VENTED PANEL ASSEMBLY AND METHOD OF FORMING THE SAME

Abstract

A wall system including one or more vented panels configured to be coupled to one another to form one or more wall structures and/or a roof structure of a building. Each vented panel may include a semi-hollow body portion defining one or more passageways therein. The one or more vented panels may be configured to fluidly communicate with one another at least by way of the one or more passageways defined therein, so as to provide continuous flow pattern of air throughout the wall and/or roof structure. The vented panels may be configured to provide a free flow of ventilation air between adjacent walls structures and/or the roof structure, thereby providing adequate ventilation of a building.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of International Patent Application No. PCT/US2013/36361, filed Apr. 12, 2013, designating the U.S. and claiming the benefit of U.S. Provisional Patent Application Ser. No. 61/623,269, filed Apr. 12, 2012, the entire disclosures of which are incorporated herein by reference.

FIELD

The present disclosure relates generally to panels for use in construction of a structure, and, more particularly, to a vented panel for use in building walls and/or roof of a structure.

BACKGROUND

Adequate ventilation of a structure, such as a home, may help prevent damage to the home. In particular, one know problem associated with inadequate ventilation and/or insulation is the excessive cost and potential harm associated with structural damage caused by excessive ice buildup, which may occur particularly in colder climates. Ice buildup may be caused by improper ventilation, particularly in the roof structure of a home or building. For example, beam-plank roof structures have been found to provide little or no adequate degree of ventilation and this problem being most attendant in roof structures exhibiting a significant degree of pitch or peak, such as cathedral ceilings. Additionally, substantially flat roof structures provide very little degree of ventilation, which may result in the build-up of ice, and potentially damage caused by the excessive weight placed upon the roof structure by the ice build-up. Additionally, ice dams may form, which, upon backing up under the shingles of a roof structure, may cause interior ceiling damage. Additionally, ice particles, including icicles, may form on the roof, which may potentially damage windows, siding and/or landscape.

In warmer conditions, such as the summertime, inadequate and/or improper ventilation may result in additional problems. For example, radiant heat upon the roof structure may penetrate through the roof and result in a heating effect to the home. In turn, active cooling of the home may be required which may result in extensive cooling (air conditioning) expenses. Additionally, undue wear associated with the roofing materials may result.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and advantages of the claimed subject matter will be apparent from the following detailed description of embodiments consistent therewith, which description should be considered with reference to the accompanying drawings, wherein:

FIG. 1 is a perspective exploded view of a vented panel assembly consistent with the present disclosure;

FIG. 2 is a perspective view of the vented panel assembly of FIG. 1 in an assembled state;

FIG. 3 is a side cross-sectional view of a portion of the assembled vened panel assembly of FIG. 1;

FIG. 4 is a top view of the assembled vented panel assembly of FIG. 1 illustrating air flow through the vented panel assembly; and

FIG. 5 is a perspective view, partly in section, of a wall structure formed by at least two vented panel assemblies consistent with the present disclosure illustrating air flow through the vented panel assemblies.

DETAILED DESCRIPTION

The present disclosure is generally directed to a wall system including one or more vented panel assemblies configured to be coupled to one another to form one or more wall structures and/or a roof structure of a building. The one or more wall structures may provide interior and/or exterior walls of the building and may be configured to provide structural support for the building. Each vented panel assembly may include a semi-hollow body portion defining one or more passageways therein. When one or more vented panel assemblies are coupled to one another to form a wall and/or roof structure, the one or more vented panel assemblies may be configured to fluidly communicate with one another at least by way of the one or more passageways defined therein, so as to provide continuous flow pattern of air throughout the wall and/or roof structure.

