Paneling system and method

Abstract

In one embodiment, a paneling system comprises interconnecting paneling units configured such that adjacent paneling units matingly abut each other. Each of the paneling units includes a first panel and a second panel. At least one joist is positioned on and connected to the first panel and the second panel. The first panel and the second panel form a volume therebetween and the volume is filled with insulation. In another embodiment, a support system for a paneling unit includes a support beam resting on a row of at least two posts, wherein the posts are positioned a distance from a structure. In this embodiment, a second support is positioned adjacent the structure. At least one paneling unit spans between the support beam and the second support. The paneling unit rests on the support beam and the second support.

Description

The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/614,007 filed Sep. 28, 2004 entitled “Sunroom Flooring System and Method”; U.S. Provisional Patent Application Ser. No. 60/617,920 filed Oct. 12, 2004 entitled “Sunroom Wall Paneling System”; and U.S. Provisional Patent Application Ser. No. 60/633,804 filed Dec. 7, 2004 entitled “Building Panel System and Method” which are hereby incorporated by reference in their entireties.

FIELD OF THE INVENTION

The present invention relates to portable paneling systems, and methods for manufacturing and assembling the paneling systems into various configurations, such as floors, roofs, ceilings and walls.

BACKGROUND OF THE INVENTION

Buildings are traditionally constructed using a combination of floors, roofs, ceilings and walls either during initial construction or as additions. Conventional systems for manufacturing and placing floors, roofs, ceilings and walls require that the raw materials are transported to a construction site, followed by measuring, custom cutting and complex assembly of the desired portions using multiple components.

In certain alternatives, some portions are pre-assembled before delivery to the construction site; however, such portions must still be mounted in place and connected together. Further, portions assembled are typically unwieldy for transport and installation due to weight and size. Moreover, pre-assembled portions typically limit the size and strength of the components in order to minimize the weight and size of the components during transport and assembly.

As an example, in many homes and buildings a desirable feature is a sunroom extending from the primary building. Typical sunrooms include three wall sections, with a fourth wall shared with the attached building and a roof over the sunroom. Many such sunrooms are slightly elevated from the ground underneath. Past systems for manufacturing and assembling such sunrooms have required the complex assembly of custom sized components and materials. Such prior systems have typically involved multiple support pieces such as multiple foundation posts of concrete. Traditional solid joists with short span lengths, for example four foot spans, were laid to span multiple rows of concrete posts. One or more flooring panel layers, sometimes with an insulation layer, were laid over the joists. Traditional solid sawn joists sometimes suffered from the environment and could deflect, warp and eventually sag over time. Such systems frequently do not satisfy local building codes. Also, the on site sizing and assembly of such systems has generally required increased time and cost to place a sunroom floor.

Traditionally when sunroom walls are assembled, they are manufactured on the site to custom sizes, requiring labor, tools, and time for the assembly of the sunroom. The on-site assembly also may require cutting of materials to custom sizes and an accompanying waste of materials.

Improved systems and methods are needed.

SUMMARY OF THE INVENTION

In one embodiment, a portable paneling system for forming a structure comprises one or more panel units assembled together. One end of each of the panel units is supported by a beam resting on a single row of concrete posts. Optionally, the single row of posts includes a pair of posts spaced a desired distance apart from each other to support the beam. The single row of posts are spaced a distance from a second support. In one form, the second support can be a ledger beam configured to receive the opposing ends of the panel units. Each of the panel units include an upper panel and a lower panel separated by an insulating material. At least one reinforcing member is sandwiched between the upper panel and the lower panel.

In a different embodiment, a method of forming a portable panel unit comprises placing a plurality of I-joists a substantially parallel distance apart from each other on a lower panel. Each of the I-joists has a web separating and connected to a first flange and a second flange. An upper panel is placed on the plurality of I-joists. The method includes filling the volume between the plurality of I-joists with an insulating material. In an optional feature, the method includes forming a plurality of portable panel units wherein adjacent panel units connect together to form a structure.

In yet another embodiment, a paneling system comprises a plurality of interconnecting paneling units configured such that adjacent paneling units can matingly abut each other. Additionally, each of the paneling units includes a first panel and a second panel and a plurality of reinforcing members spaced a distance apart from each other between the first panel and the second panel. Insulation is sandwiched between the first panel and the second panel. Optionally, an end cap is mounted to a distal end of the paneling units.

In another embodiment, a support system includes a support beam resting on a row of at least two posts. The posts are spaced a distance from a structure. A second support is positioned adjacent the structure. At least one paneling unit spans between the support beam and the second support.

