U.S. patent application number 13/291386 was filed with the patent office on 2012-03-01 for connector assemblies for connecting panels.
This patent application is currently assigned to SABIC INNOVATIVE PLASTICS IP B.V.. Invention is credited to Frans Adriaansen, Amit Israeli, Michael Matthew Laurin.
Application Number | 20120051833 13/291386 |
Document ID | / |
Family ID | 42536322 |
Filed Date | 2012-03-01 |
United States Patent
Application |
20120051833 |
Kind Code |
A1 |
Israeli; Amit ; et
al. |
March 1, 2012 |
CONNECTOR ASSEMBLIES FOR CONNECTING PANELS
Abstract
In another embodiment, a connector assembly can comprise: a
first side collector, comprising a first panel engagement region
comprising a first receiving area that has a size to attach onto an
edge of a first panel; and a second side collector, comprising a
second panel engagement region comprising a second receiving area
that has a size to attach onto an edge of a second panel. The first
side collector and second side collector can be configured to
directly mate with each other to hold to panels together.
Inventors: |
Israeli; Amit; (Madison,
WI) ; Adriaansen; Frans; (Bergen op Zoom, NL)
; Laurin; Michael Matthew; (Pittsfield, MA) |
Assignee: |
SABIC INNOVATIVE PLASTICS IP
B.V.
Bergen op Zoom
NL
|
Family ID: |
42536322 |
Appl. No.: |
13/291386 |
Filed: |
November 8, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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12778339 |
May 12, 2010 |
|
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13291386 |
|
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61177693 |
May 13, 2009 |
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Current U.S.
Class: |
403/49 |
Current CPC
Class: |
E04D 3/363 20130101;
Y10T 403/30 20150115; E04D 3/06 20130101; E04D 3/28 20130101; E04B
1/61 20130101; E04D 2003/285 20130101; E04D 3/362 20130101 |
Class at
Publication: |
403/49 |
International
Class: |
F16B 5/00 20060101
F16B005/00 |
Claims
1. A connector assembly, comprising: a first side collector,
comprising a first panel engagement region comprising a first
receiving area that has a size to attach onto an edge of a first
panel; and a second side collector, comprising a second panel
engagement region comprising a second receiving area that has a
size to attach onto an edge of a second panel; wherein the first
side collector and second side collector are configured to directly
mate with each other to hold to panels together.
2. The connector assembly of claim 1, wherein the first side
collector and the second side collector have a mating geometry
selected from the group consisting of tongue and groove, and
snap-fit.
3. The connector assembly of claim 1, wherein the first side
collector further comprises a first wall with two first arms
extending therefrom to define the first receiving area and first
energy directors extending from the first arms into the first
receiving area, and the second side collector further comprises a
second wall with two second arms extending therefrom to define the
second receiving area and second energy directors extending from
the second arms into the second receiving area.
4. The connector assembly of claim 1, wherein at least one of the
first energy directors and the second energy directors staggered
with respect to adjacent arms, except for an optional energy
director located at an end of each adjacent arms.
5. The connector assembly of claim 1, wherein the first side
collector and the second side collector have complementary openings
configured to receive an engagement of a clip that is configured to
secure the first side collector and the second side collector to a
support, wherein the engagement extends from an end of a stem that
has a length that is less than a height of the first receiving
area.
Description
CROSS REFERENCED TO RELATED APPLICATION
[0001] This application is a divisional application of U.S.
application Ser. No. 12/778,339, filed May 12, 2010, and claims
benefit to U.S. Provisional Application No. 61/177,693, filed on
May 13, 2009, which are incorporated herein by referenced in its
entirety.
BACKGROUND
[0002] The present disclosure generally relates to connectors and
collectors for connecting panels.
[0003] In the construction of naturally lit structures, such as
greenhouses, pool enclosures, solar roof collectors, stadiums and
sunrooms, glass panel roofs have been employed to allow natural
light to shine therein. The glass panels themselves can be mounted
in frame-like enclosures that are capable of providing a watertight
seal around the glass panel and provide a means for securing the
panel to a structure. These frame-like enclosures also provide for
modular glass roofing systems that can be assembled together to
form the roof.
