior
clearance
between the top and middle sheets 204, 206 and between the middle and bottom
sheets 206, 208, facilitating air flow and running pipes or wires as needed.
[0232] The multi-plenum panel 202 is preferably composed of three
sheets of
plywood or OSB preferably in the standard size of 4 x 8 foot sheets. The
sheets are
nominally 1/4 inch thickness. The sheets are spaced from, and joined to one
another
by blocks 210, preferably made of standard framing lumber of 2 x 4 inch
nominal
size (3.5 inch x 3.5 inch x 154 inch), because of the high strength to weight
ratio of
wood, combined with its relative high availability and low cost. The blocks
210 are
preferably spaced 7 inches on center each way. The blocks 210 are fastened
with
adhesive and/or mechanical means to enable the essential shear transfer to the
middle sheet 206. The blocks 210 of the lower plenum 214 are preferably
vertically
aligned with the blocks 210 of the upper plenum 212, to allow for better
transfer of
stress. The size and spacing of the blocks 210 may be changed, but should
ideally
provide for at least three unobstructed air pathways 216 per every 24 liner
inches
along the edge of the multi-plenum panels 202 in each plenum. That is, both
three
pathways 216 in the upper plenum 212 and three pathways 216 in the lower
plenum
214 per every 24 liner inches of the multi-plenum panel 202. Additionally, as
shown
in Fig. 35, there is ideally a pathway 216 between each row of backs 210,
along both
the long and short edges of the multi-plenum panel 202. In Fig. 35, there are
at
least ten pathways 216 between the two long edges and at least five longer
pathways 216 between the two short edges per each plenum 212, 214. Each
unobstructed pathway 216 should ideally measure between Sand 6 square inches,
= and preferably be over 5.5 square inches in size, and should extend
continuously
from one edge of a multi-plenum panel 202 to another, opposite edge of a multi-
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plenum panel 202. It is anticipated that only plenum taps 218, registers 220,
and
plenum tubes 222 (each described fully below) will substantially impede these
unobstructed pathways 216. These pathways 216 will allow for the easy passage
of supply and return air, and facilitate easy placement of wire, cables, and
pipes
through the multi-plenum panels 202, without substantially impeding the
passage of
air.
[0233] The multi-plenum panel 202 allows for large spans for flooring
applications
of 48 inches with minimal deflection even when using IA inch sheets 204, 206,
208.
Ideally, the top sheet 204 may be thicker ('8 inch or 1/2 inch). The
structural
mechanism is that the middle sheet 206 facilitates the necessary shear
transfer for
the multi-plenum panel 202 to act as an "I" beam with significant strength and
stiffness.
[0234] Ideally, the blocks 210 are a 15/8 inch thick, which is the
common thickness
of finished structural lumber typically used in the building trades; however,
the
thickness could be larger or smaller depending on span requirements and air
distribution requirements. =
[0235] As shown in Fig. 38, the blocks 210 may be inset
preferably 15/8 inches from
the edge. In such an arrangement, a strip 224 of 15/8 inches x 1 5/8 inches by
either
48 inches or 96 inches to be inserted along the edge for bearing strength.
Additionally, foam sealant 226 of closed or open cell material could be
applied along
one or all edges either at the factory or in the field. This is primarily for
edges of
multi-plenum panels 202 that will form the boundary of the plenums, that is,
the
edges that are not joined to other multi-plenum panels 202. The sealant 226
helps
prevent supply air from leaking from the plenums to unintended surrounding
space.
Additionally, the edge of the multi-plenum panels 202 may be sealed with
impenetrable and/or airtight tape (not shown).
[0236] Where two adjacent multi-plenum panels 202 are joined,
a maximum
= unobstructed flow of air between the respective plenums of the adjacent
multi-
plenum panels 202 is desired ¨taking into account structural support
requirements.
Therefore, a perforated strip may be used on all edges, to both increase
bearing
strength, but still allow for panel to panel flow of air. Alternatively,
blocks 210 may
be arranged flush with the edges, or additional blocks 210 or larger blocks
210 may
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CA 02873353 2014-12-05
be used to reach the edges of the sheets, to aid in bearing strength, while
still
maintaining air pathways 216. Additionally, the blocks may extend beyond the
edges of one or more sheets 204, 206, 208, on one or more edges of the multi-
plenum panels 202, and on a corresponding opposite edge of the one or more
sheets 204, 206, 208, the blocks can be recessed from the edge by a similar
amount. This will allow the blocks from a first multi-plenum panel 202 to
matingly
fit in a recess space in the plenum of an adjacent second multi-plenum panel
202
to which the first multi-plenum panel 202 is to be joined. Additionally, or
alternatively, the blocks may be convexly chamfered on one edge of the multi-
plenum panel 202, and the blocks may be concavely indented along an opposing
edge of the panel 202 ¨ either the convexly chamfered or the concavely
indented
blocks or both may extend beyond the edge of the sheets 204, 206, 208, and
fittingly
mate with one another when two multi-plenum panels 202 are abutted side by
side
with one another, parallel in plane.
[0237] The multi-plenum panels 202 would be installed like regular
sheathing using
a combination of adhesive along the joists 228 and preferably screws through a
series of blocks 210 into the joist 228. But as discussed above, because of
the
dramatically increased strength of the multi-plenum panels 202 verses regular
floor
sheathing, the joists 228 may be spaced at much greater distances from one
another, including 48 inches on center, or farther,
[0238] The locations of the blocks 210 would be marked or otherwise shown
on the
exterior of the top and the bottom sheets 204, 208 to facilitate register 220
placement and plenum taps 218, and otherwise aid in installation of the multi-
plenum
panels 202.
[0239] The multi-plenum panels 202 will preferably include necessary plenum
taps
218 in dimensions suitable for commercially available duct covers or registers
220
which are typically in size of 2x10, 2x12, 4x10, 4x12, 4x16, and other sizes.
[0240] As shown in the cutaway in Fig. 39, tapping into the upper plenum
212 only
requires cutting a hole suitably sized for the register 220. Tapping into the
lower
plenums 214, on the other hand, will normally require a lower plenum tap 213,
as
shown in Figs. 40 - 42. The opening in the top sheet 204 for the lower plenum
tap
218 is approximately 1 inch larger than the opening in the bottom sheet 208,
This
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CA 02873353 2014-12-05
facilitates cutting the bottom hole and securely attaching the plenum tap 218
to both
sheets 204, 206 with caulking and mechanical means. The lower plenum tap 218
can be sized to fit standard registers 220.
[0241] The plenum taps 218 should be installed with caulk under all
flanges and with
screws. Plenum taps 218 can be constructed from either sheet metal or plastic.
= [0242] As shown in Fig. 43, the plenum taps 218 can be constructed
with one or
more selector doors 230 and selector levers 232. If the selector lever is in a
first
position (as shown), the plenum tap selector doors 230 open an air pathway to
the
lower plenum 214 and close an air pathway to the upper plenum 212. Conversely,
if the selector levers 232 are moved to a second position, the plenum tap
selector
doors 230 fold down to open the air pathway to the upper plenum 212 and close
the
air pathway to the lower plenum 214. This way, for example, if warm air is
supplied
through the upper plenum 212 and cold air is supplied through the lower plenum
214, a given register 220 can function as a supply register 220 regardless of
whether
the upper or lower plenum 212, 214 is supplying the air. If the lower plenum
214
supplies cold air, the selector levers 232 are moved to the first position,
the plenum
tap selector doors 230 access the lower plenum 214 for air supply and close
off the
upper plenum 212, to keep air from leaking from the supply (here lower) plenum
into
the return (here upper) plenum. Conversely, if the upper plenum 212 supplies
warm
air, the selector levers 232 are moved to the second position, the plenum tap
selector doors 230 then access the upper plenum 212 for air supply and close
off the
lower plenum 214. The same principle will work for return registers 220
affixed to the
plenum taps 218 constructed with selector doors 230 and selector levers 232.