It is an object of certain embodiments of the present invention to provide an improved paneling unit.

Further objects, features and advantages of the present invention shall become apparent from the detailed drawings and descriptions provided herein.

DESCRIPTION OF THE FIGURES

FIG. 1 is a top view of a support system for a sunroom floor according to certain embodiments of the present invention.

FIG. 2 is a top view of a flooring system according to a preferred embodiment of the present invention.

FIG. 3 is an end on view of the embodiment of FIG. 2.

FIG. 4 is a cut-away end view of a panel unit according to a preferred embodiment of the present invention.

FIG. 5 is a perspective view of the panel unit of FIG. 4.

FIG. 6A is an end on view of one support according to a preferred embodiment of the present invention.

FIG. 6B is a partial side view of the support of FIG. 6A.

FIG. 7 is an end on view of an embodiment of the present invention in a gabled roof configuration.

FIG. 8 is an end on view of an embodiment of the present invention in a shed roof configuration.

FIG. 9 is an end on view of an embodiment of the present invention in a floor or ceiling configuration.

FIG. 10 is a perspective view of an embodiment of the present invention in a wall configuration.

BRIEF DESCRIPTION OF PREFERRED EMBODIMENTS

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations, modifications, and further applications of the principles of the invention being contemplated as would normally occur to one skilled in the art to which the invention relates.

Certain embodiments of the present invention provide a modular or standardized panel system for facilitating the manufacturing, assembly and placement of floors, roofs, ceilings and/or walls for buildings, for example including homes, sunrooms or similar building additions. Preferably panels according to the present invention satisfy local building codes for a specific configuration, while minimizing the required support system and the accompanying assembly time and complexity. An optional feature of certain embodiments allows longer spans of materials, thus minimizing the foundation or support pieces required. Certain panel units used in some of the embodiments may be preassembled or may be assembled in place at a desired construction location. The panel units may internally incorporate and protect the joists and insulation. Each unit preferably meets the local building codes in providing support and bearing load while also providing substantial insulation, strength and durable materials.

In certain embodiments, panel units are formed with a sandwich construction of an upper panel, a lower panel and interior integrated support members, such as I-joists. Optionally, spaces or cavities between the joists and between the panels are filled with an insulating and strengthening material. The panel units can be sized in various lengths, and preferably are sufficiently strong that the panel units can be supported with a pair of support points adjacent the panel ends. In certain embodiments, the panel widths are configured to abut adjacent panels to form a minimal gap and seam and to provide shared support. The panel units may optionally be used in floors, roofs, ceilings or walls, depending on a specific and desired configuration.

One example of a support system for panel units assembled together to form a floor, includes a first support at one end of the panel units and a second support at the opposite end of the panel units. In one form, the first support includes a row, such as a pair of concrete posts spaced a distance from the second support. The concrete posts can be precast or cast-in-place concrete. In one form, one or more extension modules or units can be mounted on standard sized concrete posts to raise the post height to a desired elevation. Preferably, a beam spans between the pair of concrete posts to provide continuous support for one end of the panel units.

In one form, the opposing end or second support includes a row of concrete posts spaced a distance from the first support. These concrete posts can be similar to the posts described above. In another form, the second support can be a beam or ledger attached to a structure, such as a house.

Other embodiments of the present invention provide a system of structures and method for manufacturing, placing and assembling panel units to form a complete sunroom. Typically an enclosed sunroom includes three walls forming three sides of a rectangle or square with a fourth wall shared with and providing access to an adjacent building or house. A typical sunroom is rectangular in shape although alternate geometries can be used. A typical sunroom shares at least one wall with an adjacent building. A rectangular style sunroom is described here for simplicity.

A sunroom is generally built on a base of an in-ground foundation or a supported subfloor, such as panel units, which forms the support for the walls of the sunroom. The walls extend vertically a desired distance such as 8, 9 or 10 feet and a roof preferably extends over the sunroom. Common styles of roofs include a gable style having a peak in the middle and two downward pitches or a shed style roof having one continuous pitch along the length or width of the wall or sunroom. Panel units placed as walls typically incorporate one or more windows or doors in selected locations and the surface of the panel unit facing the interior of the room may be finished with wall board and other finishes to make the room more decorated and useable. The ceiling/roof volume of the sunroom may be open to allow windows in the upper side wall panel units, or a finished ceiling may be installed.

Yet other embodiments provide a standardized system and method for assembling panel units. Preferably the system incorporates standard sized components to minimize and eliminate cutting and sizing on-site the components. Additionally, the components are connectable using only a minimum of tools.

