Static structures (e.g. – buildings) – Intersection of wall to floor – ceiling – roof – or another wall
Reexamination Certificate
1998-09-23
2001-01-30
Stephan, Beth A. (Department: 3635)
Static structures (e.g., buildings)
Intersection of wall to floor, ceiling, roof, or another wall
C052S273000, C052S288100, C052S462000, C052S467000, C052S640000
Reexamination Certificate
active
06178708
ABSTRACT:
FIELD OF THE INVENTION
This invention relates generally to structural panels for buildings and is particularly directed to the joinder of structural insulated panels having an insulating core where the joined panels may be oriented at virtually any angle relative to one another.
BACKGROUND OF THE INVENTION
Structural Insulated Panels (SIPs) are commonly used in building construction and are comprised of two outer rigid faces on either side of a light insulating foam core. Panels of this type are generally joined by means of lumber and nails, but are increasingly connected using steel studs rather than the conventional 2× dimensional lumber approach. The junctures of such panels typically employ a lumber spline with nails and screws for joining.
Referring to
FIG. 1
, there is shown a sectional view of a prior art panel coupling arrangement
10
for connecting adjacent first and second structural insulated panels
12
and
14
which are oriented with an obtuse angle between the planes of each of the panels. The relative orientation of the first and second panels
12
,
14
is such as would be encountered in the ridge of a roof. The first structural insulated panel
12
includes first and second outer facings
12
a
and
12
b
and an insulating core
12
c
disposed between and attached to each of the outer facings. Similarly, the second panel
14
includes first and second opposed outer facings
14
a
and
14
b
and an insulating core
14
c
disposed between and affixed to the two outer facings. The outer facings of each of the panels may be comprised of any of the more conventional construction materials such as wood, waferboard, sheet metal, gypsum, or oriented strand board (OSB). Each of the insulating cores
12
c
and
14
c
is preferably comprised of a plastic foam such as expanded polystyrene (EPS), extruded polystyrene (XPS) or polyurethanes or polyisocyanurates. Each of the outer facings is securely bonded to its inner rigid foam core by conventional means such as mastic, epoxy cement or urethane glue. As shown in the prior art panel coupling arrangement
10
of
FIG. 1
, the ends of the insulating cores
12
c
and
14
c
of the first and second panels
12
,
14
have been omitted or removed from the edge of the panel. This permits adjacent edges of the first and second panels
12
,
14
to each receive a respective panel support beam
16
a
and
16
b
between the outer facings of the panel. First and second sealant beads or strips
18
a
and
18
b
are respectively positioned between beam
16
a
and insulating core
12
c
and between beam
16
b
and insulating core
14
c
. The first and second panels
12
,
14
are respectively attached to panel support beams
16
a
and
16
b
by means of upper connectors
20
and
22
, and lower connectors
24
and
26
. Each of the connectors
20
,
22
,
24
and
26
is in the form of either a nail or screw and is inserted through an outer facing of a panel and into one of the panel support beams. Thus, connectors
20
and
24
are respectively inserted through outer facings
12
a
and
12
b
and into panel support beam
16
a
. Similarly, connectors
22
and
26
are respectively inserted through outer facings
14
a
and
14
b
and into panel support beam
16
b.
Referring to
FIG. 2
, there is shown a sectional view of another common prior art coupling arrangement
30
for connecting adjacent structural insulated panels
32
and
34
such as in forming the ridge of a roof. Adjacent edges of the first and second panels
32
,
34
are positioned on a ridge beam
36
. First and second threaded connectors
38
and
40
are respectively inserted through the first and second panels
32
and
34
and into ridge beam
36
.
Another prior art panel coupling arrangement
30
for connecting first and second structural insulated panels
48
and
50
which are oriented at 90° relative to one another is shown in the sectional view of FIG.
3
. The panel coupling arrangement
46
shown in
FIG. 3
is typical of a connection between adjacent corner wall panels. Adjacent ends of the first and second panels
48
,
50
are hollowed out, or are provided with a channel, to respectively receive wood splines
54
and
58
. The first wood spline
54
is attached to the outer facings of the first panel
48
by means of connectors
56
a
and
56
b
. Similarly, the second wood spline
58
is connected to the outer facings of the second panel
50
by means of connectors
60
a
and
60
b
. Sealant beads
62
and
64
are respectively positioned on the first and second wood splines
54
and
58
between the wood spline and its associated insulating core, and extend the length of the wood spline. A threaded coupler
52
is inserted through the end of the first panel
48
and into the second wood spline
58
of the second panel
50
as shown in
FIG. 3
for connecting the two panels.
The panel coupling arrangements described above involve the use of substantial amounts of lumber which increased the cost of the installation. These prior art panel coupling arrangements also frequently require the ripping of lumber to special angles in the field, particularly in the case of pitched roofs, which also increases the cost and complexity of the installation. In some cases, the lumber spline is in contact with the outer and inner facings of the panel and acts as a through-conductor for heat resulting in energy loss. In addition, the panel corner coupling arrangement of
FIG. 3
is not easily adapted to receive electrical wiring around the corner. Access holes must be cut or drilled in at least two wood splines to accommodate electrical wiring around the corner. Finally, the aforementioned panel coupling arrangements employ connectors such as nails and screws extending through plastic panel facings and into wood splines and beams which affords only limited joint strength.
The present invention addresses the aforementioned limitations of the prior art by providing a metal faced angled spline for use in connecting adjacent structural insulated panels arranged at virtually any relative angular orientation in forming a high strength, sealed joint.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a metal reinforced joint for connecting adjacent structural insulated panels as used in roofs, ceilings, walls or floors.
It is another object of the present invention to securely join adjacent structural insulated panels oriented at virtually any relative angle.
Yet another object of the present invention is to provide a metal-faced flexible spline for use in connecting adjacent structural insulated panels which may be configured in the field for the specific panel arrangement in which it is to be used.
A further object of the present invention is to provide a metal reinforced composite gypsum or cement joint for joining structural insulated panels which is impervious to moisture, fire resistant, of high strength, and makes use of readily available construction materials.
This invention contemplates a coupling arrangement for connecting first and second structural insulated panels each having a respective insulating core and first and second outer facings attached to opposed sides of the insulating core in forming a planar structure, wherein the first and second panels are arranged in edge-abutting contact and form an angle a therebetween, where &agr;>0°, the coupling arrangement comprising: an elongated linear spline comprised of a metal strip and a backer member affixed to each other along the lengths thereof, wherein the metal strip and backer member are adapted for folding along the lengths thereof so as to form first and second spline sections having an angle &bgr; therebetween, where &agr;=&bgr;; and coupling means for connecting the first and second spline sections to respective edge portions of adjacent outer facings of the first and second panels.
REFERENCES:
patent: 919057 (1909-04-01), Moore
patent: 1250594 (1917-12-01), Knapp
patent: 2111922 (1938-03-01), Borkenstein
patent: 3557840 (1971-01-01), Maybee
patent:
Dorsey Dennis L.
Emrich & -Dithmar
Stephan Beth A.
LandOfFree
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