The vented panel assemblies may be configured to provide a free flow of ventilation air between adjacent walls structures and/or the roof structure, thereby providing adequate ventilation of a building. The vented panel assemblies may be configured to allow free flow of ventilation from various directions, while still providing structural support to the building. The free and continuous flow pattern of ventilation air may offset both thermal gain and/or thermal loss conditions occurring along the roof and/or exterior walls of the building. The vented panel assemblies may be configured to allow at least the roof structure to remain relatively cool in both cold and warm conditions, thereby resulting in a decrease in ice formation in colder conditions and decrease in penetration of radiant heat from the roof structure into the home in warmer conditions.

Turning to FIG. 1, an exploded view of a vented panel assembly 10 consistent with the present disclosure is illustrated and FIG. 2 is a perspective view of the vented panel assembly of FIG. 1 in an assembled state. Generally, the vented panel assembly 10 may include a first panel 12, a second panel 14 and a plurality of spacing members 16 positioned therebetween. As shown, the first and second panels 12, 14 may be coupled to one another by way of the spacing members 16. As described in greater detail herein, the spacing members 16 may provide one or more passageways (shown in FIG. 3) extending along an interior of the vented panel assembly 10 between the first and second panels 12, 14 and permit air to circulate between the first and second panels 12, 14.

The shape and/or size of the first and second panels 12, 14 may be based on a desired shape and/or size of the vented panel assembly 10. In the illustrated embodiment, for example, the first and second panels 12, 14 are generally planar and rectangular in shape, thereby forming a generally planar and rectangular vented panel assembly 10. It is to be understood, however, that the first and second panels 12, 14, and in turn the vented panel assembly 10, may take a variety of regular and irregular geometric configurations. For example, the first and second panels 12, 14 may have generally square shapes, etc.

Similarly, the spacing members 16 may include a variety of shapes and/or sizes. As shown, the spacing members 16 may be generally rectangular in shape. It is to be understood, however, that one or more spacing members 1 may take a variety of shapes, including, but not limited to, a generally square shape, cylindrical shape, pyramidal shape, irregular geometric shape, etc.

Although the vented panel assembly 10 is shown including two panels (first and second panels 12, 14) it should be noted that a vented panel assembly consistent with the present disclosure may include multiple panels and spacing members positioned between such multiple layers. For example, the vented panel assembly may include at least three panels, wherein spacing members are positioned between adjacent panels.

The vented panel assembly 10 may be shaped and/or sized such that it may be coupled to adjacent vented panel assemblies in order to form a single continuous wall and/or roof structure of two or more vented panel assemblies (shown in FIG. 5, for example). This will be described in greater detail herein.

FIG. 3 is a side cross-sectional view of a portion of the assembled vented panel 10 of FIG. 1. As shown, the first and second panels 12, 14 may be coupled to one another by way of the spacing members 16 positioned therebetween. More specifically, the first and second panels 12, 14 may include interior surfaces 18, 20 and exterior surfaces 22, 24, respectively, and the spacing members 16 may be directly coupled to the interior surfaces 18, 20 of the first and second panels 12, 14, such that the interior surface 18 of the first panel 12 generally opposes the interior surface 20 of the second panel 14. The first and second panels 12, 14 may be spaced a distance D apart from one another. The distance D can vary depending on the size of the spacing members 16. In one embodiment, the distance D may range from 0.025 inches to 24 inches. In another embodiment, the distance D may range from 0.5 inches to 12 inches.

As shown, the first and second panels 12, 14 may have a thickness T₁, T₂. In one embodiment, the thickness T₁ and/or T₂ may range from 0.05 inches to 24 inches. In another embodiment, the thickness T₁ and/or T₂ may range from 1 inch to 12 inches. Similarly, each spacing member 16 may have a thickness T₃. In one embodiment, thickness T₃ may range from 0.025 inches to 24 inches. In other embodiments, the thickness T₃ may range from 1 inch to 12 inches.