Illustrated in FIG. 1 is a top down view of a support system for an elevated floor, for example in a sunroom, according to one embodiment of the present invention. In this embodiment, a portion of the support system is designed to be attached to a house 10 or a similar building as an add-on feature. A ledger beam 20 is attached to house 10, typically slightly below the level of the corresponding floor in house 10. Ledger beam 20 can be of one or more pieces. As an example, a ledger beam 20 can have a rectangular cross-section using a 2×10 piece of lumber. Ledger beam 20 can be various materials such as wood or metal to name a few. Ledger beam 20 can be attached to house 10 by various forms such as, bolts, nails, screws, adhesive, or a weld. One or more, and preferably at least two foundation pieces, such as concrete posts 25, are spaced a distance from the house. The concrete posts 25 are preferably placed in a single row. In example embodiments, the concrete posts 25 are spaced approximately 12 feet, 14 feet, 16 feet, or 20 feet from the house 10. Post brackets 26 are preferably mounted to the top of concrete posts 25 and optionally are adjustable in height.

A support beam 28 is mounted to post brackets 26 and preferably is leveled so the top surface of support beam 28 is parallel to and level with the desired corresponding surface of ledger 20. Support beam 28 can be one or more pieces. For example, support beam 28 can be a layered beam of three pieces of treated lumber, wherein each piece is a 2×8 rectangular piece of lumber. In another example, support beam 28 is a layered beam of three pieces of treated lumber, wherein each piece can be a 2×10 rectangular piece of lumber. The two or more concrete posts 25 are spaced desired distances apart under support beam 28 in order to optimize support for the load eventually applied to support beam 28. Optionally, the concrete posts 25 are evenly spaced apart from each other. For example, the concrete posts 25 can be spaced 8 feet apart. In another form, the concrete posts 25 can be spaced at varying distances from each other.

Illustrated in FIG. 2 are multiple panel units 30 placed to span from the house 10 to at least the support beam 28 or over the support beam 28. Each of the panel units 30 is rectangular in shape and has a length, a width, and a depth. In one form, a proximate end 31 of each panel unit 30 abuts the house 10 and rests upon ledger 20. Additionally, each of the panel units 30 rests upon support beam 28 with a distal end 32 of each of the panel units 30 typically extending beyond the support beam 28. In one form, the distal end 32 of each of the panel units 30 extends approximately 4 feet beyond the support beam 28. In a preferred embodiment, one or more panel units 30 can be placed adjacent each other to form a desired width of a sunroom floor. In this embodiment, between each pair of adjacent panel units 30 is a seam 48. Seams 48 extend the length of adjacent panel units 30 and may optionally be sealed. An optional end cap 38 can be mounted across the distal end 32 of each of the panel units 30 or across multiple panel units 30 simultaneously.

FIG. 3 illustrates an end on view of multiple panel units 30 atop support beam 28 and concrete posts 25. One panel unit 30 is shown in a partially cut-away view to illustrate interior joist 40, side beam 42 and insulation 44.

More detailed cut-away and perspective views of a panel unit 30 are illustrated in FIGS. 4 and 5. In certain preferred embodiments, the panel unit 30 includes a lower panel 34 such as a sheet of plywood or an OSB (Oriented Strand Board) sheet. If it will be exposed to the environment, lower panel 34 can optionally include a protective layer, such as an exterior skin 35 made of a vinyl or aluminum, to mention a few materials, to weather proof and protect lower panel 34. In one design, skin 35 is made of 5 mil. plastic. Spaced across lower panel 34 at preferred intervals, such as 16 inches to satisfy most building codes, are I-joists 40. The use of engineered I-joists 40 may also allow the panel units 30 to satisfy building codes while using wider spacings, such as 19.2 or 24 inches, between adjacent pairs of I-joists 40. I-joists 40 are generally laminated wood assemblies with an “I” cross-section composed of a web 41 sandwiched between and attached to a pair of flanges 43. The I-joists 40 have a higher load strength and allow longer span lengths between ledger beam 20 and support beam 28 than traditional wooden joists standing alone. The I-joists 40 are typically attached to lower panel 34 with fasteners such as adhesive, bolts, nails or screws.

