VENTILATED STRUCTURAL PANELS AND METHOD OF CONSTRUCTION WITH VENTILATED STRUCTURAL PANELS
A single plenum structural panel comprising a top sheet and a bottom sheet. The top sheet and the bottom sheet being parallel to one another. A plurality of spacing structural elements fixedly attach the top sheet to the bottom sheet, such that a yield strength of an assembled single plenum structural panel is greater than a sum of individual yield strengths of the top sheet and the bottom sheet. A plenum is defined by a spacing between the top sheet and the bottom sheet. The plurality of spacing structural elements are formed such that a first plurality of spaced apart unobstructed pathways are created in the plenum for air to move in a first direction from at least one edge of the single plenum structural panel to at least one of an opposite and an adjacent edge of the single plenum structural panel.
This application is a divisional of U.S. patent application Ser. No. 15/459,620 filed Mar. 15, 2017, which is a divisional of U.S. patent application Ser. No. 14/711,943 filed May 14, 2015, which claims priority to U.S. patent application Ser. No. 13/782,406 filed Mar. 1, 2013, both of which are incorporated by reference as if fully restated herein. This application also claims priority to U.S. patent application Ser. No. 14/099,100 filed Dec. 6, 2013, which is Continuation-in-Part of U.S. patent application Ser. No. 13/539,919 filed Jul. 2, 2012, now U.S. Pat. No. 8,615,945 issued Dec. 31, 2013, which is a Continuation-in-Part of U.S. patent application Ser. No. 13/016,320 filed Jan. 28, 2011, now U.S. Pat. No. 8,534,018 issued Sep. 17, 2013, which is a Continuation-in-Part of U.S. patent application Ser. No. 12/987,832 filed Jan. 10, 2011, now U.S. Pat. No. 8,490,355 issued Jul. 23, 2013, which claims the benefit of U.S. provisional Patent Application Ser. No. 61/376,333, filed Aug. 24, 2010, all of which are fully incorporated by reference into the present disclosure as if fully restated herein. Any conflict between the incorporated material and the specific teachings of this disclosure shall be resolved in favor of the latter.
FIELD OF THE INVENTIONResidential and commercial sheathing for roofs, walls, floors, and ceilings.
BACKGROUND OF THE INVENTIONSheathing is an essential component of any residential or commercial structure and provides structural support for roofs, walls and floors, as well as providing a surface of sufficient thickness and strength for the attachment of roofing materials such as asphalt shingles and metal roofing, siding materials such as wood clapboards or vinyl siding and flooring finishes such as tile, wood, hardwood, laminates, vinyls or carpets and the like.
Sheathing has traditionally been supplied in 4′×8′ sheets, made of plywood or OSB, which provide a desirable modular size that can be handled by one worker. The means of attachment depends on the function, thickness and strength requirements of the application and may include mechanical fasteners such as nails or staples and/or adhesives. Roofs, walls, and flooring use sheets of similar sizes, though varied thickness.
Complex, costly, and non-commercially feasible systems have been proposed to incorporate in some manner ventilation systems into sheathing, but they lack the structural strength and other benefits of the present invention.
SUMMARY OF THE INVENTIONWherefore, it is an object of the present invention to overcome the above mentioned shortcomings and drawbacks associated with the prior art by providing a ventilated structural panel that allows for ventilation out of and throughout a structure, while simultaneously providing a panel of substantially increased strength, formed of readily available construction materials, for small additional cost.
Another object of the present invention is to provide a ventilated structural panel comprising a first sheet, having edges that define a horizontal axis with a first horizontal edge and a second horizontal edge, and vertical axis with a first vertical edge and a second vertical edge. The panel additionally comprises a second sheet being of substantially the same planar dimensions as the first sheet and having edges that define a horizontal axis and vertical axis, with a first horizontal edge and a second horizontal edge and a first vertical edge and a second vertical edge; the first and second sheet being parallel in plane and preferably matched in at least one of the vertical axis and the horizontal axis. A plurality of spacing structural elements (also referred to as “structural spacing elements”) fixedly attaches the first sheet to the second sheet, such that the strength of the combined panel is multiple times greater than the combined individual strength of the first and second sheet. The ventilated structural panel can be at least semi-permeable to the passage of gases and liquids and the first or bottom sheet of the panel could have one or more perforations.
The invention is an interlocking construction panel of the same size and approximate weight of conventional sheathing products that incorporates integral ventilation into the structure. The invention may be used as a conventional sheathing and is attached with the same mechanical methods of nailing and/or adhesives. It is cut and fitted in the same manner. It interlocks to provide continuity of strength and ventilation.
The panel is engineered such that it provides the same or superior strength of conventional methods of providing construction strength and ventilation, with fewer materials. The materials involved in the construction of the panel are relatively inexpensive and readily available.
The panels facilitate the use of a wide variety of insulation possibilities without the need for special consideration for ventilation, since the ventilation is integral with the panels. This is useful for common fiberglass as well as blown products such as fiberglass, Rockwool, cellulose and other products. This is especially useful for the new high performance spray foam expanding insulations that are becoming popular because of their high energy efficient performance and ability to seal infiltration, as the foams can break, plug or destroy conventional foam, plastic, or cardboard ventilation products, or intrude into the seams.
The panels could be combined with a multitude of construction materials and methods in the same way conventional sheathing is used today. The panels could be used with conventional soffit and ridge vents by cutting the sheathing on the panels for access to the ventilation cavity. Drip edges would have to have an extended leg to cover the side ventilation or it could be blocked with conventional trim.
The panel may be constructed sheets of commonly available 4′×8′ sheathing of a thickness determined by structural and roof fastening requirements, but may preferably vary from ¼″ to 1½″ in thickness, and more preferably vary from ⅜″ to ¾″ in thickness. The top and bottom sheets may also vary in thickness.
The two sheets are attached to each other via the spacing structural elements, with adhesive and/or mechanical means such as nailing, stapling, screwing or machine impressed metal connections, so as to provide for the transfer of forces.
In essence, the two sheets function as the top and bottom chords of a truss or “I” beam providing superior strength, load carrying capacity, and resistance to deflection (stiffness). As a result, rafter or stud or purloin spacing may be increased where these panels are used, which would reduce material requirements, allowing the elimination of rafters and trusses with the greater spacing.
The spacing structural elements may protrude beyond two contiguous edges of the panel, and the spacing structural elements may be chamfered to enhance interlocking with adjacent panels. The spacing structural elements would likewise be indented on the two opposite contiguous edges.
Another embodiment of the invention is a panel comprised of two sheets of the same size (i.e., same area, but perhaps different thicknesses) connected to each other with a matrix of crossed spacing structural elements such that the combined entity is one structural panel. Ideally, the panel is the same size as conventional building sheathing, generally 4′×8′, but can be of any size or thickness. The sheets are connected so as to be are parallel in plane and matched in the vertical axis, one on top of the other, such that they can be used in place of traditional sheathing materials currently used in building construction such as plywood sheathing, OSB sheathing and other composite sheathing materials.
In one embodiment, the panel includes a first and a second 4′×8′ sheet of plywood, Oriented Strand Board (OSB), or a composite board of wood and/or plastic, each sheet having a thickness of ¼″ to ¾″ depending on the application. Roofs would usually consist of the two sheets measuring ¼″ to ⅝″ in thickness, depending on strength and span requirements and shingle attachment requirements, and whether the shingles are attached by staples or nails. Wall sheathing sheet thickness would also be of ¼″ to ½″ thickness depending on strength requirements. The top wear layer of the flooring panel will usually have a ½″ to ¾″ finish layer depending on strength requirements and floor covering.
Blocks may be used as the as the spacing structural elements, spacing the sheets ideally 1½″ from each other. Blocks of a preferably of square or rectangular form, but the blocks could be of any shape or size, including circular, oval, regular polygons, and irregular shapes. The spacing can vary depending on the application and ventilation requirements—more spacing not only enhances ventilation and potentially increases the strength of the assembly, but would also require closer spacing of the blocks or spacers. While panels constructed with blocks would not have the degree of added strength as panels constructed of elongated members (discussed below), panels constructed of blocks would potentially be less expensive, and provide sufficient increased strength for construction with conventional 16 or 24 inch spaced of stud, rafter, truss, or joist is used.
The blocks are generally spaced from 1 to 12 times their own width apart horizontally and vertically. The specific spacing would depend on the sheet thickness and strength requirements. Blocks were found to only increase the strength of the panel, over the combined individual strength of the separate sheets comprising the panel, by approximately one half the amount of increase as panels utilizing rectangular shaped elongated members. But, using blocks does offer additional construction possibilities over rectangular elongated members due to the increased contagious space inside a panel offered by using blocks compared to using a matrix of elongated members. The blocks can be oriented on the same axis of the sheets or arranged on an angle of preferably 45°; but other orientations, such as 30° or 60°, are possible depending on the application. The angled orientation strengthens the plywood or OSB assembly.
Another embodiment of the invention uses spacing structural elements consisting of a matrix of rectangular shaped elongated members, preferably comprised of wood members with a square cross section, arranged in layers, each layer oriented perpendicular to the next, and each layer interconnected to each adjacent layer or adjacent sheet with mechanical means and/or adhesives. The individual elongated members would ideally be of ¾″×¾″, but could be larger or smaller. The individual elongated members would ideally be long enough to stretch from one edge of a sheet to another—this required length varying depending on the orientation of the elongated member.