One
register 220 connected to such a plenum tap 218 may be used as a return
register
220 regardless of which plenum is supplying air, as the plenum for return air
may be
selected with the selector lever. This way, dedicated supply registers 220 can
be
placed near the exterior walls of the building and dedicated return registers
220 may
be placed more toward the interior of the building, each accessing the upper
or lower
plenums 212, 214 as need be.
[0243] This multi-plenum panel flooring/air supply system
would provide many
advantages. For example, the multi-plenum panels 202 allow air distribution
with
substantially less or no ductwork. This leads to shorter construction time,
cost
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CA 02873353 2014-12-05
savings, and decreased space requirements. The cost of ductwork for an average
sized house can easily be $6,000 to $10,000, depending on complexity and
design.
If the savings are assumed to be $7,000 on an average house this would equate
to
a savings value potential of $86.15 per multi-plenum panel 202 used for
flooring.
[0244] Also, the multi-plenum panels 202 easily allow air distribution
to any location
in any room. The multi-plenum panel 202 allows air distribution to smaller
spaces
that conventionally are not supplied conditioned air due to the cost relative
to room
size such as small bathrooms, laundry rooms, walk-in closets, pantries, small
dens/studies. Because of the cost effectiveness, the multi-plenum panel 202
can
inexpensively deliver conditioned air to and provide a cold/hot air return
from every
room, including closets. This is something only very elaborate and expensive
systems now provide, because of the high costs providing a complete dual duct
system involve.
[0245]
As an additional benefit, if the upper plenum 212 is used to deliver
heated air
in the winter, the warmed upper plenum 212 can radiantly create and provide a
warm floor to every room on a given level. This is a very desirable feature
normally
only available by using an expensive liquid radiant heating system.
=
[0246] The same procedure is used for providing cool air distribution
in the summer.
However, to prevent cold floors, if they are undesired, the cool supply could
be
directed to the lower plenum 214 while the return warmer air to the upper
plenum
212.
[0247] If the two plenums are un-insulated between one another, the
return air
traveling through the return air plenum may be tempered, that is, heated or
cooled,
by the supply air in the supply air plenum. This offers the benefits of a
built in air
= exchanger recapturing heat loss or cooling losses.
[0248]
Testing shows deflections in the range of 1/200 for a 150 pound per
square
foot load having a 48 inch span. For a load more typical of residential
design, the
multi-plenum panel 202 would expect a deflection of 1/600 for a 48 inch span -
greatly exceeding typical design criteria and expanding design building
possibilities.
[0249]
Using a 48 inch span for flooring would reduce the number of joists 228
required for the flooring by two thirds, saving significant material and labor
costs.
These savings could be around $3,000 for a typical house. Additionally, the
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CA 02873353 2014-12-05
electrical, mechanical, and plumbing trades would also benefit from having two
thirds
less obstacles (joists 228) to run their various wires, ducts and pipes.
Again, savings
could be significant to these trades, and could be around $2,000 for a typical
house.
Thus, there are significant savings in time, labor, and money that are
associated with
utilizing a multi-plenum panel 202 for combined flooring and air supply.
Savings of
around $12,000 for a typical house are envisioned, equating to a $127 savings
per
multi-plenum panel 202, for the 94 multi-plenum panels 202 in such a house.
[0250] The multi-plenum panels 202 can provide for the distribution of air
through the
ceiling of a lower level 234 (e.g., first story) and the floor of an upper
space (e.g.,
second story), to the air of an upper level 236. This means one multi-plenum
panel
202 directly connected to a central heating and/or cooling unit 238 can supply
and
return air to two stories or levels at once. For such a design, flooring multi-
plenum
panels 202 used to support a second story 236 would use longer plenum taps 218
to access air distribution from a first story 234 for the second story 236.
That is, to
reach and be flush with the first story ceiling, directly below the second
story flooring
multi-plenum panels 202, longer plenum taps 218 would be required to
accommodate the inter-story joist 228 thickness. Such first story 234 to
second
story 236 plenum taps 218 would allow direct condition air supplied multi-
plenum
panels 202 under the first story 234 to supply conditioned and return air a
two story
building,
[0251] Turning now to Fig. 44, an air distribution system using multi-
plenum panels
202 as described is shown. In the example shown, in a basement or lowest level
240 of a building a central heater/air conditioner 238 supplies heated air
through a
supply trunk 242 to an upper plenum 212 of the multi-plenum panels 202 of a
first
story 234. The forced heated air spreads out across the upper plenum 212,
remaining separate from the lower plenum 214, and exits the upper plenum 212
in
one of a plurality of registers 220 tapped into the upper plenum 212 (only one
upper
plenum 212 register 220 is shown). The heated air dissipates through the first
story
234 air space, heating the first story 234 air. The heated air continues to
rise,
passing through a longer second story plenum tap 218 and register 220 and into
a
second story 236 air space. Some of the air will cool down and pass from the
second story 236 air space, through an additional longer second story 236
plenum
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CA 02873353 2014-12-05
tap 218 and back into the first story 234 air space. It is also envisioned
that the
longer second floor plenum taps 218 may be electrically wired and narrow fans
(not
shown) will be placed in the longer second story 236 plenum taps 218 to aid in
air
circulation. Once cooler air is in the first story 234 air space, it is then
returned via
suction or lower air pressure through one of a plurality of registers 220
tapped into
the lower plenum 214 of the multi-plenum panels 202 of the first story 234
(only one
lower plenum 214 register 220 is shown). A return trunk 244 then brings the
cooler
return air from the lower plenum 214 back to the central heater/air
conditioner 238
in the lowest level 240, to be heated, and begin the process over again.
[0252] In a further example of an air distribution system using multi-
plenum panels
202, as shown in Fig. 45, the central heater/air conditioner 238 supplies
forced air
and receives return air directly from both the first and second story 234, 236
multi-
plenum panels 202. A separate supply trunk 242 attaches to the upper plenum
212
of the multi-plenum panels 202 on each of the first and second stories 234,
236.
Similarly, a separate return trunk 244 attaches to the lower plenum 214 of the
multi-
plenum panels 202 on each of the first and second stories 234, 236. By
directly
supplying and returning air from each of the two stories 234, 236, the climate
of the
two stories 234, 236 may be controlled to a higher specificity, resulting in
higher
comfort levels for building occupants.
