Apparatus and method for aligning and connecting building panels in close proximity

Abstract

An improved apparatus and method for joining and connecting two panels in substantially planar or substantially perpendicular arrangement when panels are in near-abutted proximity. The improved apparatus and method comprises a fitted recess positioned in the edge of a first panel and a corresponding fitted recess positioned in either the edge or face of a second panel such that both fitted recesses are in alignment when first and second panel are placed in aligned abutted position. The present invention further comprises a semicircular disc-shaped connector fully placed within one of the fitted recesses prior to first and second panels being placed in abutted alignment. A key provides a means for rotating said connector approximately 90 degrees after first and second panels are placed in abutted alignment causing said connector to be partially contained within each of the two aligned fitted recesses, thus providing a connection between the panels.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS (CLAIMING BENEFIT UNDER 35 U.S.C. 120)

None.

FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT STATEMENT

This invention was not developed in conjunction with any Federally sponsored contract.

MICROFICHE APPENDIX

Not applicable.

INCORPORATION BY REFERENCE

None.

BACKGROUND OF THE INVENTION

1. Field of The Invention

This invention relates to mechanisms and methods for interconnecting construction panels.

2. Background of the Invention

Modular building panels have been used to reduce the cost of constructing buildings such as houses, office partitions, walls and the like. As the modular building 10 panels can be made in the factory and assembled on site, the panels can be made more uniform in the factory which lessens the labor required for building the walls of a building or similar. However, when two or more building panels need to be jointed together to form a wall, the panels need to be more or less accurately aligned with each other in order to produce a smooth wall having a pleasing appearance. One example of the building panels used to make walls, partitions or the like are straw-based panels made from compressed straw.

In the past, compressed straw panels have required the use of external metal connectors to join two adjacent panels together. The metal connectors can take a variety of different forms. One particular form is a double saddle or double yoke arrangement interconnected through a web portion in opposed facing relationship. Each yoke or saddle straddles the end of one of the panels so that when the two panels are adjacent to each other, one yoke or saddle engages one panel and the other yoke or saddle engages the other panel to join the panels together when the connector is fastened to both of the panels. The use of previously available connectors, including the metal connector, have suffered from one or more problems or shortcomings. One of the major disadvantages of using metal connectors is alignment of two adjacent panels when joining them together. As the metal connectors need to be reasonably flexible to accommodate adjustment of the panels, the clips are made from relatively light weight metal with the effect that the clips can be easily bent out of shape when joining two panels together which causes misalignment of the panels when forming the wall or partition. Additionally, the metal clips require fastening to the outside surfaces of the panels by suitable fasteners such as nails, screws and the like, which results in part of the clips being exposed on the external surfaces of the wall panels. The exposure of the metal clips is unsightly and detracts from the appearance of the walls as well as having the potential to inflict damage and injury. Further, extra operations to finish the wall are required in order to mask or cover the clips such as, for example, by plastering over the clips. This extra finishing operation is time consuming and expensive in materials and labor costs. Additionally, because of the light weight nature of the clips, the wall panels can flex or move slightly with respect to each other which in turn has a tendency to crack the plaster covering the clip which ultimately exposes the clip and leads to increased misalignment of the panels.

Another problem of using existing clips is that they do not provide any means for aligning the two panels with respect to each other when joining the panels together. As the clips can move or distort when the panels are being positioned in abutting relationship, it is difficult to accurately align the panels and maintain the panels in this aligned position while fixing the panels into place. Even if the panels were originally aligned, the use of the clips does not necessarily maintain the panels in alignment.

Recently issued U.S. Pat. Nos. 6,634,077 and 6,789,977 provide a solution that overcomes the alignment and connection shortcomings of previously available clips and the like discussed supra by providing a flat disc, or comparably shaped connector that resides in fitted recesses located along the edges of building panels. However, there remains a need for a means for connecting panels in close abutted relation when said panels cannot be moved laterally.