The individual elongated members would be aligned in layers and spaced, parallel, apart from one another preferably between 1 to 18 times the thickness of the elongated member, or ¾″ to 13.5 inches for elongated members with cross sections measuring ¾″×¾″, and more preferably between 5 and 16 times the thickness of the elongated member, and most preferably between 8 and 12 times the thickness of the elongated member. In another embodiment, each elongated member preferably measures between 0.25 and 1.50 inches in height and between 0.25 and 1.50 inches in width, more preferably measures between 0.5 and 1.0 inches in height and between 0.5 and 1.0 inches in width, and most preferably measures between 0.7 and 0.8 inches in height and between 0.7 and 0.8 inches in width. The matrix of elongated members could consist of two layers perpendicular to each other or of multiple successive perpendicular layers. The matrix can be attached to the sheets either parallel to the sheet axis or on an angle. If an angular orientation is used, the elongated members will be ideally oriented 45° to each axis of both sheets, but other orientations such as 30° or 60° are possible depending on the application. The length of the elongated members would be of a length that they stretched from a first edge of a first sheet, to a second edge of the first sheet. Chamfered elongated members would preferably measure the “edge to edge” length of a sheet, but would be shifted in the direction of the chamfered end. This would allow for the terminal chamfered end of a given elongated member to extend into a mating indented end on an abutting panel, while simultaneously allowing room for a chamfered end on an opposing abutting panel to mate with the indented end of the given elongated member. For example, chamfered mating elongated members would measure 48 inches and 96 inches in an orientation parallel to the sheet axis, and chamfered mating elongated members with a 45° orientation would measure approximately 69 inches or 137 inches respectively at the greatest measurements.
In another embodiment, the indented end of an elongated member can have a concave face that will accept all or a portion of the chamfered end of a mating elongated member. In such an embodiment, the total length of the elongated member would preferably be extended by the length in which the chamfered end recesses within the concave portion of the indented end. In the manufacturing of the panels, the elongated members may initially be secured to the sheets at lengths greater then required, and then be trimmed to finished length at a later point in the manufacturing process.
The spacing structural elements can also be constructed of elongated members comprised of a plurality of plywood veneers, each veneer being typically ⅛″ thick. This plywood matrix would be built up by multiple layers of veneered elongated members, each veneered elongated member being ideally ½″ to ¾″ thick and spaced from ½″ to 4″ apart. The plywood matrix would consist of a first layer of similarly shaped and parallel aligned veneered elongated members, followed by one or more additional layers laid perpendicular to the first and/or immediately preceding layer, until a multi-layer plywood matrix of desired thickness is assembled. The veneered elongated members would be attached with adhesives. The resulting plywood matrix can be attached to the sheets either parallel to the sheet axis or on an angle. If an angular orientation is used, the veneered elongated members will be ideally oriented 45° to each axis of both sheets, but other orientations such as 30° or 60° are possible. The length of the veneered elongated members would be similar to that of the non-veneered elongated members above depending, depending on the angle of the orientation of the members to the axis of the sheets, and whether or not the veneered elongated members were chamfered.
In all cases, including spacing blocks and elongated members, the spacing structural elements can protrude on two contiguous edges and be chamfered to enhance interlocking with adjacent panels. The spacing structural elements can be similarly matingly indented on the two opposite contiguous edges. The extension is normally less than or equal to 1 inch and ideally between ½″ to ¾″. Additionally, the elongation and indentation may be modified to provide for both contiguous mating of adjacent panels and a spacing gap between adjacent panels of between 0.0625 inches and 0.25 inches. For example, the elongated members length could be increased by, for example, ⅛ inch, or the indentation could be reduced by ⅛ inch, or both, such that the elongated members may mating abut, but the neighboring first and second sheets would be spaced between 0.0625 inches and 0.25 inches apart.
The panels with all attributes herein described can also be manufactured similarly to plywood except that the two exterior sheets are instead separated by a plurality of elongated members that are spaced apart and, in layers, are laid on to one another perpendicular to each other to permit the passage of air and the transfer of forces. These elongated members function as the spacing structural elements. The number of elongated members can vary as can the thickness of the elongated members, the width of the elongated members, the spacing of the elongated members and the orientation of the elongated members, for instance, some may be oriented on an or arranged in the same axis of the sheets.
In all cases where there are matrices of elongated members acting as the spacing structural elements, there may be one, two, three, or four layers of elongated members, and where veneer elongated members are used, up to twelve layers may be used. Each additional layer potentially adds cost and weight, but also potentially adds strength.
The apparatus may include three layers of elongated members, with two layers perpendicular to one another and diagonally oriented to the axis of the sheets, and one layer perpendicular to an axis of the sheets. The apparatus may include three layers of elongated members, with two layers perpendicular to one another and each perpendicular to an axis of the sheets, and one layer diagonally oriented to the axes of the sheets. The apparatus may include four layers of elongated members, with two layers perpendicular to one another and each perpendicular to an axis of the sheets, and two layers perpendicular to one another and diagonally oriented to the axes of the sheets. The apparatus may include three or four layers of elongated members, with each layer oriented perpendicular to the next, and all layers either perpendicular to an axes of the sheets, or all layers diagonally oriented to the axes of the sheets.
In one embodiment, the individual sheets for each panel are spaced equally apart from each other in parallel planes and in the same vertical axis, ideally at a distance of 1½″ from each other, with a matrix of spacing structural elements or members arranged in a cross hatch pattern between the two sheets. The matrix of members would ideally consist of a first layer of elongated members, each parallel, coplanar, and spaced equally from one another, the first layer being perpendicular to a second layer of elongated members, each parallel, coplanar, and spaced equally from one another. Each elongated member would generally have a square cross section and would extend in length from one side of the panel to another. For a perpendicular arrangement to the panels, where the panels are spaced at 1½″ apart, this would require members of ¾″ square faces with lengths of 48″ and 96″, or, if chamfered, longer, depending on the length of the chamfer.
A layer of screening (e.g., fiberglass, aluminum, plastic) could be affixed between the first and the second layers of elongated members. This would aid in adhesion and/or fastening of elongated members, and would facilitate the running of wires through the interior of the panels.
The elongated members are generally spaced apart from a neighboring elongated member in the same layer from 1 to 12 times their own width, more preferably 3 to 9 times their own width, and most preferably 5 to 7 times their own width. The specific spacing would depend on the sheet thickness and strength requirements.
For roofing sheathing, the top layer would preferably be laid in the long horizontal direction, and have a length of 96 inches, with a repeat of 5⅝″ for shingle attachment if using nails for shingles and the object is to nail into the elongated member. The panel faces could be stamped, painted, or otherwise visibly marked with the orientation of the underlying matrix for ease of use by the workman.
The elongated members would usually be oriented perpendicular to one another on the same axis of the sheets but other orientations are possible depending on the application. Testing indicates that the perpendicular orientation significantly strengthens the plywood or OSB assembly more than any other orientation, allowing the use of thinner exterior sheets. Tests have demonstrated that a strength increase in bending stiffness for an assembly of two ¼ inch sheets, with a perpendicular matrix of two layers of ¾″×¾″ elongated members spaced 5 inches apart, has a bending strength approximately 10 times greater than a single sheet of ½″ of plywood alone.
The elongated members of the matrix can consist of square members made of wood, wood composite, plastic, or similar material, arranged perpendicular or close to perpendicular for an offset matrix, and interconnected to each other with mechanical means and/or adhesives.
The individual matrix members would ideally be ¾″×¾″ square, and long enough to extend beyond the panel edge. The size of the elongated members could be larger or smaller and long enough to complete the required matrix of the sheets, which depends on the orientation, and extend to or beyond one edge. Spacing would be 1 to 12 times the thickness of the elongated member or ¾″ to 9 inches. The matrix of “elongated members” could consist of two layers perpendicular to each other or multiple layers. The matrix can be attached to the sheets either parallel to the sheet axis or on an angle of 45°, but other orientations are possible depending on the application. In all cases, a provision is made so that the panels interconnect structurally.
For the matrix of elongated members, the elongated members may be indented preferably between ¼″ and ⅝″ and more preferably between ⅜″ and ½″ on two contiguous sides, while the other two sides would be extended by between preferably ¼″ and ⅝″ and more preferably between ⅜″ and ½″ with an end member. Additionally, the length of the elongated members could be between ¼″ and ¾″ longer than the sheet on two contiguous sides to machine a tongue and groove attachment.
In all embodiments, the spacing structural elements can protrude on two contiguous edges and may be chamfered to enhance interlocking with adjacent panels. The spacing structural elements would be similarly indented on the two opposite contiguous edges. The extension would normally be no more than 1 inch and would ideally be between ½″ to ¾″.
Additionally, the one or both sheets can be manufactured from plastic materials. These plastic sheeted panels could be used for waterproof applications such as for roofing or basement wall applications, with one or both sheets providing a barrier to liquid water and/or water vapor. The joints would be waterproofed with an application of waterproof mastic or tape. The panels could be combined with a multitude of construction materials and methods in the same way conventional sheathing is used today. Further, a top sheet of one panel may be extended in length and attached such that it overlaps a top sheet of an abutting lower adjacent panel by approximately two to four inches.