[0004] Glass panel roofing systems generally provide good light
transmission and versatility. However, the initial and subsequent
costs associated with these systems limits their application and
overall market acceptance. The initial expenses associated with
glass panel roofing systems comprise the cost of the glass panels
themselves as well as the cost of the structure, or structural
reinforcements, that are employed to support the high weight of the
glass. After these initial expenses, operating costs associated
with the inherently poor insulating ability of the glass panels can
result in higher heating expenses for the owner. Yet further, glass
panels are susceptible to damage caused by impact or shifts in the
support structure (e.g., settling), which can result in high
maintenance costs. This is especially concerning for horticultural
applications wherein profit margins for greenhouses can be
substantially impacted due to these expenditures.
[0005] As a result, multiwall polymeric panels (e.g.,
polycarbonate) have been produced that exhibit improved impact
resistance, ductility, insulative properties, and comprise less
weight than comparatively sized glass panels. As a result, these
characteristics reduce operational and maintenance expenses.
Polymeric panels can also be formed as solid panels. Solid panels
are solid plastic between their front and rear faces, and are
useful where high impact resistance (e.g., bulletproofing), high
clarity, and/or the ability to thermoform the panel is desired.
Multiwall panels have voids between their front and rear faces,
e.g., the panel may be extruded as a honeycomb with an array of
passages extending along the extruded length of the panel.
Multiwall panels are useful where a high insulation value,
lightweight, and easy installation, are desired.
[0006] For ease of design and assembly, multiwall panels can be
produced in modular systems. The modular systems comprise multiwall
panels with integral panel connectors, wherein the panel connector
assemblies are employed to join the panels together and/or secure
the panels to a structure on which they are employed. Standard
panels can also be used, which are formed continuously and
uniformly, i.e., they are extruded slabs and are cut to size and
installed in the same manner as glass. These standard panels
require a frame or the like to hold them in place.
[0007] Modular panels are advantageous for their extreme ease of
installation, but are disadvantageous owing to their limited
versatility in that modular panels cannot be cut to a desired size
if such cutting involves loss of a connecting edge, because the
modular panel will no longer be readily connectable to other panels
at the cut edge. As a result, if a panel with an unusual or
non-standard width is desired, a new extrusion die must be
commissioned, at great expense, so as to be able to extrude panels
of the desired width, and having the desired connecting edges.
Further, modular panels are naturally limited to use with modular
panels having complementary attachment structure (i.e., a
tongue-and-groove panel will connect to other tongue-and-groove
panels having the same tongue/groove configuration, but will not
connect to standing seam panels).
[0008] Thus, greater flexibility in the size of the modular panels,
without the requirement for expensive equipment and retooling, and
the ability to connect to a variety of panels is desired.
BRIEF DESCRIPTION
[0009] Disclosed herein are side collectors and connector
assemblies and methods for connecting panels with the side
collectors and/or connector assemblies, methods for making the side
collectors and/or connector assemblies, and panels using the side
collectors and/or connector assemblies.
[0010] In one embodiment, a connector assembly can comprise: a
connector and a pair of side collectors. Each side collector can
comprise a connector engagement region having a size and geometry
to mate with the connector so as to hold ends of two adjacent
panels together, and a panel engagement region comprising a
receiving area having an energy director extending into the
receiving area, and having a size to attach onto an edge of the
panel.
[0011] In another embodiment, a connector assembly can comprise: a
first side collector, comprising a first panel engagement region
comprising a first receiving area that has a size to attach onto an
edge of a first panel; and a second side collector, comprising a
second panel engagement region comprising a second receiving area
that has a size to attach onto an edge of a second panel. The first
side collector and second side collector can be configured to
directly mate with each other to hold to panels together.
[0012] In yet another embodiment, a connector assembly can
comprise: a pair of side collectors, and a connector having a
support and an extension protruding therefrom. Each side collector
can comprise a cavity that when assembled with the other side
collector forms a connector engagement region, and a panel
engagement region comprising a receiving area having a size to
attach onto an edge of the panel. The extension and the cavity can
have a size and shape to enable the extension to be inserted into
the cavity so as to hold ends of two adjacent panels together.