In one embodiment, shown in FIG. 5, a lateral side of the panel unit 30 does not have an extending I-joist 40, but is configured to receive a side portion of an I-joist 40 extending from an abutting panel unit 30 (not shown). Optionally, one or more side beams 42 (FIG. 4) can be added to the lateral sides of panel unit 30 to close the sides. The side beams 42 can be various materials such as laminated wood assemblies, wood, or metal. The side beams 42 may be inset so as not to protrude from the lateral sides of the panel unit 30. In an alternate option, a cap or side bracket beam 45 can be used to cover a protruding joist portion. In one embodiment, the side bracket beam 45 is made with a “C” cross-section. The side bracket beam 45 can be made of wood, laminated wood assemblies, metal, or plastic, to name a few types of materials.

Over the top of I-joists 40 is an upper panel 36 fastened to the I-joists 40, for example, by nails, screws, adhesive or similar methods. In the sunroom example, upper panel 36 would generally be considered the subfloor of the sunroom to eventually be covered by a desired flooring material of a conventional type such as carpet, tile or wood. In a sunroom, panel unit 30 with upper panel 36 is preferably mounted at a height where the addition of the desired flooring material will place the final floor height at a desired height relative to an inside floor of house 10. In other examples, upper panel 36 can be covered with materials to form a ceiling, floor, roof or wall.

In certain preferred embodiments of the present invention, upper and lower panels 34 and 36 of each panel unit 30 are made of engineered and strengthened materials such as OSB (Oriented Strand Board) decking. Alternately, other panel materials, such as plywood or a composite style material, such as metal and wood, can be used for upper and lower panels 34 and 36.

The panel unit 30 has a preferred feature of the I-joists 40 being internally incorporated into the panel unit 30 at a pre-assembly location and not requiring a separate step of on-site installation. This incorporation reduces the steps in comparison to a traditional on-site assembly method, wherein joists are placed and then upper and lower panels (if any) and insulation are placed over and between the joists.

In certain embodiments, joists 40 are engineered I-joists made with reduced and sometimes recycled materials, yet having a stronger strength and longer span length, for example 16 to 40 feet, depending on load, than traditional rectangular cross-sectional solid cut lumber joists. An additional feature of engineered I-joists 40 is retaining long-term leveling of the panel unit 30 and the minimization of warp or shrinkage which, for example, can cause floor squeaks.

One embodiment of the present invention integrates the I-joists 40 for protection from the weather, environment or wear and tear during use of the structure. This integration of the I-joists 40, insulation 44, and upper and lower panels, 36 and 34, preferably provides an easy to assemble or pre-assembled system reducing the time and cost of materials and installation.

Filling the spaces or volumes between I-joists 40 and between the upper and lower panels, 36 and 34, is an insulating material 44, such as an expanded polystyrene foam or similar cellular material. The insulating material 44 is preferably a relatively lightweight yet solid and thick core foam for enhanced strength in supporting the upper and lower panels, 36 and 34, and the I-joists 40, while providing superior insulation qualities, for example, up to R-47. In one form, the insulating material 44 in the form of foam is sprayed in place and expands and hardens to a desired density and strength to further support the spacing between lower panel 34 and upper panel 36, while also encapsulating and securing I-joists 40 in place against relative movement. Alternatively, solid pieces of foam can be placed between the I-joists 40, or in a less preferred version, a loose fill insulation can be used. The insulating material 44 between the I-joists 40, and upper and lower panels, 36 and 34, form a sandwich wherein the insulating material 44, I-joists 40 and upper and lower panels, 36 and 34, are integral.

In certain preferred embodiments, panel units 30 are preassembled in a modular standardized manner and can be moved to a building location and then set and secured in place upon a prepared foundation and support. Alternately, panel units 30 can be assembled on site, preferably with standardized components to allow a minimum of cutting or sizing, materials and steps of assembly. While not required, preferably panel units 30 are made in standardized widths and lengths to facilitate construction of floors, roofs, ceilings and walls without requiring custom sizing and cutting of materials.

In one option, panel sections are assembled in long lengths and portions are cut off at desired or custom lengths. These smaller portions can be moved to a building location and assembled on site to form a structure. As should be appreciated, the smaller portions can facilitate transportation and installation of the portions to form a structure as compared to the panel sections in long lengths.

In one example embodiment, engineered I-joists 40 are used with a length of approximately 16 feet and a depth of approximately 9½ inches. Upper and lower panels 36 and 34 are cut from 4′×8′× 7/16″ OSB and the panel units 30 have widths in multiples of 16″ such as 48″. In a preferred option, depending on the size of joist 40 used, joists 40 can be chosen in various lengths while only needing two support points, for example, the ledger beam 20 on a house 10 and one row of concrete posts 25 with a support beam 28.