The panels could also be manufactured with a perforated bottom sheet to facilitate ventilation into the panel matrix. The perforations would ideally be round in shape, sized ¼″ to 1″ in diameter, and arranged in a matrix that is ideally staggered from the adjacent holes with a spacing of 4 to 12 diameters in widths. A layer of screening (e.g., fiberglass, aluminum, plastic) could be affixed along the interior or exterior surface of the perforated sheet. The perforations allow for the exhausting of heat, gases, and moisture in attics and non-living spaces. The holes should be such that the panel can still transfer necessary tensile and compressive forces. Both solid and perforated panels can be used together in building assembly, such as a roof.
The panels can facilitate the use of a wide variety of insulation possibilities without requiring special consideration for ventilation since the ventilation is integral with the panels. This is useful for common fiberglass as well as blown products such as fiberglass, Rockwool, cellulose and other products. This is especially useful for the new high performance spray foam expanding insulations that are becoming popular because of their high energy efficient performance and ability to seal infiltration.
The panels can be used in both residential and commercial construction. The panels can be used both for on site installation and for factory built modular homes. The panels would be useful for manufactured homes and trailers.
To facilitate construction, the exterior of one or both sheets could be marked with exterior lines showing the location of the interior elongated members. The exterior facing sheet could also be of waterproof construction and made of waterproof material, such as some form of plastic, providing for the exposed layer of roofing or wall covering. The top sheet could be sized larger than the bottom sheet such that a top sheet of a first panel would extend to overlap a top sheet of an adjacent, and preferably vertically lower, panel.
In addition to wall and roof sheathing, a flooring system of the ventilated structural panels as described would have many benefits. Increased structural strength, spanning capability and reduced deflection, all of which would result in less materials needed for supports (joists or trusses or composite joists) and better performance in terms of strength and stiffness. A properly engineered panel could be used for flooring providing a plenum for air distribution providing warmed and cooled air to be distributed within the floor. The warmed air would be a desirable characteristic in bathrooms.
A properly engineered panel could be used for flooring providing a plenum for electrical distribution where wires and data communication cables could be easily run. A properly engineered panel could be used for flooring to provide a plenum for radiant heat or forced hot air heat. In this case, one interior surface would generally receive a layer of reflecting material and the spacers would have to be mechanically connected. A properly engineered panel could be used for flooring providing a plenum for plumbing distribution where pipes, tubes and conduits of proper size could be run. Finally, a flooring system with this panel construction is naturally quieter than one sheet of sheathing, providing a nose buffer. This noise buffering benefit would also apply to walls and roofing.
This panel offers three main simultaneous advantages of ventilation, ease of use, and significantly increased strength. First, these panels offer ventilation both through the panel sheets and between the panel sheets. In this way, the panels may remove moisture and gasses passing through an interior facing sheet, and exhaust them via the continuous air channel created between the sheets by the spacing structural elements. This air channel will be approximately the width and height of the combined width and height of any contiguous surface formed by the ventilated structural panels being attached contiguous with one another. Such a large air channel can provide for dramatically increased air flow over the interior facing sheet, and thus dramatically increased ventilation between the interior and exterior—even if only passively. A particular advantage this offers is for roofing situations in colder climates to assist in avoiding ice dams.
A ventilated structural paneled roof provides for ventilation of moisture and gasses from the house, and allows a flow of cold air along the entire roof surface, in the interior of the panels, to prevent the formation of ice dams. A ventilated structural paneled roof allows for the entire roof to remain cold in the winter, preventing snow from melting and ice dams from forming. Any heat that migrates into the ventilation plenum is exhausted to the outdoors and does not melt the snow on the roof. Similarly, ventilation of a wall surface provides the same benefits noted above. Ventilation in warm climates or during warm months can exhaust hot air from the attic space, extending the life of roofing materials and reducing cooling costs. Also, the inventive panels can typically achieve ventilation of at least 1/50, when compared to free, unobstructed end area, greatly exceeding many code requirements.
Second, the structural connection between the two sheets of material interconnected with spacing structural elements with adhesive and or mechanical means to transfer shear forces provides that the entire entity becomes a synergistic structural panel with characteristics that exceed the strength of the individual parts. The top and bottom sheets act like the flanges on a beam or truss and provide better load carrying strength, increased span capability and less deflection than the individual sheets together. Preliminary tests indicate that an assembly of two ¼ inch sheets of plywood spaced with ¾ inch blocks is 4 times stronger than just one sheet of ½ inch plywood alone, and two ¼ inch sheets of plywood spaced with a matrix of two ¾″ by ¾″ members can be 10 times stronger than just one sheet of ½ inch plywood alone.
This extra strength can be used advantageously to increase the load capacity or the length of the unsupported span of the panel, which reduces the required number of underlying supporting rafters, studs, joists, trusses or purloins, and thus cost of building.
The spacing structural elements material, size, arrangement, thickness, shape and orientation can vary with the application and be adapted to the specific need of the application.
The plurality spacing structural elements may be arranged such that a number of linear pathways are created. Each pathway's dimensions are limited by the dimensions and arrangements of the spacing structural elements. Utilizing blocks, the pathways may measure in height the full distance separating the first and the second sheet; the width measurement is dependent on how far apart the blocks are spaced from one another. Utilizing two layers of elongated members, the height of the pathways will measure approximately one half of the distance that separates the two sheets. Like the blocks, the width of the pathways formed with elongated members will be equal to the distance separating two neighboring elongated members in the same layer. When the two layers of elongated members are arranged perpendicular to each other, the pathways will also be orthogonal. Each pathway allows air to move along each pathway unobstructed from at least one edge of the panel to at least one opposite edge of the panel.
The spacing structural elements can protrude on two contiguous sides with chamfered edges. The extent of the protrusion could be matched by an indention of the spacing structural elements on the opposite contiguous two edges which would provide for interlocking of panels. This interlocking of panels would provide structural continuity, increasing structural integrity and minimizing discontinuous deflection and buckling.
Third, the panel offers significant advantages as to ease of use. Since the panel is assembled from readily available building materials, it is familiar to the designers, suppliers and trades in terms of size and weight. It can be cut, sized and attached in the same manner of conventional sheathing. No special tools or skills are needed. No special orientation is needed to ensure the continuity of ventilation, except that the interlocks should be maintained for increased structural integrity. Ventilation is maintained without any special considerations or the use of any special additional materials, except insect and moisture blocking at the exposed edges.
In another embodiment, the panels can also be constructed as two sheets separated by a single layer matrix as described in paragraph 28. The matrix members can consist of wood, plywood, OSB, medium-density fiberboard (MDF), other wood composites, plastic or other materials and shaped in a rectangular or most likely square profile and extending either the length in the longitudinal direction or the width in the perpendicular direction. Said matrix can be extended on two contiguous edges and chamfered and indented on the opposite two edges to facilitate interlocking as previously described.
The members would be placed parallel to each other and fastened to both the top and bottom panels with adhesives and/or mechanical means. The spacing between members would be from 2 times the thickness an individual matrix member to 16 times the thickness, but ideally from 4 times to 12 times.
The single layer panels could also have perforations as previously described. The perforations would ideally be round but could also be other shapes such as oblong, oval, square or rectangular or a combination of geometric shapes such as square with rounded corners.
The single layer panels would be useful for wall sheathing applications where the strength of the perpendicular matrix may not be as important or for some flooring applications. The panels may be used for decorating concrete formwork. The orientation of the single layer matrix may be either longitudinal, lateral, or diagonal depending on the specific application.
In an additional embodiment, the panel may be comprised of simply one sheet of panel with a matrix of members, without a second sheet. It could be constructed of plywood, OSB, MDF or other materials such as plastic or other composite wood material. In a further additional embodiment, the matrix of spacing structural elements can also be manufactured integrally (also termed unitary) with the panels in either OSB or Plywood or other materials such as MDF, plastics or other wood composites.
Manufacturing integral spacing structural elements, including the matrix of elongated members, would eliminate the need to separately attach the elongated members to each sheet.
Integral raised members would serve as the matrix of elongated members. Two similar sheets may have integral elongated members formed longitudinally in a first sheet and laterally in a second sheet. The two sheets would then be joined together by adhesives and/or mechanical means, with the matrix members in contact with one another. The finished flat panel surface would be exposed on the top and bottom. An alternative arrangement would provide for the integral raised members to be formed at angles to the edges of each respective sheet. Preferably the integral raised members on the first sheet would be formed such that, when they are mated with the integral raised members on the second sheet, the integral raised members of the first sheet will be perpendicular to the integral raised members of the second sheet.
The same characteristics regarding the size, shape and spacing, and ranges therein, of the individual integral elongated members would be as the elongated members previously described.
In producing panels utilizing integral raised elongated members, plywood sheets, for example, could be manufactured with a plurality of raised ridges or strips. The raised ridges or strips would function as the integral elongated members. Two sheets would then be attached to each other with adhesives and/or mechanical means via the plurality of integral elongated members, preferably with the integral elongated members of each sheet in perpendicular orientation to the other respective sheet. These panels could also be manufactured from OSB, medium density fiberboard, or other wood composite materials or plastics. These panels and the sheets and integral elongated members could be manufactured in multiple steps, or in a single step. The integral members could be added during the panel production, or material could be removed after production to leave the plurality of elongated members, or the sheet and members could be formed substantially simultaneously, including with a mold.