In an assembled state, the spacing members 16 may provide one or more passageways 26 extending between the first and second panels 12, 14. For example, at least a first spacing member 16(1) and adjacent second spacing member 16(2) form a first passageway 26(1) between the interior surfaces 18, 20 of the first and second panels 12, 14. At least the second spacing member 16(2) and a third spacing member 16(3) form a second passageway 26(2). As described in greater detail herein, the passageways 26 may be configured to allow air to flow through the vented panel assembly 10. The number of passageways 26 formed between the first and second panels 12, 14 may depend on the number of spacing members 16 included in the vented panel assembly 10. Similarly, the size and/or shape of each passageway 26 may vary depending on the size and/or shape of the spacing members 16.

The first and second panels 12, 14 and spacing members 16 may include materials including, but not limited to, wood, carbon fiber, polymers, resins, recycled materials, and combinations thereof configured to provide strength, rigidity, and/or durability required to withstand forces placed there upon. For example, a vented panel assembly 10 consistent with the present disclosure may be constructed so as to meet local building codes and requirements such that the vented panel assembly 10 may provide structural support of a building. For example, the vented panel assembly 10 may be configured to serve as a wall of a building sufficiently strong to support a load thereon, such as, for example, a roof structure or a floor of the building. Alternative (or in addition to), the vented panel assembly 10 may be configured to serve as a roof of the building.

The first and second panels 12, 14 may be configured to prevent contaminants from entering an interior portion of the vented panel assembly 10. For example, in the event the vented panel assembly 10 is utilized as a wall structure that may be exposed to the elements (e.g. exterior wall of a building, fence, etc.), at least exterior surfaces 22, 24 of the first and second panels 12, 14 may include a material configured to prevent the elements from compromising the integrity of the vented panel assembly 10, including the passageways 26 within. For example, in one embodiment, the exterior surfaces 22, 24 may include a waterproof material. Additionally, ends of the vented panel assembly 10 may include any known means of preventing contaminants and/or unwanted debris from entering the interior of the assembly 10. For example, a screen or other known component may be included at the exposed ends of the assembly, wherein the screen may be configured to prevent debris from entering the passageways 26 while still allowing air to enter. In another embodiment, a vented drip edge, for example, may be included in the edges.

A vented panel assembly consistent with the present disclosure may be formed by any known methods generally understood by one of ordinary skill in the art. For example, in one embodiment, a vented panel assembly may be manufactured in an assembly line fashion. A first panel may be laid flat on a conveyer and an adhesive, or equivalent, may be applied to an interior surface of the first panel in a desired pattern upon which spacing members may be directly coupled to the interior surface of the first panel by of the adhesive. Pressure may be applied to the spacing members in order to obtain adequate contact with the first panel. An adhesive, or equivalent, may be applied to an exposed end of the spacing members, upon which a second panel may be placed against the spacers and pressure may be applied to the second panel in a direction against the spacers and first panel. It should be noted that, alternatively, or in addition to, any known fastening means may be used to couple one or more spacing members to the first and second panels. For example, nails, screws, bolts, rivets and the like, or combinations thereof, may be used to directly couple a spacing member to the first and/or second panels.

FIG. 4 is a top view of the assembled vented panel assembly 10 of FIG. 1 illustrating air flow through passageways 26. It should be noted that internal features and/or surfaces are illustrated in phantom in FIG. 4. In the illustrated embodiment, the vented panel assembly 10 may include a rectangular configuration including a length L and a width W. In one embodiment, the length L and width W may each range from 2 inches to 48 feet. In another embodiment, the length L and width W may each range from 1 foot to 24 feet.

As shown, a plurality of passageways 26 may be formed within the vented panel assembly 10 by the spacing members 16. For ease of description, four passageways 26(1)-26(4) are further described, however, it should be noted that the vented panel assembly 10 may include any number of passageways.

As shown, the vented panel assembly 10 may include at least a first and a second passageway 26(1), 26(2) extending along an entire length L of the vented panel assembly 10. The first and second passageways 26(1), 26(2) may be configured to allow air to flow in a direction, as indicated by the arrows, from one end of the vented panel assembly 10 to another. The vented panel assembly 10 may further include at least a third and a fourth passageway 26(3), 26(4) extending along an entire width W of the vented panel assembly 10. The third and fourth passageways 26(3), 26(4) may be configured to allow air to flow in a direction, as indicated by the arrows, from one end of the vented panel assembly 10 to another.

