Note: Descriptions are shown in the official language in which they were submitted.
CA 02916690 2016-01-05
[0001] FRAMELESS CONSTRUCTION USING
SINGLE AND DOUBLE PLENUM PANELS
[0002] CROSS REFERENCE TO RELATED APPLICATIONS
[0003] This application claims priority to United States Provisional
Patent
Application Nos. 62/210,616 filed August 28, 2015, the contents of which
are incorporated herein by reference in its entirety, and 62/100,660 filed
January 7, 2015, the contents of which are incorporated herein by reference
in its entirety.
[0004] FIELD OF THE INVENTION
[0005] This invention relates to methods and devices for frameless
building construction utilizing single and multi-plenum panels with various
spacing structural elements.
[0006] BACKGROUND OF THE INVENTION
[0007] Conventional wood homes and structures are built in stages,
with
wood framing erected first, and sheathing attached at a later date. Usually,
homes and other wooden structures are built using "2 by" framing, normally
from the ground up. For example, 2x10's are normally used for joists for
floors, typically 16 inches on center, and are covered with sheathing for a
floor deck, typically in 4' x 8' sheets of OSB or plywood.
[0008] Walls are then constructed using 2x4 or 2x6 lumber with a
continuous sill plate, a double top plate, and vertical studs every 16 inches.
Openings for windows and doors require double studs and jack studs to hold
headers and sills.
[0009] Once the wall frames are erected, they are then usually
sheathed
with an OSB or plywood product typically in 4' x 8' sheets. Sometimes this
sheathing is also utilized in the resistance of shear force. Holes must be cut
for windows and doors. For two story homes, this floor and wall framing /
sheathing process is repeated.
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[00010] A roof structure is then constructed using 2x lumber for
rafters ¨
typically 2x8's or 2x10's or 2x12's depending on snow load. The rafters are
typically 16 inches on center. The roof is then covered with sheathing of 3/8"
thickness to 5/8" thickness, typically in 4' x 8' sheets of OSB or plywood.
Waterproof roofing material can then be applied to the roof deck.
[00011] Ceiling joists must also be installed to support interior
finishes.
Ceiling joists are typical 2x6 or 2x8 and installed at 16 inches on center.
[00012] The framing of a building involves cutting, nailing, erecting
and
attaching studs, headers, jack studs, joists, rim joists, trusses, and
rafters.
All of this framing incurs costs of time, labor, materials, and extended
exposure of the interior building materials to the elements while the building
remains uncovered.
[00013] And although traditional modular construction results in an
expedited house once the modular pieces are at the construction site,
modular homes still use stick framing at the factory and still has the
associated time, labor, materials and cost as stick built or conventionally
framed buildings. Additionally, modular homes incur extra costs and special
requirements for transporting the modular pieces to the construction site.
[00014] Similarly, manufactured housing, whether single wide, double
wide
or triple wide, is also constructed using traditional use stick framing at the
factory and still has the associated time, labor, materials and cost as stick
built or conventionally framed buildings. Additionally, manufactured homes
incur extra costs and special requirements for transporting the modular
pieces to the construction site.
[00015] In all cases, insulation is typically applied around the
existing
framing members. The framing members cause a thermal short in the
thermal envelope and also allows for incomplete insulation installation
because of framing members and the many of corners, blocking, headers,
as well as the many hap-hazard holes drilled for the installation of plumbing,
mechanical and electrical systems. The result with conventional framing is
an insulating layer that is incomplete with leaks and thermal breaks at the
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studs; all reducing thermal performance.
[00016] SUMMARY OF THE INVENTION
[00017] Wherefore, it is an object of the present invention to
overcome the
above mentioned shortcomings and drawbacks associated with the prior art.
[00018] The disclosed inventive methods and devices allow construction
of
primarily and / or substantially wooden structures of sufficient strength such
that conventional framing with lumber is not necessary. This will save time,
cost, and resources in constructing structures while providing for better
insulation. The disclosed methods and devices utilize single and multi-
plenum structural panels as described in United States Patents 8,490,355,
8,534,018, 8,635,822, 8,615,945, 9,091,049, and 9,050,766. All six patents
are incorporated by reference herein. Any conflict between any document
incorporated herein and the specific teachings of this specification shall be
resolved in favor of the latter. Likewise, any conflict between an art-
understood definition of a word or phrase and a definition of the word or
phrase as specifically taught in this specification shall be resolved in favor
of
the latter.
[00019] The single plenum panels comprise two parallel and
substantially
overlapping sheets connected to one another by spacing structural
elements. The spacing between the two sheets forms a plenum that air may
pass through. The combined strength of the single plenum panel is typically
greater than the sum of the strength of the two individual sheets. The
spacing structural elements are typically blocks or matrix members and are
arranged to provide a plurality of unobstructed passageways through the
plenum from one edge of the panel to another. The single plenum panels
have a height and width typically around 4 feet by 8 feet in measurement,
but can be larger depending on manufacturing ability and structural need.
The depth of the single plenum panels is typically between one and six
inches.
[00020] The multi-plenum panels comprise three parallel and
substantially
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overlapping sheets. A first sheet is connected to a first surface of the
second sheet by spacing structural elements creating a first plenum, similar
to a single plenum panel. The third sheet is connected to a second opposite
surface of the second sheet by spacing structural elements creating a
second plenum. As the second sheet is connected to both the first and the
third sheet, a combined multi-plenum panel is created. The height and width
of the multi-plenum panel is comparable to that of the single plenum panel.
The depth of the multi-plenum panel is typically between two and eight
inches.
[00021] The inventive methods and devices described herein provide a
method of constructing homes and similar wood framed structures without
conventional framing. Because the disclosed single and multi-plenum
panels have very high inherent strength, they are able to span considerable
distances and carry significant loads. As such, conventional framing is not
necessary in most situations.
[00022] The walls of a building constructed of single plenum panels,
without framing, have more bearing area than conventionally framed walls.
For example, a 1/2" inside bearing sheet of a single plenum panel wall has
more bearing area than conventional 2x4 studs at 16" on center, and has
approximately the same area as 2x6 framing at 16" on center. Single
plenum panels can also be used for a roof without framing and providing
similar strength. Similarly, multi-plenum panel flooring has considerable and
typically even greater span and load carrying capacity than single plenum
panels.
[00023] In addition to the inherent ventilation attributes of single
plenum
panels and air distribution capabilities of multi plenum panels, these panels
can be constructed in large continuous panels allowing a home to be
assembled in about a day. The panels may be preassembled in a factory,
transported to the build site, and assembled with a crane. A crane at
construction sites is becoming a more common piece of equipment that is
used for a variety of purposes and sometimes a crane is at the site
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throughout the construction period.
[00024] These panels are strong and offer more potential than just a
normal sheathing panel. With continuous manufacturing mills, it is possible
to use full undivided continuous sheets to construct single plenum panels
and multi plenum panels that span an entire face of a building, or span of a
wall, floor, ceiling, or roof. The Single plenum panel load-bearing walls
could
be a single, long panel with perforations for windows and doors.
Additionally, the windows and doors themselves could be constructed in the
factory and added in the factory or at the building site.
[00025] The single plenum panels are very strong. Long span panels can
be used for roofing together with the roof connecting device and/or in
conjunction with conventional framing.
[00026] Continuous panel ceilings are also possible with either single
plenum panels or multi-plenum panels.
[00027] The benefits of frameless single and multi-plenum panel
construction include easy transportation of materials to the field, especially
compared to modular homes, and providing a home that can be assembled
in the field in one day. The savings associated with just these two benefits
are significant in materials, time and labor.
[00028] Additionally, using exterior weatherproof sheathing on the
exterior
sheet of the panels, such as the Zip System (a product and trademark of
Huber), or applying weather-tight materials to one or more sheets of the
panel in the factory and having the windows and doors pre-installed means
the structure can be erected and closed to the weather in one day.
[00029] Having the home closed in one day means the trades can start
the
next day. This is again a significant savings in time and money.
[00030] This technology is ideally suited for the modular and
manufactured
home industries with immediate benefits. Of course, it is also suitable and
valuable for everyday home construction, as well as other currently
conventionally framed structures such as apartments, schools, motels,
hotels, restaurants, churches, etc.
PO-
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[00031] Single plenum panels can have an El value per foot exceeding
15,000,000 lb-in2, and can be easily double that value depending on spacing
structural members, sheet thickness and makeup, and methods of
attachment. Multi-plenum panels are significantly greater. This allows
significant loads and spans, which Means most walls, roofs, ceilings and
floors can be spanned with one continuous panel. The limiting factor is the
manufacturing width.
[00032] The inherent configuration of single plenum panels with two
sheets and an interior matrix for use as a load bearing wall has the
additional feature of stabilizing the load-bearing sheet from buckling so that
it
can bear its capacity in compression and with little concern for instability.
[00033] The disclosed frameless construction method also substantially
eliminates thermal breaks which always exist with conventional framed
construction. There are no studs making a thermal short-cut to the outside.
Nor are there rafter's shortcutting an occupied upper space. The disclosed
method provides a full thermal envelope with full exterior ventilation. A
significant benefit in building safety, comfort, and stability.
[00034] Ventilation is assured for code compliance where applicable
and
health and energy efficiency in the walls and roofs. Air distribution with
multi-plenum panels eliminates the need for ductwork.
[00035] There are various devices described herein such as roof
connectors and insulation gauges. It is intended, though not required, that
these devices be constructed from extruded, formed or folded or otherwise
constructed from a material including, but not limited to aluminum, other
metals, plastics, wood fiber, carbon fiber, fiberglass, magnesium oxide,
sheet metal or composites of a combination of any of the above.
