U.S. patent application number 12/279719 was filed with the patent office on 2010-09-02 for a wall system.
Invention is credited to Rodney Mark GIBSON.
Application Number | 20100218453 12/279719 |
Document ID | / |
Family ID | 38371790 |
Filed Date | 2010-09-02 |
United States Patent
Application |
20100218453 |
Kind Code |
A1 |
GIBSON; Rodney Mark |
September 2, 2010 |
A WALL SYSTEM
Abstract
A method of constructing an external weatherpoof wall of a
building 1 by way of a series of posts 6, 10 and panels 9. The
method involves orienting a post 6, 10 vertically between the roof
and wall and securing it in place. A panel is then oriented
vertically and moved against the post. A further post is placed
against the free side of the panel and the procedure repeated until
a wall is established panel after post. The wall can be
disassembled without the application of destructive force.
Preferably only the posts are bolted to the roof and floor and the
panels are held between the posts without receiving fixing means
such as screws, bolts, or the like to hold them there.
Inventors: |
GIBSON; Rodney Mark;
(Wellington, NZ) |
Correspondence
Address: |
BLAKELY SOKOLOFF TAYLOR & ZAFMAN LLP
1279 OAKMEAD PARKWAY
SUNNYVALE
CA
94085-4040
US
|
Family ID: |
38371790 |
Appl. No.: |
12/279719 |
Filed: |
February 16, 2007 |
PCT Filed: |
February 16, 2007 |
PCT NO: |
PCT/NZ07/00030 |
371 Date: |
June 22, 2009 |
Current U.S.
Class: |
52/745.1 ;
52/745.09 |
Current CPC
Class: |
E04B 1/3444
20130101 |
Class at
Publication: |
52/745.1 ;
52/745.09 |
International
Class: |
E04B 1/344 20060101
E04B001/344; E04B 2/56 20060101 E04B002/56 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 17, 2006 |
NZ |
545411 |
Claims
1. A method of constructing at least a part of an external
weatherproof wall of a building comprising the steps of: i)
obtaining a structural post which has a first slot running along
one side thereof and a second slot running along an opposite side
thereof, the slots facing substantially different directions, ii)
obtaining a wall panel which has a first edge part and second edge
part, each edge part opposite the other, iii) arranging the post so
that it is substantially vertical between a roof and a floor with
its slots running substantially vertically, and securing the post
in that disposition, iv) arranging the wall panel so that its first
edge part is fitted in the first slot in a watertight manner, v)
obtaining a second structural post with slots substantially the
same as for the first mentioned post and arranging and securing it
between the roof and floor so that one of the slots of that second
post receives the second edge part of the panel in a watertight
manner, vi) arranging a second panel with edge parts substantially
the same as those of the first mentioned panel so that one of the
edge parts of that second panel is within the other slot of the
second post to create a watertight fit therebetween, and vii)
repeating steps v) and vi) with but using further posts having
substantially similar slots and further panels having substantially
similar edge parts to substantially create the wall or part
thereof, the wall being such that it can be disassembled without
the application of destructive force to the panels or posts.
2. A method according to claim 1, wherein the posts are secured to
the roof and floor with fixing members (eg bolts) and the panels
are fitted to the posts without fixing members.
3. A method according to claim 1 or 2, wherein the slots of the
posts and the edge parts of the panels are complimentary to enable
female/male fitting therebetween.
4. A method according to claim 1, 2 or 3, wherein the roof has a
generally down facing channel, and an upper part of each post
and/or an upper part of each panel is fitted into that channel.
5. A method according to claim 4, wherein upper ends of the posts
and/or panels are fitted into the channel of the roof and then
swung downwards until they are substantially vertically
oriented.
6. A method according to claim 4 or 5 wherein the channel is
generally "" shaped.
7. A method according to any one of the preceding claims wherein
the posts and/or panels are swung downwards onto an extrusion
forming part of the floor after engaging the roof.
8. A method according to any one of the preceding claims, wherein
the floor has a generally shaped extrusion, or in the case of
dependency on claim 7 the extrusion is generally shaped, and a
lower part of each post and a lower part of each panel is fitted
against that extrusion.