A vented panel assembly 10 consistent with the present disclosure may include a plurality of spacing members 16 having generally uniform size and distribution. As shown, each spacing member 16 is generally rectangular in shape and may be spaced equidistantly apart from one another. It should be noted that, in other embodiments, the spacing members 16 may have varying size in a varying distribution.

FIG. 5 is a perspective view, partly in section, of a wall structure 100 formed by at least two vented panel assemblies 10a and 10b consistent with the present disclosure illustrating air flow through passageways of the vented panel assemblies 10a and 10b. As shown, a first vented panel assembly 10a consistent with the present disclosure may be shaped and/or sized such that it may be coupled to an adjacent second vented panel assembly 10b in order to form a single continuous wall structure 100. The first and second vented panel assemblies 10a, 10b may be arranged in either or both of sideways or end-to-end communication fashion such that the passageways of the first and second assemblies 10a, 10b may align with and fluidly communicate with one another.

As shown, when the first and second vented panel assemblies 10a, 10b are aligned and coupled to one another, associated passageways may align and form single continuous passageways (e.g., but not limited to, first and a second passageways 28(1) and 28(2)) that may extend from one end of wall structure 100 (end of the first vented panel assembly 10a) to an opposing end of the wall structure 100 (end of the second vented panel assembly 10b). For example, in the illustrated embodiment, when the first and second vented panel assemblies are aligned and coupled to one another, the wall structure 100 may include at least a first and a second passageway 28(1), 28(2) extending along an entire width W of the wall structure 100. The first and second passageways 28(1), 28(2) may be configured to allow air to flow in a direction, as indicated by the arrows, from one end of the wall structure 100 to another.

It should be noted that a wall structure 100 may include more than two vented panel assemblies as shown. In other embodiments, a wall structure may be formed from a plurality of vented panel assemblies in a variety of configurations.

As previously described, a wall structure 100 formed by at least two of the vented panel assemblies consistent with the present disclosure may be used as an exterior (and/or interior) wall of a building. Alternatively, or in addition to, the wall structure 100 may be used as a roof of a building. In one embodiment, a wall structure serving as a roof of a building may be coupled to a wall structure serving as an exterior wall of the building, such that passageways of the wall structures may be aligned and communicate with one another, thereby allowing air to flow and circulate between the exterior wall and roof structures.

A wall structure having at least two vented panel assemblies consistent with the present disclosure may be configured to provide free flow of ventilation air between adjacent vented panel assemblies, thereby providing adequate ventilation of a building. The vented panel assemblies of the wall structure may be configured to allow free flow of ventilation in various directions, while still providing structural support to the building. The free and continuous flow pattern of ventilation air may offset both thermal gain and/or thermal loss conditions occurring along the roof and/or exterior walls of the building. The vented panel assemblies may be configured to allow at least the roof structure to remain relatively cool in both cold and warm conditions, thereby resulting in a decrease in ice formation in colder conditions and decrease in penetration of radiant heat from the roof structure into the home in warmer conditions.

According to one aspect consistent with the present disclosure, there is provided a vented panel assembly. The vented panel assembly includes a first panel and a second panel coupled to the first panel by way of at least one spacing member positioned between the first and second panels. The at least one spacing member has a first portion directly coupled an interior surface of the first panel and a second portion directly coupled to an interior surface of the second panel opposing the interior surface of the first panel. The vented panel assembly further includes at least one passageway defined by the opposing interior surfaces of the first and second panels and the at least one spacing member positioned therebetween. The at least one passageway is configured to allow movement of air between the first and second panels.