[00036] BRIEF DESCRIPTION OF THE DRAWINGS
[00037] The accompanying drawings, which are incorporated in and
constitute a part of the specification, illustrate various embodiments of the
invention and together with the general description of the invention given
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above and the detailed description of the drawings given below, serve to
explain the principles of the invention. It is to be appreciated that the
accompanying drawings are not necessarily to scale since the emphasis is
instead placed on illustrating the principles of the invention. The invention
will now be described, by way of example, with reference to the
accompanying drawings in which:
[00038] Fig. 1 is a partial see through perspective view of a building
constructed according to the invention with each of the walls, roof spans,
floor, and ceiling panels constructed of continuous single or multi-plenum
panels;
[00039] Fig. 2 is a partial see through perspective view of a building
constructed according to the invention with each of the walls, roof, floor,
and
ceiling panels constructed of multiple single or multi-plenum panels;
[00040] Fig. 3 is a sectional view of a building according to Fig. 1
also
showing two roof connectors;
[00041] Fig. 4 is a sectional view of a roof connector according to
the
present invention;
[00042] Fig. 5 is a partial perspective view of a roof connector
according to
the present invention;
[00043] Figs. 6A and 6B are partial perspective views of two
additional
embodiments of roof connectors according to the present invention;
[00044] Figs. 7A and 7B are side sectional views of two further
additional
embodiments of roof connectors according to the present invention;
[00045] Fig. 8 is a partial sectional view of a floor, wall, and
foundation of a
building according to the present invention, were the wall is a single plenum
panel and the floor is a multi-plenum panel;
[00046] Fig. 9 is a partial perspective sectional view of a floor,
wall, and
foundation of a building according to the present invention, were the wall is
a
single plenum panel and the floor is a multi-plenum panel and holes are
present in the exterior sheet of the single plenum panel;
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[00047] Fig. 10 is partial sectional view of a of a floor, wall, and
foundation
of a building according to the present invention, were the wall is a single
plenum panel and the floor is a multi-plenum panel and holes in the exterior
sheet of the single plenum panel allow for fasteners to be attached directly
from the interior sheet of the single plenum panel;
[00048] Fig. 11 is a partial sectional view of an alternate embodiment
of
Fig. 8, where both the wall and the floor are single plenum panels;
[00049] Fig. 12 is a partial sectional view of an another alternate
embodiment of Fig. 8, where the wall is a single plenum panel and the floor
is conventional flooring with floor joists;
[00050] Fig. 13 is a partial sectional view of a of a wall, ceiling,
and roof of
a building according to the present invention, where the wall, ceiling, and
roof are all single plenum panels;
[00051] Fig. 14A is a partial sectional view of an alternate
embodiment of
Fig. 11, where both the wall and roof are single plenum panels and the
ceiling is a multi-plenum panel and in Figs. 14A to 14D, details of four
embodiments of louvers are shown;
[00052] Fig. 15 is a partial sectional view of a wall and
floor/ceiling of a
multi-floor building according to the present invention, where the first and
second level walls are both single plenum panels and the first level
floor/second level ceiling is a multi-plenum panel;
[00053] Fig. 16 is a partial sectional view of an alternate embodiment
of
Fig. 15, where the first and second level walls and the first level
floor/second
level ceiling are all single plenum panels, and the first and second level
walls
provide a continuous vertical ventilation path;
[00054] Fig. 17 is a partial sectional view of another alternate
embodiment
of Fig. 15, where the first and second level walls are both single plenum
panels and the first level floor/second level ceiling is a multi-plenum panel,
and the first and second level walls provide a continuous vertical ventilation
path;
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[00055] Figs. 18A and 18B is a partial sectional view and a close-up
perspective view of a device to facilitate installing insulation and drywall
on
an inclined single or multi plenum wall of a building according to the present
invention;
[00056] Fig. 19 is a partial sectional view of a of a wall and a roof
according to the present invention, where the wall is a single plenum panel
and the roof uses conventional trusses
[00057] Fig. 20 is a perspective view of an insulation guide according
to
the present invention;
[00058] Fig. 21 is a perspective view of three installed insulation
guides,
including an electric box on the middle depicted insulation guide, according
to the present invention;
[00059] Fig. 22 is a perspective view of an installed insulation guide
with a
"T" wall flange and an electric box according to the present invention;
[00060] Fig. 23 is a simplified perspective view of a door or window
frame
box according to the present invention;
[00061] Fig. 24 is a perspective view of another embodiment of the
door or
window frame box according to the present invention;
[00062] Fig. 25 is a partial sectional view of the door or window
frame box
according to Fig. 24 installed in a single plenum panel wall;
[00063] Figs. 26A to 260 are a top, a first partial side omitting the
screw
shaft, a second partial side omitting front and back cutting teeth, and a
bottom view of a two layer self-seating toothed screw according to the
present invention;
[00064] Fig. 27 is a first partial sectional view of the self-seating
toothed
screw according to Figs. 26A to 26D being seated in a single plenum panel;
[00065] Fig. 28 is a second partial sectional view, temporally after
the view
of Fig. 27, of the self-seating toothed screw according to Figs. 26A to 26D
being seated in a single plenum panel;
[00066] Fig. 29 is a partial sectional view of double-head screw
seated in a
single plenum panel according to the present invention;
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[00067] Figs. 30A to 300 are partial see through and exploded partial
perspective views of insertion connecting blocks connecting two adjacent
single plenum panels and a perspective view of the insertion connecting
block;
[00068] Figs. 31A to 310 are partial see through and exploded partial
perspective views of insertion connecting blocks connecting two adjacent
single plenum panels and a perspective view of the insertion connecting
block;
[00069] Figs. 32A to 320 are partial see through and exploded partial
perspective views of H connectors connecting two adjacent single plenum
panels and a partial perspective view of the H connector;
[00070] Figs. 33A to 330 are partial see through and exploded partial
perspective views of perforated H connectors connecting two adjacent single
plenum panels and a partial cut-out perspective view of the perorated H
connector;
[00071] Figs. 34A and 34B are partial see through and exploded partial
perspective views of a further embodiment for connecting adjacent single
plenum panels to one another with blocking and a ridged/tensile strip;
[00072] Fig. 35A and 35B is a partial perspective view of a method of
joining two adjacent single plenum panels via spikes and an up close
partially see through perspective view of a spike;
[00073] Figs. 36 and 37 two temporally spaced partial sectional views
of a
three layer self-seating long toothed screw for multi plenum panels
according to the present invention;
[00074] Fig. 38A is a sectional view of a roof arrangement constructed
with
single plenum panels with a continuous ridge vent;
[00075] Figs. 38B and 380 are exemplary router bit designs which could
form / cut a ventilation strip according to one embodiment of the present
invention;
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[00076] Figs. 39A is an isomeric view of a single plenum panel with a
ventilation strip being cut or formed into the interior sheet of the panel
according to one embodiment;
[00077] Fig. 39B and is an isomeric view of an interior of an attic
constructed with single plenum panels and including a ventilation strip;
[00078] Fig. 40A is a diagrammatic cross section of two adjacent
sheets of
two adjacent single or multi-plenum panels with a block edge to edge joint;
[00079] Fig. 40B is a diagrammatic cross section of two adjacent
sheets of
two adjacent single or multi-plenum panels with a block edge to edge joint
with a compressed foam gasket;
[00080] Fig. 41A is a diagrammatic cross section of two adjacent
sheets of
two adjacent single or multi-plenum panels with an overlap/shiplap joint;
[00081] Fig. 41B is a diagrammatic cross section of two adjacent
sheets of
two adjacent single or multi-plenum panels with a tongue and groove joint;
[00082] Fig. 42A is a diagrammatic cross section of two adjacent
sheets of
two adjacent single or multi-plenum panels with a V and V groove joint;
[00083] Fig. 42B is a diagrammatic cross section of two adjacent
sheets of
two adjacent single or multi-plenum panels with block edge to edge clip joint;
[00084] Fig. 43A is a diagrammatic cross section of two adjacent
sheets of
two adjacent single or multi-plenum panels with a miter joint;
[00085] Fig. 43B is a diagrammatic cross section of two adjacent
sheets of
two adjacent single or multi-plenum panels with a miter joint with a snap lock
feature having a convex element on one miter edge and a mating concave
element on the other miter edge;
[00086] Fig. 44 is a diagrammatic cross section of two adjacent sheets
of
two adjacent single or multi-plenum panels with a V and V groove joint with a
snap lock feature;
[00087] Fig. 45 is a diagrammatic cross section of two adjacent sheets
of
two adjacent single or multi-plenum panels with a V and V groove joint with a
plurality of convex elements or teeth on the V groove and a mating plurality
of concave element notches on the V;
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[00088] Fig. 46 is a diagrammatic cross section of two adjacent sheets
of
two adjacent single or multi-plenum panels with a tongue and groove joint
with plurality of concave element recesses on the top and bottom of the
tongue and a mating plurality of convex element ribs in the groove, and a
sealant and/or adhesive and/or gasket on the inner vertical wall of the
groove;
[00089] Fig. 47A is a diagrammatic exploded cross section of two
adjacent
sheets of two adjacent single or multi-plenum panels having a V and V
groove joint with a compressible teeth insert attached to the to the male V,
with the teeth extending from the surface of the male V; and
[00090] Fig. 47B is a diagrammatic cross section view of a V and V
groove
joint of Fig. 47A.
[00091] DETAILED DESCRIPTION OF THE INVENTION
[00092] The present invention will be understood by reference to the
following detailed description, which should be read in conjunction with the
appended drawings. It is to be appreciated that the following detailed
description of various embodiments is by way of example only and is not
meant to limit, in any way, the scope of the present invention. In the various
Figures, single plenum panels 2 and multi-plenum panels 4 are depicted.
Such panels 2, 4 are disclosed and described in detail in the incorporated
patents and briefly in the Summary section above.
[00093] Turning now to Fig. 1, a brief description concerning the
various
components of the present invention will now be briefly discussed. As
shown in this embodiment, a whole house or building 2 is constructed using
continuous single plenum panels 8 and continuous multi plenum panels 10
for construction. This typical home 6 has a front and first/left side wall 12
shown, each constructed of continuous single plenum panels 8, back and
second/right side wall 12 (partially visible in background) are also each
constructed of continuous single plenum panels 8. The left sloping portion
and right sloping portion of the roof 14 are also each constructed of
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continuous single plenum panels. The front and back vertical triangular
portions of the roof 14 are each also constructed of single plenum panels,
with could be the same continuous single plenum panel as the vertical front
and back wall 12 beneath each vertical roof 14 section or could be separate
continuous single plenum panels. The ceiling 16 and the floor 18 are each
constructed of multi plenum panels.
[00094] This is the preferred embodiment, but other arrangements are
possible within the scope of this invention. For example, all of the walls 12,
roof 14, ceiling 16, and floor 18 can be constructed of a continuous single
plenum panel 8, or all could be constructed of a continuous multi-plenum
panel 10, or some other combination thereof in addition to that described in
the preferred embodiment, as desired to fulfill particular space and cost
constraints of the building 6.
[00095] As shown in Fig. 1, holes are cut where desired for openings
for
windows 20, doors 22, and other necessary penetrations as for utilities,
vents, etc. Further embodiments addressing the installation of doors 22 and
windows 20 is discussed below.
[00096] Advantageously, because of the multiple connection points
between and distributed across the areas of the two opposing sheets 24 of
the single and multi-plenum panels 2, 4, 8, 10, which are provided by the
numerous spacing structural elements 26, placement of a window 20 or door
22 hole does not substantially decrease the strength of a wall 12. The load
is distributed to the multiple connection points surrounding the hole.
[00097] Typically, a single plenum panel 2, 8 has an outer or exterior
sheet
58 of W to 1/2" and an interior or inner load bearing sheet 54 of 3/8" to 1",
but
more commonly W to 3/4". The spacing structural elements 26 for the single
plenum panel 2, 8 are typically matrix members 60, which are typically
elongated rectangular prisms formed of wood extending from one edge of
the panel to an opposite or an adjacent edge of the panel and having a with
cross sections measuring preferably 1/4"x3/4".
[00098] Typically, a multi-plenum panel 4, 10 has a top 62, a middle
64,
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and a bottom 66 sheet, each measuring between Yi" to 1 inch in thickness.
It is not uncommon for one or two of the sheets 62, 64, 66 to be thicker or
thinner than the other two, but all three sheets may be the same thickness or
of different thicknesses also, based on construction strength and weight and
size requirements, for example. The spacing structural elements 26 for
multi-plenum panels are typically spacing blocks 68, preferably sized
between 2.5" and 4.5" in length and width, and between 1" and 2.5" in
height.
[00099] Turning next to Fig. 2, a second embodiment is shown. In this
embodiment, the house 6 is also built without a frame, but instead of
continuous panels 8, 10, its walls 12, floor 18, ceiling 16, and roof 14 are
built of smaller single and multi-plenum panels 2, 4 ¨ typically sized 8 feet
by
4 feet, and herein referred to as unit panels 2, 4. These unit panels 2,4 are
each easier to handle and individually are faster to erect. But, because of
the many number of unit panels necessary, the total installation time can be
longer than the house in Fig. 1 utilizing continuous panels.
[000100] It should also be noted that an embodiment (not shown)
utilizing a
combination of both unit 2, 4 and continuous 8, 10 panels in a single building
6 construction falls within the scope of this invention. As just one example,
the building may have walls 12 with unit panels 2, 4 as shown in Fig. 2, and
floors 18, ceiling 16, and roof 14 with continuous panels 8, 10 as shown in
Fig. 1.
[000101] Turning next to Fig. 3, a cross section of a house 6 such as
the
house 6 of Fig. 1 is shown. This house 6 utilizes continuous single plenum
panels 8 for the walls 12 and for the roof 14. The floor 18 is a constructed
of
a continuous multi plenum panel 10. The ceiling 16 may be constructed of a
single plenum panel 8 (shown) or a multi plenum panel 10 (not shown) as
desired. As can be seen, no framing in present in this building 10. Because
of the inherent strength in the single and multi-plenum panels 2, 4, 8, 10¨ in
bending, compression, shear, and stability against buckling with
compressive loads ¨ there is no need for conventional framing.
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[000102] This method of construction is ideally suited for manufactured
housing as well as conventional site built housing, and any construction built
with conventional wood framing, including light construction such as
apartment buildings, motels, hotels, restaurants, schools, shopping centers,
etc.
[000103] As is described in further detail below, a continuous single
plenum
panel 8 wall 12 would be installed on the foundation 28 sill plate 30 and be
temporarily braced. Once two continuous single plenum panel 8 walls 12
are installed on the foundation 28 and joined to one another at an
approximately ninety degree angle (for example, the front and first left side
wall 12 of the house 6 in Fig. 1) the two walls 12 will be substantially
stable.
However, it is advisable to retain the bracing until the ceiling panel 16 is
installed.
[000104] Preferably before all the walls 12 are erected, a continuous
multi-
plenum panel 10 flooring 18 is installed and joined to the single plenum
panel 8 walls 12 currently erected. Then the remaining wall(s) 12 are
attached to the foundation 28 sill plate 30, the floor panel 18, and the
adjacent walls 12.
[000105] A continuous single plenum panel 8 or multi-plenum panel 10 is
then installed for the ceiling 16. As described in greater detail below, the
ceiling panel 16 will ideally be attached to wall blocking 32 which will have
been previously installed adjacent to the top of the single plenum panel 8
walls 12. After this step, the structure 6 will be quite stable, and the
temporary wall bracing can be removed.
