Structural panel system

Abstract

A structural panel has unitary load transfer members with their length subdivided into shorter, stiffer load-transfer portions separated by stabilization zones. These members are in mutually inclined back-to-back relation, and can be flexible or substantially rigid, with plain or profiled section, being of board, metal or plastic to provide an integrated high load-bearing capacity. A concertina assembly of such lightweight struts can replace a number of orthodox studs. The strut members are fastened together, and mutually secured, in back-to-back pairs or stabilized by the adjoining frame and/or the panel face members. Reinforcement by tension elements, strapping and foamed plastic may be used.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation in Part of application Ser. No. 10/761,307 filed Jan. 22 2004.

BACKGROUND OF THE INVENTION

This invention is directed to a structural panel system, and in particular to a frame structure incorporating slender unitary load-transfer members extending between the frame end members in load transfer relation, the load-transfer members having one or more stabilization zones located along their length in contacting relation with a lateral stabilizer, such that the load transfer members are stiffened against lateral deformation under load.

2. In the past, structural panels, such as walls and partitions have largely consisted of a sill and lintel end member, with a number of regularly spaced upright stud members in supporting, load bearing relation therebetween. The faces of the partition are then enclosed with sheeting, such as drywall, wallboard etc, which is nailed to the studs and frame members. The studs, which may be referred to as 2× (or “two by”) can range in size from 2″ by 3″, 2 by 4 (commonly called “two by four”), 2″ by 6″, even 2″ by 8″ being used.

The centre-distance spacing of the stud members is usually sixteen inches, so that standard four foot wide sheeting fits edge to edge of the frame side members.

Studs at two-foot centres also may be used in the same fashion, to the same effect.

Generally the members consist of wooden two-by-fours, although in some instances sheet-metal stud members have replaced the wood ‘2 by 4’ stud members.

These traditional structures require large quantities of wood, are bulky and heavy to transport, and expensive.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a structural panel system, suitable for use as a wall or other framed structure incorporating unitary load-transfer members arranged in laterally stabilized relation within a containing framework.

The subject strut members are of slender section modulus, such that under typical longitudinal thrust loads, being flexible, they would individually buckle.

By providing a stabilization zone located midway along its length, with stabilization means contacting the stabilization zone in lateral constraining relation with the load transfer (strut) member, the tendency of the load transfer members to deform under load is substantially reduced; i.e. its buckling load capacity can be effectively doubled. Use of a greater number of stabilization zones, such as two or three creates three or four strut portions, with a corresponding tripling or quadrupling of the stiffness of the respective load transfer strut portions, depending on the number of stabilization zones that are provided.

In one embodiment, by arranging load transfer strut members in pairs, having their outer ends joined, and by laterally constraining the strut pairs at their centre-points, the load-bearing capacity of an integrated series of such pairs may be effectively doubled, and made adequate for the strength requirements of a partition or non-load-bearing wall, the load-bearing ‘column’ length of each strut having been effectively at least halved.

The lateral constraint for the pairs of strut members may be supplied by adjoining strut pairs in mutual abutting relation, and by the frame side members or by one or more standard frame stud members that may be retained for that purpose, as frame side members.

As an example, an eight foot long section of partition wall, constituting a structural panel unit, normally having seven two-by-four (2×4—actually 1¾ inch by 3¾ inch) wood stud members, can have four of the eight-foot 2×4 studs replaced by two assemblies, each consisting of four pairs of the subject inclined strut members. A wooden stud member separates the two strut assemblies as part of the framing, and helps to secure them in place.

Typically, the upper and lower ends of a pair of strut members may be secured to each other to form a juncture, by gluing, sewing or stapling, and glued to the adjoining end (sill and lintel) members of the containing frame; being glued/stapled at their centres to the adjoining pair of strut members, and glued, nailed or stapled to the abutting 2×4 frame side members.

Alternatively, by nailing/stapling and/or gluing the centre portions of the two outer strut members of a strut assembly to the adjoining frame studs, so as to laterally secure the strut assembly in its ‘working’ position, the individual struts can be stabilized in that position by gluing the juncture portions at their edges to the adjoining face sheeting which encloses the structure.