9. A method according to any one of the preceding claims, wherein
strips of sealing material are used to achieve watertight fittings
between the panels and posts, and/or between the panels and the
roof and floor, and/or between the posts and the roof and
floor.
10. A method of constructing at least a part of an external
weatherproof wall of a building, substantially as herein described
with reference to the accompanying drawings.
11. A method according to any one of the preceding claims, wherein
the building can be disassembled and parts of the roof and floor
swung inwards about hinges so that the building assumes the shape
of a shipping container.
12. A weatherproof wall or part thereof formed according to a
method as set out in any one of the preceding claims.
13. A kit of parts suitable for forming a weatherproof wall or part
thereof by way of the method of any one of claims 1 to 11,
comprising the posts and panels and, if the claim dependency
adopted permits, the channel and/or the extrusion.
Description
FIELD OF INVENTION
[0001] This invention relates to a wall system. A particularly
preferred form of the invention relates to a wall system which can
be used in the context of transportable buildings.
BACKGROUND
[0002] It is known from New Zealand patent No. 532620 (in the name
Habode IP Limited) to create a building which can be shipped in the
manner of a freight container. The building can then be assembled
on site. Installation may involve swinging a floor and a roof
outwards from a housing by way of pivot connections. More
specifically, the floor may swing down and the roof may swing up.
When the floor and roof have been arranged in this way it is
desirable to create a wall therebetween. It is accordingly an
object of at least one form of the present invention to go at least
some way towards facilitating this, or to provide the public with a
useful choice. While reference has been made to New Zealand patent
No 532620, it should be understood that the present invention is
not limited to buildings described in that document.
[0003] The term "comprising" or derivatives thereof, if and when
used in this document should not be interpreted to exclude the
possibility of other features.
SUMMARY OF THE INVENTION
[0004] According to one aspect of the invention there is provided a
method of constructing at least a part of an external weatherproof
wall of a building comprising the steps of: [0005] i) obtaining a
structural post which has a first slot running along one side
thereof and a second slot running along an opposite side thereof,
the slots facing substantially different directions, [0006] ii)
obtaining a wall panel which has a first edge part and second edge
part, each edge part opposite the other, [0007] iii) arranging the
post so that it is substantially vertical between a roof and a
floor with its slots running substantially vertically, and securing
the post in that disposition, [0008] iv) arranging the wall panel
so that its first edge part is fitted in the first slot in a
watertight manner, [0009] v) obtaining a second structural post
with slots substantially the same as for the first mentioned post
and arranging and securing it between the roof and floor so that
one of the slots of that second post receives the second edge part
of the panel in a watertight manner, [0010] vi) arranging a second
panel with edge parts substantially the same as those of the first
mentioned panel so that one of the edge parts of that second panel
is within the other slot of the second post to create a watertight
fit therebetween, and [0011] vii) repeating steps v) and vi) with
but using further posts having substantially similar slots and
further panels having substantially similar edge parts to
substantially create the wall or part thereof, the wall being such
that it can be disassembled without the application of destructive
force to the panels or posts.
[0012] Preferably the posts are secured to the roof and floor with
fixing members (eg bolts) and the panels are fitted to the posts
without fixing members.
[0013] Preferably the slots of the posts and the edge parts of the
panels are complimentary to enable female/male fitting
therebetween.
[0014] Preferably the roof has a generally down facing channel, and
an upper part of each post and/or an upper part of each panel is
fitted into that channel.
[0015] Preferably upper ends of the posts and/or panels are fitted
into the channel of the roof and then swung downwards until they
are substantially vertically oriented.
[0016] Preferably the channel is generally "" shaped.
[0017] Preferably the posts and/or panels are swung downwards onto
an extrusion forming part of the floor after engaging the roof.
[0018] Preferably the floor has a generally shaped extrusion and a
lower part of each post and a lower part of each panel is fitted
against that extrusion.
[0019] Preferably strips of sealing material are used to achieve
watertight fittings between the panels and posts, and/or between
the panels and the roof and floor, and/or between the posts and the
roof and floor.
[0020] Preferably the building can be disassembled and parts of the
roof and floor swung inwards about hinges so that the building
assumes the shape of a shipping container.
[0021] According to a further aspect of the invention there is
provided a weatherproof wall or part thereof formed according to a
method as set out above.