[000106] The roofing 14 is then attached to the structure 6. Ideally,
roof
connectors 34 will have been pre-installed to the roofing panels 14. The roof
connector 34 is a preferably continuous structural member having preferably
the same length as the roof panel 14 for continuous panels 8, 10 or the
same length as the entire roof edge when used with unit panels 2, 4. The
roof connector 34 will be described in greater detail below. If the roof 14 is
installed in two continuous panels 8, 10 with a joint at the top, the first
roof
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panel 14 will preferably be braced or suspended until the second roof panel
14 is assembled and attached.
[000107] The structure and sheathing is now complete. The home 6 is a
sound structure constructed without conventional framing.
[000108] A weather barrier can now be applied, as needed. The roofing
(e.g., shingles, felt, etc.) and the wall covering (e.g., siding) can be
installed.
If not done before hand, penetrations must be cut and finished for windows
20 and doors 22. Insulation 36 can also be installed.
[000109] The savings in time, materials, and labor is significant.
[000110] Turning now to Fig. 4, a first embodiment of the roof
connector 34
is shown. The roof connector 34 is anticipated to be continuous hollow
triangular prism, most likely formed of the same material along each side.
The roof connectors are designed to resist downward and upward forces as
well as lateral or horizontal sheer forces and bending forces or moments.
The roof connectors 34, via mechanical and/or adhesive connections to
adjacent single and/or multi plenum panels, are designed to be an integral
part of the structural system increasing the structural strength of the
building.
[000111] This is a typical roof connector 34 made of wood. It is
anticipated
that it would be constructed of long strips of plywood or OSB with staggered
joints, and / or finger-jointed material. The roof connector 34 could also be
constructed from typical "2x" lumber of 1-1/2" thickness.
[000112] The roof connector 34 will typically have at least one roof
adjacent
surface 38 that attaches to the roof panel 14. For roof connectors 34 used
at the roof 14/ceiling 16 connection, there will also be a ceiling adjacent
surface that attaches to the ceiling panel 16 and an inner building facing
surface 42 that faces the interior of the building, typically an attic space.
An
angle formed by the roof adjacent surface 38 and the ceiling adjacent
surface 40 will preferably have the same desired slope as the roof 14.
[000113] For the roof connector 34 used at the ridge 44 of the roof 14
in
addition to a first roof adjacent surface 38 there will be a second roof
adjacent surface 38 and an inner building facing surface 42. The roof ridge
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CA 02916690 2016-01-05
44 roof connector 34 would have an apex (top most) angle formed by the
two roof adjacent surfaces 38 that matches the interior angle formed by the
two roof panels 14 joining one another. The same roof connector 34 can be
used for both the roof 14/ceiling 16 eve location as well as the ridge 44
location if the slope is the same on both sides of the roof 14. Salt-box style
homes 6 ¨ with roofs 14 of different angle in the front and back of the house
6, would use roof connectors 34 of different angled measurements.
[000114] Though the roof connector 34 is shown as an isosceles
triangle,
other triangle cross sections could be used. For example, in instances
where the roof 14 is steep, an isosceles triangle would cause the ceiling
adjacent surface 40 base to be narrower than may be desired. In such an
instance, a non- isosceles triangle with a larger apex angle may be desired,
causing the non-adjacent inner building facing surface 42 to extend further
into the interior of the building, causing the base to be wider.
Alternatively, a
lateral extension extending from the ceiling adjacent surface 40 base past a
point where the inner building facing surface 42 intersect the base may be
provided, to allow for a larger base while maintaining a smaller apex angle.
Conversely, with a very low sloping roof 14, a more acute apex angle than
would be present for an isosceles triangle may be desired to keep the ceiling
adjacent surface 40 base from being longer than necessary. However, if a
non- isosceles triangle is used for the roof connectors 34 at a location where
the roof 14 connects to the ceiling 16, a different angled roof connector 34
will most likely be required at the roof ridge 44.
[000115] Ideally, the roof connector 34 is attached to the adjoining
panels
14, 16 with both mechanical and adhesive fastening. This preferably
includes attaching to the single plenum panel 2, 8 roof 14 and either the
single or multi plenum panel 2, 4, 8, 10 ceiling 16 or the single plenum panel
2, 8 walls 12. In some embodiments, the roof connector may be at least
mechanically fastened to each of the wall, ceiling, and roof panels.
[000116] It is anticipated that the roof connector 34 for the roof 14 /
ceiling
16 connection would be filled with insulation 36, foam or fiberglass or other
17
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typical insulating material. However, the roof connector 34 for the roof 14 /
roof 14 ridge 44 connection could be hollow and / or have perforations 46 to
enhance the escape of hot attic gasses to a continuous ridge vent 48.
[000117] Additionally, or alternatively, perforations 46 can be made in
the
single plenum 2, 8 roof panels 14 near the roof connector 34 to facilitate a
ventilation flow to the ridge vent 48.
[000118] The bottom / ceiling adjacent surface 40 dimension of the roof
connector 34 is anywhere between 6" and 72" as required for strength.
Wider bottom lengths are anticipated where the bottom of the roof connector
34 is also serving as the ceiling 16 for the upper level of a "cape cod" style
home 6.
[000119] Turning next to Fig. 5, another embodiment of the roof
connector
34 is shown. In this embodiment, the roof connector 34 is formed from an
extrusion or mold of, for example, aluminum, plastics, wood fiber, fiberglass,
composites, or carbon fiber. Additionally, the roof connector 34 could also
be formed of bent sheet metal, plastics, fiberglass, and carbon fiber.
[000120] The roof connector 34 is ideally a continuous structural
member
and has the same length as the roof panel 14 or roof 14 / ceiling 16 edge.
Similar to the embodiment shown in Fig. 4, the roof connector 34 of this
embodiment would preferably have the same desired slope as the roof 14,
and the same roof connector 34 would be able to be used for both the roof
14/ ceiling 16 eve location as well as the roof ridge 44 location. However,
just as in the previous embodiment, there are instances where roof
connectors 44 having non-isosceles triangle sections may be preferable.
[000121] Ideally, as in the previous embodiment, the roof connector 34
is
attached to the adjoining panels 12, 14, 16 with both mechanical and
adhesive fastening. This preferably includes attaching to the single plenum
panel 2, 8 roof 14 and either the single or multi plenum panel 2, 4, 8, 10
ceiling 16 or the single plenum panel 2, 8 walls 12. In some embodiments,
the roof connector 34 may be at least mechanically fastened to each of the
wall 12, ceiling 16, and roof 14 panels.
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[000122] As in the previous embodiment it is anticipated that the roof
connector 34 shown in Fig. 5 for the roof 14 / ceiling 16 connection would be
filled with insulation 36, foam or fiberglass or other typical insulating
material.
However, the roof connector 34 for the roof ridge 44 connection could be
hollow and / or have perforations 46 to enhance the escape of hot attic
gasses into a continuous ridge vent 48.
[000123] Additionally, or alternatively, as in the previous embodiment,
perforations 46 can be provided in the single plenum 2, 8 roof panels 14
near the roof connector 34 to facilitate a ventilation flow into the ridge
vent
48.
[000124] As in the previous embodiment, the bottom / ceiling adjacent
surface 40 dimension of the roof connector 34 is anywhere between 6" and
72" as required for strength. Wider bottom lengths are anticipated where the
bottom of the roof connector 34 is also serving as the ceiling 16 for the
upper
level of a "cape cod" style home 6.
[000125] Turning next to Figs. 6A and 6B, two further embodiments of
the
roof connector 34 are shown. These embodiments are ideal for attaching
inclined single plenum panels 2, 8 (likely roof panels 14) to vertical
surfaces
(likely single plenum 2, 8 wall panels 12). These embodiments of the roof
connector 34 are essentially a "half roof connector" as previously described.
That is, they are hollow triangular prisms, but they have a cross section
shaped like one half of an isosceles triangle, or a right triangle. Both
embodiments in Figs. 6A and 6B are formed or extruded from aluminum,
plastics, wood fiber, carbon fiber, fiberglass, composites, sheet metal, etc.
[000126] In the embodiment shown in Fig. 66, a vertical flange 50
extends
below the main body to allow for easier connection of the roof connector to
the adjacent vertical surface. This flange can also extend upwards onto a
vertical wall for a better connection where the adjacent vertical wall extends
further upward.
[000127] These two embodiments allow the roof connector 32 to be
attached to the single plenum 2, 8 roof panel 14 on the exterior portion of
the
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building, or, for example, with a soffit the interior of an attic space.
Additionally, these embodiments allow the roof connector 34 to be directly
adhesively and mechanically attached to the exterior sheet 58 of the single
plenum 2, 8 wall panels 12, especially the embodiment with the vertical
flange 50. It is understood that if desired, both a roof connector 34 as shown
in Fig. 5 and a roof connector 34 as shown in one of the embodiments of
Figs. 6A and 6B could be used at a single wall 12 / roof 14 / ceiling 16
connection ¨ a roof connector 34 from Fig. 5 where the roof 14 is adjacent to
the ceiling 16 / edge blocking 70 (see Fig. 13), and a roof connector from
Figs. 6A and 6B where the roof is adjacent to the wall 12 / edge blocking 70.
[000128] Turning next to Figs. 7A and 7B, another two additional
embodiments of the roof connector 34 are shown. These two embodiments
are essentially the same as the two roof connectors previously described in
Figs. 6A and 6B, but the roof connectors in Figs. 7A and 7B are made of
wood.
[000129] Turning now to Fig. 8, one embodiment of the connection
between
the wall 12, the floor 18, and the foundation 28 of a building 6 according to
the invention is shown. In this embodiment the walls 12 are constructed of
continuous single plenum panels 8 and the floor 18 is constructed of multi-
plenum panels 4, 10. The load bearing single plenum wall panels 8 would
have as their main structural compressive member the inside facing interior
sheet 54. The interior sheets 54 would bear on a top surface of the sill plate
30, adjacent to an outer edge of the sill plate 30. The inside sheets 54
would be located adjacent a 2x4 sill plate blocking 56 installed on top of the
sill plate 30. The sill plate blocking 56 would preferably be installed in the
field.
[000130] Connections would then be made between the single plenum 8
wall panel 12 and the 2x4 sill plate blocking 56. Ideally, this would be both
a
mechanical and adhesive connection. Mechanical connectors 74 such as
screws can penetrate the full single plenum panels 2, 8, or connector holes
76 came be provided in the exterior sheet 58 of the single plenum panels 2,
CA 02916690 2016-01-05
8 to facilitate installation of screws 74 directly into the interior sheet 54
(as
shown in later figures) at desired locations.
[000131] Next, the flooring 18 system would then be installed on the
2x4 sill
plate blocking 56. The flooring 18 shown in this embodiment is a multi-
plenum panel 4, 10. The multi plenum panel 4, 10 has a 2x4 edge blocking
70 installed along its outer edge in the top plenum 78 and bottom plenum 80
to facilitate attachment to the wall 12 and the sill plate 30 and sill plate
blocking 56. The height of the edge blocking 70 in this embodiment matches
the height of the respective plenums 78, 80, though other heights are
possible. The length of the edge blocking 70 in this embodiment is along the
entire outer edge of the floor panel 18 adjacent to the wall 12, but it may be
shorter and/or in multiple spaced units. The edge blocking 70 in this
embodiment is present in both the top and bottom plenum 78, 80, though
could be in just one or the other. The edge blocking 70 may be larger or
smaller in height, width, and length as required by strength.
[000132] The single plenum panel 2, 8 is then attached to the flooring
system 18, ideally with both adhesive and mechanical means. As shown,
screws 74 can be driven through the entire single plenum panel 2, 8 wall 12,
directly mechanically fastening both the interior and exterior sheets 54, 58
to
the sill plate blocking 56 and/or the floor panel 18 edge blocking 70.
Additionally or alternatively, as described below, connector holes 76 can be
provided in the outer exterior sheet 58 to facilitate screws 74 driven
directly
through the load bearing interior sheet 54 of the single plenum panel 2, 8
into the sill plate blocking 56 and/or the floor panel 18 edge blocking 70,
with
the head of the screw 74 adjacent the load bearing interior sheet 54.
[000133] Although it is anticipated that screws 74 will be primarily
used in
fastening, it should be noted that unless the text states "only screws," the
term screw used in this disclosure is not meant to be limiting, and shall
include other mechanical fasteners 74 including, for example, nails, bolts
and braids, as would be apparent to one of skill in the art.