The integral raised elongated members could be made during the panel manufacturing process with special tools, equipment, rollers, molds and other such means as necessary. The shape of the integral raised member could take many shapes depending on the tooling, rollers, presses, machinery and other factors, including flat or round tops, sharp or rounded edges, and flattened or rounded sides. They could have rounded chamfered corners with or without a flat top, they could have angled chamfered corners, they could be rectangular or square in shape.
The integral raised members could be either manufactured simultaneously with the sheets or could be shaped by removing material after manufacturing a sheet of extra thickness, to accommodate the finished thickness and integral raised member. Applications of the panels utilizing integral spacing structural elements would include roofing, flooring, and siding for residential and commercial construction.
The panels with integral matrices' could be manufactured out of Plywood, OSB, MDF or other similar material, including plastics.
The panels with integral matrices' could also have perforations as previously described. The perforations would ideally be round but could also be other shapes such as oblong, oval, square or rectangular or a combination of geometric shapes such as square with rounded corners.
A further embodiment utilizing integral spacing structural elements would utilize the first sheet utilizing spacing structural elements, and a second sheet without integral spacing structural elements. In this embodiment non-integral spacing structural elements can also be used to attach the second sheet to the integral spacing structural elements of the first sheet to the second sheet.
A still further embodiment utilizing integral spacing structural elements would utilize both the first and the second sheet, each with integral spacing structural elements, being connected to one another via non-integral spacing structural elements.
Yet another embodiment utilizing integral spacing structural elements involves manufacturing the panel such at that the location where the integral members of the first sheet contact the integral members of the second sheet, there is provided that at least one first integral member of the first sheet may enter into a recess of at least one second integral member of the second sheet. The recess in the at least one second integral member functioning as a notch for the at least one first integral member to be received into. The at least one first and at least one second integral member could also be adhesively and/or mechanically joined. Additionally the least one first integral member may also be provided with a recess in which the at least one second integral member may enter. It is envisioned that the notched recesses may be provided only on the integrated members of one sheet, could be provided on the integrated members on both sheets. The notches could be provided uniformly on every elongated member one or both sheets, or could be staggeredly provided at alternating locations and/or on alternating integrated members on one or both sheets. It is also envisioned that this notch/recess arrangement could similarly be employed with non-integrated member embodiments.
This notch like interface between members of multiple layers of members may also be utilized for panels including non-integral spacing structural elements, such as those discussed above.
It should be noted, that the edges of the sheets on any panels in this application may be shaped with tongues on two contiguous edges and corresponding groves on the remaining two contiguous edges for interlocking of multiple panels, and/or interlocked with the indented and overlapped spacing structural elements arrangement described in paragraphs above.
It should also be noted a number of different arrangements are contemplated in which spacing structural elements create unobstructed pathways for air to move through the panel, from at least one edge of the panel to at least one of an opposite and an adjacent edge of the panel. The height of the unobstructed pathways will normally be equal to the height of the members. The width of the pathways will normally be equal to the spacing between adjacent members of a common layer. The number of parallel unobstructed pathways created in the panel for air to move in any one direction will preferably range from between 1 and 30, more preferably between 2 and 25, even more preferably between 4 and 20, yet even more preferably between 5 and 19, and most preferably between 6 and 12. If the elongated members were spaced at approximately 16 inches on center, the pathways could be approximately 15 inches in width. Similarly, if the elongated members were spaced at approximately 24 inches on center, the pathways could be approximately 23 inches in width. In such a way it is achievable to have at least between two to three unobstructed pathways in a first direction, and between four and six unobstructed pathways in a second, preferably perpendicular direction, each measuring approximately ¾″ in height and 15″ to 23″ in width. It is also achievable to have at least between four and ten unobstructed pathways in a first direction, and between eight and twenty unobstructed pathways in a second, preferably perpendicular direction, each measuring approximately ¾″ in height and 4″ to 12″ in width.
It should also be noted that the spacing structural elements, and in particular the elongated members, can be formed in specialized shapes to convey additional qualities to the spacing structural elements, and thus the panels. Some specialized shapes include non-perforated and perforated I-beam, truss, skip truss, honeycomb, and corrugated shaped engineered matrix members.
It should further be noted that the invention will preferably be configured in one of the four ways following ways. First, a panel could be configured as a single sheet with a single layer of elongated members attached to the sheet, the elongated members arranged parallel with one another, and parallel with one axis of the panel and perpendicular to the other axis. That is, the elongate members could be arranged parallel to a long axis or a short axis of the sheet. In a second panel configuration, a single layer of members, as described in the first alternative, may be arranged between and connected to two sheets. Third, a panel could be configured as at least a double layer of elongate members attached to a single sheet, with each layer of elongate members arranged perpendicular to each adjacent layer of elongate members, at least one layer arranged parallel to one of a long or a short axis of the single sheet, and the elongate members being attached to one another where the multiple layers of elongate members intersect. Fourth, an at least double layer of elongate members, as described in the third alternative, may be arranged between and connected to two sheets.
To reiterate, the panels, and their constituent sheets and spacing structural elements, can be constructed or made from porous or non-porous wood, cellulose or other organic material, composite, ferrous, metallic, plastic, or any other material that can be shaped into a flat sheets and/or the spacing structural elements. The top and bottom sheets and the spacing structural elements can each be of different materials and thicknesses. The top sheet can be waterproof and the bottom sheet can be perforated to facilitate ventilation.
It should further also be noted that the panel typically has an empty volume of approximately 70%, but can range from 40% to 90%, or preferably from 50% to 80%, or more preferably from 65% to 75%, depending on sheet thickness and spacing structural element size, shape, and placement.
The panels may have a clear, unobstructed airflow of approximately 30% of the area of the end of any panel assembly, but can range from 10% to 60%, or preferably from 20% to 50%, or more preferably from 25% to 40%. With the use of special engineered matrix members, discussed in further detail below, the clear, unobstructed airflow can be up to around 75%, but can range from 65% to 85%, or more preferably from 70% to 80% of the end area of the panel assembly.
The clear unobstructed airflow on a panel with solid matrix members of a range from approximately 1/50 to 1/70 when comparing free, unobstructed end area with panel coverage. This depends on roof slope, matrix member size and spacing. Some building codes require ventilation of 1/300, and some codes are contemplating requiring or recommending ventilation of 1/150. The inventive panels could provide 6 to 12 times greater ventilation performance.
A further object of the present invention is to provide a multi-plenum structural panel comprising a top sheet, a middle sheet, and a bottom sheet, each sheet having a first horizontal edge and a second horizontal edge, and a first vertical edge and a second vertical edge, all three sheets being parallel in plane, and all three sheets having at least one of both vertical edges and both horizontal edges aligned along a same plane; a first plurality of spacing structural elements, fixedly attaching the top sheet to the middle sheet, and a second plurality of spacing structural elements fixedly attaching the middle sheet to the bottom sheet, such that the yield strength of the combined multi-plenum structural panel is greater than the combined individual yield strengths of the top, the middle, and the bottom sheets; an upper plenum defined by a spacing between the top or first sheet and the middle or second sheet; a lower plenum defined by a spacing between the middle or second sheet and the bottom or third sheet; the plurality of spacing structural elements being formed such that a plurality of unobstructed pathways are created in each plenum for air to move from at least one edge of the multi-plenum structural panel to at least one of an opposite and an adjacent edge of the multi-plenum structural panel.
A yet further object of the present invention is to provide a method of constructing a building including one or more multi-plenum structural panels comprising a top sheet, a middle sheet, and a bottom sheet, each sheet having a first horizontal edge and a second horizontal edge, and a first vertical edge and a second vertical edge, all three sheets being parallel in plane, and all three sheets having at least one of both vertical edges and both horizontal edges aligned along a same plane; a first plurality of spacing structural elements, fixedly attaching the top sheet to the middle sheet, and a second plurality of spacing structural elements fixedly attaching the middle sheet to the bottom sheet, such that the yield strength of the combined multi-plenum structural panel is greater than the combined individual yield strengths of the top, the middle, and the bottom sheets; an upper plenum defined by a spacing between the first sheet and the second sheet; a lower plenum defined by a spacing between the second sheet and the third sheet; the plurality of spacing structural elements being formed such that a plurality of unobstructed pathways are created in each plenum for air to move from at least one edge of the multi-plenum structural panel to at least one of an opposite and an adjacent edge of the multi-plenum structural panel, the method comprising the steps of supporting the mass of one of an interior and exterior wall with the multi-plenum structural panel; and connecting one of an air heater and an air conditioner in a fluid tight connection with the at least one of the upper and the lower plenums.
An additional embodiment of the ventilated structural panels can consist of a multi-layered or multi-plenum panel consisting of two plenums, constructed out of three sheets of material separated by spacing structural elements of preferably blocks. One plenum would supply treated, heated, cooled, humidified, dehumidified, or otherwise conditioned air while the other plenum would provide the return air to be conditioned. The original design of the multi-plenum panels provides at least two distinct and significant benefits—inexpensive multi-location air supply and return, and much greater strength and structural integrity for subflooring.
Floor sheathing in residential homes is usually a ⅝ or ¾ inch thick plywood or OSB panel supported on joists or engineered lumber joists which are usually spaced at 12 inches on center or 16 inches on center. By contrast, multi-plenum panels are much stronger than regular floor sheathing because its multi-layer design acts like a specialized “I” beam and can provide for long spans with better performance than standard sheathing.