[0013] In an embodiment, a connector can comprise: two cavities
defined by flexible walls, wherein each of the cavities has a
geometry and is configured to mate with connector engagement
regions from a pair of side collectors; and a header located
between the two cavities. The cavities can enable two sets of
panels to be stacked and connected with the connector.
[0014] In an embodiment, a side collector comprises: a connector
engagement region comprising head having a size and geometry to
mate with a panel connector; and a panel engagement region
comprising a receiving area having an energy director extending
into the receiving area, and having a size to attach onto an end of
a panel.
[0015] Embodiments of panel assemblies comprise any of the
connector assemblies attached to panels.
[0016] These and other non-limiting characteristics are more
particularly described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The following is a brief description of the drawings, which
are presented for the purposes of illustrating the exemplary
embodiments disclosed herein and not for the purposes of limiting
the same. It is noted that various elements of the embodiments are
interchangeable with other embodiments as long as collectors and if
used, clip, are matable and/or, for side seams, the connector and
associated collectors, and if used, clip, are mateable, as would be
readily understood. However, for simplicity, not every single
combination has been illustrated.
[0018] FIG. 1 is a front view of a clip for use in assembling a
structure.
[0019] FIG. 2 is a cross-sectional end view of a panel with an
integrated side collector.
[0020] FIG. 3 is a front view of a connector for use in assembling
a structure.
[0021] FIG. 4 is a front view of FIG. 1 to FIG. 3 assembled.
[0022] FIG. 5 is a front view of a connector for use in assembling
a structure.
[0023] FIG. 6 is an elevation view of a clip for use in assembling
a structure.
[0024] FIG. 7 is a front view of a panel with an integrated side
collector.
[0025] FIG. 8 is a front view of FIG. 5 to FIG. 7 assembled.
[0026] FIG. 9 is a front view of FIG. 5 and FIG. 7 assembled in an
inverted fashion with the connector attached to the support.
[0027] FIG. 10 is a front view of a connector for use in assembling
a structure.
[0028] FIG. 11 is a front view of an assembled structure with
integrated side collectors connecting stacked panels.
[0029] FIG. 12 is a front view of an assembled structure with
integrated side collectors connecting stacked panels, wherein the
connector is attached directly to the support, i.e., without a
clip.
[0030] FIG. 13 is a front view showing panels with integrated side
collectors, a double-sided connector, and additional panels without
integrated side collectors.
[0031] FIG. 14 is a front view of a clip for use in assembling a
structure.
[0032] FIG. 15 is a front view of FIG. 13 and FIG. 14
assembled.
[0033] FIG. 16 is a front view showing panels with integrated side
collectors, a double-sided connector, and additional panels without
integrated side collectors.
[0034] FIG. 17 is a front view of a clip for use in assembling a
structure.
[0035] FIG. 18 is a front view of FIG. 16 and FIG. 17
assembled.
[0036] FIG. 19 is an elevation view of a panel and an un-integrated
side collector.
[0037] FIG. 20 is a front view of a connector for use in assembling
a structure.
[0038] FIG. 21 is a front view of a clip for use in assembling a
structure.
[0039] FIG. 22 is a front view of FIG. 19 to FIG. 21 assembled.
[0040] FIG. 23 is an elevation view of a panel and a side collector
not integrated with the panel.
[0041] FIG. 24 is a front view of a connector for use in assembling
a structure.
[0042] FIG. 25 is a front view of a clip for use in assembling a
structure.
[0043] FIG. 26 is a front view of FIG. 23 to FIG. 25 assembled.
[0044] FIG. 27 is an elevation view of a panel and a side collector
separate from the panel.
[0045] FIG. 28 is a front view of a connector for use in assembling
a structure.
[0046] FIG. 29 is a front view of a clip for use in assembling a
structure.
[0047] FIG. 30 is a front view of FIG. 27 to FIG. 29 assembled.
[0048] FIG. 31 is a side view of a standing seam side
collector.
[0049] FIG. 32 is a front view of a connector for use with the
collector of FIG. 31.
[0050] FIG. 33 is another front view of a connector.
[0051] FIG. 34 is a front view of a standing seam side collector
with a spacer between collector halves.
[0052] FIG. 35 is a side view of a standing seam side collector
with extensions having energy directors and a panel to be connected
thereto.