[000134] Turning now to Fig. 9, a further embodiment of the floor 18
/wall
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12 /foundation 28 connection of Fig. 8 is shown. This Figure shows
perforations or through connector holes that can be provided in the exterior
sheet 58 of the single plenum panel 2, 8 to facilitate the connection of the
single plenum panel 2, 8 wall 12 to the flooring 18 and foundation 28 system.
The connector holes 76 can be provided either in the factory or field. The
screws 74 used to mechanically attach the various elements to one another
are not shown in this Figure to show greater detail.
[000135] Additionally, a bottom portion of the exterior sheet 58 of the
single
plenum panels 2, 8 can be removed in the factory or field to facilitate
directly
connecting the load bearing interior sheet 54 to the interior structure 6,
especially the flooring 18 and foundation 28 system.
[000136] Turning
now to Fig. 10, this figure shows a side view of the
embodiment shown in Fig. 9. As can be seen the connector holes 76 allow
for easy access to directly screw the screws 74 into the interior sheet 54 of
the single plenum panel 2, 8 wall 12. This facilitates the connection of the
single plenum panel 2, 8 wall 12 to the flooring 18 and foundation 28 system.
The connector holes 76 can be provided either in the factor or field.
Additionally, as shown in Fig. 12, in the same wall 12, screws 74 can be
driven both through the exterior and interior sheets 58, 54 of the single
plenum panel 2, 8 wall 12 and into the sill plate blocking 56 and also through
connector holes 76 directly into the load bearing interior sheet 54 and into
the sill plate blocking 56.
[000137] Turning
now to Fig. 11, an additional embodiment of a floor 18
/wall 12 /foundation 28 connection of a building 6 according to this invention
is shown. In this embodiment a load bearing single plenum panel 2, 8 wall
12 is attached to a single plenum panel 2, 8 floor 18 system, instead of the
multi plenum panel 4, 10 floor 18 system shown in Figs. 6-8.
[000138] The
single plenum panel 2, 8 wall 12 is located with a 2x4 sill plate
blocking 56 attached to the preferably pressure treated sill plate 30. The
connection is ideally both mechanical and adhesive. In the
shown
embodiment screws 74 are driven through the both sheets 54, 58 of the
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CA 02916690 2016-01-05
single plenum panel 2, 8 and into both the floor 18 edge blocking 70 and sill
plate blocking 56 in the single plenum panel 2, 8 flooring 18.
[000139] As with the previous embodiments the size and continuity of
the
floor 18 edge blocking 70 may vary based on strength need. Also as with
the previous embodiments, connector holes 76 may be provided in the
exterior sheet 58 of the single plenum panel 2, 8 wall 12 or a lower portion
of
the exterior sheet 58 of the single plenum panel 2, 8 wall 12 may be
removed to allow for direct screwing of screws 74 into the load bearing
interior sheet 54 of the single plenum panel 2, 8 wall 12.
[000140] Turning now to Fig. 12 a still further embodiment of the floor
18!
wall 12 / foundation 28 attachment is shown. In this embodiment a
frameless load bearing single plenum panel 2, 8 wall 12 is attached to a
conventionally framed flooring system made of 2x10 joists 72. In this
embodiment there would be a rim joist 82 to which the single plenum panel
2, 8 would be attached, preferably with both mechanical and adhesive
means.
[000141] This embodiment also shows screws 74 being driven both through
the entire single plenum panel 2, 8 into the rim joist 82, and via provided
connector holes 76 being driven directly into the load boarding interior sheet
54 and into the rim joist 82.
[000142] Turning now to Fig. 13, a first embodiment of a wall 12 / roof
14!
ceiling 16 connection of a building 6 according to the invention is shown. In
this embodiment the load bearing single plenum panel 2, 8 wall 12 is
connected to a single plenum panel 2, 8 ceiling panel 16 and a single
plenum panel 2, 8 roof 14.
[000143] A 2x4 or larger wall blocking 32 is attached to the top of the
load
bearing single plenum panel 2, 8 wall 12 continuously along its length. This
wall blocking 32 is ideally attached from the inside of the building to the
interior sheet 54 of the single plenum panel 2, 8 with screws 74 or other
mechanical fasteners 74 but could also be attached from the exterior sheet
58 of the single plenum panel 2, 8. Ideally, the wall blocking 32 is also
23
CA 02916690 2016-01-05
attached with adhesive 84.
[000144] The ceiling panel 16 can be made of either single plenum
panels
2, 8 (shown) or multi plenum panels 4, 10 (shown in Fig. 12) and has edge
blocking 70 of approximately 2x4 size. Screws 74 are then run through the
ceiling panel 16 into the wall blocking 32 attached to the load bearing single
plenum panel 2, 8 wall 12. Ideally, the connection is both mechanical and
with adhesive 84. In contrast to the floor panel 18 edge blocking 70, which
is preferably laterally adjacent to the wall panel 12, the ceiling panel edge
blocking 70 in this embodiment is vertically above the wall panel 12.
[000145] The roof panel 14 is connected using the previously described
continuous roof connector 34 that has been ideally previous attached to the
roof panel 34 or the ceiling panel 16 with both mechanical and adhesive
means. In attaching the roof panel 14 to the ceiling panel 16, ideally an
adhesive connection 84 is established between any of the roof panel 14 and
the ceiling panel 16 that have not previously be attached to the roof
connector 34. The roof connector 34 is screwed into the roof panel 14. One
screw 74 is ideally longer and screws into the 2x4 edge blocking 70 in the
edge of the ceiling panel 16. The ceiling panel 16 can have a Mag/Ox
bottom layer /interior sheet 54, or 1/4" OSB/plywood and 1/4" drywall or wood
for ceiling tile or ornamented wood patern.
[000146] Turning now to Fig. 14A, a second embodiment of a wall 12 /
roof
14 / ceiling 16 connection of a building 6 according to the invention is
shown.
In this embodiment the load bearing single plenum panel 2, 8 wall 12 is
connected to a multi plenum panel 4, 10 ceiling 16 and single plenum panel
2, 8 roof 14. The multi plenum panel 4, 10 ceiling panel 16 (or ceiling-floor
panel 16/18 for the multi-story building) has edge blocking 70 that is
connected to 2x4 (or larger) wall blocking 32 that was preferably previously
attached on the interior sheet 54 of the single plenum panel 2, 8 walll 2.
[000147] A 2x4 or larger wall blocking 32 is attached to the top edge
of the
load bearing single plenum panel 2, 8 wall 12 continuously along its length.
The wall blocking 32 is ideally attached from the inside of the building 6
with
24
CA 02916690 2016-01-05
screws 74 but could also be attached from the outside. Ideally, the wall
blocking 32 is also attached with adhesive 84.
[000148] Screws 74 are then run through the top sheet 62 of the multi
plenum 4, 10 ceiling panel 16, passing through the upper edge blocking 70,
the middle sheet 64, the lower edge blocking 70, the bottom sheet 66, and
into the wall blocking 32 attached to the load bearing single plenum 2, 8
panel wall 12. Ideally, the connection is both mechanical and with adhesive
82. In contrast to the floor panel 18 edge blocking 72, which is preferably
laterally adjacent to the wall panel 12, the ceiling panel 16 edge blocking 72
in this embodiment is vertically above the wall panel 12. The roof panel 14
can now be connected.
[000149] The roof panel 14 is connected using the previously described
continuous roof connector 34 that has been ideally previous attached to the
roof panel 14 or the ceiling panel 16 with both mechanical and adhesive
means 74, 82. In attaching the roof panel 14 to the ceiling panel 16, ideally
an adhesive connection 82 is established between any of the roof panel 14
and the ceiling panel 16 that have not previously be attached to the roof
connector 34. The roof connector 34 is screwed into the roof panel 14. One
screw 74 is ideally longer and screws into the 2x4 edge blocking 72 in the
edge of the ceiling panel 16.
[000150] Also shown in Figs. 14A to 140 are four different embodiments
of
louvers or fascia or other permeable occlusions 88 that provide limited
passage into the plenum 88 of the roof panel 14. These permeable
occlusions 88 or end details could be accomplished with aluminum or vinyl
and stapled 74 on the end of the single plenum panels 2, 8. The purpose of
the fascia 88 is to provide a finished end of the single plenum panels 2, 8
and to also facilitate ventilation, while screening out insects. The end
details
could be attached at a terminal edge of the roof panel 14 plenum 88, or
along a gap provided in the lower (interior) sheet 54 of the roof panel 14.
Other types of permeable occlusions and similar locations may be used.
[000151] Turning now to Figs. 15 -17, three different embodiments are
CA 02916690 2016-01-05
shown of wall 12 and ceiling-floor 1 6/1 8 attachments for multi-level
buildings
6 according to the present invention.
[000152] In Fig. 15, an upper and a lower single plenum panel 2, 8 wall
12
are joined to a multi plenum panel 4, 10 ceiling-floor 16/18. The section
shown is similar to Fig. 14A in that it shows the method of connecting ceiling
panels 16 to the single plenum panel 2, 8 load bearing wall 12 by placing the
ceiling-floor 1 6/1 8 edge blocking 70 vertically above the lower single
plenum
panel 2, 8 wall 12. This, in turn, has the upper single plenum panel 2, 8 wall
12 directly above the ceiling-floor 1 6/1 8 edge blocking 70.
[000153] A 2x4 or larger wall blocking 32 has been attached to the top
of
the lower load bearing single plenum panel 2, 8 wall 12 continuously along
its length. This is ideally attached from the building 6 inside with screws 74
but could also be attached from the outside. Ideally, this attachment is also
made with adhesive 84.
[000154] The ceiling-floor panel 16/18, having edge blocking 70
inserted
therein, is then placed on top of the lower wall panel 12 and lower wall
blocking 32 and (not shown) screws 74 are screwed down through the
ceiling-floor panel 16/18 from the top and into the lower wall blocking 34.
Ideally, the ceiling-floor panel 16/18 will also be attached to the lower wall
blocking 32 with adhesive 84.
[000155] Next, a 2x4 upper wall blocking 32 is attached to the top of
the
multi-plenum panel 4, 10 ceiling-floor panel 16/18 and is inset so that the
thickness of the single plenum panel 2, 8, upper wall 12 matches that of the
single plenum panel 2, 8 lower wall 12 below. The interior sheet 54 of the
upper and lower single plenum panels 2, 8 are load bearing, so they must be
fit continuously. The load bearing interior sheet 54 of the upper wall panel
12 can be attached with screws 74 from the building interior or the building
exterior (shown) through the upper wall blocking 32. Ideally, the upper wall
panel 12 is also attached to the upper wall blocking 32 with adhesive 84.
Vertical aligned vertical perforations 46 could be provided in the ceiling-
floor
panel 16/18 edge blocking 70 and the in the top, middle, and bottom sheets
26
CA 02916690 2016-01-05
62, 64, 66 of the multi-plenum panel. This would allow gasses from the
plenum 88 of the lower wall panel 12 to pass upward through the vertically
aligned vertical perforations 46 of the edge blocking 70 and sheets 62, 64,
66, and into the plenum 88 of the upper wall panel 12, allowing continuous
vertical wall ventilation.
[000156] Alternatively or additionally, permeable occlusions 86 could
be
located in the upper portion of the exterior sheet 58 of the lower wall panel
12 and in the lower portion of the exterior sheet 58 of the upper wall panel
12, as shown. This venting gasses and in to the wall 12 plenums 88 though
permeable occlusions 86 allows for a vertical movement of gasses through
the plenum 88 of the wall panels 12, though not directly from the lower to the
upper.
[000157] For a two story structure, the top of the upper wall panel 12
could
then be as shown in Figs. 13 or 14A, where the ceiling and roof panels 16,
14 are connected to the wall panel 12.
[000158] Turning
to Fig. 16, a second embodiment of a wall 12 and ceiling-
floor 16/18 attachment for a multi-level building 6 is shown. In this
embodiment, a load bearing single plenum panel 2, 8 wall 14 (either upper
and lower unit panels 2 as shown, or continuous 8) is attached to single
plenum panel 2, 8 ceiling-floor 16/18. A plane marking the level of the lower
and upper wall panel 12 intersection is marked by the horizontal dashed line
L-U. A lower single plenum panel 2, 8 wall panel 12 is assembled using
methods previously described as a load bearing wall 12. Lower wall blocking
32 is preferably mechanically and adhesively attached adjacent to the top of
the interior sheet 54 of the lower single plenum panel 2, 8 wall 12 to support
a horizontal single plenum panel 2, 8 used for both the lower level ceiling 16
and the upper level floor 18. This horizontal single plenum panel 2, 8 has
edge blocking 70 to facilitate mechanical and adhesive attachment to the
lower wall blocking 32.