The two cavities or plenums could allow for the distribution of conditioned air to the home or building. In the winter, warm air could be pushed into the upper plenum and tapped with vents in each room, as required, with a standard commercially available metal or plastic register placed into the upper plenum.
Return air would be tapped into the lower plenum by a special “plenum tap” system made of metal or plastic that penetrates the top and middle sheets and is fixed into the top and middle sheets with mechanical means and/or adhesives. The “plenum tap” is now ready to accept a standard, commercially available register.
The same procedure is used for providing cool air distribution, however, to prevent cold floors, the cool supply could be directed to the lower plenum while the return warmer air is directed through the upper plenum.
In one embodiment an extruded or deposited glob of uncured semi-liquid or foam substance is used as the spacing structural element. The glob would preferably be dispensed at various locations on the surface of the bottom or middle sheet, analogous to various placements of the spacing structural elements described above, but compositions with greater strength could be spaced farther apart.
The globs may be extruded alone, or may be used in conjunction with one or more inserts. The inserts can be shaped as spheres, boxes, rods, spikes, barricade shapes, barred, flanged, or spindle shaped, for example. The inserts can be three-dimensional shapes as in a sphere or a box, and can be hollow or solid. The inserts can have smooth outer surfaces, or can have protrusions lining their surface. The inserts serve multiple functions. First, they add structural integrity to the glob. Second, they can perform as spacers to prevent the two sheets on either side of the glob from pressing too close together. That is, they can mechanically define a minimum clearance between the two adjacent sheets. Also, protrusions or spikes on the surface of the inserts can aid in mechanical connection between two adjacent sheets to one another. The inserts can additionally be used without the globs, and function as the spacing structural elements themselves.
Though preferably 4×8 feet in measurement, as mentioned above, the sheets can be a variety of sizes. For example, larger sheets could be used and make larger panels in a first step, that could be cut down to 4×8 foot or 1×2 meter panels in a second step.
Depending on the different situations, the sheets used in the single or multi-plenum panels, that is the top, middle, or bottom sheets, could be made of be made of many and a variety of materials, including but not limited to: wood and wood fibrous materials; wood fiber panels; wood plywood panels; wood masonite material; plastic materials; fiberglass materials; carbon fiber materials, drywall, or some combination of thereof.
Composite sheets composed of a combination of materials could be made of fibers and some binding agent. Said fibers could be wood, cellulose, hemp and other plant materials such as cotton, man-made materials such as glass, plastics, metal, carbon, etc. The binding agent can be made of a variety of materials that have the qualities to bind fibers and cure with or without heat or other agents to a usable structural material with compressive and tensile strength capabilities.
The sheets can be layers of different materials. For example, the sheets can be composed of metal or have a metal layer. As another example, the bottom sheet can be drywall or a composite drywall panel where the bottom sheet is composed of the gypsum material placed on a wood or other substrate with tensile strength.
The sheets can be a variety of shapes depending on the use. For example, the sheets can be flat or corrugated or shaped for additional strength with geometric patterns. Also, for sheets of composite construction, corrugated materials can also be used to face the sheet.
The sheets can also have insulating properties beyond that of normal plywood or OSB sheets. The sheets can be made of insulating material, or be a composite sheet of an insulating material with one or more layers of surface materials (like metal or plastic) capable of providing the needed strength and performance. Additionally, any or all of the sheets may have a reflective radiant barrier applied to any surface to further aid in insulation.
To aid in microbial, rot, mold, mildew, and pest prevention, any or all sheets may have an anti-fungal, anti-mold, or other effective preventative treatment applied to any or all surfaces, including surfaces of spacing structural elements. Any wood sheet could be made of pressure treated lumber if condensation or an application against concrete is anticipated. Similarly, any or all sheets can have a painted or protective coating applied to any surface, depending on the need.
In one production embodiment, the single or multi plenum panels may be constructed with a 3D printing process, using a variety of available materials including fibrous compounds, plastics, carbon fiber, metal compounds, and other materials suitable for 3D printing applications. 3D printing can be utilized for the entire panel construction or for portions of the panels such as a sheet and the spacing structural elements, or any combination thereof.
The spacing structural elements can be made of a variety of materials and shapes and may include the following but not limited to: wood blocks in any shape and thickness; wood composite blocks in any shape and thickness; wood blocks cut from existing OSB and plywood products; solid plastic materials; adhesives of any type; foams, both closed and open cell; plastics, permeable materials including plastics and foams and adhesives; metal, and composites.
The spacing structural elements may be extruded, molded, cut, welded, pressed, glued, or punched, or otherwise formed.
The spacing structural elements may be spaced at various positions, in addition to those shown, as required for strength for various applications.
The spacing structural elements may be made of various shapes, including square, round, rectangular, triangular, elongate, tubular, truss like, honeycomb, corrugated shapes, and of various thicknesses. These include tubes of round, square or rectangular shapes, and hollow extrusions.
Where the shape of the spacing structural element has an orientation, like tubes, it can be oriented with the shape (e.g. tube) axis perpendicular to the sheet, or with the shape axis parallel to the sheet. For elongate spacing structural elements or sticks in a matrix, the matrix may be oriented perpendicular to each other. Spacing structural elements with openings may be arranged in a grid type matrix, with spacing structural elements perpendicular to one another, to allow air flow.
Further description will be provided with reference to the Figures below.
Below is a brief description of the drawings of the inventive panel, in which:
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These matching indents and overlaps aid in fittingly mating a first panel 2 to a neighboring second panel 2 in a secure “tongue in grove” fashion. By providing corresponding indent and overlap on all four edges, a surface formed of multiple panels may be assembled faster, have increased strength and rigidity as a unit, and helps ensure a continued smooth panel surface. As in the embodiment shown, the first distance 34 of indent and overlap with respect to the horizontal edges can be of the same value as the second distance 36 of indent and overlap in the horizontal direction. It is to be noted that the indent and overlap have been exaggerated in
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In a like manner a portion of the second protruding segments 37 that overlap the second vertical edges 28, 32 of the first and the second sheet 4, 6, have a chamfered edge 38 (not shown). These chamfered edges similarly facilitate inserting the second protruding segments 37 of the first 10 and the second layer 12 of a first panel 2 into a second adjacent panel 2, and specifically into the space provided by the inward indent of the elongated members 14 the second distance 36 from the first vertical edges 26, 30 of the first 10 and the second layer 12 of the adjacent panel. The chamfer on the chamfered edge 38 would terminate between ⅛″ and ⅜″ from the second vertical edges 28, 32 of the first and the second sheet 4, 6, and preferably would terminate approximately ¼″ from the second vertical edges 28, 32 of the first and the second sheet 4, 6.
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In a related embodiment, integrated elongated members 14A of a first and second sheet 4A, 6A could be arranged parallel such that, instead of nesting within respective spacing distances 16 in the posing sheets 4A, 6A, as shown in
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Additional embodiments of the elongated matrix members 14 are envisioned. In their simplest form, an elongated matrix member 14 is a stick or extrusion with a square or rectangular cross section and a length equal to a parallel axis of the sheet 4, 6 to which it is attached. The elongated matrix members 14 are ideally ¾″×¾″ in cross section, but, as mentioned above, can be larger (2″ or greater) or smaller (¼″ or smaller) as required for the application. The elongated matrix members 14 are preferably attached to at least one sheet 4, 6 and to one another where multiple layers of elongated matrix members 14 intersect, in order to transfer shear stresses, though the elongated matrix members 14 may have one or more locations where they intersect that they are not attached, in order to increase flexibility of the overall panel, as may be required in certain situations.
Additionally, engineered matrix members 120 can be utilized and manufactured from a variety of materials, like organic, wood, cellulose or other fibrous materials, plastics, metals or other materials that can be shaped or extruded, and can be formed into the square or rectangular cross sectional shapes discussed previously, or formed into one of many specialized shapes.
Specialized shaped engineered matrix members 120 will preferably have a first flat section 122 with a rectangular outer face, an opposed second flat section 124 with a rectangular outer face, and transverse section 126 connecting an inner face of the first flat section 122 to an inner face of the second flat section 124. The outer face of at least one of the first and the second flat section 122, 124 will preferably be attached to at least one of a sheet 4, 6 and an outer face of a first or a second flat section 122, 124 of an additional specialized shaped engineered matrix member 120 disposed in an adjacent layer. The range of shapes and structures of the specialized shaped engineered matrix members 120 will vary mainly based upon the design of the transverse section 126.
In a first embodiment of specialized shaped engineered matrix members 120, “I” beam shaped members 125 are formed by the first and second flat sections 122, 124 of engineered matrix members 120 being joined by a relatively thin and elongate transverse section 126. The thin elongate transverse section 126 and the inner faces of the first and the second flat sections 122, 124 define two narrow channels, one on each side of the thin elongate transverse section. These narrow channels act to increase the size of parallel, contiguous, unobstructed pathways 5 for air to pass between two adjacent “I” beam shaped members 125 of a common layer, as compared to similarly spaced elongated members 14 with a square or rectangular cross section.