This would consist of spot-gluing edge portions of the strut, at their joined ends and at their intermediate juncture portions, by coating the edges of these parts with glue just prior to applying the face sheeting, on enclosing the face of the structure.

Other means of stabilizing the strut members of an assembly include lateral grooving of the sill and lintel members to receive the strut ends, or the use of spacer strips located between adjacent struts, and secured to the sill or lintel.

In addition to containing the bowing of the combined strut members by way of the frame side members, the use of a transverse tie member such as metal or wood strapping or a nylon or other high strength filament or wire, extending between the frame side members is contemplated, wherein the tie member would be secured to the stabilization zones of the struts. Such tie members thus serve to stabilize the strut member portions at their junctures.

Strapping tie members may be located beside the struts, to secure the struts at their juncture lateral edges, while the wire, cable or filament is preferably passed through the centre of each juncture, and secured to each strut, to maintain their mutual spacing, as well as to tie the frame side members against outward bowing, in the plane of the structure.

The combined strut members may use a variety of materials, one embodiment utilizing a flexible wood-based pressed sheetboard of predetermined thickness and longitudinal stiffness, such as “Masonite” (T.M.). Other material embodiments such as metal or plastic strut members may be readily adopted, in which profiled sections with stiffening side flanges are used. The materials include aluminum sheet.

While one embodiment consists of strut members having two inclined load-bearing portions of its length, it will be understood that multiples of this arrangement may be adopted, with struts having four, six or even possibly eight inclined, load bearing portions along its length, to provide an eightfold increase in stiffness and load-transfer capability.

With adequate lateral stabilization, the adoption of shorter load bearing strut portions has the effect of correspondingly increasing the Euler (buckling) stiffness of the struts. The promotion of lateral strut stability may include the use of plastic foam injected in lateral supporting relation into the interstices of the struts, to bear against the strut faces, wherein use is made of the high compression strength of these plastic foams, even those of comparatively low density. Fire and other safety considerations have to be observed, using self-extinguishing foams. Foams also serve to suppress noise transmission.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Certain embodiments of the invention are described by way of illustration, without limitation thereto other than as set forth in the accompanying claims, reference being made to the accompanying drawings, wherein:

FIG. 1 shows a side elevation of a typical section of Prior Art partition wall framework in a partially enclosed condition;

FIG. 2 is a side elevation of a partially completed partition construction in accordance with the present invention;

FIG. 3 is a front perspective view of the FIG. 2 embodiment;

FIG. 4 is a perspective view similar to FIG. 3 of a panel structure incorporating profiled section strut members and a tensioned lateral tie;

FIG. 5 is an enlargement of a portion of FIG. 4;

FIG. 6 is a perspective view of an undeformed strut member of the FIG. 4 embodiment;

FIG. 7 is a side elevation of a partially completed wall section showing the nailing installation of a strut assembly, and an electrical wiring installation;

FIG. 8 is an elevation of an enclosed partition section; before taping and plastering;

FIG. 9 shows a further subject strut embodiment in a wall construction, and

FIG. 10 shows a panel embodiment as a portion of a floor installation.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, a typical Prior Art framework 10 of a partition has a sill member 12, a lintel member 14, and stud members 16, all of which members are usually of wood, in nominal ‘two-by-four’ (2″×4″) section. Frame sections may range from ‘2 by 2’ to ‘2 by 8’, or even deeper (ie members of two inch nominal thickness by up to eight inch or greater width).

The partition is shown having the reverse face enclosed, such as by drywall.

In the FIGS. 2 and 3 embodiment of the present invention, a prefabricated “concertina” assembly 20 consisting of pairs of strut members 22, having their upper and lower outer ends 24 secured together, as by gluing and/or stitching and/or stapling and entered into slots 26 in the top and bottom (sill and lintel) members 12, 14 of a partially enclosed structure.

The assembly 20 has the mid point stabilization zone 28 of the adjoining outer faces of the members 22 similarly secured in back-to-back relation as part of the fabrication process. In this embodiment the flexible strut members 22 are originally planar.