[000159] After installation of the horizontal single plenum panel 2, 8,
an
upper (vertically oriented) load bearing single plenum panel 2, 8 wall panel
27
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12 is placed on and vertically aligned with the lower wall panel 12, as shown
in Fig. 16. The upper wall panel 12 is preferably mechanically and
adhesively attached to the edge blocking 70 and an additional upper wall
blocking 32 is added to the second floor level. The upper wall blocking 32 is
preferably also mechanically and adhesively attached to the edge blocking
70.
[000160] This embodiment allows the continuous and substantially
unobstructed ventilation and air/gas flow 90 along the single plenum panel 2,
8 walls 12.
[000161] Turning next to Fig. 17, a third embodiment of a wall 12 and
ceiling-floor 16/18 attachment for a multi-level building 6 is shown. Similar
to
the first embodiment shown in Fig. 15, this third embodiment includes upper
and lower single plenum panel 2, 8 wall panels12, and a multi plenum panel
4, 10 floor-ceiling panel 16/18, with the plane marking the level of the lower
and upper wall panel 12 intersection marked by the horizontal dashed line L-
U. But, similar to the second embodiment the upper and lower single
plenum panel 2, 8 walls 12 are directly adjacent to one another and the edge
blocking 70 for the ceiling-floor panel 1 6/1 8 is horizontally adjacent to
the
wall panel(s) 12, not vertically adjacent.
[000162] In this third embodiment, a lower single plenum panel 2, 8
wall
panel 12 is assembled using methods previously described as a load
bearing wall 12. Lower wall blocking 32 is preferably mechanically and
adhesively attached to top of the interior sheet 54 sheet of the lower single
plenum panel 2, 8 wall 12 to support a horizontal multi plenum panel 4, 10,
which is used for both the lower level ceiling 16 and the upper level floor
18.
This horizontal multi-plenum panel 4, 10 has edge blocking 70 to facilitate
mechanical and adhesive attachment to the lower wall blocking 32.
[000163] After installation of the horizontal multi-plenum panel 4, 10,
an
upper (vertically oriented) load bearing single plenum panel 2, 8 wall panel
12 is placed on and vertically aligned with the lower wall panel 12, as shown
in Fig. 17. The upper wall panel 12 is preferably mechanically and
28
CA 02916690 2016-01-05
adhesively attached to the edge blocking 70 and an additional upper wall
blocking 32 added to the second floor level. The upper wall blocking 32 is
preferably also mechanically and adhesively attached to the edge blocking
70. The blocking shown in this third embodiment includes two upper wall
blockings 32, one horizontal wall blocking 32 adjacent to the upper wall
panel 12 and the multi-plenum panel 4, 10 ceiling-floor 16/18 and a second
vertical wall blocking 32 adjacent to the upper wall panel 12 and the
horizontal wall blocking 32. The extra upper wall blocking 32 could also be
used for the second embodiment of Fig. 16 and vice versa.
[000164] This third embodiment also allows the continuous and
substantially unobstructed vertical ventilation and flow of air/gas 90 along
the
single plenum panel 2, 8 walls 12.
[000165] Turning now to Figs. 18A and 18B, a flanged circle guide
device
92 is shown to aid installation of drywall and insulation 36 on the inside of
inclined single plenum panel 2, 8 walls 12 or roofs 14.
[000166] The flanged circle guide device 92 can be extruded or formed
from
plastics, metal, vinyl, fiberglass, composites, and many other materials. A
cross section has a circular portion 94 and a protruding flange portion 96
extending tangentially from the circular portion 94. It has a rounded edge
and the circular portion 94 has a diameter anywhere from 1/2" to 6". The
protruding flange portion 96 extends 2" to 8" from the circular portion 94.
The flanged circle guide device 92 is manufactured in substantial lengths,
such that it can be installed in continuous lengths anywhere from 4' to 40'.
[000167] The flanged circle guide device 92 is used for to retain batt
insulation 36 on an inclined surface. This flanged circle guide device 92 is
also used as a gauge for foam insulation 36 so that the foam insulation 36 is
installed to a certain desired depth. This depth would be consistent with the
insulation guides 98 discussed further in this description.
[000168] The flanged circle guide device 92 are installed with screws,
staples or nails or other mechanical connectors 74 and/or adhesives 84
along the flange portion 96.
29
CA 02916690 2016-01-05
[000169] Turning now to Fig. 19, a third embodiment of a wall 12 / roof
14 /
ceiling 16 connection of a building 6 according to the invention is shown. In
this embodiment the load bearing single plenum panel 2, 8 wall 12 is
connected to a roof 14 and ceiling 16 of conventional construction building 6
(with trusses 100).
[000170] This embodiment shows three different methods of connecting
the
top wall blocking 32 to the single plenum panel 2, 8 wall 12 to facilitate the
installation of the ceiling 16 and roof 14 panels (in the embodiments of Figs.
11 and 12) or trusses 100 and rafters of the embodiment of Fig. 19.
[000171] Three different methods of screwing the top wall blocking 32
are
shown ¨ a first method where the screw 74 passes through the complete
single plenum panel 2, 8 from the outside of the building 6 with the head of
the screw 74 seated on the outer surface of the exterior sheet 58 and the tip
of the screw 74 in the wall blocking 34, a second method where the screw
74 passes through a connector hole 76 through the exterior sheet 58 of the
single plenum panel 2, 8 from the outside of the building 6 with the head of
the screw 74 seated on the inner surface of the inner plenum facing surface
of the interior sheet 54, and the third, and likely easiest method where the
screw passes from the wall blocking 32 to the load bearing interior sheet 54
of the panel 2, 8 with the head of the screw 74 seated on the wall blocking
32. One, two, or all three of the methods may be used in this and other
embodiments of wall blockings 32.
[000172] The top wall blocking 32 is attached to the load bearing
interior
sheet 54 of the single plenum panel 2, 8 with screws 74 in one or more of
three methods described above, ideally in conjunction with adhesive 84.
The wall blocking 32 can be 2x4, 2x6, and 2x8 or other dimensions such as
4x6 or 4x8. The wall blocking 32 will be preferably hidden by the insulation
36 which is installed later.
[000173] In the embodiment shown in Fig. 19, the ceiling 16 and roof 18
construction is conventional and a truss 100 is shown to be attached to the
top of the single plenum panel 2, 8 wall 14 and the wall blocking 32. The
CA 02916690 2016-01-05
truss 100 could be toe-nailed in, but most likely would be attached with metal
clips, sometimes called "hurricane clips" for a better connection and one that
can offset uplift, or some other mechanical connector 74.
[000174] It is also noted that a permeably occluded 86 upper terminal
gap
may be provided in the exterior sheet 58 (as shown in Fig. 15) of this and
other wall panels 12 at the wall 12 / ceiling 16! roof 14 connections to allow
warm air flow 90 to exit the plenum 88. Alternatively a fluid connection,
through vertical perforations, for example, can be made between the upper
portion of the plenum 88 of the wall panel 12 and the lower edge of an above
single plenum panel 2, 8 roof 14.
[000175] Turning now to Fig. 20, an insulation guide or gage 98 is
shown.
The insulation guide 98 is used to install either batt or foam insulation 36
against a flat surface. The depth of the insulation guide 98 would match
either the thickness of the batt insulation 36 or the desired depth of the
foam
insulation 36. The rear face or expanse 102 of the insulation guide 98 would
be stapled or nailed to the adjacent vertical flat surface, which is shown
here
as a wall 12, for a vertical orientation of the insulation guide 98.
[000176] Other non-vertical orientations for the insulation guide 98
could be
for a ceiling 16 in the horizontal orientation or for a sloped surface, such
as
the inside wall 12 of a so called "cape cod" style house 6. It is anticipated
that there are situations where the insulation guide 98 and/or the flanged
circle guide device 92 shown in Figs. 18A and 18B above could be used to
aid in installing insulation 36 in a frameless building 6 constructed of
single
and multi-plenum panels 2, 4, 8, 10.
[000177] Holes or chases 104 are preferably provided in the transverse
expanse 106 of the insulation guide 98 at intervals for the trades to install
plumbing, heating, electrical, data wires, communication and other services
and utilities as would be commonly installed and hidden in the walls 12. The
chases 104 could be rounded or chamfered so that a doughnut would not
have to be installed for wire installation as would be required if the edges
of
the chases 104 were sharp.
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[000178] The insulation guide 98 can be made of extruded plastic,
vinyl,
aluminum, composite or any other material that could be extruded or made
continuously. The insulation guide 98 can also be made from bent metal or
formed from a variety of materials including vinyl, plastic, aluminum,
corrugated products, carbon fiber, fiberglass, composites, or any planer
materials.
[000179] The insulation guide 98 is installed to the wall 12 or ceiling
16
surface with staples or nails 74. It can be cut horizontally or vertically as
necessary to avoid obstacles such as blocking 34, 72. Although the
insulation guide 98 may stretch from floor 18 to ceiling 16, it is not
necessary
that it do so.
[000180] For foam insulation 36 applications, the insulation guide 98
will
serve as the guide for the trimming of the foam insulation 36 after
application.
[000181] For batt insulation 36, the guides or gauges 98 would
preferably
be installed at a certain increments along the wall 12 or ceiling 16
determined by the width of the insulation bans 36. For foam insulation 36
applications, the insulation guides 98 would preferably be installed at an
increment less than the length of the cutting/trimming device for foam
insulation 36.
[000182] An optional "T" shape flange 108 ¨ shown in Fig. 22 and in
dotted
lines in Fig. 20¨ can be incorporated to the rear expanse 102 for stability if
necessary. Similarly, the front expanse 110 may be T shaped as well, but
will normally have a single flange extending from the transverse expanse
106 in an opposite direction as the flange extending from the rear expanse
102 (see Fig. 21). It is to be noted that the insulation guides 98 normally do
not carry any load of the structure 6. Indeed, there may be a gap provided
between the upper edge of the insulation guide 98 and the ceiling 16 to allow
wide wire harnesses or pipes through. Additionally, there may be a gap
between the lower edge of the insulation guide 98 and the floor 18 to allow
passage of wide wire harnesses or pipes. Finally, there may also be a
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complete break along the vertical length of the insulation guide 98 to allow
for passage of wide wire harnesses or pipes. Any of these scenarios would
substantially prevent any load being carried by the insulation guides 6.
[000183] Turning now to Fig. 21, and embodiment is shown where
numerous insulation guides or gauges 98 are installed along a wall 12 (three
shown). Oln the middle insulation guide 98 an electric box 112 is attached
for an electrician to install an electrical outlet. Electrical or data boxes
112
can be attached to the transverse expanse 106 or side of the insulation
guides 98 as needed.
[000184] Turning next to Fig. 22, a view of an insulation guide having
a "T"
shaped flange 108 on the rear expanse 102 is shown. This drawing is
similar to the middle insulation guide 98 of Fig. 21, but the insulation guide
98 depicted in this drawing also has the optional "T" shaped flange 108,
which can be used for added rigidity when required. The electrical / data
box 112 is also shown installed on the insulation guide 98.
[000185] Figs. 23-25 describe embodiments for installing windows 20 and
doors 22 into the unit and continuous load bearing single plenum panel 2, 8
walls 12.
[000186] Turning first to Fig. 23, this figure shows a simple method of
providing for the framing and installation of windows 20 or doors 22 in the
load bearing single plenum panel 2, 8 wall 12. The desired opening is first
cut in the wall 12. A box 114 of the desired rough opening is then attached
to the inside of the single plenum panel wall with screws or nails. This
design is made of nominal 2" lumber and with a depth as required.
[000187] Turning next to Fig. 24, a second embodiment for window 20 and
door 22 installation is described. In this embodiment, windows 20 and doors
22 are installed in a load bearing single plenum panel 2, 8 wall 12 using a
nested shell 116 with a depth desired for insulation. The entire nested shell
116 opening can be pre-made, especially for certain standard rough
openings of windows 20 and doors 22 and used as appropriate.
Alternatively, the nested shell 116 can be made in various lengths and cut
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and assembled as required for the desired opening.
[000188] The desired opening is cut through the single plenum panel 2,
8
for the window 20 or door 22. An interior shell 118, either as a single unit
or
in sections, is then installed through the opening or, as shown an interior
flange 120 is stapled 74 to the outer surface of the interior sheet 54 of the
wall panel 12 (the surface shown in the Figure). Only three staples 74 are
=
shown to maintain clarity of the drawing. This interior shell 118 is the
portion
of the nested shell 116 that extends into the interior of the building 6.