In a typical construction scenario for a sunroom floor (FIGS. 1-3), the building 10 is prepared by mounting a ledger 20 to the building 10, preferably a distance below the desired floor level substantially equal to the height of the final flooring material to be used, to allow for a “face-on” attachment between the ledger 20 and panel unit 30, for example with hanging brackets. Alternately, the ledger 20 may be spaced a distance downward corresponding to the height of the final flooring material plus the panel unit 30, and the ledger 20 configured for the proximate end 31 to rest upon the ledger 20.

Concrete forms are preferably spaced in a row outward from and parallel to the building 10 in desired locations and in one option concrete is poured or mixed in place to form each desired concrete post 25. Generally while the concrete is still wet, a post bracket 26 is mounted in the top of each of the concrete posts 25 and positioned to receive a support beam 28. Support beam 28 is preferably mounted parallel to ledger 20 across the row of concrete posts 25 with the beam upper surface preferably level with the desired support level on the ledger 20, i.e., top or side.

In an alternate embodiment, pre-made or precast concrete posts or tubes or concrete-in-pipes are used. Precast concrete posts are made with concrete that can be reinforced, prestressed, and/or post-tensioned for greater load strength to allow a reduced diameter and materials. In another embodiment, the pre-made posts are made of another material, such as metal or plastic. In one form, the concrete post 25 is a cylinder with a circular cross-section. In one example, the concrete post 25 has an 8 inch diameter and is approximately 3 feet in length. In another form, the concrete post 25 can have a different cross-section, such as square, rectangular or oval. In one embodiment, the concrete post 25 includes a base section 21 and one or more spacers 22, as discussed below.

FIG. 6A illustrates a precast concrete post 25 resting on a precast concrete footing 23. Each precast concrete post 25 can be placed on a buried footing 23 and aligned with a dowel or threaded rod 24 through the center and may include an adjustable height post bracket 26. Preferably, the footing 23 is buried in the soil to the frost depth required by the applicable building code. The footing 23 can be various shapes, such as, circular, rectangular, or oval, to name a few. Optionally, the footing 23 has a raised or inset portion 100 sized to align with one end of the concrete post 25.

As shown in FIG. 6A, a plate 101 or similar receiver such as a nut is embedded in the footing 23 and an alignment rod 24 aligns the plate 101, the footing 23 and the center of the post 25. The footing 23 includes a bore 102 sized to receive the rod 24. A longitudinal passageway 103 along the length of concrete post 25 is also configured to snugly receive the rod 24. The plate 101 can be various shapes. The plate 23 can be various materials, such as metal, plastic or ceramic, to name a few. Preferably, the plate 101 is configured to receive the rod 24 for example with a threaded hole 104 to receive a threaded rod. The rod 24 can be made of various materials such as metal, plastic, or wood. In one example, the rod 24 has a one-inch diameter and the rod 24 is made of steel. The rod 24 can be threaded along all or portions of its length. Optionally, the rod 24 can extend from an assembled and aligned post and can be cut to a desired length on-site.

An opposite or upper end of the concrete post 25 is preferably sized and configured to mount a bracket 26 or a spacer such as precast concrete module or booster 22. For example, the concrete post 25 can have a raised portion 105 to mate with an indentation 106 in one end of a spacer or module 22. One or more modules 22 can be sized and configured to stack on top of one another and/or the concrete post 25 to extend the overall height of the support to a desired elevation. For example, each of the modules 22 can have an end configured to connect with another end of another module 22 to stack one module 22 on top of another module 22. In one form, the module 22 has a height of approximately 1 foot; however, in other embodiments the module 22 can have a different height. The module 22 can have a passageway 107 sized to receive the rod 24 for alignment. Optionally, the rod can be cut to a desired height/length after placement in the post, any modules, a fastener and a bracket.

In one form, the post bracket 26 is mounted to the top of the module 22 and to rod 24. For example, the rod 24 can extend through the post bracket and a fastener, such as a nut, can hold the bracket in place against the module. Optionally, the post bracket 26 can be adjustable in height and/or adjustable in width. For example, the post bracket 26 can be adjustable in height and/or width in a 2 inch range. In this example, a shim plate or spacer 108 is mounted over the nut and between the top of the module 22 and the bottom of the post bracket 26 after a desired adjustment. The shim plate 108 can include an opening 109 sized to surround the fastener. In this form, the shim plate 108 is sized to fill a gap created between the top of the module 22 and the bottom of the post bracket 26. In other examples, the gap formed around the fastener and between the top of the module 22 and the bottom of the post bracket 26 is filled by other forms, such as, concrete, one or more washers, another nut, or any other mechanism that fills the gap. Additionally, the height of the post bracket 26 can be raised or adjusted by raising the height of the shim plate 108 or other filler.