[0053] FIG. 36 is a front view of an assembled connector and side
collectors with a thermal expansion clearance.
[0054] FIG. 37 is a side view of an embodiment wherein the
connector is the male component and the side collector is the
female component of an exemplary connector assembly.
[0055] FIG. 38 is a side view of an exemplary embodiment of a side
collector configured to mate with another side collector, e.g.,
snap-fit, without the use of a connector.
[0056] FIG. 39 is a side view of an exemplary embodiment of a side
collector configured to mate with another side collector, e.g.,
tongue and groove, without the use of a connector.
[0057] FIG. 40 is a top view of assembled panels illustrating that
with the side collectors, the panels can be assembled on all four
sides.
DETAILED DESCRIPTION
[0058] Disclosed herein are various embodiments of connector
assemblies, e.g., connector(s) and collector(s), and optionally
clip(s). The connectors can attach to a support via the clip or can
connect directly. The connectors can also be single or double
sided; e.g., can be capable of engaging one or two sets of
collectors, and optionally of engaging the ends of one or two
additional panels with no collectors. The collectors can be
integral with the panel (formed as part of the panel, e.g., as a
single, unitary component), or separate from the panel as an
independent component. If the collector is a separate component,
many different width panels (e.g., measured in the X direction) can
be used with the same collector and connector. Additionally, many
different thicknesses (measured in the Y direction) and/or
different width panels can be used with the same connector by using
different, separate collectors. Additionally, the optional clips
can be designed to enable the panels to be level when assembled (in
the Y direction).
[0059] The connector assemblies generally comprise a connector, a
side collector, and optionally a clip for attaching panels
together. The connectors and collectors are designed as mating
pairs with one acting as the male and the other as the female
connector. In many of the embodiments illustrated in the figures,
the connector is illustrated as the female component, while the
collector is illustrated as the male component. It is noted that
this is merely for illustration and ease of discussion. The
opposite configuration is also covered herein and contemplated
hereby, wherein the connector is the male component and the
collector is the female component (e.g., see FIG. 37). Therefore,
the discussion of the cavity for the connector and the connector
engagement region for the collector can readily be reversed and is
hereby understood.
[0060] The connector can be designed with a cavity that has a size
and shape to mate with a pair of side collectors (from adjacent
panels) in order to hold the panels together. The specific size and
shape of the cavity is dependent upon the size and shape of the
side collectors. Desirably, the connector securely attaches to the
panels, over the side collectors. In other words, the size of the
cavity can be about equal to the size of the side collectors such
that when the connector is assembled onto the side collector,
physical contact between the outer surface of the side collector
and the inner surface of the cavity is attained (e.g., over greater
than or equal to 80% of the outer surface of the collector). It is
noted that when a clip is utilized having an engagement (e.g.,
cross-member 24, wings 36) that will be located between the
connector and the collector, the size of the collector inner
surface is sufficient to enable the engagement to be located
between the connector and collector. For ease of installation and
minimization of the use of fasteners, the connectors can be
designed to snap-fit onto the collectors (e.g., see FIG. 4), to
slide onto the collectors from an end of the panel (e.g., see FIG.
30), and/or to otherwise attach.
[0061] It is noted that the connector is complementary to the
combination of collectors to which is connects. However, both
collectors do not need to be identical. Different collectors can be
used on each panel so long as the connector is designed to receive
that combination of collectors.
[0062] Further, panels using the side collector(s) (and/or
connectors) disclosed herein can have all of their edges--not just
two opposing edges--bearing attachment structures. (See FIG. 40)
For example, panels for a wall might bear edge connectors with
standing seams where the horizontal panel edges are to be joined,
and edge connectors with tongue and groove attachments where the
vertical panel edges are to be joined.
[0063] For example, referring to FIGS. 1-4, the connector 100 has a
cavity (interior portion 102) with a size and shape complementary
to two side collectors 210 arranged adjacent to one another such
that the collector assembly (two adjacent side collectors) can be
inserted into the cavity 102. For example, such that the peaks 216
and slopes of the adjacent side collectors form a valley that
receives the connector protrusion 120. Similarly, complementary
flange 104 and ledge 220 of the connector 100 and collector 210,
respectively, can be in physical contact when the connector is
attached to the panels.