[000189] An exterior shell 122 is then installed form the outside and
fits
inside the interior shell 118 previously installed. The exterior shell 122 has
an exterior flange 124 (shown in dashed lines) which is stapled to the outer
surface of the exterior sheet 58 of the wall panel 12 (outer surface facing
away in the drawing). The joint between the exterior flange 124 and the wall
panel 12 to the can be caulked, sealed or taped as desired to be waterproof,
or flashing can be installed at a later time when the window 20 or door 22 is
installed. The exterior shell 122 can interlock with the interior shell 118 or
otherwise be mechanically or adhesively secured one to the other.
[000190] Turning next to Fig. 25, a cross section of the second
embodiment
for window 20 and door 22 installation, described in Fig. 24, is shown.
[000191] An optional shell blocking 126 can be installed across the top
of
the opening should it be required or desired for extra strength.
[000192] If more stability to the nested shell 116 is required, then
flange
tabs 128 could be included at intervals of 4" to 12" as shown. As can be
seen, the interior shell 118 extends back into the building 6 as far as the
insulation 36 and drywall. As can also be seen, the exterior shell 122
extends through and preferably 1" to 3" past the hole in the single plenum
panel 2, 8. In the innermost portion of the interior shell 118, a trim flange
130
extends out from the interior shell 118. The trim flange 130 could be
attached to the drywall mechanically or adhesively to the inner and/or outer
surface of the drywall.
[000193] Turning next to Figs 26A ¨ 29, these drawings show multiple
34
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mechanical connectors or fasteners 74 that are specially designed for
fastening single and double plenum panels 2, 4, 8, 10, as described above.
[000194] Turning to Figs. 26A - 26D, a toothed screw 132 is shown which
allows an load bearing interior sheet 54 of a single plenum panel 2, 8 wall 12
to be directly fastened to a supporting structure (other panel or blocking,
for
example), without a pre-drilled access connector hole 76 in the exterior
sheet 58 of the single plenum panel 2, 8 walll 2.
[000195] The Figs. show four views of the toothed screw 132: a top view
(Fig. 26A), a partial side view with the shank 134 of the toothed screw 132
omitted (Fig. 26B), a partial side view with the front and rear cutting teeth
136 omitted (Fig. 26C), and a bottom view (Fig. 26D). In the partial side
view of Fig. 26B, the toothed screw 132 is shown with an enlarged flat head
138 having with cutting teeth 136 fixedly attached to and extending
downward from the head 138 parallel to the shank 134. The cutting teeth
136 are 2 to 16 in number, and preferably 2 to 4 in number. The cutting teeth
136 are of a length equal to the thickness "" of the exterior sheet 58 of the
single plenum panel 2, 8 wall 12, which is the first layer of the panel wall
12
to be penetrated.
[000196] The partial side view of Fig. 260 shows the toothed screw 132
orientation while the partial side view of 26B shows one embodiment of the
cutting teeth 136. This particular example has four cutting teeth 136, also
shown in the bottom view of Fig. 260.
[000197] The diameter of the top head 138 is as determined for the
application and can be anywhere from 1/4" to 3". The diameter of the screw
shank 134 would be as required for strength.
[000198] The top view of Fig. 26A shows a star drive 140, but other
screw
drives 140, including hex, square, Torx, and Phillips may be used.
[000199] Turning to Fig. 27 and 28, the operation of the toothed screw
of
Fig. 26A-26D is shown. In the figures, the upper sheet in the drawing is
preferably the exterior sheet 58 of the single plenum panel 2, 8 and the
lower sheet in the drawing is preferably the interior sheet 54 of the single
CA 02916690 2016-01-05
plenum panel 2, 8. As shown in Fig. 27 the toothed screw 132 is first driven
into the exterior sheet 58 of a single plenum panel 2, 8, preferably without
benefit of a pre-drilled connector hole 76.
[000200] As can be seen, the depth ";t" of the cutting teeth 136 is
substantially the same thickness "f of the exterior sheet 58. To continue
operation of the toothed screw 132, the toothed screw 132 continues to be
driven downward into the exterior sheet 58 until the cutting teeth 136 contact
the exterior sheet 58. At this point, continued rotation of the toothed screw
132 causes the cutting teeth 136 to cut into the exterior sheet. As the
toothed screw 132 is rotated further, the cutting teeth 136 cut entirely
through the exterior sheet 58 and a wood plug 142 (formed from the cut out
portion of the exterior sheet 58) is seated in the head 138 of the toothed
screw 132. At this point, a connector hole 76 has been automatically
provided in the exterior sheet 58 by operation of the toothed screw 132, and
the toothed screw 132 is no longer restrained by the exterior sheet 58 and
may progress downward into the interior sheet 54, as shown in Fig. 28.
[000201] In Fig. 28, the toothed screw 132 is shown after it has been
directly screwed in into the interior sheet 54 all the way down until the
cutting
teeth 136 are contacting the interior sheet 54. However, because the wood
plug 142 fills the cavity in the screw head 138, it spaces and blocks the
cutting teeth 136 from advancing further into the interior sheet 54. In
effect,
the wood plug 142 acts as a washer to self-seat the toothed screw 132 onto
the interior sheet 54 of the single plenum panel 2, 8. On the opposite side of
the interior sheet 54 from the toothed screw head 138 would be some type
of structural support (e.g., a blocking 32, 56, 70) for the single plenum
panel
2, 8 to attach to the structure 6.
[000202] With the disclosed self-seating toothed screw 132, no special
tools
are required, other than perhaps an extended screw drill bit.
[000203] Turning next to Fig. 29, a second mechanical connector 74 or
fastener, in the form of a double-head screw 144, is disclosed to connect
single plenum panels 2, 8 to supporting structures without predrilled access
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connector holes 76. Similar to Figs. 27 and 28, the upper sheet in the figure
is an exterior sheet 58 of a single plenum panel 2, 8 and the lower sheet is
an interior sheet 54 of a single plenum panel 58. As shown in the Figure, a
double headed screw 144 is fully sunk into a single plenum panel 2, 8. The
double headed screw 144 has a larger diameter flat upper or "top" head 146
at a terminal end of the double headed screw 144 and has an intermediate
head 148, with a twisted bit base 150, spaced at a distance from the top
head 146. The distance between the top of the intermediate head 148 and
the bottom of the larger top head 146 is the same as the distance from the
inner surface of the interior sheet 54 and the outer surface of the exterior
sheet 58.
[000204] Because of the spacing between the two heads 146, 148, when
the double headed screw 144 is screwed into the single plenum panel 2, 8,
the twisted bit portion 150 of the intermediate head 148 will first screw
through the exterior sheet 58 and continue downward. The shank 134 of the
double headed screw 144 will screw through the interior sheet 54 (and into a
blocking 32, 56, 70, or some other support of the structure) and as the
twisted bit 150 of the intermediate head 148 begins to drill into the interior
sheet, the larger top head 146 will seat on the outer surface of the exterior
sheet 58, will substantially close off the just formed connector hole 76 and
will preferably provide a compressive force on the exterior sheet 58.
[000205] Turning now to Figs. 30A to 31C, a first and second method of
securely connecting adjacent single plenum panels 2, 8 with coupling blocks
152 are shown. These methods will also work with multi-plenum panels 4,
(not shown). The coupling blocks 152 will aid in constructing a building 6
out of unit panels 2, 4 without a frame, while maintaining the structural
integrity and strength benefits of the single and multi-plenum panels 2, 4.
Solid coupling blocks 152 are shown in Figs. 30A ¨ 30C and hollow coupling
blocks 152 are shown in Fig. 31A ¨ 31C, but are otherwise substantially the
same. The coupling blocks 152 have a thickness that is preferably either the
same as the interior clear dimension between the sheets 54, 58 of a single
37
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plenum panel 2 or the thickness of the clearing between one sheet 54, 58
and a matrix member 60. The coupling blocks 152 are easily inserted into
the plenum 88 of each panel 2, 4 in the field and easily attached using
mechanical and/or adhesive methods, such as screws 74 and/or glues 84.
The length of the coupling blocks 152 are determined by the matrix
dimensions and strength requirements.
[000206] Optional variations of the solid coupling blocks 152 are shown
in
Fig. 310. When inserting in panels 2 having matrix members 60, depending
on the spacing of matrix members, the edge of the panel 2 on one side may
have a full clearance between the two sheets 54, 58 (for at least a minimal
distance), and the edge of the panel 2 on the opposing side will have a
reduced clearance, part of the clearance being occupied by one matrix
member running parallel to the edges of the panels 2 being coupled. To
maximize contact area between the two sheets 54, 58 of the two panels 2,
the coupling block 152 of Fig. 310 has a full clearance side 154, which has a
thickness equal to the clearance between the two sheets 54, 58, and a
matrix clearance side 156, which has a thickness equal to the distance
between a matrix member 60 and the sheet 54, 58 the matrix member 60 is
not directly attached to. The portion removed 158 from the matrix clearance
side 156 is substantially equal to the height of the matrix member 60 from
the sheet 54, 58 it is attached to. The full clearance side 156 could also
have a portion removed 158 along a portion of its length, especially the
portion that is inserted first into the plenum 88. In this way, the full
clearance
side 154 of the coupling block 152 could also fit between at least one matrix
member 60 and its opposing sheet 54, 58 while also filling the full clearance
between the matrix member 60 and the edge of the panel 2.
[000207] Additionally, the coupling block 152 of Fig. 31C has a raised
center guide 160 which helps to quickly center the coupling blocks 152, with
respect to length, so equal lengths of the coupling blocks 152 are in both
panels 2, when securing the coupling blocks 152 in the respective panels 2.
Also, the coupling block 152 of Fig. 310 has a plurality of cleats or raised
38
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protrusions 162 with help to frictionally lock the coupling blocks 152 in
place
once inserted, without the need for further mechanical fasteners 74 or
adhesives 84. Only nine cleats 162 are shown in Fig. 300 to maintain
clarity, but preferably the number would be significantly higher, the cleats
162 be located on all sides of the coupling blocks that would contact sheets
54, 58 or matrix members 60, and the cleats 162 would be angled toward
the raised center guide 160 (or where a raised center guide would be if one
was not present) ¨ which would cause the coupling blocks 152 to dig into the
adjacent sheets 54, 58 and lock into place after being inserted into the
plenum 88 of the two panels 2, locking the two panels 2 together.
[000208] The solid coupling blocks 152 can be made of wood, wood fiber,
aluminum or other metals, plastics, composites, carbon fiber, fiberglass, bent
metal or other materials.
[000209] The hollow coupling blocks 152 of Figs. 31A -310 can be made
of
wood, wood fiber, aluminum or other metals, plastics, composites, carbon
fiber, fiberglass, bent metal or other materials. It is anticipated the blocks
could be also extruded or formed from these materials. The variations of
Fig. 300 can also be made with the hollow coupling blocks 152.
[000210] Although a horizontal connection is shown, the same method
could be utilized for a vertical connection as would be required at the gable
ends of a home 6.
[000211] Turning now to Figs. 32A ¨ 330 a first and second method of
securely connecting adjacent single plenum panel with "H" shaped couplers
164 are shown. In Figs. 32A - 320 "H" couplers 164 with a solid mid-portion
166 is shown, and in Figs. 33A ¨ 330 "H" couplers 164 with a mid-portion
166 with perforations 46 is shown. These H couplers 164 can be the full
length of the single plenum panel 2 or (not shown) can be shorter clips of
desired length using several to connect the two adjacent panels 2, or (not
shown) could be longer than the full length of the single plenum panel 2 and
connect more than two adjunct panels 2 together (two adjacent panels on a
first level and two adjacent panels 2 on a second level directly above the
first
39
CA 02916690 2016-01-05
two panels 2). The H coupler 164 is inserted in the field and attached using
mechanical 74 and/or adhesive 84 methods.
[000212] The perforated 46 H couplers 164 facilitate complete
ventilation
between the adjacent panels 2.
[000213] The dimensions and thickness of the H couplers 164 are
determined by strength requirements. Although the H couplers 164 are
shown with smooth engaging surfaces 168 on the parallel opposing capping
portions 170, engaging surfaces 168 could also be ribbed, rough, or rigged,
with the ridges angled inward toward a the mid portion. Additionally, one or
many barbs or cleats 162 could be provided on the engaging surfaces 168,
preferably with the barbs or cleats angled inwardly and back toward the mid
portion, such that the H couplers 164 were easy to slide on the panel 2, but
where trying to remove the H coupler 164 would cause the barbs or cleats
162 to dig into the surface of the engaged sheet 54, 58 ¨ in a similar fashion
to the optional cleats 162 used in the coupling blocks in Fig. 300.