In one embodiment the struts 22 were flexible strips of composite panel board, a thickness of ⅛ inch being used, the panel board being plywood.

Other suitable forms of flexible board may include wood, particle board, OSB (wafer board), LDF, MDF or HDF (low, medium or high density fiberboard) panels, hardboard, and combinations of laminated panels and fiberglass.

A “concertina” consisting of eight strips of board, is made up as four pairs of flexible strip, each pair having their upper and lower outer ends 24 secured together, and adjoining pairs having their mid-section outer surfaces 28 secured together in back-to-back mutually attached relation.

The composite “concertina” of struts is cut to length so as to fit, under axial compression, into the slots 26, so as to fill the aperture of the frame members 12, 14, 16. It will be understood that slots 26 may be eliminated, and gluing and other spacer means may be substituted, to secure the struts in place.

In FIGS. 4, 5 and 6, the struts 32 are of metal or moulded or extruded plastic, having side flanges 34, with planar end portions 36 and planar intermediate centre portions 38, which may be pre-perforated to accommodate a tensioned member 40.

Side reliefs may accommodate straps.

A tensioned monofilament member or wire 40 is shown, the ends of which are secured to the frame side members 16. The member 40 serves to hold outer frame members 16 against outward bowing under the effect of the lateral reaction forces produced by the struts 32, while also retaining the struts 32 in aligned relation with the frame members 16, prior to their being enclosed by the enclosing wall board or paneling.

The struts 32 are shown in a substantially planar condition. However, it will be understood that the ultimate angles of inclination of the end portions 36 and centre portion 38 may be pre-set to substantially the desired angles.

In FIG. 7, the normally concealed, behind-the-wall portions of a wall switch 42, electrical outlets 44 and wiring 46 are shown; also nails 48 that secure the strut concertina assembly 20 to the frame side members 16.

FIG. 8 shows the manner of closure of a portion of an assembled wall structure, by way of paneling or wall-board, which is nailed, stapled or glued to the frame members. It is at this stage that plastic foam, such as engineering foam with high compression strength may be applied, to limit or prevent buckling deflection of the struts. If used, the foam has a significant noise suppression effect.

The wall joints are then taped and plastered.

In FIG. 9, a wall assembly having a doorway and window opening also shows the use of nails to secure the flexible strut concertina assembly 20 to the frame side members 16. The strut assembly 20 shows the use of commercial staples 50 to reinforce the mid-section glued attachment of adjoining pairs of struts in joined relation. Staples 50 may also be used in attaching the strut assembly 20 to the adjoining frame side members 16. The final step of installing a strut assembly may consist of gluing parts of the strut assembly to the enclosing wall board. This is done as a substitute for, or to reinforce the use of the slots 26. The glue is applied to edge portions of the strut members 22, 32, to secure them to the adjoining drywall, panel board or other member by which the partition structure is enclosed. This glue application is preferably focused at or adjacent the ends 24, 36 of the struts, and also at the outer edge surfaces of the stabilization zones 28.

In FIG. 10, a structure 60 in accordance with the present invention is shown mounted upon floor joists 62 as a flooring panel. The panel structure 60 has substantially rigid frame edge members 66, 68, with panel lower face member 64 and upper face member 70. The load transfer members 72 are illustrated as being a sandwiched corrugate, wherein the edge presentation of the corrugate provides great crushing strength to the panel structure 60. It is contemplated that the face members 64, 66 contact in bonded relation with frame members 66, 68 and the top and bottom edge surfaces of the members 72.

In the illustrated embodiments of FIGS. 2, 3 and 4, the angle of inclination of the bowed strut members 22, 32 is approximately 20 degrees, which means that the potential vertical load capacity of each strut member is approximately 94% of its developed longitudinal compressive strength.

Correspondingly, the lateral component of thrust load, which is contained by the frame side members 16 together with the tensioned member 40 (or side strapping when used), amounts in this instance to about a mere 6% of the strut thrust load.