[0253] Turning now to Figs. 46 and 47, the connection of the air supply
and return
trunks 242, 244 to the multi-plenum panels 202 will be discussed. As shown,
the air
supply and return trunks 242, 244 preferably to do not deliver and receive air
from
the multi-plenum panels 202 through a single large opening. Rather, a
plurality of
smaller, preferably circular, openings or mating holes 246 are coupled to
circular
plenum tubes 222 to form the connection between the trunks 242, 244 and the
respective plenums 212, 214. In this embodiment, the trunks 242, 244 extend to
the
lower face of the bottom sheet 208. For the return trunk 244, a plurality of
smaller
circular plenum tubes 222 extends from the trunk 244, through circular mating
holes
= 246 in the bottom sheet 208, and into the lower plenum 214. The return
plenum
tubes 222 will preferably each have flanges to be secured to the inside face
of the
bottom sheet 208. For the supply trunk 242, a similar plurality of smaller
plenum
tubes 222 extends from the trunk 242, through circular mating holes 246 in the
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CA 02873353 2014-12-05
bottom sheet 208, and into the lower plenum 214, and continues through the
lower
plenum 214, through circular matting holes 246 in the middle sheet 206, and
into the
upper plenum 212. Though the supply plenum tubes 222 extend through the lower
plenum 214, they do not exchange air with the lower plenum 214. Similarly, the
supply plenum tubes 222 will preferably have flanges to be secured to the
upper
face of the middle sheet 206. The supply plenum tubes 222 may be insulated to
prevent heat exchange when crossing the lower plenum 214.
[0254] By transitioning between the trunks 242, 244 and the plenums 212,
214 via
the plurality of smaller openings (mating holes 246), the structural integrity
of sheets
208, 206 and the multi-plenum panel 202 as a whole are better maintained.
Additionally, by shaping the openings 246 as circles, the openings 246 avoid
high
stress/lower strength corners of regular polygon shapes. The supply and return
trunks 242, 244 may both be connected to the same multi-plenum panel 202, but
preferably are connected to separate multi-plenum panels 202, to better
dissipate
the structural weakness caused by forming the mating holes 246 in the sheets.
[0255] Turning to Fig. 48, a single multi-plenum panel 202 is shown
supported by
joists 228 spaced 48 inches off center. Preferably, the joists 228 will be
aligned
under the blocks 210, to aid in stress transfer. At the intersection of two
multi-
plenum panels 202, additional blocks 210, longer blocks 210, or some other
insert
may be placed in the plenums to aid in stress transfer.
[0256] Turning to Fig. 49, a detail of the edge of a lower level or first
story multi-
plenum panel 202 is shown. Along the perimeter of the multi-plenum panel 202,
a
strip 224 has been inserted to better bear the load of the exterior wall 248
above.
The joist 228 below the multi-plenum pane! 202 is vertically aligned with the
strip
above the joist 228 and the foundation wall 250 below.
[0257] As seen in Figs. 50 - 52, different means may be used to connect
adjacent
multi-plenum panels 202 to one another. As the multi-plenum panels 202 will be
carrying pressurized air in at least one of the two plenums 212, 214, it is
important
to minimize air leakage from the pressurized plenum to the surrounding air
space.
Further, because, unlike traditional ductwork, the multi-plenum panels 202
serve a
primary structural support function also, it is important to transfer stresses
at the
edge of the multi-plenum panels 202 and provide structural continuity among
all
CA 02873353 2014-12-05
multi-plenum panels 202 joined on a single floor. To assist in reducing air
leakage
at the intersection of two adjacent multi-plenum panels 202, special shaped
sheet
edges or joining attachments are used.
[0258] Fig. 50 shows a tongue and groove pattern 252 along the edges of
adjacent
multi-plenum panels 202. The tongue of a first sheet 204, 206, 208 will be
inserted
into a mating groove of an adjacent sheet 204, 206, 208, and provides a
continuous
connection that transfers stress in both directions and minimizes air flow.
Adhesive
and/or caulking would also preferably be applied in the tongue and groove
fitting
252, to increase the strength of the bond and decrease any air losses.
[0259] Fig. 51 shows a lap joint 254, where two mating edges are
joined. This
method may be easier to be used with thinner sheets 204, 206, 208 are joined
together. Adhesive and/or caulk would preferably be applied along the joint to
help
minimize air loss and also increase joint strength in both directions of
vertical
stresses.
[0260] Fig. 52 shows an elongated "He clip 256, which could be
constructed from
metal or plastics, to connect the sheets 204, 206, 208 of adjacent multi-
plenum
panels 202. Adhesive and/or caulk could be used in conjunction with the clips
256.
The clips 256 would be attached to the edges of the sheets 204, 206, 208, and
are
intended to be continuous and either 48 inches or 96 inches in length. Though
the
edges shown in this figure are rectangular, alternate shaped edges, like those
shown
in Figs. 50 and 51, or other non-rectangular edges could be used with clips
256 that
= are shaped to be flush with each connecting edge. Such alternate clips
256 would,
therefore, not necessarily be shaped like the "H" in Fig. 47, but would shaped
to
mirror whatever non-rectangular edges of the sheets 204, 206, 208 joined, An
advantage of using the clips 256 to mate the edges of two sheets 204, 206, 208
together is that if the clips 256 are formed of high strength material, the
clips 256
could add additional structural integrity to the naturally potential weak
location of the
intersection two multi-plenum panels 202,
[0261] With each connection, an impervious and/or airtight
adhesive tape can be
applied to joined edges to ensure air tightness. Further, an impervious and/or
adhesive tape can be applied to the entire edge wrapping into the multi-plenum
panel 202 at the top and bottom to ensure all the edges are airtight.
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CA 02873353 2014-12-05
[0262] A floor multi-plenum panel 202 prototype was tested with the
following results.
Three separate 1/4 inch thick 2 x 4 foot CDX plywood sheets were used for the
top,
the middle and the bottom sheets 204, 206, 208 of the multi-plenum panels 202.
The matrix used to join the bottom and the middle sheet 208, 206 and the
middle
and the top sheet 206, 204 respectively were 3 1/2 inch by 3 1/2 inch
Pine/Spruce
blocks 210, with approximately 3 1/2 inch spacing between the blocks 210. That
is,
three blocks 210 were spaced evenly in 24 inches, and six blocks 2,10 were
spaced
evenly in 48 inches. As a result of the bock 210 size and spacing, there was
nine
square inches of unobstructed free vent area per linear foot. The blocks 210
were
attached to the sheets 204, 206, 208 using an interior wood glue type of
adhesive
¨ specifically a polyvinyl acetate glue.
[0263] The multi-plenum panel 202 was loaded with 1,200 lbs. spaced
uniformly
across the multi-plenum panel 202 creating a pressure of 150 pounds per square
foot. The weighted multi-plenum panel 202 was supported along the short two
foot
edges creating a 48 inch simple span, with 44 inches clear between the
supports.
The multi-plenum panel 202 had a maximum deflection of 0.250 inches, an "L I"
of
192 and an area moment of inertia, l in4 per foot, equal to 20.00.
[0264] A control panel was used for comparison. The control panel was a
single 1/2
inch sheet of plywood measuring two feet by four feet. The control panel was
loaded with 600 lbs. spaced uniformly across the sheet, creating a pressure of
75
pounds per square foot. The control panel was similarly supported along its
shorter
two foot edge, creating a 48 inch simple span, with 44 inches clear between
the
supports. The control panel displayed over an inch of deflection, with only
half the
load of the floor panel. In more detail, the control panel had a maximum
deflection
of 01,10 inches, an "L I" of 44 and an area moment of inertia, ix, in4 per
foot, equal
to 0.016.
[0265] Thus, the multi-plenum panel 202 demonstrated a bending strength of
9 times
greater than the equivalent thickness of plywood alone. The multi-plenum panel
202
demonstrated a significant strength at a 48 inch spacing and would be
serviceable
for residential and commercial uses at this span with only 1/4 inch sheets
204, 206,
208. These results were a better than predicted strength, despite using an
inferior
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polyvinyl acetate adhesive instead of using a preferable thermoset phenol-
formaldehyde adhesive between the blocks 210 and the sheets 204, 206, 208.