[000214] The coupling blocks 152 and H couplers 164 can be made of
wood, wood fiber, aluminum or other metals, plastics, composites, carbon
fiber, fiberglass, bent metal or other materials. It is anticipated that
embodiments of each 152, 164 could be also extruded or formed from these
materials.
[000215] Although a horizontal connection is shown, the same method
could be utilized for a vertical connection as might be required at the gable
ends of a home.
[000216] In the embodiment shown in Figs. 32A ¨ 33C, the mid-portion
166
of the H coupler 164 spaces the parallel capping portions 170 from one
another such that engaging surfaces 168 of the capping portions 170
engage the outer surfaces of the interior and exterior sheets 54, 58 of each
of the adjacent panels 2. That is, the two engaging surfaces 168 on the
respective capping portions 170 face one another.
[000217] In another embodiment (not shown), a shorter mid-portion 166
would space the parallel capping portions 170 such that their engaging
CA 02916690 2016-01-05
surfaces 168 are on the opposite side, and they 168 engage the inner
surfaces of each of the interior and exterior sheets 54, 58 of adjacent
panels.
[000218] In a further embodiment (not shown), two spaced end caps 170
would be positioned at each end of the mid-portion 166 such that the end
caps 170 engaged both the inner and the outer surfaces of each of the
interior and exterior sheets 54, 58 of each adjacent panel 2.
[000219] In a still further embodiment, the H couplers 164 instead of
just
being linier (like a lower case "L"), could can be formed in a "T" shape or a
"+" shape to connect three adjacent or four adjacent panels 2 respectively.
The H couplers 164 could be used alone, or with the coupling blocks 152.
[000220] Turning next to Figs. 34A - 34B, an embodiment for connecting
adjacent panels using two methods is shown. A first method uses panel
blocking 172, which is inserted into the plenum 88 of the single plenum
panel 2, or, as shown, is attached exterior of one of the two sheets 54, 58,
covering the seam between the two adjacent single plenum panels 2, or is
used on both sides of the panel 2 (attached to the exterior of both sheets 54,
58, covering the seam on both sides). The second method uses rigid /
tensile strips 174, which can be attached to the exterior surface to either
side
of the single plenum panel 2, covering the seams, or used on both sides.
The two methods can be combined, such as shown Figs. 34A and 34B,
where the panel blocking is attached to one side of the panels seam and the
tensile strip 174 is attached to the other side.
[000221] The panel blocking 172 and tensile strips 174 are easily
installed
in the field and attached using mechanical 74 and/or adhesive 84 methods.
[000222] The panel blocking 172 is ideally placed on the exterior
surface of
the load bearing interior sheet 54 of the single plenum panel 2, since it
would
be hidden by insulation 36 installed later.
[000223] The tensile strip 174 is anticipated to be of minimal
thickness with
fibrous strength as well as ridged strength. The strip is applied in the field
with adhesives or installed and activated with an additional field treatment
such as for a fiberglass or carbon fiber strip. If both panel blocking 172 and
41
CA 02916690 2016-01-05
tensile strip 174 methods are used in combination at the same side of a
panel/panel seam, preferably the tensile strip 174 would be attached first
and the 172 blocking attached over the tensile strip 174.
[000224] The dimensions and thickness of the panel blocking 172 and the
tensile strip 174 connectors are determined by strength requirements. They
could be the full length of the single plenum panel 2, or just part of the
length, and could each 172, 174 be of different length. For example, the
tensile strip 174 could be attached from one edge of the seam to the other,
and the panel blocking 172 could be attached of the tensile strip 174 and
cover just half of length of the seam.
[000225] The panel blocking 172 connector can be made of wood, wood
fiber, aluminum or other metals, plastics, composites, carbon fiber,
fiberglass, bent metal or other materials. It is anticipated the panel
blocking
172 could be also extruded or formed from these materials.
[000226] The tensile strip 174 connector is probably a thin strip of
aluminum
or other metal, plastic, reinforced plastics, composites, fiberglass, carbon
fiber or other suitable material.
[000227] Although a horizontal connection is shown, the same method
could be utilized for a vertical connection as might be required at the gable
ends of a home 6.
[000228] Turning next to Figs. 35A and 35B, a quick method of
mechanically connecting spacing structural elements 26 / matrix members
60 of adjacent single plenum panels 2 is shown using spikes 176 that are
ideally initially installed in the edges of the matrix members 60.
[000229] Adjacent single plenum panels 2 are thus connected in the
field by
the movement of a first panel 2 toward an already installed second single
plenum panel 2 (shown by arrows in the Fig. 35A) by means of applying
pressure probably by hammering a wood block to lock the adjacent single
plenum panels 2 together. The spikes 176 could be attached in the field, but
are ideally preinstalled in the factory.
[000230] A design of a possible spike 176 is shown in Fig. 35B. The
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CA 02916690 2016-01-05
dimensions and thickness of the spike 176 connectors are determined by
strength requirements. Though the spike shanks 178 shown are smooth,
they could also be ribbed, twisted, or barbed. The spike also has a midline
plate 180 used to aid in forcing a spike 176 into a matrix member 60 and
seating the spike shank 178 at a given depth in the matrix member 60.
[000231] The spikes 176 can be made of metals including aluminum,
strong
plastics, composites, or other materials.
[000232] Although a horizontal connection is shown, the same method
could be utilized for a vertical connection as might be required at the gable
ends of a home.
[000233] Although embodiments of the connectors 152, 164, 172, 174,
176,
and methods of connection in Figs. 30A-358 are for shown for single plenum
panels 2, the connectors and variations of the connectors may be used for
multi-plenum panels 4. For example, a variation of the H couplers 164 for
the multi-plenum panels 4 could resemble an H coupler 164, except with a
transvers engaging edge bisecting the mid-portion 166, with the transverse
engaging edge engaging a top or bottom surface of the middle sheet 64 of
the multi plenum panels4. Alternatively, a second variation of the H coupler
164 would resemble an H coupler 164 with two closely spaced transvers
engaging edges bisecting the mid-portion 166 of the H coupler 164. The two
transverse engaging edges would be spaced apart at a distance
approximately equal to the thickness of the middle sheet 64 of the multi-
plenum panel 4, and when installed, one transverse engaging edge would
engage a top surface of the middle sheet 64 of the multi-plenum panel 4,
and one transverse engaging edge would engage a bottom surface of the
middle sheet 64 of the multi plenum panel 4. Additionally, coupling blocks
152 can be easily inserted in one or both of the plenums 78, 80 of the multi-
plenum panel 4 to connect two adjacent multi plenum panels 4. These
connectors could also be used to securely connect a single plenum panel 2
adjacent to a multi-plenum panel 4 as part of, for example, a same wall 12,
floor 18, roof 14, or ceiling 16.
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[000234] Turning now to Figs. 36 and 37 a self-sealing long-toothed
screw
132 for multi-plenum panels 4, 10 is shown, which is similar to the toothed
screw 132 for single plenum panels 2, 8 described above in Figs. 26A to 28.
The length of the teeth 136 on the long tooth screw 132 is substantially
equal to the sum of the thickness of the top and middle sheet 62, 64 of the
multi-plenum panel 4, 10. Though the top and middle sheets 62, 64 are
shown as being the same thickness (f), and thus the length of the long
teeth shown is 2t, other variations are possible. For example, the middle
sheet 64 could be wider or thinner than the top sheet 62, but the length of
the long teeth 136 would still be the sum of the two thicknesses, whatever
that may be.
[000235] The long toothed screw 132 operates in a similar manner as the
toothed screw 132 of Figs. 26A to 28, except the long toothed screw 132 will
cut through both the first and middle sheets 62, 64 before being seated on
the inner surface of the bottom sheet 66.
[000236] Turning next to Figs. 38A to 39B, multiple embodiments of
methods to ventilate attic spaces when using the single or multi plenum
panels 2, 4, 8, 10 are described.
[000237] Although the single plenum panels 2, 8 and the multi-plenum
panels 4, 10 provide ventilation in excess of code requirements, in some
cases, it may be desirable or necessary to ventilate the adjacent attic space.
It is possible some officials may have a strict interpretation of governing
official provision, such as International Residential Code (IRC) R806.1 -
ventilation required for enclosed attics and enclosed rafter space.
[000238] One method to provide additional ventilation of attic space
constructed of single and multi-plenum panels 2, 4, 8, 10 is to remove a '4"
ventilation strip along the edge of the interior or bottom sheet of the single
or
multi-plenum panels 2, 4, 8, 10 before they are installed. This can be done
in the factory or on site. Alternatively, the panels can be built originally
with
the, for example, 3/4" gap, without the need to remove material later.
[000239] This ventilation strip 182 would preferably be used in
conjunction
44
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with an open continuous ridge vent 48. The continuous ridge vent 48 is
preferable, as it would provide an escape for moist air 90 that may migrate
into the attic space. A sketch of a continuous ridge vent 48 with the single
plenum panels 2, 8 is shown in Fig. 38A. Also shown is a ridge gap 184
allowing air flow 90 from the two panel plenums 88 to exit into the ridge vent
48. Other venting, such as whirly birds and horizontal vents from the vertical
wall of the attic and perforations in the interior sheet 54 of the panel 2
could
also be used.
[000240] The following example describes the ventilation strip 182
method
used with a single plenum panel 2, 8. For median homes 6, this would
normally be approximately 10 unit panels 2 that a ventilation strip 182 would
be cut into. A router bit 186 set to remove the thickness of the interior
sheet
54 (1/4", 3/8" or other thickness of the sheet) and set to remove a depth of
3/1" is used along the long edge of panels 2, 8. This would provide the
ventilation described in IRC R806.1. As shown in Fig. 38C, these panels 2,
would then be assembled well clear of insulation 36 blown or installed in
the attic. This would not be applicable with insulation 36 applied to the roof
panels 14.
[000241] Turning to Fig. 39A, this figure shows a router 188 removing
the
3/4" ventilation strip 182 along the long edge of the interior sheets 54 of a
single plenum panel 2. As mentioned above, the ventilation strip 182 can be
cut before or after assembly of the panel 2, at the factory or at the jobsite.
Alternatively, one of the sheets 54 of the single plenum panel 2 could be
originally sized 3/4" shorter than the other sheet 58, thus automatically
creating the ventilation strip 182 once the panel 2 is assembled.
[000242] Turning next to Fig. 39B, shows the interior of an attic
formed unit
single plenum panels 2, with the ventilation strip 182 running the length of
the attic space. Though not shown, panels 2 with perforated interior sheets
54 may be used in addition or alternatively to the ventilation strips to
increase ventilation in enclosed spaces.
[000243] Turning next to Figs. 35 and 36, multiple router bits which
could be
CA 02916690 2016-01-05
used to cut the strip are shown. It is understood that strips greater than or
less than 1/4" in size could be used depending on the desired amount of
increased ventilation.
[000244] Turning next to Figs. 40A ¨ 47B, multiple embodiments for
securely joining adjacent panels 2, 4 together is discussed. Single and multi-
plenum panels 2, 4 are normally installed adjacent to one another. In many
or most cases, it is desirable to utilize a method of interconnecting the
panels 2, 4 in the methods already described in the incorporated patents,
with offset interior spacing structural elements 26 (preferably matrix
members 60 for single plenum panels 2 and blocks 68 or other separators
for multi-plenum panels 4). These interconnections provide for the transfer
of stresses to adjacent panels. There may be instances where the
interlocking offset feature may not be used.
[000245] In addition to interconnecting panels 2, 4 for structural
purposes,
with offset interior spacing structural elements 26, adjacent sheets 24 in
adjacent panels 2, 4 can also be interconnected to one another. Such
interconnected sheets 24 would preferably act to transfer stresses as well as
fluidly/gaseously sealing the sheets 24 and plenums 78, 80, 88, preferably
with minimal obstruction to the plenum 78, 80, 88. Interconnecting sheets
24 between adjacent panels 2, 4 would also check possible warping in the
sheets 24.
[000246] The following methods can be used at the joints 190 of the
single
and multi-plenum panels 2, 4, among other methods. These methods can
be similar for all sheets 24 in a single or multi-plenum panel 2, 4, or can
vary
with each sheet 24.
[000247] Additionally, these methods can be used with or without the
already disclosed offset matrix members 60 or blocks 68, and various means
of connecting adjacent panels disclosed herein.
[000248] In Fig. 40A, two sheets with block edges are just joined edge
190
to edge 190.