Additionally, the thin elongate transverse sections 126 in the “I” beam shaped members 125 may be solid or perforated. The perforated “I” beam shaped members 125 offer the benefit of enhanced cross ventilation performance and increase the interior cabling options of the panels, as the perforations 128 provide additional pathways 129 for air and/or cables to pass through the panel 2, and through the very “I” beam shaped members 125. Either perforated or solid, the “I” beam shaped members 125 offer the benefit of being easily extruded and utilized in a panel 2.
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In a first embodiment of truss shaped members 130, the truss web 126 is comprised of a plurality of diagonal truss web supports 134 that form a continuous series of triangles down the length of the truss shaped member 130. That is, except for terminal ends of the truss shaped members, at each intersection of a diagonal truss web support 134 with the inner face of the first and the second flat sections 122, 124, another diagonal truss will also intersect the same inner face of the first and the second flat sections 122, 124 at an adjacent location. Such adjacent intersections form a triangulated parallel chord truss. The truss web supports 134 can be comprised of folded or formed material, and similar to the perforated “I” beam shaped members 125, the truss shaped members 130 to facilitate additional air flow and additional pathways for running cables and pipes through the panels 2, especially with the additional pathways diagonally and orthogonally through the specialized shaped engineered matrix members 120.
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The specialized shaped engineered matrix members 120 may be used in all situations as the rectangular shaped elongate members 14. The specialized shaped engineered matrix members 120 may be formed in a separate process and later attached to the sheets 4, 6, or, similar to the integrated elongated members 14A, the specialized shaped engineered matrix members 120 may be formed, in whole or part, together with the sheets 4A, 6A. Panels 2 may be constructed out of all non-engineered spacing structural elements 8, all engineered matrix members 120, or some combination of each.
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The multi-plenum panel 202 is preferably composed of three sheets of plywood or OSB preferably in the standard size of 4×8 foot sheets. The sheets are nominally ¼ inch thickness. The sheets are spaced from, and joined to one another by blocks 210, preferably made of standard framing lumber of 2×4 inch nominal size (3.5 inch×3.5 inch×1⅝ inch), because of the high strength to weight ratio of wood, combined with its relative high availability and low cost. The blocks 210 are preferably spaced 7 inches on center each way. The blocks 210 are fastened with adhesive and/or mechanical means to enable the essential shear transfer to the middle sheet 206. The blocks 210 of the lower plenum 214 are preferably vertically aligned with the blocks 210 of the upper plenum 212, to allow for better transfer of stress. The size and spacing of the blocks 210 may be changed, but should ideally provide for at least three unobstructed air pathways 216 per every 24 liner inches along the edge of the multi-plenum panels 202 in each plenum. That is, both three pathways 216 in the upper plenum 212 and three pathways 216 in the lower plenum 214 per every 24 liner inches of the multi-plenum panel 202. Additionally, as shown in
The multi-plenum panel 202 allows for large spans for flooring applications of 48 inches with minimal deflection even when using ¼ inch sheets 204, 206, 208. Ideally, the top sheet 204 may be thicker (⅜ inch or ½ inch). The structural mechanism is that the middle sheet 206 facilitates the necessary shear transfer for the multi-plenum panel 202 to act as an “I” beam with significant strength and stiffness.
Ideally, the blocks 210 are a 1⅝ inch thick, which is the common thickness of finished structural lumber typically used in the building trades; however, the thickness could be larger or smaller depending on span requirements and air distribution requirements.
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Where two adjacent multi-plenum panels 202 are joined, a maximum unobstructed flow of air between the respective plenums of the adjacent multi-plenum panels 202 is desired—taking into account structural support requirements. Therefore, a perforated strip may be used on all edges, to both increase bearing strength, but still allow for panel to panel flow of air. Alternatively, blocks 210 may be arranged flush with the edges, or additional blocks 210 or larger blocks 210 may be used to reach the edges of the sheets, to aid in bearing strength, while still maintaining air pathways 216. Additionally, the blocks may extend beyond the edges of one or more sheets 204, 206, 208, on one or more edges of the multi-plenum panels 202, and on a corresponding opposite edge of the one or more sheets 204, 206, 208, the blocks can be recessed from the edge by a similar amount. This will allow the blocks from a first multi-plenum panel 202 to matingly fit in a recess space in the plenum of an adjacent second multi-plenum panel 202 to which the first multi-plenum panel 202 is to be joined. Additionally, or alternatively, the blocks may be convexly chamfered on one edge of the multi-plenum panel 202, and the blocks may be concavely indented along an opposing edge of the panel 202—either the convexly chamfered or the concavely indented blocks or both may extend beyond the edge of the sheets 204, 206, 208, and fittingly mate with one another when two multi-plenum panels 202 are abutted side by side with one another, parallel in plane.
The multi-plenum panels 202 would be installed like regular sheathing using a combination of adhesive along the joists 228 and preferably screws through a series of blocks 210 into the joist 228. But as discussed above, because of the dramatically increased strength of the multi-plenum panels 202 verses regular floor sheathing, the joists 228 may be spaced at much greater distances from one another, including 48 inches on center, or farther.
The locations of the blocks 210 would be marked or otherwise shown on the exterior of the top and the bottom sheets 204, 208 to facilitate register 220 placement and plenum taps 218, and otherwise aid in installation of the multi-plenum panels 202.
The multi-plenum panels 202 will preferably include necessary plenum taps 218 in dimensions suitable for commercially available duct covers or registers 220 which are typically in size of 2×10, 2×12, 4×10, 4×12, 4×16, and other sizes.
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The plenum taps 218 should be installed with caulk under all flanges and with screws. Plenum taps 218 can be constructed from either sheet metal or plastic.
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This multi-plenum panel flooring/air supply system would provide many advantages. For example, the multi-plenum panels 202 allow air distribution with substantially less or no ductwork. This leads to shorter construction time, cost savings, and decreased space requirements. The cost of ductwork for an average sized house can easily be $6,000 to $10,000, depending on complexity and design. If the savings are assumed to be $7,000 on an average house this would equate to a savings value potential of $86.15 per multi-plenum panel 202 used for flooring.
Also, the multi-plenum panels 202 easily allow air distribution to any location in any room. The multi-plenum panel 202 allows air distribution to smaller spaces that conventionally are not supplied conditioned air due to the cost relative to room size such as small bathrooms, laundry rooms, walk-in closets, pantries, small dens/studies. Because of the cost effectiveness, the multi-plenum panel 202 can inexpensively deliver conditioned air to and provide a cold/hot air return from every room, including closets. This is something only very elaborate and expensive systems now provide, because of the high costs providing a complete dual duct system involve.
As an additional benefit, if the upper plenum 212 is used to deliver heated air in the winter, the warmed upper plenum 212 can radiantly create and provide a warm floor to every room on a given level. This is a very desirable feature normally only available by using an expensive liquid radiant heating system.
The same procedure is used for providing cool air distribution in the summer. However, to prevent cold floors, if they are undesired, the cool supply could be directed to the lower plenum 214 while the return warmer air to the upper plenum 212.
If the two plenums are un-insulated between one another, the return air traveling through the return air plenum may be tempered, that is, heated or cooled, by the supply air in the supply air plenum. This offers the benefits of a built in air exchanger recapturing heat loss or cooling losses.
Testing shows deflections in the range of 1/200 for a 150 pound per square foot load having a 48 inch span. For a load more typical of residential design, the multi-plenum panel 202 would expect a deflection of 1/600 for a 48 inch span—greatly exceeding typical design criteria and expanding design building possibilities.
Using a 48 inch span for flooring would reduce the number of joists 228 required for the flooring by two thirds, saving significant material and labor costs. These savings could be around $3,000 for a typical house. Additionally, the electrical, mechanical, and plumbing trades would also benefit from having two thirds less obstacles (joists 228) to run their various wires, ducts and pipes. Again, savings could be significant to these trades, and could be around $2,000 for a typical house. Thus, there are significant savings in time, labor, and money that are associated with utilizing a multi-plenum panel 202 for combined flooring and air supply. Savings of around $12,000 for a typical house are envisioned, equating to a $127 savings per multi-plenum panel 202, for the 94 multi-plenum panels 202 in such a house.
The multi-plenum panels 202 can provide for the distribution of air through the ceiling of a lower level 234 (e.g., first story) and the floor of an upper space (e.g., second story), to the air of an upper level 236. This means one multi-plenum panel 202 directly connected to a central heating and/or cooling unit 238 can supply and return air to two stories or levels at once. For such a design, flooring multi-plenum panels 202 used to support a second story 236 would use longer plenum taps 218 to access air distribution from a first story 234 for the second story 236. That is, to reach and be flush with the first story ceiling, directly below the second story flooring multi-plenum panels 202, longer plenum taps 218 would be required to accommodate the inter-story joist 228 thickness. Such first story 234 to second story 236 plenum taps 218 would allow direct condition air supplied multi-plenum panels 202 under the first story 234 to supply conditioned and return air a two story building.
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In a further example of an air distribution system using multi-plenum panels 202, as shown in
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By transitioning between the trunks 242, 244 and the plenums 212, 214 via the plurality of smaller openings (mating holes 246), the structural integrity of sheets 208, 206 and the multi-plenum panel 202 as a whole are better maintained. Additionally, by shaping the openings 246 as circles, the openings 246 avoid high stress/lower strength corners of regular polygon shapes. The supply and return trunks 242, 244 may both be connected to the same multi-plenum panel 202, but preferably are connected to separate multi-plenum panels 202, to better dissipate the structural weakness caused by forming the mating holes 246 in the sheets.