In another form, while casting the concrete module 22, the post bracket 26 is mounted to the top of the wet module 22. For example, after the concrete has been placed into a mold or form in the shape of the module, the bracket can be placed in the concrete. After the concrete has hardened and dried, the module 22 with the bracket 26 is removed from the mold.

The post bracket 26 is sized and configured to receive the support beam 28 as discussed above. In one form, the support beam 28 is attached to the post bracket 26 with bolts 29 that extend through the support beam 28 and the post bracket 26 as shown in FIGS. 6A and 6B. For example, post bracket 26 is a “U” shaped plate consisting of one plate with bends or three individual plates welded together to form a “U” shape. The plates can be the same size or different sizes. Further, the plates can be welded on-site or preassembled. Optionally, the height of the side plates is equal to or slightly less than the height or depth of the support beam. In other forms, the support beam 28 can be attached to the post bracket 26 using fasteners such as adhesive, nails, screws, brackets or other conventional means. Optionally, the bracket can be detached from the module. In one form, the support beam 28 is a layered beam of three pieces of lumber.

When the support system is prepared, one or more panel units 30 are placed to span from ledger 20 across support beam 28, preferably in a level configuration. The panel units 30 may be secured in place to the ledger 20 and support beam 28 using traditional fasteners such as adhesive, bolts, nails, screws, brackets, hangers or other conventional means. Preferably one or more panel units 30 are placed adjacent each other and abutted against the house 10 to form a desired sunroom floor width. Side beams 42 or side cap beams 45 may be used on the sides of the floor. Seams 48 between panel units 30 preferably form a close fit and may be further closed and sealed with a flush insert or molding or with a separate material such as a caulking material. As a further option, the panel sides may form a connecting structure, such as a snap-fit together bracket or a tongue-in-groove profile. Once the desired number of panel units 30 are secured in place, a sunroom or similar structure can be erected using the prepared floor.

A scenario for a gable style roof using panel units 30 is illustrated in FIG. 7. In the side view shown, panel units 30 on opposing sides are supported by side walls 50 and extend to a central gable 52. In an alternate embodiment, panel units 30 on opposing sides may be supported by other panel units placed vertically. Vertical placement of panel units is discussed below. In FIG. 7, each of the panel units 30 can rise from an outer edge of the side wall 50 to the central gable 52 to form a pitch. The pitch for the panel units 30 can vary, although it is illustrated with a similar pitch for all panel units 30. The gable style roof using panel units 30 typically rises from two directions to a central peak at the gable 52 and roofing materials such as plywood, sheathing and shingles are placed and supported by the panel units 30.

Additionally, the panel units 30 can be designed to support other loads, such as, snow, and wind, to name a few. In a gable roof, typically a transverse beam 54 is mounted adjacent and below gable 52 to support the proximate ends 31 of panel units 30. Optionally, the central or proximate ends 31 of the panel units 30 are vertically plumb cut to allow the proximate ends 31 to meet at the gable 52 with a minimal gap or seam which can be sealed or alternatively the proximate ends 31 can be connected to the gable 52 and/or a transverse beam 54. In certain embodiments, fasteners, such as bolts 56 extend vertically or at an angle to secure panel units 30 to side walls 50 or to beam 54. In some embodiments, panel units 30 have seat cuts 58, formed adjacent walls 50, and/or beam 54 to more securely seat the panel units 30 on the walls 50 or beam 54.

Optionally, the distal ends 32 of the panel units 30 may have extending portions 59 extending beyond walls 50 to form eaves and optionally a vertically plumb cut outer end to allow gutters or gutters, fascia or gutter boards to be mounted. The extending portions 59 are not substantial load bearing structures, therefore extending portions 59 can have a reduced depth. As one example, the lower flange of the I-joists may be removed in the extending portion 59, allowing a portion of the lower panel to be raised. As another example, a joist portion with a reduced height web can be used.

In a gable arrangement, panel units 30 are preferably placed in parallel pairs between the side walls 50 and gable 52 to form a desired roof width. Optionally, each panel unit 30 includes a protruding I-joist on one side and gap on the other side, so that the panel units 30 can be placed snugly adjacent each other with minimal gaps and seams. Ultimate sides of the assembly are closed with side beams or caps. Seams between adjacent panel units 30 can be sealed or connected as discussed above. In one option, the interior of the gable may form a cathedral style ceiling.