46
CA 02916690 2016-01-05
[000249] In all methods, a sealer such as a foam strip can preferably
be
utilized. Most usually, it would be adhered to one face on a first sheet 24
and pressed against another, preferably coplanar, face on an abutting sheet
24. Similarly, as shown in Fig. 40B, a gasket 194 of vinyl, plastic, foam,
etc.
that is extruded or formed compressible, preferably hollow, solid can be
utilized in the joint. Additionally, an impermeable tape can be applied to the
joints on the faces of the panel joints.
[000250] Turning to Fig. 41A an overlap or shiplap joint 190 can be
formed
by the two sheet 24 edges 192. This provides an increase surface area of
attachment while also providing an edge to prevent horizontal movement.
[000251] Turning to Fig. 41B a tongue and grove joint 190 can be formed
by
the two sheet 24 edges 192. This provides a significant increase in surface
area of attachments, and resists movement in two vertical directions and one
horizontal direction. A drawback is that a small tongue 200 may be more
liable to break.
[000252] Turning to Fig. 42A, a V with V grove joint 190 can be formed
by
the two sheet 24 edges 192. The convex V 202 self-centers in the concave
V grove, providing increased surface area of attachment, and preventing
movement in two vertical directions and one horizontal direction, while likely
being more structurally robust than the tongue and grove joint shown in Fig.
41B
[000253] As shown in Fig. 42B, separate clips 196 or external elements
can
be used to join adjacent sheets 24. A sealer can be used with the clip 196,
and the clip 196 can have multiple teeth or cleats 162 in each top and
bottom surface of each side to cleat lock the clip 196 onto the respective
sheet 24 edge 192 when forced on the edge 192. The clips 196 could also
have one or more horizontally extending and preferably ribbed, toothed, or
barbed elements 198 projecting from the vertical surface of the clip 196.
Such horizontally extending elements 198 would puncture the face of the
edge 192 of the sheet 24, and extend horizontally into the sheet 24 when the
clip 196 was pressed onto the side edge 192 of the sheet 24.
47
CA 02916690 2016-01-05
[000254] Turning to Fig. 43A, a miter joint 190 can be formed by the
two
sheet 24 edges 192. This provides an increased surface area of
attachment, but does not prevent horizontal movement as well as other
joints.
[000255] Turning to Fig. 43B, a miter with snap/lock feature joint 190
can be
formed by the two sheet 24 edges 192. This provides the increased surface
area of a miter joint, but the snap lock feature 206 also aids in resisting
horizontal motion in both directions once the snap lock 206 is engaged.
[000256] Turning to Fig. 44, a miter with snap/lock feature joint 190
can be
formed by the two sheet 24 edges 192. This provides the increased surface
area of a miter joint, but the snap lock feature 206 also aids in resisting
horizontal motion in both directions once the snap lock 206 is engaged.
[000257] Turning to Fig. 45, the joints can be both secured to one
another
and sealed by the use of small teeth or projections 208 or other shaped
convex mechanical attachment elements that could be tooled on both a
tongue and groove joint and the V-V joint, for example. These projections
208 would grip the adjacent sheet 24 when joined, providing integrated
mechanical connection, and also help to fluidly/gaseously seal the joint 190.
[000258] The projections 208 can also be made out of vinyl, plastic,
metal
or other material and applied individually or as a unit to the male or female
edge 192 of the joint 190. The edge 192 with the projections 208 would then
attach and seal to the adjacent sheet 24 edge 192 when joined.
Additionally, the projections 208 could be applied to both male and female
sides of the joint 190, either offset so that opposing projections 208 do not
interact as the two sheets 24 are joined, or aligned so that opposing
projections 208 pass over one another and interlock as the sheet 24 edges
192 are joined. Fig. 45 shows teeth like projections 208 on a convex V 202
and mating recesses 210 on the concave V grove 204.
[000259] Additionally, the V with V grove and the tongue and groove
joint,
for example, can also incorporate rib like projections 208 and mating
recesses 210 whereby the projections 208 and recesses 210 would mesh
48
CA 02916690 2016-01-05
when joined to attach adjacent sheets 24 and substantially fluidly/gaseously
seal them.
[000260] The mechanical attachment elements could be formed into the
edges, unitary with the sheet and out of the same material as the sheet.
Alternatively, structures 212 with mechanical attachment elements (such as
projections 208 and recesses 210) could be attached onto the blocked or V /
V grove edges 192. The dashed lines in Figs. 48 and 49 indicating one
potential location where the structures 212 could be attached. Alternatively,
the convex projection elements 208 (e.g., each separate tooth) could be
made of different material than the sheet and attached separately to one or
both of the male or female edge, with or without concave mating recess
elements 210 disposed on the other of the male or female edge.
[000261] Preferably concave recesses 210 (e.g., notches) are present on
one or both edges with mating convex projections 208 (e.g., teeth) on the
other or both edges, but projections 208 could be used alone. For example,
a V groove 204 edge 192 with teeth projections 208 could be used with a
convex V 202 edge 192 that does not have any notches or recesses 210.
Alternatively, a convex V 202 edge 192 with teeth projections 208 could be
used with a V groove 204 edge 192 that does not have any notches or
recesses 210. Or both a V groove 204 edge 192 and a convex V 202 edge
192 could have teeth projections with neither having any notches or
recesses 210.
[000262] In a further embodiment, both the male and female edges 192
could have interlocking projections 208, such that when, for example, a tooth
projection 208 on a convex V 202 edge 192 pushed past a tooth projection
208 on a V groove 204 edge, the two teeth projections 208 would interlock
with each other and mechanically attach the two edges 192 together.
[000263] Additionally, the projections 208 and recesses 210 could be
narrow, less than 3 mm wide, or moderate size, 3-50mm wide, or could even
be substantially be as wide as the length of the abutting edge 192 of the
panel 2, 4.
49
CA 02916690 2016-01-05
[000264] Additionally, the teeth/ribs or other projections 208 can be
disposed on one non-vertical edge 192, and preferably a mating notch or
other recess 210 can be disposed on an abutting non-vertical edge 192 of a
sheet 24 of an adjacent panel 2, 4. For example, an overlapping half of a
shiplap joint could have one or more rib projections 208, and an overlapped
half of a shiplap joint could have one or more mating recesses 210. Once
the panels 2, 4 are secured to the underlying housing structure 6, the mating
elements 208, 210 would provide a mechanical horizontally interlocking joint
190.
[000265] Additionally, one or more horizontally extending convex
elements
on one sheet can mate with one or more horizontally defined interior
concave elements ¨ such as the tongue and grove joint of Fig. 41B. Such a
mating of horizontally aligned concave and convex elements on abutting
edges of adjacent panels provides for a mechanically vertically interlocking
joint
[000266] Turning to Fig. 46, a further embodiment of adjacent edge 192
attachments are shown with a tongue and grove arrangement. In this
embodiment concave recesses 210 are disposed preferably on opposing
upper and lower surfaces of a male portion of a first edge 192, e.g., the
tongue 200, and mating rib projections 208 are disposed in opposing upper
and lower surfaces of a female portion of a second edge 192, e.g., the grove
214.
[000267] Foam, gel, or other adhesive 84 and/or watertight, and
preferably
at least initially liquid or malleable substance inserted in space between two
adjacent edges (as shown in the Figure by substance on inner vertical wall
of the grove 214). The adhesive 84 could alternatively or additionally be
applied to the inner ribs 208, recesses 210, vertical surfaces / surfaces with
no projections 208 or recesses 210, or some combination thereof.
Alternately a hollow flexible, resiliently compressible, and preferably hollow
gasket 194 could be used instead of or in addition to the adhesive 84. The
gasket 194 itself could be adhesive 84.
CA 02916690 2016-01-05
[000268] Tuning next to Figs. 47A and 47B, a further embodiment is
shown.
In this embodiment an edge insert 216 is attached to the edge(s) 192 of one
or both of the adjacent sheets 24. The edge insert 216 would preferably
have compressible "teeth" projections 208 that would both grasp the
adjacent sheet 24 and provide an air barrier to prevent air from passing from
or to the plenum 88 through the joint 190. In the embodiment shown, the
edge insert 216 is adhered to the convex V 202 edge 192 of a V and V
groove joint 190. This edge insert 216 would most likely be produced with
vinyl, but could also be made out of metal, plastics or similar materials. In
another version of this embodiment, a first compressible teeth projection 208
insert 216 would be adhered to the convex V 202 edge 192, with the teeth
extending from the surface of the convex V 202 edge192, and a second
compressible teeth projection 208 insert 216 would be adhered to the V
groove 204 edge 192, with the teeth projections 208 extending from the
surface of the V groove 204 edge 192. When pressed together, the two
compressible teeth projection 208 inserts 216 would interlock, providing
increased surface area for the seal, and increased friction and mechanical
locking to secure the edges 192 to one another. Glues 84 and / or other
chemical and mechanical 74 adhesives and / or sealants can be used in
addition to the compressible teeth projections 208 insert 216.
[000269] While various embodiments of the present invention have been
described in detail, it is apparent that various modifications and alterations
of
those embodiments will occur to and be readily apparent those skilled in the
art. However, it is to be expressly understood that such modifications and
alterations are within the scope and spirit of the present invention, as set
forth in the appended claims. Further, the invention(s) described herein is
capable of other embodiments and of being practiced or of being carried out
in various other related ways. In addition, it is to be understood that the
phraseology and terminology used herein is for the purpose of description
and should not be regarded as limiting. The use of "including," "comprising,"
or "having" and variations thereof herein is meant to encompass the items
51
CA 02916690 2016-01-05
listed thereafter and equivalents thereof as well as additional items while
only the terms "consisting of" and "consisting only of" are to be construed in
the !imitative sense.
52
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REFERENCE NUMBERS
2 Single Plenum Panel, Unit Single Plenum Panel
4 Multi-Plenum Panel, Unit Multi-Plenum Panel
6 Home, House, Building
8 Continuous Single Plenum Panel
Continuous Multi-Plenum Panel
12 Wall
14 Roof
16 Ceiling
18 Floor
Windows
22 Doors
24 Sheet
26 Spacing Structural Elements
28 Foundation
Sill Plate
32 Wall Blocking
34 Roof Connector
36 Insulation
38 Roof Adjacent Surface
Ceiling Adjacent Surface
42 Inner Building Facing Surface
44 Ridge
46 Perforations
48 Vent
Vertical Flange
52 Wall Facing Surface
54 Interior Sheet
56 Sill Plate Blocking
58 Exterior Sheet
Matrix Members
53
CA 02916690 2016-01-05
62 Top Multi-Plenum Panel Sheet
64 Middle Multi-Plenum Panel Sheet
66 Bottom Multi-Plenum Panel Sheet
68 Spacing Blocks For Multi-Plenum Panel
70 Edge Blocking
72 Joists
74 Mechanical Connectors
76 Connector Holes
78 Top Plenum
80 Bottom Plenum
82 Rim Joists
84 Adhesive
86 Permeable Occlusions
88 Single Plenum Panel Plenum
90 Air Flow
92 Flanged Circle Guide Device
94 Circular Portion
96 Flanged Portion
98 Insulation Guides
100 Trusses
102 Inner Expanse Of Insulation Guide
104 Chase (Hole In Insulation Guide)
106 Transverse Expanse Of Insulation Guide
108 T Shape Flange
110 Front Expanse Of Insulation Guide
112 Electric / Data Box
114 Box (Door / Window Box)
116 Nested Shell
118 Interior Shell
120 Interior Flange
122 Exterior Shell
54
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124 Exterior Flange
126 Shell Blocking
128 Flange Tabs
130 Trim Flange
132 Toothed Screw
134 Shank, Screw
136 Teeth, Screw
138 Head, Screw
140 Drive, Screw
142 Wood Plug
144 Double Headed Screw
146 Top Head
148 Intermediate Head
150 Twisted Bit Base
152 Coupling Blocks
154 Full Clearance Side
156 Matrix Clearance Side
158 Removed Portion
160 Raised Center Guide
162 Cleats
164 H Couplers
166 H Coupler Mid Portion
168 Engaging Surface
170 Capping Portions
172 Panel Blocking
174 Rigid/Tensile Strip
176 Spikes
178 Spike Shank
180 Midline Plate
182 Ventilation Strip
184 Ridge Gap
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186 Router Bit
188 Router
190 Joint
192 Edge
194 Gasket
196 Clips
198 Horizontally Extending Elements
200 Tongue
202 Convex V
204 Concave V Grove
206 Snap Lock
208 Projections
210 Mating Recesses
212 Structure
214 Grove of Tongue and Grove
216 Edge Insert
56