Therefore, it is an object of the present invention to provide a connecting system and a connector that allows two closely abutted adjoining panels to be connected together in alignment wherein the two panels are in close abutted proximity prior to said connection being made and little or no lateral relative movement is possible.

SUMMARY OF THE INVENTION

The present invention provides a means for joining two panels in substantially planar or substantially perpendicular arrangement that are in close near-abutted proximity. Said invention comprises a fitted recess positioned in the edge of a first panel and a corresponding fitted recess positioned in either the edge or face of a second panel such that both fitted recesses are in alignment when first and second panel are placed in aligned abutted position. The present invention further comprises a semicircular disc-shaped connector fully placed within one of said fitted recesses prior to first and second panels being placed in abutted alignment. Present invention further comprises a key that provides a means for rotating said connector approximately 90 degrees after first and second panels are placed in abutted alignment causing said connector to be partially contained within both of two aligned fitted recesses, thus providing a connection between first and second panels.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention should be more fully understood when the written description is considered in conjunction with the drawings, both contained herein, wherein:

FIG. 1 shows a side view detail of a connector;

FIG. 2 (a) illustrates an isometric view of a first panel with a fitted recess therein;

FIG. 2 (b) shows an isometric view of first panel with a connector placed within a fitted recess;

FIG. 3 shows an isometric view of first and second panel, each having a fitted recess, aligned in abutted parallel relation with a connector inserted within recess in first panel;

FIG. 4 shows the isometric view contained in FIG. 3 with a key inserted between panels and properly positioned for turning;

FIG. 5 shows the isometric view contained in FIG. 4 with the key having been turned and connector having been properly displaced.

FIG. 6 shows an isometric view of a second panel positioned for perpendicular alignment with a fitted recess located on the panel face;

FIG. 7 shows the second panel of FIG. 6 with a connector placed within a fitted recess;

FIG. 8 shows the second panel of FIGS. 6 and 7, with a first panel having a fitted recess and positioned in perpendicular alignment therewith;

FIG. 9 shows the panels of FIG. 8 with a key properly inserted between first and second panels;

FIG. 10 shows the invention as illustrated in FIG. 9 with key in the turned position and connector having been displaced approximately 90 degrees'

FIG. 11 shows the panels and connector of FIG. 10 with the key removed;

FIG. 12 (a) shows an isometric view of the preferred embodiment of key;

FIG. 12 (b) shows an isometric view of an alternate embodiment of key;

FIG. 13 shows an isometric view of a key with alternate guide collar properly positioned between two abutted panels.

DETAILED DESCRIPTION OF THE INVENTION

Although the present invention will be described with particular reference to one form of the connector, namely a semicircular disc, and one form of a key comprised of a spine with lateral arms located at each end, it is to be noted that the scope of the present invention is not limited to the described embodiment but rather the scope of the invention is more extensive so as to include other forms and arrangements of the connector and the connecting system and to the use of the various forms of the connectors in joining abutted substrates together in substantial alignment with each other.

The detailed description will begin with FIG. 2 (a) which shows a first panel (4) provided with a fitted recess (2) and a semicircular disc-shaped connector (1), shown adjacent to the edge of first panel (4). In the preferred embodiment first panel (4) is a compressed straw panel such as those manufactured by Affordable Building Systems of Whitewright, Tex. Referring to FIG. 2 (b), it can be seen that connector (1) has a radially symmetric shape, thus can be rotated about the center of symmetry. More importantly, connector (1) has a shape that closely matches the interior shape of recess (2), thus providing for a generally snug friction fit when connector (1) is inserted into recess (2) as shown. FIG. 1 shows a side view of connector (1) and illustrates the radially symmetric shape of said connector (1) and shows the center of radial symmetry (13).

FIG. 3 shows first panel (4) with connector (1) fully inserted into first recess (2). After insertion of connector (1) into first recess (2) first panel (4) will be placed into aligned abutted position relative to second panel (5) generally such that panels form segments of a wall. First recess (2) and second recess (3) are located in first panel (4) and second panel (5) respectively, such that upon alignment of said panels, first recess (2) and second recess (3) are also in aligned abutted relation. This alignment provides for the rotation of connector (1) within the aligned recesses as will be discussed infra.