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With each connection, an impervious and/or airtight adhesive tape can be applied to joined edges to ensure air tightness. Further, an impervious and/or adhesive tape can be applied to the entire edge wrapping into the multi-plenum panel 202 at the top and bottom to ensure all the edges are airtight.
A floor multi-plenum panel 202 prototype was tested with the following results. Three separate ¼ inch thick 2×4 foot CDX plywood sheets were used for the top, the middle and the bottom sheets 204, 206, 208 of the multi-plenum panels 202. The matrix used to join the bottom and the middle sheet 208, 206 and the middle and the top sheet 206, 204 respectively were 3½ inch by 3½ inch Pine/Spruce blocks 210, with approximately 3½ inch spacing between the blocks 210. That is, three blocks 210 were spaced evenly in 24 inches, and six blocks 210 were spaced evenly in 48 inches. As a result of the bock 210 size and spacing, there was nine square inches of unobstructed free vent area per linear foot. The blocks 210 were attached to the sheets 204, 206, 208 using an interior wood glue type of adhesive—specifically a polyvinyl acetate glue.
The multi-plenum panel 202 was loaded with 1,200 lbs. spaced uniformly across the multi-plenum panel 202 creating a pressure of 150 pounds per square foot. The weighted multi-plenum panel 202 was supported along the short two foot edges creating a 48 inch simple span, with 44 inches clear between the supports. The multi-plenum panel 202 had a maximum deflection of 0.250 inches, an “LI” of 192 and an area moment of inertia, Ix, in4 per foot, equal to 20.00.
A control panel was used for comparison. The control panel was a single ½ inch sheet of plywood measuring two feet by four feet. The control panel was loaded with 600 lbs. spaced uniformly across the sheet, creating a pressure of 75 pounds per square foot. The control panel was similarly supported along its shorter two foot edge, creating a 48 inch simple span, with 44 inches clear between the supports. The control panel displayed over an inch of deflection, with only half the load of the floor panel. In more detail, the control panel had a maximum deflection of 01.10 inches, an “LI” of 44 and an area moment of inertia, Ix, in4 per foot, equal to 0.016.
Thus, the multi-plenum panel 202 demonstrated a bending strength of 9 times greater than the equivalent thickness of plywood alone. The multi-plenum panel 202 demonstrated a significant strength at a 48 inch spacing and would be serviceable for residential and commercial uses at this span with only ¼ inch sheets 204, 206, 208. These results were a better than predicted strength, despite using an inferior polyvinyl acetate adhesive instead of using a preferable thermoset phenol-formaldehyde adhesive between the blocks 210 and the sheets 204, 206, 208.
Alternate embodiments of the multi-plenum panel are envisioned. The invention consists of three sheets 204, 206, 208 of the same size and assembled in parallel planes separated ideally by blocks 210 of wood in a square shape, but the blocks 210 could also be rectangular, round or the sheets 204, 206, 208 could also be separated by a matrix of elongated wood members, or an extruded or engineered matrix, in a stacked perpendicular matrix or otherwise arranged as described in the above embodiments of the ventilated structural panels 2, 2′, 2A. The interior could also be an arrangement of plastic or metal extruded or formed members as described above. Additionally, a single plenum panel embodiment, with two sheets connected by a plurality of spacing structural elements, as described above, may be connected in an air tight manner to a central heater and air conditioner 238 to one of deliver conditioned air to or receive return air from an entire level of a building, or some part thereof.
The sheets 204, 206, 208 can be of various thicknesses. The top sheet 204 could be ¼ inch to ½ inch to even ⅝ inch, ¾ inch or 1 inch to accommodate floor covering and structural needs. The middle sheet 206 only needs to be ¼ inch in thickness to accomplish the structural needs of a 48 inch span. The bottom sheet 208 also needs to only be ¼ inch thick to accomplish the structural needs for a 48 inch span, but each sheet 204, 206, 208 may have the various thickness options listed for of the top sheet 204, as the specific designs may require. Also, the sheets 204, 206, 208 can be of different thicknesses to accommodate different needs. The sheets 204, 206, 208 are ideally 4′×8′ sheets, as this size is typically used in the building trade, but the sheets 204, 206, 208 can be sized larger or smaller.
The sheets 204, 206, 208 are ideally constructed of plywood or OSB, but could also be of a plastic, vinyl, metal or other man made or natural material.
The sheets 204, 206, 208 may be treated with an antibacterial agent or even with a waterproofing to prevent the formation of mold should the multi-plenum panels 202 be used for cooling and where condensation is a risk due to cool supply air and high humidity environments. Additionally, the interior of the multi-plenum panels 202 could be entirely coated with a waterproofing covering.
The multi-plenum panels 202 and blocks 210 could also be constructed out of pressure treated lumber and plywood to inhibit any decay or possible mold. An alternative solution is to provide supply air at a temperature where condensation is not in the probable range of the design. Alternatively, if condensation is possible, then the system could be programmed to air dry the plenums 212, 214 sufficiently after achieving desired room ambient temperatures.
Additionally, the sheets 204, 206, 208 could be coated to prevent condensation absorption if it occurs, and could be insulated with a “blanket” of thin reflective insulation on the inside and/or outside faces of each sheet 204, 206, 208.
Turning now to
Turning to
The anticipated process utilizing the globs 258 is to deposit the required amounts of semi-solid/semi-liquid material in a predetermined pattern, as required for structural needs, on the bottom sheet 6, 208 of the panel 2, 202. The top sheet 4, 204 (or middle sheet 206 for a multi-plenum panel 202) is then laid on the bottom sheet 208 and compressed to the desired thickness causing some lateral expansion in the globs 258, such that they attain a circular shape of preferably between 2″ to 8″, as required for structural needs. The quantity of material in each glob 258 is preferably between 1.5 cubic in. and 50 cubic in., not including consideration of the displacement of volume from any imbedded insert 260 (see
As shown in
The glob 258 material is semi-liquid/semi-solid adhesive or foam or similar material. The glob 258 may have a flat-bottomed teardrop or “Hershey's kiss” shape after being deposited and before compression. The glob 258 material preferably has a viscosity and quantity such that when the sheets 204, 206, 208 are pressed together the resulting thickness of the assembly is of the desired panel 2, 202 thickness. Spacers 262 and/or inserts 260, described below, may be used to insure proper spacing when the sheets 204, 206, 208 are pressed together. Spacers 262 can be placed around the perimeter and interior between the adhesive deposits to insure the desired thickness when pressed. The spacers 262 can be permanently attached to one or both sheets 204, 206, 208 or just be temporarily placed, to be later removed. The spacers 262 can be positioned on the sheets 204, 206, 208 before, during, or after the globs are deposited.
The spacers 262 can consist of pressed metal shapes that penetrate one sheet 204, 206, 208 when pressed, and/or could have one or more protrusions or spikes 264 that penetrates the adjacent sheet 204, 206, 208 when the other sheet 204, 206, 208 is pressed into the panel 2, 202 assembly (see
Referring to
The inserts 260 may be either hollow or solid depending on weight, cost, and the material requirement. Though only a single large sphere is shown in
The inserts 260 may have a continuous surface, as shown in
The inserts 260 may have a smooth surface, as shown in
In another, and likely a preferable embodiment, the inserts 260 would have a surface that included spikes 264, barbs, or other such projections. The spikes 264 would aid in the glob 258 bonding to the insert 260, allowing the glob 258 material to envelop the spikes 264, and would provide a means for mechanical adhesion of the insert 260 to the adjacent sheets 204, 206, 208. The spikes 264 would need to be of a quantity, thickness, length, and with a sufficiently sharp apex and/or edge, that the spike 264 would perforate but not damage the adjacent sheets 204, 206, 208. The spikes 264 would preferably protrude or extend from the surface of the insert 260 a length less that the thickness of the adjacent sheets 204, 206, 208, so that the spike 264 would not fully pierce through the sheets 204, 206, 208, from one surface to the other. The spikes 264 could be uncoated, or could be coated with a cement, vinyl, or resin coating that melts with the heat generated from the friction during insertion, but that solidifies when cooled. The coating would provide extra adhesion between the spike 264 and the sheets 204, 206, 208.
There are a variety of shapes that the inserts 260 may take, depending on if used with glob 258 material or not, and other panel 2, 202 requirements, like strength, air flow, and weight. The inserts 260 may be shaped as spheres or spheroids, cylinders, pyramids, rectangular or triangular prisms or other polyhedrons. The inserts 260 may have one or more bores or passageways extending partially or fully through the shape to allow passage of air or glob 258 material.
The inserts 260 may also be shaped, as shown in
The inserts 260 may also have an elongate mid-section 268 that extends and spaces top and bottom portions 270, 272 of the insert 260 from each other. One embodiment, shown in
The inserts 260 may also extend completely through one or more of the sheets 204, 206, 208. See, for example,
The rods 276 may be smooth sided, the least expensive and easiest embodiment to manufacture. Alternatively or additionally, the rods 276 may have vertical ridges around the axis of the rod 276, have horizontal ribs or rings up the length of the rod 276, have a helical ridge twisting up the length of the rod 276, and/or have a textured surface 276.
The through inserts 260 like the rod 276 can be forced, screwed, or punched through the sheet 206 after the sheet 206 is formed.