Roofing materials, such as paper and shingles, may be directly applied to the upper panel of the panel units 30. In an alternate embodiment, roof panel units 30 may be pre-made with all or portions of the roofing materials pre-placed. In a still further embodiment, the upper panel may directly serve as the roof using preformed materials, textures or with a protective skin such as vinyl, copper or aluminum.

A configuration for a shed style roof using panel units 30 is illustrated in FIG. 8. In the side view shown, panel units 30 are supported by a shorter first side wall 50 and extend to a taller second side wall 50. In an alternate embodiment, panel units 30 can be supported by a pair of panel units placed vertically. Each of the panel units 30 can rise from the shorter first side wall 50 and extend to the taller second side wall 50 to form a pitch. The pitch for the panel units 30 can vary, although as shown the pitch for all the panel units 30 is similar. A shed style roof typically has a lower pitch and longer span than a gable style roof. In one form, the proximal ends 31 of the panel units 30 are vertically plumb cut to allow the panel units 30 to abut the taller second side wall 50 with a minimal gap or seam which can be sealed. Typically, a hanger 57 or beam is mounted to the taller second side wall 50 to support each of the proximal ends 31 of the panel units 30. In some embodiments, fasteners, such as bolts 56 extend vertically or at an angle to secure panel units 30 to the first side wall 50.

In certain embodiments, panel units 30 have underside seat cuts 58 formed adjacent the first side wall 50 to more securely seat the panel units 30 for support. Panel units 30 are preferably placed in parallel between the side walls 50 to form a desired roof width. Optionally, each panel unit 30 includes a protruding I-joist on one side and a gap on the other side as shown in FIG. 5, so that the panel units 30 can be placed snugly adjacent each other with minimal gaps or seams. Ultimate sides of the assembly are closed with side beams or caps.

As discussed above for a gable roof arrangement, the distal ends 32 of the panel units 30 may have an extending portion 59, having a reduced depth, extending beyond walls 50 to form eaves and/or to allow gutters or gutter boards to be mounted. The upper panels of the panel units 30 may be suitable for applying roofing materials, similar to the upper panels of the panel units 30 for a gable style roof.

Since roofs are typically not rated for live loads, panel units 30 can extend longer distances as roofs while satisfying building codes. In certain examples, spans up to 40 feet as roofs and/or cathedral type ceilings may be obtained with panel units 30. Optionally, the insulation within panel units 30 can eliminate the need for air chutes in roofs and ceilings.

A configuration for a horizontal interior ceiling and/or floor or a horizontal roof using panel units 30 is illustrated in FIG. 9. In the side view shown, panel units 30 are supported with face-on connections at a partial height between side walls 50. In another embodiment, panel units 30 are supported with face-on connections at a partial height between a pair of panel units placed vertically in lieu of the side walls 50. Hangers 57 are mounted to each of the side walls 50 to support the proximate ends 31 and distal ends 32 of panel units 30. Alternately, in a stacked connection, the proximate ends 31 and distal ends 32 of the panel units 30 are placed atop both side walls 50 or within the wall framing. Fasteners, such as bolts are typically used to secure panel units 30 to the side walls 50.

Panel units 30 are preferably placed in parallel between the side walls 50 to form a desired floor or ceiling width. In one form, each panel unit 30 includes a protruding I-joist on one side and gap on the other side, so that the panel units 30 can be placed snugly adjacent each other with the protruding I-joist of a first panel unit 30 abutting the gap of a second panel unit 30 to form minimal gaps and seams. Seams between adjacent panel units 30 can be sealed or connected as discussed above. When used as a floor, support spans are used which allow the panel units 30 to satisfy live load building codes.

Flooring or ceiling materials, such as carpet, tile, hardwood, linoleum, concrete board, plaster board and/or paint or plaster, may be directly applied to the upper panel or lower panel of the panel units 30 to form a respective floor or ceiling. In an alternate embodiment, desired panel units 30 may be pre-made with all or portions of the floor or ceiling materials pre-placed. In a still further embodiment, the upper panel may directly serve as a floor using preformed materials, textures or with a protective skin such as vinyl or plastic. Similarly, the lower panel may directly serve as a ceiling using preformed materials, textures, drywall or with a protective skin such as vinyl or plastic. In yet another embodiment, the upper panel may directly serve as a roof using roofing materials, such as paper and shingles, directly applied to the upper panel.