[0064] As can further be seen in FIGS. 10 and 11, the connector can
have an angled portion 124 that decreases the connector diameter
toward the base 144 so as to enable the connector to be snap-fit
onto side collector, optionally even in the presence of multiple
panels. For example, the panels 200 and 206 can be stacked and/or
arranged accordingly, with clip 10 extending from the support
structure 300 to the outer portion of the collector, slide region
214. Then, the connector 100 can be forced over the side collectors
210 such that the arms 132 contact the slide region 214, forcing
the walls 168 (e.g., comprising leg(s) 126 and angled portion(s)
124) outward toward the panels 206 until the flange 104 moves past
the edge of ledge 220. When the flange 104 moves past the edge of
ledge 220, the connector snaps onto the side collector, whereby the
walls 168 would move back inward, toward the side collector and
away from the panel. In the various designs of the connector, the
walls 168 can be designed to have a sufficient length such that,
once the connector has been attached to the side collectors, the
base (e.g., base 128) physically contacts the panel surface. In the
snap-fit embodiments, the walls 168 can have a sufficient
flexibility to enable the walls to deflect outward as the side
collectors are inserted into the cavity.
[0065] Similar snap-connection of the connector 100 occurs when the
clip 10 is not utilized. Without the clip 10, the connector 100 can
be directly attached to the support 300. The side collectors 210
can then be forced into the cavity of the connector 100, thereby
causing the legs 126 to move outward, allowing the arms 132 to
travel across the slide region 214 until the flanges 104 engages
the ledges 220.
[0066] The connector can be configured to attach to multiple panels
as is illustrated in FIGS. 11-12. In this design the connector
further comprises a panel attachment that extends from the leg 126
away from the base 128 forming a ledge 130 with a member 136
connecting the ledge 130 to the header 134. The member 136 can
extend from the header 134 at any desirable angle so as to form a
sufficient ledge 130 to enable the additional panel to be securely
engaged by the connector 100. Although the ledge 130 could directly
engage the additional panel 206 with optional adhesive disposed
therebetween (e.g., see FIG. 12), in this illustration, the
connector further comprises a gasket 138 configured to form a
pressure fit between the connector 100 and the second panels 126.
The gasket 138 can be attached to the connector 100 in any fashion,
including a mechanical connection such as illustrated. For example
the head 140 of the gasket 138 can be located in a space 140 such
that the diameter of the head 140 is greater than the diameter of
the opening 142 into the space 144 through ledge 130. Thereby, the
gasket 138 is not unintentionally removed from the space 144. As is
illustrated, the gasket 138 extends from the space 144 to the area
between the ledge 130 and the panel 206.
[0067] In embodiments that do not employ clip(s), the connector can
be located between the panels and the support, attaching the panels
to the support. For example, as is illustrated in FIGS. 9 and 12,
the clip 10 (see FIGS. 8 and 11) has been eliminated and the
fastener 302 attaches the connector 100 to the support 300 via the
header 134. In order to allow the insertion of the fastener 302
into the connector 100, the protrusion 120 can have a sufficiently
large opening to enable the insertion of the fastener 302 into the
chamber 146 defined by sides 148, e.g., the opening can be larger
than the diameter of the fastener head. The sides 148 can
optionally be employed to provide further structural integrity to
the connector 100, and/or an alignment element (protrusion 120) for
alignment with the collectors 210 and/or clip 10.
[0068] Some embodiments of the connectors 100 are "double"
connectors, i.e., they have cavities 102 on two opposite sides for
receiving pairs of side collectors (e.g., see FIGS. 13 and 16). In
these embodiments, a cavity 102 is located on each side of the
header 134. Each of these cavities 102 comprises the flanges 104 to
engage the ledges 220 of the side collectors 210. As with the other
connectors 100, each cavity 102 of the double connectors are
configured to mate with a specific pair of side collectors 210 and
therefore has a complementary inner geometry that matches the outer
geometry of the side collectors (or, as is mentioned above wherein
the connector is the male element, the connector will have a
complementary outer geometry to match the inner geometry of the
collector, wherein the collector will extend from the end of the
panel). As is clear from the exemplary embodiments illustrated in
the figures, each of the connectors in the double connector does
not have to be identical. A combination of different connectors can
be used. As can be seen from FIG. 16, the connector can have
different shaped cavities 102 that are configured to receive the
same shaped pairs of side collectors. It is also contemplated that
different shaped pairs of collectors can be received in each cavity
that is shaped accordingly. Here, the difference in shape is to
enable the additional receipt into one of the cavities, the clip
engagement (e.g., cross-member(s) 24 and/or wing(s) 36).