The arrangement of the strut members 22, 32 in inclined, mutually supporting, back-to-back relation, with mid-point stabilization gives two thrust-bearing strut portions, which sensibly halves the Euler (buckling) strut length of each strut portion, with a corresponding approximate doubling in load-bearing capacity of the total strut.

For strut members with quarter point stabilization, having four inclined load-bearing segments, the stiffness or thrust load transfer capacity is substantially quadrupled.

The foregoing embodiments of the present invention disclose its use in panels of limited size. However, it will be understood that other, less limited embodiments are contemplated, within the scope of the present claims.

Claims

1. A structural panel unit having an enclosing frame with a pair of mutually opposed frame end members and a pair of mutually opposed frame side members; a plurality of unitary load-transfer members extending between said end members in load transfer relation therebetween, each said load-transfer member having at least one stabilization zone located along its length intermediate said frame end members; stabilization means contacting said stabilization zones in lateral constraining relation with said load transfer members, whereby the tendency of said load transfer members to deform under load is substantially reduced.

2. The structural panel unit as set forth in claim 1, wherein some of said load transfer members have another said load transfer member in adjoined mutual stabilizing contact relation at said at least one stabilization zone.

3. The structural panel unit as set forth in claim 1, wherein at least one said load transfer member has an adjacent said frame side member in stabilizing contact relation at said at least one stabilization zone.

4. The structural panel unit as set forth in claim 1, wherein said enclosing frame is substantially filled with pairs of said load transfer members, with some of said pairs of members arranged in back-to-back mutually stabilizing relation; and with said frame side members contacting some of said load transfer members in transverse stabilizing relation therewith.

5. The structural panel unit as set forth in claim 1, said load transfer members having a plurality of said stabilization zones in mutually spaced relation along their length, to provide a plurality of shortened strut portions connected in end-to-end relation, each said shortened portion having substantially greater resistance to buckling than a laterally non-stabilized said load transfer member.

6. The structural panel unit as set forth in claim 2, said load transfer members having a plurality of said stabilization zones in mutually spaced relation along their length, to provide a plurality of shortened strut portions connected in end-to-end relation, each said shortened portion having substantially greater resistance to buckling than a laterally non-stabilized said load transfer member.

7. The structural panel unit as set forth in claim 3, said load transfer members having a plurality of said stabilization zones in mutually spaced relation along their length, to provide a plurality of shortened strut portions connected in end-to-end relation, each said shortened portion having substantially greater resistance to buckling than a laterally non-stabilized said load transfer member.

8. The structural panel unit as set forth in claim 4, said load transfer members having a plurality of said stabilization zones in mutually spaced relation along their length, to provide a plurality of shortened strut portions connected in end-to-end relation, each said shortened portion having substantially greater resistance to buckling than a laterally non-stabilized said load transfer member.

9. The structural panel unit as set forth in claim 1, portions of the length of said load transfer members being of non-planar cross-section, having enhanced resistance to buckling deformation under load transfer conditions.

10. The structural panel unit as set forth in claim 1, portions of the length of said load transfer members being flanged, to provide enhanced resistance to buckling deformation under load transfer conditions.

11. The structural panel unit as set forth in claim 2, portions of the length of said load transfer members being of non-planar cross-section, having enhanced resistance to buckling deformation under load transfer conditions.

12. The structural panel unit as set forth in claim 11, portions of the length of said load transfer members being flanged, to provide enhanced resistance to buckling deformation under load transfer conditions.

13. The structural panel unit as set forth in claim 3, portions of the length of said load transfer members being of non-planar cross-section, having enhanced resistance to buckling deformation under load transfer conditions.

14. The structural panel unit as set forth in claim 13, portions of the length of said load transfer members being flanged, to provide enhanced resistance to buckling deformation under load transfer conditions.

15. The structural panel unit as set forth in claim 4, portions of the length of said load transfer members being of non-planar cross-section, having enhanced resistance to buckling deformation under load transfer conditions.

16. The structural panel unit as set forth in claim 15, portions of the length of said load transfer members being flanged, to provide enhanced resistance to buckling deformation under load transfer conditions.