[0266] Alternate embodiments of the multi-plenum panel are envisioned.
The
invention consists of three sheets 204, 206, 208 of the same size and
assembled in
parallel planes separated ideally by blocks 210 of wood in a square shape, but
the
blocks 210 could also be rectangular, round or the sheets 204, 206,208 could
also
be separated by a matrix of elongated wood members, or an extruded or
engineered
matrix, in a stacked perpendicular matrix or otherwise arranged as described
in the
above embodiments of the ventilated structural panels 2, 2', 2A, The interior
could
also be an arrangement of plastic or metal extruded or formed members as
described above. Additionally, a single plenum panel embodiment, with two
sheets
connected by a plurality of structural spacing elements, as described above,
may be
connected in an air tight manner to a central heater and air conditioner 238
to one
of deliver conditioned air to or receive return air from an entire level of a
building, or
some part thereof.
[0267] The sheets 204, 206, 208 can be of various thicknesses. The top
sheet 204
could be 1/4 inch to 1/2 inch to even 5/8 inch, 3/4 inch or 1 inch to
accommodate floor
covering and structural needs. The middle sheet 206 only needs to be 1/4 inch
in
thickness to accomplish the structural needs of a 48 inch span. The bottom
sheet
208 also needs to only be 1/4 inch thick to accomplish the structural needs
for a 48
inch span, but each sheet 204, 206, 208 may have the various thickness options
listed for of the top sheet 204, as the specific designs may required. Also,
the
sheets 204, 206, 208 can be of different thicknesses to accommodate different
needs. The
sheets 204, 206, 208 are ideally 4' x 8' sheets, as this size is
typically used in the building trade, but the sheets 204, 206, 208 can be
sized larger
or smaller.
[0268] The
sheets 204, 206, 208 are ideally constructed of plywood or OSB, but
could also be of a plastic, vinyl, metal or other man made or natural
material.
[0269] The sheets 204, 206, 208 may be treated with an antibacterial
agent or even
with a waterproofing to prevent the formation of mold should the multi-plenum
panels
202 be used for cooling and where condensation is a risk due to cool supply
air and
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high humidity environments. Additionally, the interior of the multi-plenum
panels 202
could be entirely coated with a waterproofing covering.
[0270]
The multi-plenum panels 202 and blocks 210 could also be constructed out
of pressure treated lumber and plywood to inhibit any decay or possible mold.
An
alternative solution is to provide supply air at a temperature where
condensation is
not in the probable range of the design. Alternatively, if condensation is
possible,
then the system could be programmed to air dry the plenums 212, 214
sufficiently
after achieving desired room ambient temperatures.
[0271]
Additionally, the sheets 204, 206, 208 could be coated to prevent
condensation absorption if it occurs, and could be insulated with a "blanket"
of thin
reflective insulation on the inside and/or outside faces of each sheet 204,
206, 208.
[0272]
Turning now to Fig. 53, the various structural spacing elements for the
single
and multi-plenum panels 2, 202 will be further described.
[0273]
Turning to Fig. 53, various embodiments of the spacing structural
elements
8 are further described. The spacing structural elements 8 can also be
constructed
by extruding or depositing a predetermined amount of adhesive or plastic or
foam
in a regular geometrical pattern or specialized pattern forstructural
purposes. These
deposits or globs 258 would be a deposit of semi-liquid material with adhesive
and
structural qualities when cured. The material may cure with or without heat,
and/or,
for example, with exposure to oxygen or various wavelengths of electromagnetic
radiation. Once cured, the glob 258 can have the same qualities of the block
210
spacing structural elements 8 above, with similar orthogonal intersecting air
flow
paths, spacing between, height and width measurement, and other qualities.
[0274]
The anticipated process utilizing the globs 258 is to deposit the
required
amounts of semi-solid/semi-liquid material in a predetermined pattern, as
required
for structural needs, on the bottom sheet 6, 208 of the panel 2, 202, The top
sheet
4, 204 (or middle sheet 206 for a multi-plenum panel 202) is then laid on the
bottom
sheet 208 and compressed to the desired thickness causing some lateral
expansion
in the globs 258, such that they attain a circular shape of preferably between
2" to
8", as required for structural needs. The quantity of material in each glob
258 is
preferably between 1.5 cubic in, and 50 cubic in., not including consideration
of the
= displacement of volume from any imbedded insert 260 (see Fig. 55).
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[0275] As shown in Fig. 53, for multi-plenum panels 202, the
deposits or globs 258
= are also made to the top surface of the middle sheet 206 and the top
sheet 204 is
then placed on the middle sheet 206 and compressed to the desired thickness.
[0276] The glob 258 material is semi-liquid/semi-solid adhesive or foam
or similar
material. The glob 258 may have a flat-bottomed teardrop or "Hershey's kiss"
shape
after being deposited and before compression. The glob 258 material preferably
has
a viscosity and quantity such that when the sheets 204, 206, 208 are pressed
together the resulting thickness of the assembly is of the desired panel 2,
202
= thickness. Spacers 262 and/or inserts 260, described below, may be used
to insure
proper spacing when the sheets 204, 206, 208 are pressed together. Spacers 262
can be placed around the perimeter and interior between the adhesive deposits
to
insure the desired thickness when pressed. The spacers 262 can be permanently
attached to one or both sheets 204, 206, 208 or just be temporarily placed, to
be
later removed. The spacers 262 can be positioned on the sheets 204, 206, 208
before, during, or after the globs are desposited,
[0277] The spacers 262 can consist of pressed metal shapes
that penetrate one
sheet 204, 206, 208 when pressed, and/or could have one or more protrusions or
spikes 264 that penetrates the adjacent sheet 204, 206, 208 when the other
sheet
204, 206, 208 is pressed into the panel 2, 202 assembly (see Fig. 56). The
spacers
262 can also be blocks 210 of wood or plastic that can be adhered to one or
both of
the adjacent sheets 204, 206, 208, Spacers 262 can also consist of plastic
shapes
spaced or glued to one sheet. The spacers 262 can be also be free from
adhesive,
or only have non-permanent adhesive, and be designed to be removed after the
globs 258 cure.
10278] Referring to Fig. 55, a first example of an insert 260
is shown. A ball or
sphere of diameter between V2' and 3" is embedded in a quantity of adhesive
and/or
foam glob 258. The insert 260 and the glob 258 may be dispensed or extruded at
the same time through a common dispenser or extruder, or they may be dispensed
via separate dispensers at the same or different times. The insert 260 may be
solid
or hollow, and may have a continuous surface as shown, a perforated surface,
or a
cage surface, as shown in Fig, 57. The surface of the insert 260 may be
smooth,
as shown in Fig. 55, textured, or, Fig. 57, have protruding studs or spikes
264 of
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sufficient strength to penetrate the sheets 204, 206, 208 being pressed into
to create
the glob 258/insert 260 combination. The inserts 260 may be constructed of a
variety of materials compatible with the adhesive and/or foam. Additionally,
the
inserts 260 may be used independently of and/or without the glob 258 material,
Other embodiments of inserts 260 are shown in Figs. 98 and 99. Fig. 98 shows a
wire frame triangular pyramid shaped insert 260 pressed into a sheet 204, 206,
208,
or embedded into a glob 258. Fig. 99 shows a solid triangular pyramid shaped
insert
adhering to a sheet 204, 206, 208, or embedded into a glob 258. Some of the
various qualities of the inserts 260 are discussed further below.