Referring to FIG. 4, first panel (4) and second panel (5) will be placed in aligned abutted position such that a slight gap exists therebetween. Said gap provides for the insertion of key 6. As illustrated, key 6 will be inserted to a depth such that a portion of said pin 11 lies adjacent to and in substantial alignment with the upper half of connector (1).

As illustrated in FIG. 5, key (6) is then rotated approximately 90 degrees clockwise. Rotation of key (6) forces connector (1) to rotate about its center of radial symmetry, causing partial displacement from first recess (2) and simultaneous placement into second recess (3). To return connector (1) to its original position, key can be counter rotated approximately 270 degrees. Further, key can be rotated an additional 90 degrees to fully position connector (1) within second recess (3). It is recommended that the vertical center of each recess (2) (3) is located and a corresponding mark is placed on the face of each panel prior to alignment. Further, for ease of use, it is recommended that the proper insertion depth be marked on the shaft (1) of key (6) prior to use.

The invention disclosed herein not only provides for a connection between two panels in an edge to edge, substantially co-planar configuration, but also provides for connection of two panels in an abutted edge to face, substantially perpendicular relative configuration. The later providing a useful connection means when a wall terminates at the face of a second wall. FIG. 6 shows a second panel (8) provided with a properly positioned recess (7). Edge lines (16) (17) are provided to show the inner and outer edge of a first panel that is to be placed in perpendicular abutted relation to said second panel (8). FIG. 7 then shows a connector (1), placed with recess (7) such that the edge of connector (1) and the face of panel (8) are in a substantially flush relation. FIG. 8 shows first panel (5), provided with properly positioned recess (3), positioned in a perpendicular abutted position relative to second panel (8) such that first recess (3) and second recess (7) are in alignment. FIG. 9 shows a key (6) inserted between first panel (5) and second panel (8). FIG. 10 then shows key (6) having been rotated approximately 90 degrees and connector (1) having been displaced accordingly to the proper final position. Finally, FIG. 11 shows the perpendicular panel to panel termination with connector (1) in the final position and key (6) fully removed.

A detail of the preferred embodiment of key (6) is provided by FIG. 12 (a). As can be seen, key (6) is comprised of a pin (11), handle (12), and a shaft (1), connecting the two together. In the preferred embodiment, pin (11) and handle (12), are offset approximately 90 degrees with respect to their connection to shaft (10). This offset allows key (6) to be inserted then rotated 90 degrees when placed between two perpendicularly abutted panels, such as those illustrated in FIG. 10 and 11. An alternative embodiment is shown in FIG. 12 (b) wherein pin (11) and handle (12) are offset 180 degrees with respect to their connection to shaft (1). This alternative embodiment provides easy use with panels in edge to edge abutted relations, but will prove difficult to use when panels are abutted perpendicularly.

Finally, referring to FIG. 12 (c), it should be noted that during normal use, the amount of torque required to turn key (6) and displace a connector (1) may vary. In the event additional torque is required, an alternative turning collar (13) may be necessary. Said turning collar (13) is further comprised of guide tube (14) and plate (15) with said guide tube (14) being slidably disposed about shaft (10) such that shaft (10) can freely rotate. Said plate 15 is shaped to allow insertion between two abutted panels and is further rigidly attached to guide tube (14). Plate (15) will act to prevent shaft (10) from damaging panel edges under high torque loading. Both plate (15) and guide tube (14) are preferably made from 0.20-0.022 gauge steel, but can be made from any material of comparable strength and stiffness.

The embodiments shown and described above are exemplary. Many details are often found in the art and, therefore, many such details are neither shown nor described. It is not claimed that all of the details, parts, elements, or steps described and shown were invented herein. Even though numerous characteristics and advantages of the present inventions have been described in the drawings and accompanying text, the description is illustrative only, and changes may be made in the detail, especially in matters of shape, size, and arrangement of the parts within the principles of the inventions to the full extent indicated by the broad meaning of the terms of the attached claims.

