US20050188640A1 - Quick frame construction system and method - Google Patents

Abstract

A structural wall system including a plurality of structural members, a plurality of preformed connecting elements and a skin positioned thereover. The plurality of structural members include a first structural member having a first receiving channel and a second structural member having a second receiving channel. The plurality of preformed connecting elements include a connecting element positioned in the first receiving channel and in the second receiving channel. The skin is positioned over a side of the plurality of structural members and the connecting element.

Description

CROSS REFERENCE TO RELATED APPLICATIONS
• This is a non-provisional application based upon U.S. provisional patent application Ser. No. 60/548,060, entitled “QUICK FRAME CONSTRUCTION METHOD”, filed Feb. 26, 2004.
BACKGROUND OF THE INVENTION
• 1. Field of the Invention
• The present invention relates to a method of wall construction, and, more particularly, to a method of joining structural members in a wall.
• 2. Description of the Related Art
• Construction of frames and walls are often undertaken utilizing a jig for the placement of metal members, which are then subsequently welded together to form the structural frame or wall unit. Welding is a technique requiring a high skill level in order to yield high quality welds for a structural unit. The high skill level equates to a high level of pay for individuals who are employed as welders. The heat from welding can sometimes cause a warping in the frame even though it is laid out at a jig.
• In the recreational vehicle industry, long structural walls are utilized for the exterior framing of the recreational vehicle. The exterior of the vehicle includes a skin which is connected to the frame with adhesive and/or fasteners. The recreational vehicle industry is highly competitive and requires adaptive methods to produce new models each year.
• What is needed in the art is an adaptive, cost effective method for constructing wall systems.
SUMMARY OF THE INVENTION
• The present invention provides a frame construction method that requires only a low skill level for implementation.
• The invention comprises, in one form thereof, a structural wall system including a structural wall system including a plurality of structural members, a plurality of preformed connecting elements and a skin positioned thereover. The plurality of structural members include a first structural member having a first receiving channel and a second structural member having a second receiving channel. The plurality of preformed connecting elements including a first connecting element positioned in the first receiving channel and in the second receiving channel. The skin is positioned over a side of the plurality of structural members and the first connecting element.
• An advantage of the present invention is that the structural members may be positioned and connected with a low skill level worker.
• Another advantage of the present invention is that welding is not required for the connection of the structural members.
• Yet another advantage is that the structural system of the present invention does not require a cool down from a welding operation before the application of the skin thereover.
• Still another advantage of the present invention is that it is very cost effective as compared to convention construction methods.
BRIEF DESCRIPTION OF THE DRAWINGS
• The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
• FIG. 1 illustrates a side view of an embodiment of the structural wall system of the present invention;
• FIG. 2 is a perspective view of the detail of one of the joints of the system ofFIG. 1;
• FIG. 3 is a perspective view of the wall system ofFIGS. 1 and 2 additionally showing a laminate applied thereover;
• FIG. 4 is an enhanced perspective view of a structural element of the wall system ofFIGS. 1-3;
• FIG. 5 is a perspective view of a connecting element of the wall system ofFIGS. 1-4; and
• FIG. 6 is a cross-sectional view of the wall system ofFIGS. 1-4.
• Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
• Referring now to the drawings, and more particularly toFIGS. 1-3, there is shown astructural wall assembly10 includingstructural members12,gussets14 and askin layer16.Wall assembly10 can be any structural construct even though here illustrated as a side panel for a recreational vehicle.Structural members12 are positioned on a jig (not shown) andgussets14 are installed utilizing a hammer to completelyseat gussets14, thereby connectinggussets14 tostructural members12.Gussets14 are applied to at least one side of each intersection ofstructural members12. When an intersection of a structural member with another structural member is utilized to enclose an opening for a window, door or an access opening,gussets14 may be omitted on one side of the intersection ofstructural members12. Even thoughstructural members12 may additionally be held in place with a welding operation, significant strength ofwall assembly10 comes from the unitizing of the assembly by way of the adherence ofskin16 over a surface ofstructural members12 andgussets14.
• Now, additionally referring toFIG. 4,structural members12 may be an extrusion having a hollow core.Structural members12 each includechannels18 each having afirst wall20 and asecond wall22.First wall20 includes at least oneprotrusion24 along the length thereof. Additionally,first wall20 is shorter thansecond wall22, and does not extend to the level of the surface ofstructural member12, in order to accommodate the thickness ofgussets14. Gussets14 are installed against a end ofwall20, the outer side ofgusset14 being substantially coplanar with a surface ofstructural members12. This advantageously provides for a flat surface for the lamination ofskin16 over bothstructural members12 andgussets14.Protrusions24, although only shown onfirst wall20 may also be positioned onsecond wall22.Protrusions24 interact with a feature ofgusset14 to enhance the retaining ofgusset14 inchannels18.
• Now, additionally referring toFIG. 5, agusset14 is illustrated including anangular portion26, a firstengaging portion28 and a secondengaging portion30 all shown in a perspective view.Angular portion26 provides structural strength towall assembly10 whengusset14, also known as connectingelement14, is assembled withstructural members12. As can be seen inFIG. 2, firstengaging portion28 interacts with achannel18 of onestructural member12 and secondengaging portion30 interacts with anotherchannel18 of anotherstructural member12.
• Connectingelement14 additionally includes anedge enhancement32 along an edge of both firstengaging portion28 and secondengaging portion30.Edge enhancement32 may be simply a bending of the edge to effectively increase the cross section, which interacts withchannel18 andprotrusions24 therein. Additionally,edge enhancement32 may be a thickened portion of material positioned along an edge ofgusset14.
• Now, additionally referring toFIG. 6, during the assembly ofwall assembly10,structural members12 are precut and positioned on a fixture (not shown). Wherestructural members12 intersect,gussets14 are positioned withengaging portions28 and30 positioned to enterchannels18 of adjacentstructural members12. A hammering operation, utilizing a mallet (not shown), seats gusset14 inchannels18 thereby connectingstructural members12 together. The thickness of the material used in forminggusset14 may be the same width aschannel18 or somewhat thinner.Edge enhancement32 interacts withprotrusions24 to retaingusset14 inchannels18. Advantageously, the skill level of theindividual applying gussets14 tostructural members12 is only that of a semi-skilled worker rather than a skilled worker such as a welder.
• Askin16 is laminated over the assembly ofstructural members12 andgussets14 utilizing an adhesive and/or mechanical fasteners.Skin16 may be a plastic, a composite material, a thin metal and/or a combination thereof The lamination ofskin16 provides structural integrity ofstructural members12 along withgussets14 to thereby unitizewall assembly10. While this method is described and illustrated for one side ofstructural members12, the method also applies equally to an opposite side ofstructural members12.
• Although the structural method has been illustrated in the use of substantially perpendicular intersections betweenstructural members12, any angle of interaction accompanied by a gusset of a corresponding angle can likewise be utilized inwall assembly10. Additionally, even though illustrated in a planar sense,structural members12 can have three-dimensional variations with appropriate gussets applied thereto.
• Advantageously, no special tools are required for assembly and no specially trained workforce is needed for producing the assembly. This advantageously allows for a start-up manufacturer to make framing with very little investment in tools. Once the joint betweengusset14 andstructural members12 is made,shorter wall20 allowsgusset14 to be substantially coplanar with a surface ofstructural members12. This allows for easy lamination of the assembly ofmembers12 andgussets14. Additionally, an insulation or filler may be placed betweenstructural members12, which can likewise be adhered or laminated toskin layer16.
• While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.