According to another aspect consistent with the present disclosure, there is provided a wall structure. The wall structure includes a first vented panel assembly. The first vented panel assembly includes a first panel and a second panel coupled to the first panel by way of at least one spacing member positioned between the first and second panels. The at least one spacing member has a first portion directly coupled an interior surface of the first panel and a second portion directly coupled to an interior surface of the second panel opposing the interior surface of the first panel. The first vented panel assembly further includes at least one passageway defined by the opposing interior surfaces of the first and second panels and the at least one spacing member positioned therebetween. The at least one passageway is configured to allow movement of air between the first and second panels of the first vented panel assembly.

The wall structure further includes a second vented panel assembly coupled to the first vented panel assembly, wherein the second vented panel assembly includes at least one additional passageway configured to allow movement of air within the second vented panel assembly. The passageways of the first and second vented panel assemblies are coupled to one another and further configured to fluidly communicate with one another to allow movement of air between the first and second vented panel assemblies by way of the passageways.

According to yet another aspect consistent with the present disclosure, there is provided a vented panel assembly. The vented panel assembly includes a first panel and a second panel coupled to the first panel by way of a first set of a plurality of spacing members positioned between the first and second panels. Each of the first set of spacing members has a first portion directly coupled an interior surface of the first panel and a second portion directly coupled to an interior surface of the second panel opposing the interior surface of the first panel. The vented panel assembly further includes a third panel coupled to the second panel by way of a second set of a plurality of spacing members positioned between the second and third panels. Each of the second set of spacing members has a first portion being directly coupled to an exterior surface of the second panel and a second portion being directly coupled to an interior surface of the third panel opposing the exterior surface of the second panel.

The vented panel assembly further includes a first passageway defined by the opposing interior surfaces of the first and second panels and the first set of the spacing members positioned therebetween. The first passageway is configured to allow movement of air between the first and second panels. The vented panel assembly further includes a second passageway defined by the opposing exterior and interior surfaces of the second and third panels, respectively, and the second set of the spacing members positioned therebetween. The second passageway is configured to allow movement of air between the second and third panels.

While several embodiments of the present disclosure have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the functions and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the present disclosure. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present disclosure is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the disclosure described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, the disclosure may be practiced otherwise than as specifically described and claimed. The present disclosure is directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the scope of the present disclosure.

All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.”

The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified, unless clearly indicated to the contrary.

Claims

1. A vented panel assembly comprising:

a first panel;

a second panel coupled to said first panel by way of at least one spacing member positioned between said first and second panels, said at least one spacing member having a first portion directly coupled an interior surface of said first panel and a second portion directly coupled to an interior surface of said second panel opposing said interior surface of said first panel; and

at least one passageway defined by said opposing interior surfaces of said first and second panels and said at least one spacing member positioned therebetween, said at least one passageway configured to allow movement of air between said first and second panels.

2. The vented panel assembly of claim 1, further comprising a plurality of spacing members positioned between said first and second panels, wherein said plurality of spacing members are spaced equidistantly apart from one another.

3. The vented panel assembly of claim 2, further comprising a plurality of passageways defined by said plurality of spacing members and said opposing interior surfaces of said first and second panels.

4. The vented panel assembly of claim 1, wherein said at least one spacing member is coupled to said first and second panels by an adhesive

5. The vented panel assembly of claim 1, wherein said at least one spacing member is coupled to said first and second panel by one or more fasteners.

6. The vented panel assembly of claim 5, wherein said one or more fasteners is selected from the group consisting of nails, screws, bolts and rivets.

7. The vented panel assembly of claim 1, wherein said opposing interior surfaces of said first and second panels are spaced a distance apart from one another ranging from 0.025 inches to 24 inches.

8. The vented panel assembly of claim 7, wherein said opposing interior surfaces of said first and second panels are spaced a distance apart from one another ranging from 0.5 inches to 12 inches.

9. The vented panel assembly of claim 1, wherein said first and second panels and said at least one spacing member comprise one or more materials configured to provide sufficient strength, rigidity and/or durability to withstand forces placed thereupon.