A configuration for a wall 50 using panel units 30 is illustrated in FIG. 10. In the side view shown, panel units 30 are vertically arranged upward from a base 60. The base 60 can be made of panel units, or foundation materials, such as concrete. In one form, the base 60 is sized and configured to receive panel distal ends 32. In another form, fasteners are used to secure the distal ends 32 to the base 60. The proximate ends 31 of the panel units 30 can attach to a support structure (not shown), or the panel units 30 can form a cantilever arrangement with the distal ends 32 fully supported in the base 60 and the proximate ends 31 unsupported. Panel units 30 are preferably placed in parallel to form desired width walls and can abut as described herein. When used as a wall, the I-joists are preferably sized and arranged to support an applied load from a roof or ceiling or a load applied to the outer panel such as wind. Optionally, the panel units 30 can include a window 62. In another form, the panel units can include a door 64.

In certain preferred embodiments, the panel units 30 are sized to be delivered and quickly assembled on location. Preferably the standardized size of the panel units 30 eliminates or minimizes cutting and waste of materials on-site, facilitates simple assembly of the panel units 30 into walls, and reduces the time and complexity in completing and installing the panel units 30 to form a room.

Wall finishing materials, such as plasterboard or drywall, paneling, wood and/or paint or plaster, may be directly applied to the interior surfaces of the panel units 30 to form an interior wall. In an alternate embodiment, the panel units 30 may be pre-made with all or portions of the walls pre-placed. In a still further embodiment, the outer or exterior surfaces of the panel units may be sealed and insulated to allow exterior wall materials to be directly applied or may directly serve as an outer wall with suitable protection. Examples of exterior wall materials include brick, wood, siding, stone or a protective skin.

In certain embodiments, panel units 30 may include accessory hardware installed during assembly of the panel units 30 or on the construction site. Examples of accessories within panel units 30 can include electrical wiring, fixture mountings or vent ducts.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.

Claims

1. A portable paneling system for forming a structure, comprising:

a. a lower panel;

b. a plurality of joists positioned on and connected to said lower panel, wherein each of said plurality of joists has a web positioned between and connected to a first flange and a second flange;

c. an upper panel positioned on and connected to said plurality of joists; and

d. insulating material substantially filling a cavity between said lower panel and said upper panel and between said joists.

2. The paneling system of claim 1, wherein said plurality of joists are restricted from movement by said insulating material.

3. The paneling system of claim 1, further comprising an outer protective layer on said lower panel.

4. The paneling system of claim 1, further comprising a side beam sandwiched between said upper panel and said lower panel.

5. The paneling system of claim 1, further comprising a side bracket beam positioned to abut said upper panel and said lower panel.

6. The paneling system of claim 1, wherein said insulating material comprises polystyrene.

7. The paneling system of claim 1, wherein said upper panel comprises wood.

8. The paneling system of claim 1, wherein said lower panel comprises wood.

9. A method of forming a portable panel unit, comprising:

a. positioning a first panel;

b. positioning a plurality of I-joists on said first panel, wherein each of said I-joists is a substantially parallel distance apart from another of said I-joists, further wherein each of said I-joists has a web positioned between and connected to a first flange and a second flange;

c. placing a second panel on said plurality of I-joists to create a volume between said first panel and said second panel, wherein said plurality of I-joists is positioned between and connected to said first panel and said second panel; and

d. filling said volume substantially with insulation.

10. The method of claim 9, further comprising forming a plurality of portable panel units to matingly connect together.

11. The method of claim 9, further comprising cutting said portable panel unit into a plurality of portable panel units.

12. The method of claim 11, further comprising connecting a pair of panel units together wherein said pair of panel units matingly abut each other.

13. The method of claim 9, wherein said insulation secures said plurality of I-joists to resist movement relative to said first panel and said second panel.

14. The method of claim 9, wherein filling said volume includes spraying insulation material into said cavity to form said insulation.

15. The method of claim 9, wherein filling said volume includes placing said insulation in said cavity.

16. The method of claim 9, wherein said insulation is cellular material.

17. A plurality of the paneling units according to claim 1, further comprising a support system, having:

a. a support beam resting on a row of at least two posts, wherein said at least two posts are positioned a distance from a structure;

b. a second support positioned closely adjacent said structure;

c. wherein each of said paneling units are configured to span between said support beam and said second support, and wherein said support beam and said second support are configured to support said paneling units.

18. The support system of claim 17, wherein said at least two posts comprise concrete.

19. The support system of claim 17, wherein said second support is a ledger beam.

20. The support system of claim 17, wherein a distal end of at least one of said paneling units extends beyond said support beam.

21. The support system of claim 17, wherein a first post of said at least two posts is spaced approximately 8 feet from the second post.