[0022] According to a further aspect of the invention there is
provided a kit of parts suitable for forming a weatherproof wall or
part thereof by way of the method as set out above, the kit
comprising the posts and panels, and optionally the channel and/or
the extrusion.
DESCRIPTION OF THE DRAWINGS
[0023] Some preferred forms of the invention will now be described
by way of example and with reference to the accompanying drawings,
of which
[0024] FIG. 1 is a perspective view of a portable building in a
disassembled state ready for shipping in the manner of a freight
container,
[0025] FIG. 2 is a perspective view of the building in a partially
assembled state,
[0026] FIGS. 3 & 4 are perspective views showing opposite sides
of the building when fully assembled,
[0027] FIG. 5 is a perspective view of a panel used in assembling
the building,
[0028] FIG. 6 provides elevation views of various optional panels
for use in the building,
[0029] FIGS. 7 & 8 illustrate the way panels may be erected to
form a wall of the building,
[0030] FIGS. 9 & 10 show a channel forming part of the
building's roof in cross section and in perspective
respectively,
[0031] FIGS. 11 & 12 show a channel forming part of the
building's floor in cross section and in perspective
respectively,
[0032] FIG. 13 is a perspective view of a medial post forming part
of the building,
[0033] FIG. 14 is a perspective view detailing part of the medial
post,
[0034] FIG. 15 is a transverse cross section view of the medial
post,
[0035] FIG. 16 shows perspective and cross sectional detail of a
particular panel forming part of the building,
[0036] FIG. 17 is a perspective view showing detail of the way that
the panel engages the floor of the building, and
[0037] FIG. 18 is a transverse cross section showing a corner post
of the building fitted with panels substantially at right angles to
one another.
DETAILED DESCRIPTION
[0038] FIG. 1 shows a portable building 1 in a disassembled state,
substantially arranged as a 40 foot shipping container which
conforms to ISO standards. When in its FIG. 1 configuration the
building 1 can be shipped as an upper or lower part of a stack of
containers, and is thus able to withstand substantial compressive
force. FIG. 2 shows the building 1 in a partially assembled state
with roof 2 and floor 3 extensions proceeding outwards from a
central part 4. When the building is in the container configuration
shown in FIG. 1 the roof 2 and floor 3 extensions overlap one
another at each side of the container. To achieve the FIG. 2
arrangement these roof 2 and floor 3 extensions are swung up and
down respectively by way of a series of hinges 5. As shown in FIG.
2, corner posts 6 may be bolted in place to hold the floor and roof
3 extensions with respect to one another.
[0039] When in a fully assembled state the building 1 may appear as
shown in FIGS. 3 and 4, complete with a sun shade 7 and decking 8.
The external walls of the building are created from a series of
panels 9 and end and medial posts 6, 10. As shown, some of the
panels incorporate windows and some do not. The pattern in which
these panels 9 are employed will depend on the requirements and
preferences of the end user.
[0040] FIG. 5 shows one of the panels 9 in more detail and FIG. 6
shows various other options for the panels in terms of size and
shape. FIGS. 7 and 8 exemplify the way in which panels 9 and medial
posts 10 are installed, either before or after the corner posts 6
are set in place. Referring to FIG. 7, a panel 9 (step 1) is taken
and is angled (step 2) so that an upper edge 11 of the panel fits
into a generally "" shaped upper channel 12 secured to the roof
extension 2 (step 3). The profile of the channel 12 is shown in
more detail in FIGS. 9 and 10. The bottom edge 13 of the panel 9 is
then swung down onto a lower extrusion or channel 14 which is
generally shaped (step 4). The profile of the lower channel 14,
which is secured to the floor extension 3, is shown in more detail
in FIGS. 11 and 12. The swing of the panel 9 down onto the lower
channel 14 is interrupted when the panel is vertical by way of a
water stop or ledge 15 (see FIGS. 11 and 12) forming part of the
lower channel 14. After the panel is vertically aligned between the
upper and lower channels 12 and 14 it is slid sideways (eg to the
left of the page) to butt up against one of the posts 10 (step
5).