[0279] The inserts 260 may be either hollow or solid depending on weight,
cost, and
the material requirement. Though only a single large sphere is shown in Fig.
55, it
is anticipated that a plurality of smaller inserts 260 could be used in each
glob 258
to add structural integrity to the glob 258,
[0280] The inserts 260 may have a continuous surface, as shown in Fig. 55,
which
allows for ease of production and stronger insert 260 units. The inserts 260
may
also have a perforated surface, which, depending on the size of the
perforations,
could allow the glob 258 material to seep into and better bind with the
inserts 260.
If the inserts 260 are used without a glob 258, the perforations could allow
air to
pass through the inserts 260 and thus increase air flow through the plenum.
Also,
the inserts 260 may have a frame like or cage exterior, as shown in Fig. 67,
This
would add the least amount of weight to the panel and allow for greatest
integration
between the insert 260 and the glob 258, or, if used independent of the glob
258 the
greatest air flow. The cage surface would, all things equal, also be the
weakest of
the surfaces, which must be accounted for with increased strength via other
measures, e.g, stronger material or increased thickness of the cage, using the
cage
surfaced insert 260 in a glob 258, and/or increasing the number of cage
surfaced
inserts 260 used compared to the number of continuous surfaced inserts 260
used
in the same situation.
[0281] The inserts 260 may have a smooth surface, as shown in Fig. 55,
which
would allow for easier manufacture, but such a smooth surface would decrease
the
ability of the glob 258 material to adhere to the insert 260 and, in many
shapes,
would provide no mechanical adhesion between the insert 260 and the adjacent
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sheet 204, 206, 208. If the adjacent sheet 204, 206, 208 is of a type that
must
remain un-punctured, or has a layer one that must remain un-punctured or
intact,
smooth surfaced inserts 260 may be necessary. If used without globs 258,
smooth
surfaced inserts 260 would preferably be adhered to the sheets 204, 206, 208
with
adhesive or bonding. Additionally, the insert 260 may have a textured surface,
for
example, with dimples or bumps. This would aid in the insert 260 bonding to
the glob
258 if used with a glob 258, but would potentially increase manufacturing time
and
limit the types of materials used.
[0282] In another, and likely a preferable embodiment, the inserts 260
would have
a surface that included spikes 264, barbs, or other such projections. The
spikes 264
would aid in the glob 258 bonding to the insert 260, allowing the glob 258
material
to envelop the spikes 264, and would provide a means for mechanical adhesion
of
the insert 260 to the adjacent sheets 204, 206, 208. The spikes 264 would need
to
be of a quantity, thickness, length, and with a sufficiently sharp apex and
for edge,
that the spike 264 would perforate but not damage the adjacent sheets 204,
206,
208. The spikes 264 would preferably protrude or extend from the surface of
the
insert 260 a length less that the thickness of the adjacent sheets 204, 206,
208, so
that the spike 264 would not fully pierce through the sheets 204, 206, 208,
from one
surface to the other. The spikes 264 could be uncoated, or could be coated
with a
cement, vinyl, or resin coating that melts with the heat generated from the
friction
during insertion, but that solidifies when cooled. The coating would provide
extra
adhesion between the spike 264 and the sheets 204, 206, 208.
[0283] There
are a variety of shapes that the inserts 260 may take, depending on if
used with glob 258 material or not, and other panel 2, 202 requirements, like
strength, air flow, and weight. The inserts 260 may be shaped as spheres or
spheroids, cylinders, pyramids, rectangular or triangular prisms or other
polyhedrons. The inserts 260 may have one or more bores or passageways
extending partially or fully through the shape to allow passage of air or glob
258
material.
[0284] The
inserts 260 may also be shaped, as shown in Fig. 58 for example, as a
barricade 266. This design provides three points of contact with each sheet,
while
using minimal material and providing significant air passage. A spike 264
normal to
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the sheets 204, 206, 208 may be formed on each of the six terminal ends of the
barricade 266, or the terminal ends themselves may be sharpened, barbed, or
otherwise function as spikes 264. Additionally, if used with globs 258, the
barricade
266 shape can be easily and fully integrated in the glob 258, providing
structural
support and spacing. The three arms of the barricade 266 can each be oriented
at
90 degrees to the other two arms, or the arms can intersect at acute and/or
obtuse
angles to form taller or shorter barricades 266, and thus more or less spacing
between the two sheets 204, 206, 208.
[0285] The
inserts 260 may also have an elongate mid-section 268 that extends and
spaces top and bottom portions 270, 272 of the insert 260 from each other. One
embodiment, shown in Fig 59, adopts a spindle type design, with disc shaped
top
and bottom portions 270, 272 spaced apart by a middle rod 268. The top and/or
the
bottom portions 270, 272 could have cleats, barbs, or spikes 264 to aid in
mechanically attaching the insert 260 to the adjacent sheets 204, 206, 208,
and
could additionally or alternatively be attached to one or both sheets 204,
206, 208
with an adhesive.
[0286] The
inserts 260 may also extend completely through one or more of the
sheets 204, 206, 208. See, for example, Figs. 60 - 62. As shown in Figs. 60
and
61, these through inserts 274 could be as simple as one or more thin rods 276
that
extend through the middle sheet 206, both upwardly and downwardly, into both
the
upper and the lower plenums 212, 214. The rods 276 could be used with or
without
the glob material 258. The rods 276 could serve a spacing function for the
globs
258, easily slicing through the uncured glob 258 material and contacting the
inwardly
facing surface of the top or bottom sheet 204, 208 as the panel 202 is pressed
together. The panel 202 could also be pressed further, pressing the rods 276
into
the top and bottom sheet 204, 208 as the entire panel 202 is pressed together,
thereby providing a direct mechanical connection between the top, middle, and
bottom sheet 208. In the embodiment shown, a plurality of rods 276 would be
used
with a single glob 258.
[0287] The rods 276 may be smooth sided, the least expensive and
easiest
embodiment to manufacture. Alternatively or additionally, the rods 276 may
have
vertical ridges around the axis of the rod 276, have horizontal ribs or rings
up the
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length of the rod 276, have a helical ridge twisting up the length of the rod
276,
= and/or have a textured surface 276.
[0288] The through inserts 260 like the rod 276 can be forced, screwed,
or punched
through the sheet 206 after the sheet 206 is formed.
[0289] In another embodiment, the sheet 206 may be formed or molded
around the
through insert 260, whereby the through insert 260 is integrated into the
sheet 206
when the sheet 206 is formed. For example, Fig. 62 shows an integrated through
insert 260 where the middle sheet 206 is formed around the insert 260. The
insert
260 has an extended spindle shape with an expanded contact surface 278 on
upper
and lower surface of the middle sheet 206. The expanded contact surface helps
distribute force from the top 204 or bottom sheet 208 to the middle sheet 206,
and
maintain the through insert 260 in a fixed vertical position with respect to
the middle
sheet 206. In the embodiment shown, the through insert 260 also has a
preferably
disc shaped top and bottom portion 270, 272, contacting the inward facing
surfaces
of the top and bottom sheets 204, 208, and limiting their respective inward
movement. The top and bottom portions 270 of the through insert 260 may have
cleats, barbs, or spikes, 264 and/or adhesive applied.
[0290] The molded through or integrated insert 260 may also have a cage
or
perforated surface. For example, a cylinder with a cage surface could be
integrated
into the middle sheet 206 when the sheet 206 is formed. In such an embodiment,
the
cylinder shaped through insert 260 would project out of the top and bottom of
the
middle sheet 206. The cylinder shaped through insert 260 could then easily
encase
and integrate with a glob 258 deposited on the bottom sheet 208 and on the top
side
of the middle sheet 206 in one simple step.
