Static structures (e.g. – buildings) – Processes – Anchor – bond – etc.
Reexamination Certificate
2000-05-11
2001-11-13
Canfield, Robert (Department: 3635)
Static structures (e.g., buildings)
Processes
Anchor, bond, etc.
C052S747100, C052S271000, C052S274000, C052S284000, C052S582100, C052S586100
Reexamination Certificate
active
06314704
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to structural building components and systems, and more particularly to composite structural building panels, connection systems and related components, and to systems and methods for erecting structures including such panels.
BACKGROUND
Traditionally, housing or other building structures have been erected one component at a time, i.e., they are generally built at the erection site and include structural framework, shear sheathing, vapor barriers, protective exterior siding or finishes, such as paint, and interior finishes or paneling, such as gypsum board. For example, the structural framework may be erected from raw materials, and then other components may be successively added until a finished structure is provided. The various components are generally assembled together using a wide range of fasteners, such as, nails, nuts, bolts, screws, and/or other materials, such as gasketing, adhesives and the like.
Because of the complexity of such structures, highly skilled tradesmen are required, and building them takes substantial time. Further, during construction, ancillary components, such as plumbing, mechanical and electrical systems, architectural features, such as roofing and trim, interior features and the like, may be added to complete the structure. This may further increase labor and time demands, and consequently result in relatively costly building structures.
To reduce field costs and accelerate erection of building structures, factory assembled components have been proposed. For example, prefabricated panels, generally made up of plywood applied over a gypsum board core, may be used to reduce field assembly time. In addition, subassemblies of framing or other structural components may be built in a factory or other offsite environment, where mass production or improved efficiencies may be realized, as compared with field conditions. These components, however, may be bulky, resulting in dramatically increased shipping costs and/or requiring a factory in close proximity to the erection site.
Another problem with conventional building structures is that they often involve the use of wood products, particularly within the residential industry, which are becoming increasingly scarce and expensive. As an alternative, concrete and steel materials may be used, but these materials generally involve heavy equipment and special labor requirements, which may dramatically increase erection time and cost. Further, steel and concrete materials may not adequately resist corrosion and/or may involve complicated seismic load considerations.
More recently, plastic or composite materials, i.e., fiber reinforced plastic (“FRP”), have been considered for panel systems. These panels may simply substitute a composite material for one or more elements of the panels, e.g., the outer skins, while using foam or honeycomb core materials between the skins. Other composite panels have been suggested that use extruded or pultruded composite materials. These panel systems, however, generally still require fasteners, e.g., screws or bolts, in order to connect the panels to specially designed trim components, beams, and the like. Thus, many of the components necessary to assemble the panels and erect a building structure may be traditional non-composite materials, which may compromise the structural and durability benefits obtained from the use of composite materials.
Other composite systems have suggested tongue and groove or “H” strip connectors between panels, but these systems may also require multiple fasteners to provide a structurally integral connection between the panels. Alternatively, other composite systems may use resin-catalyst mixtures to bond panels together, but these systems may substantially increase erection time, e.g., due to the curing time of panel joints, and/or may involve specially skilled field labor knowledgeable in working with composite materials.
According, there is a need for structural building components and systems that may be assembled in a more efficient manner, and/or that may overcome problems associated with previous systems.
SUMMARY OF THE INVENTION
The present invention is directed to composite building panels and related connection systems, and to methods of assembling and using such panel systems for building structures.
In accordance with one aspect of the present invention, a composite panel for a structural building system is provided that includes a truss member formed from composite material and defining first and second planes spaced apart a predetermined distance from one another. The truss member includes a plurality of truss elements extending substantially transversely between the first and second planes. A first skin formed from composite material extends along the first plane, and a second skin formed from composite material extends along the second plane.
A connector formed from composite material extends along a first edge at least partially defined by the first and second skins. The connector includes an elongate aperture extending generally parallel to the first edge for receiving a locking member therein, whereby the composite panel may be connected to another composite panel having a similar connector and aperture. Preferably, another connector formed from a composite material may be provided that extends along a second edge at least partially defined by the first and second skins, the connector also including an aperture extending generally parallel to the second edge for receiving a locking member therein. More preferably, the connectors are provided on opposite edges from one another, thereby defining side edges of the composite panel.
The truss member preferably includes a first surface element extending along the first plane between adjacent truss elements, and a second surface element extending along the second plane between adjacent truss elements, the second surface element being staggered from the first surface element. More preferably, the truss member includes alternating sets of first and second surface elements extending along the first and second planes, respectively, along a width of the truss member.
In one form, the first skin is bonded to the first surface elements, and/or the second skin is bonded to the second surface elements. The connectors may then be bonded to the side edges between the first and second skins. Alternatively, the connectors may be integrally formed with the truss member. In a further alternative, the truss member, first skin and second skin may be integrally formed together, e.g., during a pultrusion process.
In addition, the composite panel may also include a base insert clip extending along a third edge, preferably a lower edge, at least partially defined by the first and second skins for connecting to a base connector. The composite panel may also include a cap member extending along a fourth edge, preferably an upper edge, for connecting to a roof panel clip.
Thus, in a preferred form, the composite panel includes composite connectors, preferably bonded along each edge of the panel.
In accordance with another aspect of the present invention, a modular composite panel system is provided that includes a truss member, a first skin and a second skin, each formed from composite material. The truss member is a single sheet of material having an undulated shape, thereby defining first and second planes spaced apart a predetermined distance from one another. The truss member includes a plurality of truss elements extending substantially transversely between the first and second planes, first surface elements extending along the first plane between adjacent truss elements, and second surface elements extending along the second plane between adjacent truss elements. The second surface elements alternate with the first surface elements along a width of the truss member.
The first skin is attachable to the truss member along the first plane, and the second skin is attachable to the truss member along the second plane. In a preferred form, the fi
American Structural Composites, Inc.
Canfield Robert
Lyon & Lyon LLP
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