[0041] Referring to FIG. 8, a further post 10' is then taken (step
6) and inserted between the upper and lower channels 12 and 14, and
then slid across to the panel 9 (steps 7 and 8), all in similar
fashion to the way the panel 9 has been handled. Further panels and
posts can be added in substantially the same way until the exterior
wall of the building is complete. The arrangement is such that the
sides of the posts 10/10' provide `female` slots for receiving
complimentary `male` edges of the panels 9. These are fitted
together in a water tight manner to prevent leaks into the interior
of the building.
[0042] FIG. 13 provides more detail as to the profile of the medial
posts 9. As shown, each post 9 has a tongue 16 at its upper end,
and a further tongue 17 at its lower end. These tongues are bolted
to the upper and lower channels 12 and 14 respectively. FIG. 14
shows a portion of the post 9 in perspective and FIG. 15 shows the
post in transverse cross section.
[0043] It is not essential to start an external wall of the
building from any particular place, for example it can be commenced
from a corner of the building or from a mid section of the
building's perimeter. The roof section 2 may need to be supported
in someway, for example by way of a small crane or the like, until
enough posts/panels are installed to give sufficient structural
integrity to keep the roof extension 2 up.
[0044] FIG. 16 provides detail of a preferred profile for the
panels 9. As can be seen, the vertical and horizontal framing 18 of
the panel is adapted to accommodate double cladding, whether it be
in the form of panes of glass 19 or non-transparent sheets 20 with
insulation 21 therebetween. The non-transparent sheets are
preferably formed from plywood laminated with a suitable `plastic
aluminium` substance. Further detail of the panel 9 and the way it
associates with the floor extension 3 is shown at FIG. 17. FIG. 18
provides detail of one of the corner posts when arranged between
two panels 9 at right angles.
[0045] To assist in providing a water tight seal between the panels
9 and the rest of the building, the upper channels 12 are fitted
with strips of rubber 22 pressed within generally `C` shaped
protrusions 23 (see FIGS. 9 and 16). As shown in FIG. 16, the
bottom parts of the panels are sealed with respect to the lower
channel 14 by further rubber strips 24. Rubber strips 25 or other
suitable means are also employed to seal the panes of glass 19 and
non-transparent sheets 20 with respect to the panel framing 18.
Additional rubber strips 26 (see FIG. 16) may also be employed to
provide a water tight seal between the posts 6, 10 and the panels
9.
[0046] The posts 6, 10, the channels 12, 14 and the panel framing
18 may all be formed as aluminium extrusions or the like. While the
medial and end posts 10, 6 have a different in transverse cross
section their edge parts are preferably the same for receiving the
panels 9. By following the installation steps described above a
watertight exterior wall can be created in a short time, employing
a pattern of panels in terms or window positioning which suits the
preferences of an end user. The manner in which the exterior wall
is created can be reversed so that it can be readily dismantled
and/or modified without having to apply destructive force. Thus one
does not have to destroy the wall to take it down or, destroy it in
part and then rebuild it, to enable disassembly to or modification
of the building. As will be appreciated, the wall can be created by
simply bolting the posts 6, 9 in place and then slotting the panels
in place, one after the other, without screws or bolts for the
panels. Because the panels butt tightly into and against the posts
the rubber seals between the posts and panels ensure a watertight
fit.
[0047] Those skilled in the art will appreciate that to enable
disassembly of the wall at least one of the posts will have a
profile slightly different to the others. As shown at FIGS. 14 and
15, most or the medial posts generally have an "H" profile. The
post (not shown) which enables disassembly is similar except that
it has one the "H" tails 27 missing to give a generally "h"
profile. The missing tail means that one of the panels can be swung
outwards from the post inside the building to enable access to the
bolts which proceed through the tongues 16 and 17 of that post.
From there the wall can be disassembled panel after post. A capping
(not shown) may be removably screwed in place over the area of the
"missing tail" for aesthetic purposes when the wall is in its fully
assembled state.
[0048] In some embodiments of the invention the panels 9 may have
only a glass pane or panes, ie without a non-transparent sheet or
sheets. In that case the panels may thus be windows only and in
that event, and for the purposes of this document, the arrangement
should still be regarded as a wall or part thereof.
[0049] While some preferred forms of the invention have been
described by way of example it should be appreciated that
modifications and improvements can occur without departing from the
scope of the following claims.
* * * * *