[0291] In another embodiment of a through insert 260, as shown in Figs.
63 and 64,
a nail shaped through insert 260 can be used. The nail shaped through insert
260
could, for example, be driven through the middle sheet 206 in a downward
direction,
anchored by a disk shaped top portion 270 to the rod 276 on a top surface of
the
sheet 206. As shown, the inserts 260 can be driven both upwards and downward
through the same middle sheet 206. The leading end of the insert 260 may
extend
all the way through the opposing top or bottom sheet 208, and, as shown, the
leading bottom end of the insert 260 could be pressed or crimpled below the
lower
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surface of the bottom sheet 208, or a disk shaped bottom portion 272 could be
attached. In this manner, the middle and top and bottom sheets 208 are
mechanically fixedly secured together. Additionally, or alternatively, the
nail shaped
through inserts 260 may be driven into the top sheets 204 downward and into
the
bottom sheets 208 upward, each toward the middle sheet 206.
[0292] Referring next to Figs. 65 and 66, a matrix of an orthogonal
frame 280 of thin
tubes or wires 282 consisting of metal, wire, fiberglass, carbon fiber,
plastic or other
suitable material, or combinations of such materials assembled in three
dimensional
a grid pattern is shown. Such pattern has a height of the desired spacing
between
sheets 204, 206, 208 in the panel 2, 202, not counting any optional upper or
lower
projections or spikes 264 intended to be inserted into adjacent sheets 204,
206, 208.
The orthogonal frame 280 is constructed of an upper lateral grid 284 and a
lower
lateral grid 286 joined together by a plurality of vertical straps 288. The
frame 280
may be unitary, or joined by gluing, welding, melting or otherwise fixedly
joining the
separate members together. The lateral spacing of the separate individual
wires 282
is determined by the requirements of any spacing structural elements 8 that
are to
be placed within the square or rectangular defined spaces 290, defined by
spacing
in the upper and lower lateral grids 284, 286.
[0293)
The spacing structural elements 8 that are to be placed within the
defined
spaces 290 can be wood blocks 210, plastic blocks 210, permeable material or
organic, inorganic material or plastics or composite material of a combination
of
organic and/or inorganic material such as a wood fibrous material in a resin
or
adhesive or steamed wood material and adhesive, or glob 258 material.
[0294]
The orthogonal frame can have spikes 264 that are designed to be embedded
in the adjacent sheets 204, 206, 208 when pressed in the panel 2, 202
production.
The upper or lower terminal edge of the spikes 264 may be flat, rounded,
smooth,
sharp, or barbed, depending on the mechanical adhesion requirements.
[0295] The spacing structural elements 8, whether a solid or semi-solid
adhesive or
foam, will preferably have adhesive applied or have adhesive characteristics
such
= that the spacing structural elements 8 will preferably bond to adjacent
sheets 204,
206 ,208 and transfer structural stress from one sheet 204, 206, 208 to the
other.
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[0296] As shown
in Fig. 66, the defined space 290 may be filled by either a solid or
a semi-solid material that has been compressed to take the rough shape of the
defined space 290. Specifically, Fig. 66 shows the placement of a spacing
structural
element 8 comprising a block 210 of material placed within the orthogonal
frame.
This block 210 could be of solid or permeable or semi-solid material of the
desired
thickness such that the upper and lower edges can strongly adhere to the
adjacent
sheets 204, 206, 208, without voids, when the adjacent sheets 204, 206, 208
are
pressed together. Such spacing structural elements 8 can be of wood, wood
composite material, wood steamed composite material, plastics, permeable
material,
plastic blocks 210, plastic blocks 210 with a matrix of voids such as open
cell foams,
The material would preferably be capable of transferring the desired
structural stress
from one sheet 204, 206, 208 to the other. In a further embodiment a glob 258
could
be deposited in the defined space 290 of the orthogonal frame 280.
[0297] it is to be noted that if the orthogonal frame 280 was of
sufficient strength, it
could, by itself, function as the spacing structural element 8 connecting the
two
adjacent sheets 204, 206, 208 to one another without requiring the addition of
a
separate block 210 or glob 258 in the defined space 290. Such an embodiment
would preferably include a plurality of diagonal truss members 292, described
further
below.
[0298] While in
one embodiment of the orthogonal frame 280, a block 210 or glob
258 is intended to be placed into the defined space 290, according to another
embodiment, as shown in Figs, 67 and 68, the spacing structural element 8 may
be
unitary or bonded with the orthogonal frame 280. Fig, 67 shows a three
dimensional
extruded or bonded orthogonal frame 280/block 210 assembly. Each spacing
structural element Scan be solid or hollow and is attached on the top and the
bottom
with lateral straps 292 to the adjacent spacing structural element 8. The
spacing
structural elements 8 incorporated in this assembly may be hollow, and may
additionally have an array of voids such that the flow of air is enhanced
through the
spacing structural elements 8 as well as around the spacing structural
elements 8.
[0299] The
lateral straps 292 between the spacing structural elements 8 in this
embodiment can be of the same material or a different material as the spacing
structural elements 8. The lateral straps 292 can be manufactured integrally
or
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bonded/attached to construct the orthogonal frame 280. The spacing structural
element 8 blocks 210 in this embodiment are preferably a dimension of between
2"
x 2" to 8" x 8" with a height of between /2" to 4". The spacing structural
elements 8
may also be rectangularshaped with the same dimensional constraints. The
spacing
structural elements 8 are most desirably spaced from 2" to 12" between each
other.
Fig. 68 shows the same bonded orthogonal frame 280/block 210 with the bonded
solid inserts 260 hashed for better visualization.
[03001 The three dimensional frame/block assembly would
preferably be covered
with adhesive on the top and bottom and attached to the two adjacent sheets
204,
206, 208 ¨ one on the bottom and one on the top and the adhesive cured. The
adhesive would be compatible with the materials bonded and of sufficient
quantity
for structural stress transfer.
[0301] In a production method utilizing a related design, Fig
69 shows a method of
production which could be used as shown in a continuous manufacturing
arrangement or as a partial manufacturing arrangement.
[0302] This method provides for the separate lateral grids
284, 286 to be used,
preferably without the vertical straps 288 as a net 294. The lateral grids
284, 286
in this embodiment are preferably of a plastic material with a spacing of1/4"
to 1" and
a thickness of between 12 gauge to 40 gauge. The separate lateral straps 292
are
connected in a continuous grid that is utilized to place the spacing
structural
elements 8 between the two layers of grid material 284, 286. Adhesive is
either
applied to the grids 284, 286 during its manufacture and is inherently
connected to
all fibers, or adhesive is applied before placing the spacing structural
elements 8, or
= adhesive is applied to the spacing structural elements 8, or some
combination
thereof. Regardless of the manner of adhesive, the spacing structural elements
8
are now connected in a manner of spacing from one another as previously
described
above to the upper and lower grids 284, 286, so that the spacing structural
elements
8 relative spacing from one another is fixed. Then net 294 of spacing
structural
elements 8 can be maneuvered or moved down an assembly line where two sheets
204, 206, 208 are then adhered to the spacing structural elements 8 with
adhesive
and or mechanical means. For example, spikes 264 may be used as above also to
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mechanically connect the upper or lower grids 284, 286 to the respective
adjacent
sheet 204, 206, 208.