The description and drawings of the specific examples herein do not point out what an infringement of this patent would be, but are to provide at least one explanation of how to use and make the inventions. The limits of the inventions and the bounds of the patent protection are measured by and defined in the following claims.

Claims

1. A method for joining two composite fiber panels in abutted relation comprising:

forming a first semi-radially symmetrically shaped receiving means in a first panel;

forming a second semi-radially symmetrically shaped receiving means in a second panel;

inserting a semi-radially symmetrically shaped connector into said first receiving means so that said connector resides fully within said first receiving means;

positioning said first and second panel in abutted relation such that said first and second receiving means are opposed and in substantial alignment and such that a gap for receiving a turning key is provided between said panels;

inserting a turning key between said first and second panels, said turning key rotatably engaging an edge of said connector; and

rotating said turning key such that substantially angular motion forces a portion of said connector to move from within said first receiving means to within said second receiving means.

2. The method as set forth in claim 1 wherein said turning key comprises a shaft with a first and second end, a pin member attached to first end of said shaft in substantially perpendicular relation thereto, and a handle member attached to second end of said shaft in substantially perpendicular relation thereto, and wherein said turning key is positioned such that said pin member is in substantial alignment with said connector such that rotating said turning key about said shaft member causes corresponding substantially angular motion of said connector causing a portion of said connector to move from within said first receiving means to within said second receiving means.

3. The method as set forth in claim 1 wherein said step of forming a first receiving means comprises forming a receiving means integral with said gap for receiving a turning key.

4. The method as set forth in claim 1 wherein said step of forming a first receiving means comprises forming a receiving means integral with said gap for receiving a turning key.

5. The method of claim 1 wherein said first and second receiving means have a generally semicircular interior shape and are sized to provide a friction fit when said connector is inserted therein.

6. The method of claim 2, wherein the shape of said connector comprises a substantially flat edge with radial symmetry about a center point on said edge, having a shape selected from the group of a semicircle, a half-disc, a half-polygon, a half-ellipse, a partial-disc, a partial-polygon, and a partial-elipse.

7. The method of claim 6, wherein the outer surfaces of said connector are substantially smooth.

8. The method of claim 6, wherein the outer surfaces of said connector are imparted with a non-smooth texture or otherwise roughened.

9. The method of claim 2, wherein said pin member and said handle member of said turning key extend from said shaft member in lateral directions offset between 0 and 180 degrees.

10. A connecting system for joining two composite fiber panels in abutted relation comprising:

a first panel, said first panel including a first semi-radially shaped receiving means;

a second panel, said second panel including a second semi-radially shaped receiving means;

a connector having a substantially flat semi-radially symmetric shape and adapted to be fully received within either first or second receiving means; and

a turning key comprising a shaft with a first and second end, a pin member attached to said first end of said shaft, and a handle member attached to second end of said shaft.

11. The connecting system of claim 10 wherein said pin member and said shaft are in a substantially perpendicular relative configuration.

12. The connecting system of claim 11 wherein said handle member and said shaft are in a substantially perpendicular relative configuration.

13. The connecting system of claim 10, wherein said first and second receiving means have a generally semicircular interior shape and are sized to provide a friction fit when said connector is inserted therein.

14. The connecting system of claim 10, wherein the shape of said connector comprises a substantially flat edge with radial symmetry about a center point on said edge, having a shape selected from the group of a semicircle, a half-disc, a half-polygon, a half-ellipse, a partial-disc, a partial-polygon, and partial-elipse.

15. The connecting system of claim 14, wherein the outer surface of said connector is substantially smooth.

16. The connecting system of claim 14, wherein the outer surface of said connector is imparted with a non-smooth texture or otherwise roughened.

17. The connecting system of claim 7, wherein said pin member and said handle member of said turning key extend from said shaft member in lateral directions offset between 0 and 180 degrees.