In another embodiment, the sheet 206 may be formed or molded around the through insert 260, whereby the through insert 260 is integrated into the sheet 206 when the sheet 206 is formed. For example,
The molded through or integrated insert 260 may also have a cage or perforated surface. For example, a cylinder with a cage surface could be integrated into the middle sheet 206 when the sheet 206 is formed. In such an embodiment, the cylinder shaped through insert 260 would project out of the top and bottom of the middle sheet 206. The cylinder shaped through insert 260 could then easily encase and integrate with a glob 258 deposited on the bottom sheet 208 and on the top side of the middle sheet 206 in one simple step.
In another embodiment of a through insert 260, as shown in
Referring next to
The spacing structural elements 8 that are to be placed within the defined spaces 290 can be wood blocks 210, plastic blocks 210, permeable material or organic, inorganic material or plastics or composite material of a combination of organic and/or inorganic material such as a wood fibrous material in a resin or adhesive or steamed wood material and adhesive, or glob 258 material.
The orthogonal frame can have spikes 264 that are designed to be embedded in the adjacent sheets 204, 206, 208 when pressed in the panel 2, 202 production. The upper or lower terminal edge of the spikes 264 may be flat, rounded, smooth, sharp, or barbed, depending on the mechanical adhesion requirements.
The spacing structural elements 8, whether a solid or semi-solid adhesive or foam, will preferably have adhesive applied or have adhesive characteristics such that the spacing structural elements 8 will preferably bond to adjacent sheets 204, 206, 208 and transfer structural stress from one sheet 204, 206, 208 to the other.
As shown in
It is to be noted that if the orthogonal frame 280 was of sufficient strength, it could, by itself, function as the spacing structural element 8 connecting the two adjacent sheets 204, 206, 208 to one another without requiring the addition of a separate block 210 or glob 258 in the defined space 290. Such an embodiment would preferably include a plurality of diagonal truss members 292, described further below.
While in one embodiment of the orthogonal frame 280, a block 210 or glob 258 is intended to be placed into the defined space 290, according to another embodiment, as shown in
The lateral straps 292 between the spacing structural elements 8 in this embodiment can be of the same material or a different material as the spacing structural elements 8. The lateral straps 292 can be manufactured integrally or bonded/attached to construct the orthogonal frame 280. The spacing structural element 8 blocks 210 in this embodiment are preferably a dimension of between 2″×2″ to 8″×8″ with a height of between ½″ to 4″. The spacing structural elements 8 may also be rectangular shaped with the same dimensional constraints. The spacing structural elements 8 are most desirably spaced from 2″ to 12″ between each other.
The three dimensional frame/block assembly would preferably be covered with adhesive on the top and bottom and attached to the two adjacent sheets 204, 206, 208—one on the bottom and one on the top and the adhesive cured. The adhesive would be compatible with the materials bonded and of sufficient quantity for structural stress transfer.
In a production method utilizing a related design,
This method provides for the separate lateral grids 284, 286 to be used, preferably without the vertical straps 288 as a net 294. The lateral grids 284, 286 in this embodiment are preferably of a plastic material with a spacing of ¼″ to 1″ and a thickness of between 12 gauge to 40 gauge. The separate lateral straps 292 are connected in a continuous grid that is utilized to place the spacing structural elements 8 between the two layers of grid material 284, 286. Adhesive is either applied to the grids 284, 286 during its manufacture and is inherently connected to all fibers, or adhesive is applied before placing the spacing structural elements 8, or adhesive is applied to the spacing structural elements 8, or some combination thereof. Regardless of the manner of adhesive, the spacing structural elements 8 are now connected in a manner of spacing from one another as previously described above to the upper and lower grids 284, 286, so that the spacing structural elements 8 relative spacing from one another is fixed. Then net 294 of spacing structural elements 8 can be maneuvered or moved down an assembly line where two sheets 204, 206, 208 are then adhered to the spacing structural elements 8 with adhesive and or mechanical means. For example, spikes 264 may be used as above also to mechanically connect the upper or lower grids 284, 286 to the respective adjacent sheet 204, 206, 208.
As shown in
The spacing structural elements 8 in this embodiment are preferably between 2″×2″ and 8″×8″ in width, and preferably ½″ to 4″ in height, and may be, for example, square or rectangular shaped. The matts 296 would be constructed to match the dimensions of the spacing structural elements 8. The tabs 298 would be of a size and spacing that would meet the structural stress transfer requirements without compromising the integrity of the belt 300. The belt 300 could be ⅛″ to 1″ wide.
Tuning next to
Turning now to
The dimensions of the truss matrix 308 can vary, but are preferably between 2″ and 12″ in lateral spacing between adjacent lateral wires 282 or straps 292 running in a parallel direction in the upper of lower grid 284, 286, with the height preferably between 1″ to 6″. The grid of the truss matrix 308 does not have to be square, but could be, for example, be rectangular too.
The orthogonal frame and/or the truss members can be made out of metal, wire, plastics, carbon fiber, fiberglass, and other suitable materials. It is probable that this may be the preferred embodiment used to attach two adjacent sheets 204, 206, 208 to each other in either the single or multi plenum panels 2, 202. This embodiment offers the advantages of ease of production and assembly, low expense, potentially no organic material exposed to the plenums, and potentially no curing times for adhesives.
In one embodiment, as shown in
Turning next to
The members 120 can be constructed of plastics, composites, carbon fiber, fiberglass, metal and can be extruded or formed and fused together into the desired shape. The ends of members 120 can incorporate the interlocking mechanism shapes shown in
The matrix members 120 could have a height of ½″ to 4″ and the width of the members could be from ¼″ to 4″ wide. The spacing of members could be from 2″ to 10″ and could be square or rectangular.
In a further embodiment, shown in
Additionally, the presses could be designed such that a single sheet 206 could be molded so that the spacing structural elements 8 extend both upwards and downwards from the same middle sheet 206.
In a variation of this embodiment, as shown in
Turning now to
Turning now to
Similarly, the matrix for the single plenum panel 2 can be assembled from a matrix of spacing structural elements 8 consisting of hollow tubing 322 made from metal, plastic, fiberglass, composites, or other materials in an extruded or fused or assembled form. The tubing 322 matrix members would adhere to each other and to the two sheets 4, 6 to construct the panel 2. The tubes 322 could also be perforated with holes to enhance air flow. The strips 320 or tubing 322 form of spacing structural elements 8 could also be used for multi-plenum panels 202, but would potentially decrease absolute unobstructed orthogonal flow paths, instead allowing sinusoidal flow paths in both lateral directions—over and under the elongate spacing structural elements 8 attached to the lower 208, 206 and upper 206, 204 sheet respectively.
Claims
1-20. (canceled)
21. A ventilated panel fastener comprising one of a toothed screw, a double-head screw, and a coupling block.
22. The ventilated panel fastener of claim 21 wherein the fastener is a toothed screw.
23. The ventilated panel fastener of claim 22 wherein the toothed screw further comprises a enlarged flat head with cutting teeth fixedly attached to and extending downward from the head parallel to and in a same direction as a shank.
24. The ventilated panel fastener of claim 23 wherein the cutting teeth attach to an outer perimeter of the flat head.
25. The ventilated panel fastener of claim 23 wherein the cutting teeth are between 2 and 16 in number
26. The ventilated panel fastener of claim 23 wherein the cutting teeth are between 2 to 4 in number
27. The ventilated panel fastener of claim 23 wherein the cutting teeth extend a length equal to a thickness of sheet of ventilated panel to be fastened.
28. The ventilated panel fastener of claim 23 wherein the cutting teeth extend a length equal to a thickness of two sheets of a ventilated panel to be fastened
29. The ventilated panel fastener of claim 21 wherein the fastener is double head screw.
30. The ventilated panel fastener of claim 29 wherein the double-head screw has a larger diameter top head at a terminal end of the double head screw and has an smaller diameter intermediate head spaced at a distance from the top head 14
31. The ventilated panel fastener of claim 30 wherein the intermediate head having a twisted bit base.
32. The ventilated panel fastener of claim 21 wherein the fastener is a coupling block.
33. The ventilated panel fastener of claim 32 wherein the coupling block has a has a raised center guide to aid in centering the coupling block, with respect to length, so equal lengths of the coupling block is in adjacent panels, when securing the coupling block in respective panels.
34. The ventilated panel fastener of claim 32 wherein the coupling block has a plurality of raised protrusions disposed on an exterior surface.
35. The ventilated panel fastener of claim 32 wherein the coupling block has a plurality of cleats disposed on an exterior surface.
36. A method of fastening a ventilated panel to one of another ventilated panel and a supporting structure comprising:
- inserting one of a toothed screw, a double-head screw, and a coupling block into both the ventilated panel and the one of another ventilated panel and supporting structure.
37. The method of claim 36 wherein the toothed screw is inserted into both the ventilated panel and the supporting structure.
38. The method of claim 36 wherein the double-head screw is inserted into both the ventilated panel and the supporting structure.
39. The method of claim 36 wherein the coupling block is inserted into both the ventilated panel and the another ventilated panel.
40. The method of claim 36 wherein the coupling block has one of cleats and raised protrusions disposed on an exterior surface of the coupling block.
Type: Application
Filed: Oct 27, 2017
Publication Date: May 10, 2018
Inventor: James WALKER (Franconia, NH)
Application Number: 15/795,306