[03031 As shown in Figs. 70-72, in another related embodiment, a two
dimensional
orthogonal matt 296, similar to the separate lateral grids 284, 286, may be
used to
simultaneously attach the spacing structural elements 8 to the sheets 204,
206, 208,
and provide increased strength to the sheets 204, 206, 208. The matt 296 is
preferably constructed from metal, although some plastics or composites may
also
be utilized. The matt 296 is shaped in rectangular or square patterns, and
preferably
include tab protrusions or tabs 298 that are either bent in a first direction,
e.g. down
(see Fig, 72), to penetrate a wood or wood composite block 210 or in a second
opposite direction, e.g., up, to penetrate the sheet 204, 206, 208 that is to
be laid on
the top and secured to the assembly. The tabs 298 can have smooth edged
points,
as shown, or jagged or barbed edges. The tabs 298 overlapping the blocks 210
can
all be directed into the block 210, as shown, or one or more of the tabs 298
in this
location of overlap can also be directed away from the block 210 and toward
the
adjacent sheet 204, 206, 208. The matt 296 can be used with or without
additional
adhesive which could be spread on the matts 296 and/or blocks 210. The matts
296
could be on both the top and the bottom of the blocks 210, as shown in Fig,
70.
[0304] Fig. 71 shows a detail of the metal belt 300 of the
orthogonal matt 296 used
to connect the spacing structural element 8 to the sheets 204, 206, 208.
Ideally, a
bottom matt 296 is laid down and pressed into the bottom sheet 208, with the
tabs
298 of the bottom matt 296 that are directed into the bottom sheet 208
entering and
attaching to the bottom sheet 208. The spacing structural elements 8 are
placed in
the desired location on the bottom sheet 208/bottom matt 296 and pressed into
place. The tabs 298 of the bottom matt 296 are directed into the spacing
structural
elements 8 entering and attaching to the spacing structural element 8. Next,
the
process is repeated with a top matt 296 laid down on the top sheet 204 (or
bottom
surface of the middle sheet 206 for multi-plenum panels 202) and pressed into
place. The top sheet 204 is then placed over the bottom sheet 208, with the
tabs
298 of the top matt 296 aligning over the spacing structural elements 8, and
the
entire panel is then pressed into place into the desired overall thickness.
For multi-
.
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plenum panels 202, the process is repeated for the top surface of the middle
sheet
206 and the top sheet 204.
[0305] The spacing structural elements 8 in this embodiment are preferably
between
2" x 2" and 8" x 8" in width, and preferably 1/2" to 4" in height, and may be,
for
example, square or rectangular shaped. The matts 296 would be constructed to
match the dimensions of the spacing structural elements 8. The tabs 298 would
be
of a size and spacing that would meet the structural stress transfer
requirements
without compromising the integrity of the belt 300. The belt 300 could be 118"
to 1"
wide.
[0306] Tuning next to Fig. 73, this figure shows a possible interlocking
mechanism
that may be used to better attach adjacent panels 2, 202 when assembled in the
field, that may be utilized with multiple embodiments of spacing structural
elements
8, including those with utilizing orthogonal frames 280 and orthogonal matts
296.
For example, in an embodiment using the orthogonal matts 296, the surface of
the
spacing structural elements 8 along an outer edge of the panel 2, 202 may have
a
protrusion 302 that fits into a mating indention 304 in a surface of spacing
structural
elements 8 along an outer edge of an adjacent pane! 2, 202. Two adjacent edges
of the panel 2, 202 could have spacing structural elements 8 with protrusions
302,
and the other two opposite adjacent edges on the panel 2, 202 could have
spacing
structural elements 8 with mating indentions 304. A typical design for the
interlocking mechanism is shown in the figure, although the interlocking
mechanism
can take the shape of rectangular tongue and grove or beveled edges. This
interlock mechanism of spacing structural elements 8 can be utilized in any of
the
spacing structural elements 8 in the various embodiments of single and multi-
plenum
panels 2, 202, and not only for the orthogonal frames 280 and matts 296.
[0307] Turning now to Figs. 74 ¨ 80 a variation of the orthogonal frame 280
is
shown, whereby a system of truss members 306 may be integrated in the
orthogonal
frame 280 to create a three dimensional truss matrix 308. While only a four by
four
grid section of the truss matrix 308 is shown for better visualization, it is
anticipated
that the truss matrix 308 will cover the entire horizontal span of the sheets
204, 206,
208. The truss matrix 308 could function alone as the spacing structural
element 8,
to join at a defined separation adjacent sheets 204, 206, 208 and create the
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plenums 212, 214. The truss matrix 308 may also be used with separate blocks
210, globs 258, or other spacing structural elements 8. Because of the
diagonal
truss members 306, though, it is not necessary to have blocks 210 or globs 258
for
shear stress transfer as this can be done through the plurality of diagonal
truss
members 306 and the three dimensional truss matrix 308. As shown in Fig. 80,
each apex 310, where the truss members 306 meet, may be crowned with a spike
264 to penetrate and mechanically attach the truss matrix to an adjacent sheet
204,
206, 208.
[0308] The dimensions of the truss matrix 308 can vary, but are preferably
between
2" and 12" in lateral spacing between adjacent lateral wires 282 or straps 292
running in a parallel direction in the upper of lower grid 284, 286, with the
height
preferably between 1" to 6". The grid of the truss matrix 308 does not have to
be
square, but could be, for example, be rectangular too.
[0309] The orthogonal frame and/or the truss members can be made out of
metal,
wire, plastics, carbon fiber, fiberglass, and other suitable materials. It is
probable that
this may be the preferred embodiment used to attach two adjacent sheets 204,
206,
208 to each other in either the single or multi plenum panels 2, 202. This
embodiment offers the advantages of ease of production and assembly, low
expense, potentially no organic material exposed to the plenums, and
potentially no
curing times for adhesives.
[0310] in one embodiment, as shown in Fig. 74, the truss members 306 may be
used independent of the orthogonal frame 280, to fix two adjacent sheets to
one
another. This three dimensional space truss could be used with or without
globs
258. When used with globs 258, they would preferably be placed coincident with
the
apex 310 regions.
[0311] Turning next to Figs 81 -83, an alternative method of constructing
the
spacing structural elements 8 between sheets 204, 206, 208 in a multi-plenum
panel
202 is shown. Instead of blocks 210, a matrix of preferably single layered,
branched, unitary/one piece/or bonded, engineered perforated members 120 could
be utilized to separate the sheets 204, 206, 208 while providing the necessary
air
flow, orthogonal intersecting flow paths, and structural stress transfer. Fig.
81 shows
a grid of perforated I shaped members 125.
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[0312] The members 120 can be constructed of plastics,
composites, carbon fiber,
fiberglass, metal and can be extruded or formed and fused together into the
desired
shape. The ends of members 120 can incorporate the interlocking mechanism
shapes shown in Fig. 73, such that adjacent exterior faces of the resulting
panel 2,
202 would have an interlocking mechanism into the adjacent panel 2, 202 when
assembled in the field.
[0313] The matrix members 120 could have a height of 1/2" to 4" and the
width of the
members could be from IA" to 4" wide. The spacing of members could be from 2"
to 10" and could be square or rectangular.
[0314] Fig. 82 shows a matrix of truss shaped members 130. Fig. 83
shows a matrix
of truss members 130 with spaced diagonal members, or "skip truss" members
136.
The attributes described in Fig. 81 are also applicable to the truss shaped
members
130, 136.