Claims (20)

1. A structural wall system, comprising:

a plurality of structural members including a first structural member having a first receiving channel and a second structural member having a second receiving channel;

a plurality of preformed connecting elements, at least one of said connecting elements being positioned in said first receiving channel and said second receiving channel, and

a skin positioned over a side of said plurality of structural members and a side of said connecting element.

2. The system ofclaim 1, wherein said first receiving channel and said second receiving channel each include a first wall and a shorter second wall, said second wall being substantially parallel with said first wall.

3. The system ofclaim 2, wherein said receiving channel includes at least one protrusion along a side of at least one of said first wall and said second wall.

4. The system ofclaim 3, wherein said connecting element includes a plurality of engaging portions including a first engaging portion and a second engaging portion, said first engaging portion being inserted into said first receiving channel and said second engaging portion being inserted into said second receiving channel.

5. The system ofclaim 4, wherein said plurality of engaging portions each include an edge enhancement that coacts with said at least one protrusion to cause said connecting element to be retained in said first receiving channel and said second receiving channel.

6. The system ofclaim 5, wherein said edge enhancement is at least one of a bent edge and a thickened portion.

7. The system ofclaim 1, comprising an other skin positioned on an other side of said plurality of structural members and at least a portion of said plurality of connecting members.

8. A construction joint, comprising:

a plurality of structural members proximate to each other including a first structural member having a first receiving channel and a second structural member having a second receiving channel; and

a preformed connecting element positioned in said first receiving channel and said second receiving channel.

9. The construction joint ofclaim 8, wherein said first receiving channel and said second receiving channel each include a first wall and a shorter second wall, said second wall being substantially parallel with said first wall.

10. The construction joint ofclaim 9, wherein said receiving channel includes at least one protrusion along a side of at least one of said first wall and said second wall.

11. The construction joint ofclaim 10, wherein said connecting element includes a plurality of engaging portions including a first engaging portion and a second engaging portion, said first engaging portion being inserted into said first receiving channel and said second engaging portion being inserted into said second receiving channel.

12. The construction joint ofclaim 11, wherein said plurality of engaging portions each include an edge enhancement that coacts with said at least one protrusion to cause said connecting element to be retained in said first receiving channel and said second receiving channel.

13. The construction joint ofclaim 12, wherein said edge enhancement is at least one of a bent edge and a thickened portion.

14. A construction method, comprising the steps of:

positioning a plurality of structural members proximate to each other including a first structural member having a first receiving channel and a second structural member having a second receiving channel; and

inserting a preformed connecting element into said first receiving channel and said second receiving channel.

15. The method ofclaim 14, wherein said first receiving channel and said second receiving channel each include a first wall and a shorter second wall, said second wall being substantially parallel with said first wall.

16. The method ofclaim 15, wherein said receiving channel includes at least one protrusion along a side of at least one of said first wall and said second wall.

17. The method ofclaim 16, wherein said connecting element includes a plurality of engaging portions including a first engaging portion and a second engaging portion, said first engaging portion being inserted into said first receiving channel and said second engaging portion being inserted into said second receiving channel during said inserting step.

18. The method ofclaim 17, wherein said plurality of engaging portions each include an edge enhancement that coacts with said at least one protrusion to cause said connecting element to be retained in said first receiving channel and said second receiving channel.

19. The method ofclaim 18, wherein said edge enhancement is at least one of a bent edge and a thickened portion.

20. The method ofclaim 14, further comprising the step of attaching a skin on top of said plurality of structural members and said connecting member.

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