10. The vented panel assembly of claim 1, wherein said vented panel assembly is configured to serve as a portion of an upstanding wall structure and/or a roof structure.

11. The vented panel assembly of claim 1, further comprising a third panel coupled to said second panel by way of at least one additional spacing member positioned between said second and third panels, said at least one additional spacing member having a first portion being directly coupled to an exterior surface of said second panel and a second portion being directly coupled to an interior surface of said third panel opposing said exterior surface of said second panel.

12. The vented panel assembly of claim 11, wherein said opposing exterior and interior surfaces of said second and third panels, respectively, and said at least one additional spacing member positioned therebetween define at least one additional passageway configured to allow movement of air between said second and third panels.

13. A wall structure comprising:

a first vented panel assembly comprising: a first panel; a second panel coupled to said first panel by way of at least one spacing member positioned between said first and said second panels, said at least one spacing member having a first portion directly coupled an interior surface of said first panel and a second portion directly coupled to an interior surface of said second panel opposing said interior surface of said first panel; and at least one passageway defined by said opposing interior surfaces of said first and second panels and said at least one spacing member positioned therebetween, said at least one passageway configured to allow movement of air between said first and second panels; and

a second vented panel assembly coupled to said first vented panel assembly, said second vented panel assembly comprising at least one additional passageway configured to allow movement of air within said second vented panel assembly;

wherein said passageways of said first and second vented panel assemblies are coupled to one another and further configured to fluidly communicate with one another to allow movement of air between said first and second vented panel assemblies by way of said passageways.

14. The wall structure of claim 13, wherein said first and second vented panel assemblies form a single continuous structure.

15. The wall structure of claim 13, wherein said second vented panel comprises:

a third panel; and

a fourth panel coupled to said third panel by way of at least one additional spacing member positioned between said third and fourth panels, said at least one spacing member having a first portion directly coupled an interior surface of said third panel and a second portion directly coupled to an interior surface of said fourth panel opposing said interior surface of said first panel;

wherein said at least one additional passageway is defined by said opposing interior surfaces of said third and fourth panels and said at least one additional spacing member positioned therebetween, said at least one additional passageway configured to allow movement of air between said third and fourth panels.

16. The wall structure of claim 15, wherein exterior surfaces of said first and third panels of said first and second vented panel assemblies, respectively, form a substantially planar first exterior surface of said wall structure and exterior surfaces of said second and fourth panels of said first and second vented panel assemblies, respectively, form a substantially planar second exterior surface of said wall structure.

17. The wall structure of claim 13, wherein said first and second vented panel assemblies comprise one or more materials configured to provide sufficient strength, rigidity and/or durability to withstand forces placed thereupon.

18. A vented panel assembly comprising:

a first panel;

a second panel coupled to said first panel by way of a first set of a plurality of spacing members positioned between said first and second panels, each of said first set of spacing members having a first portion directly coupled an interior surface of said first panel and a second portion directly coupled to an interior surface of said second panel opposing said interior surface of said first panel;

a third panel coupled to said second panel by way of a second set of a plurality of spacing members positioned between said second and third panels, each of said second set of spacing members having a first portion being directly coupled to an exterior surface of said second panel and a second portion being directly coupled to an interior surface of said third panel opposing said exterior surface of said second panel;

a first passageway defined by said opposing interior surfaces of said first and second panels and said first set of said spacing members positioned therebetween, said first passageway configured to allow movement of air between said first and second panels; and

a second passageway defined by said opposing exterior and interior surfaces of said second and third panels, respectively, and said second set of said spacing members positioned therebetween, said second passageway configured to allow movement of air between said second and third panels.

19. The vented panel assembly of claim 18, wherein said first, second and third panels and said first and second sets of spacing members comprise one or more materials configured to provide sufficient strength, rigidity and/or durability to withstand forces placed thereupon.

20. The vented panel assembly of claim 18, wherein said vented panel assembly is configured to serve as a portion of an upstanding wall structure and/or a roof structure.