[0315] In a further embodiment, shown in Figs. 84 ¨ 93, the
spacing structural
elements 8 may also be directly molded into the middle sheet 206 of a multi-
plenum
panel 202. That is, the spacing structural elements 8 in, e.g. block 210
shapes,
separating the sheets 204, 206, 208 in the multi-plenum panels 202 can be
fashioned as part of the middle sheet 206 from pressing a formable material
such
as metal, including aluminum and other metals, formable plastics, especially
plastics
after heating, and uncured layer of wood composite material and resin. In any
case,
the layer of formable sheet material is placed in a press and the blocks 210
are
pressed in two mating mold halves such that the sheet 204, 206, 208 and blocks
210
become an integral member after hardening or curing in the mold.
= [0316] Figs. 84 and 85 show a sheet 204, 206, 208,
preferably a middle sheet 206,
with a series of block 210 shaped spacing structural elements 8 that have been
molded by pressing two mold halves together to the form desired shape and
thickness of the sheet 206 and "bulged" blocks 210. The blocks 210 are hollow
on
the inside, and have no base. The vertical sides 312 of the blocks 210 extend
preferably orthogonally from the middle sheet 206, and connect to a lateral
cap 314.
The blocks 210 could be filled with an insulation foam 316 or other type of
insulating
material. Though a block 210 shape is used in this embodiment, all other
moldable
shapes of spacing structural elements 8 could also be employed in this molded
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middle sheet 206 embodiment. Fig. 86 shows a section of the middle sheet 206
with
molded block 210 shaped spacing structural elements 8. Figs. 87 and 88 show
the
underside of the molded sheet 206. Again, any moldable material with
sufficient
structural strength could be used to mold the integral sheet 206 and spacing
structural elements 8 including metal, plastics, carbon fiber, fiberglass and
a
composite mix of wood fibers and resin or a mix of steamed wood fibers such as
is
used in the production of Masonite.
[0317] Additionally, the presses could be designed such that a single
sheet 206
could be molded so that the spacing structural elements 8 extend both upwards
and
downwards from the same middle sheet 206. Figs. 89 - 92 show a sheet 206 of
metal, plastic, wood fiber or other structural moldable material that has been
molded
with spacing structural elements 8 protruding in both directions perpendicular
to the
plane of the sheet 206. The resulting sheet 206 contains the middle sheet 206
and
the spacing structural elements 8 for both the upper plenum 212 and the lower
plenum 214 all unitary and shaped together. Fig. 91 shows a section of a
molded
block 210 for the upper plenum 212 along with the adjacent but staggered
molded
block 210 for the lower plenum 214. Fig. 92 shows the bottom view of the
middle
sheet 206 molded with spacing structural elements 8 extending both upwardly
and
downwardly into the respective upper and lower plenums 212, 214.
[0318] In a variation of this embodiment, as shown in Fig. 93
two mirror molded
= sheets 318 each with spacing structural elements 8 molded thereto, but
only
extending in a single direction, are combined to make a single middle sheet
206.
The combined molded spacing structural elements 8 are aligned with one another
and extend in opposite upward and downward directions. The two mirror molded
sheets 318 are arranged parallel to one another, with the respective spacing
structural elements 8 in the top sheet 318 extending upwardly and the spacing
structural elements 8 in the bottom sheet 318 extending downwardly. The two
mirror molded sheets 318 are attached to one another with adhesive and/or
mechanical means to create a single middle sheet 206. Insulation is preferably
placed in the space formed between the two structural spacing elements 8
before
attaching the two mirror molded sheets 318 to one another. This way, the
molded
spacing structural elements 8 extending into the respective plenums 212, 214
can
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CA 02873353 2014-12-05
be vertically aligned with one another to better aid in transfer of stress
from the top
sheet 204 to the bottom sheet 208. As shown in the figure, the voids defined
between the two blocks 210, for example, may be filled with insulation
material to
minimized heat transfer, and potentially increase structural integrity.
[0319] Turning now to Fig. 54 an assembly of a multi-plenum panel 202,
with layers
of lining and different types of sheets 204, 206, 208 is shown. Given the
possible
materials and their best and most useful applications for the sheets 204, 206,
208
to construct a multi-plenum panel 202 the configuration described below might
be
a typical multi-plenum panel 202, though other combinations a possible
depending
on the requirements and usage of the multi-plenum panel 202, The layer of the
top
sheet 204 has a 1/2 " layer of wood product ¨ either OSB or plywood for the
subfloor
sheathing function of the multi-plenum panel 202. The bottom facing or bottom
surface of the top sheet 204 has either a sealer or radiant layer. The middle
sheet
206 is constructed from rigid insulation bonded to two facings of plastic or
metal.
The middle sheet 206 could also be constructed of Yt" plywood. The bottom
sheet
208 has an exposed facing comprised of a thin coat of gypsum with a paper
facing
suitable for typical drywall finishing applications bonded to a "A" sheet of
OSB or
Plywood. The sheets 204, 206, 208 could be spaced from and attached to one
another by the spacing structural elements 8 described above, including blocks
210,
globs 258, spacers 262 and/or inserts 260. The configuration in this
embodiment
does not have any organic materials exposed to the air moving through the
plenums,
which minimizes the potential for mold or fungal growth if by chance there was
any
condensation in the air distribution.
= [0320] Turning now to Figs. 94 ¨ 97, the bottom or
second sheet 6 of a single
plenum panel 2 is shown with round tube shaped applications of ribbons or
strips
320 of a semi-liquid/semi-solid adhesive and/orfoarn applied thereon as the
spacing
structural elements 8. The diameter of the strips 320 of adhesive and/or foam
is
preferably between 1/2" to 3" and the spacing is preferably between 2" to 12".
Fig.
95 shows the adjacent first or top sheet 4 with strips 320 of adhesive and/or
foam
applied to with the same specifications as to the second sheet 6, but
preferably
arranged orthogonally. Fig. 96 shows the two sheets 4, 6 about to be placed
together. There may be spacers 262 applied to the second sheet 6 before the
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application of the top first sheet 4 to insure the correct finished thickness
of the panel
2 assembly. Additionally, spacers 262 can be placed around the perimeter and
interior between the adhesive strips 320 to insure the desired thickness when
pressed. The spacers 262 can consist of pressed metal shapes that penetrate
one
sheet 4, 6 when pressed in and with a protrusion that penetrates the other
sheet 4,
6 when the other sheet 4, 6 is pressed into the panel 2 assembly. The spacers
262
can also be blocks 210 of wood or plastic that can be adhered to one or both
adjacent sheet surfaces or can be used without adhesion to be removed later.
Fig.
97 shows an assembled single plenum panel 2 with spacing structural elements 8
in the form the ribbons, tubes, or strips 320 of adhesive/and or foam after
being
pressed and cured,
[03211 Similarly, the matrix for the single plenum panel 2 can be assembled
from a
matrix of spacing structural elements 8 consisting of hollow tubing 322 made
from
metal, plastic, fiberglass, composites, or other materials in an extruded or
fused or
assembled form. The tubing 322 matrix members would adhere to each other and
to the two sheets 4, 6 to construct the panel 2. The tubes 322 could also be
perforated with holes to enhance air flow. The strips 320 or tubing 322 form
of
spacing structural elements 8 could also be used for multi-plenum panels 202,
but
would potentially decrease absolute unobstructed orthogonal flow paths,
instead
allowing sinusoidal flow paths in both lateral directions ¨ over and under the
elongate spacing structural elements 8 attached to the lower 208, 206 and
upper
206, 204 sheet respectively.
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