[0069] In addition to different cavity geometries, the connectors
can comprise different outer geometries, thereby enabling them to
receive additional panel(s), e.g., panel(s) that do not have a side
collector. Optionally, slot(s) (e.g., slots 150,152) can be formed
between the cavities 102. The size and geometry of these slot(s) is
dependent upon the thickness of the panel(s) intended to be
inserted into the slot(s). Note, it is desirable to only have
slot(s) on the side(s) of the double connector intended to receive
additional panels. The presence of a panel in the slot stabilizes
the sides 154,156 of the double connector, preventing flexing of
the side(s) after installation of the panel. In other words, while
the side collectors 210 are inserted into the cavities 102, the
sides 154,156 (accordingly), of the double connector, are forced
outward, causing the edges 158,160 (accordingly) defining the
slot(s) to move into the slot. Once the flange 104 passes the end
of the slide region 214 to the ledge 220, the sides 154,156 move
back out of the slot(s) 150,152. Hence, if a snap-fit arrangement
is employed, the side collectors are inserted into the double
connector prior to the insertion of the additional panels.
Furthermore, if a fastener is employed, the set of side collectors
located between the connector and the support are inserted first to
enable the attachment of the fastener 302 to the flange(s) 38. Then
the second set of side collectors are inserted into the open cavity
102 prior to the insertion of the additional panel(s). The
additional panels can have a thickness that enables a compression
fit in the slot, e.g., without damaging the end of the panel. Such
a fit will prevent inadvertent removal of the panel from the slot
and will stabilize the sides 154,156 against movement upon the
application of force to the panels.
[0070] As is illustrated in FIGS. 15 and 18 and mentioned above,
the end of panels (without collectors) can be inserted into the
slot(s). This creates an arrangement, in the Y direction, of panels
with collectors (e.g., first set of panels), gap (e.g., fluid gap
such as air), panel without collector, gap (e.g., fluid gap such as
air), panels with collectors (second set of panels). Since the
sizes of the slots are different, different thickness panels are
located on each side of the double collector. In embodiments that
employ the double connector, a clip can optionally be employed to
provide attachment of the first set of panels to a support 300. In
addition, the clip may further comprise flange(s) 38 configured to
receive fastener(s) 302. Hence, one or both of the connectors of
the double connector can be configured to receive fastener(s) to
enable further securement of the connectors (and hence the panels)
to the support. In other words, in addition to the snap connection
via the side collectors of the first set of panels, the retention
of the connectors can be further enhanced via direct attachment of
the header of the double connector to the flange(s) 38 of the clip
10.
[0071] Some further exemplary embodiments of additional connectors
are set forth in FIGS. 20, 24, 28, and 36. These embodiments
further illustrate that the specific size and geometry of the
connector is only limited by the size and geometry of the side
collectors (and, if employed, clip) to which it will be connected.
Also, as is clear with respect to the panels and the side
collectors, the connectors can optionally comprise various
combinations of ribs 162 (e.g., horizontal, vertical, diagonal, and
any combination thereof) as is desired, e.g., for additional
structural integrity (e.g., see FIGS. 1 and 16). Any rib
arrangement is based upon desired structural integrity for the
particular connector, based upon where the connector will be
employed and the loads it will experience.
[0072] The side collector(s) are located at the end of the panel,
wherein adjacent side collectors (from adjacent panels) form the
seam between the panels to be connected. As noted above, the side
collectors can have various designs that are complementary to the
design of the connector and clip so as to enable the collectors
(male portion; connector engagement region 222 with a head 234) to
mate with the connector (female portion; cavity 102) (or collectors
(female portion) to mate with the connector (male portion)).
[0073] The specific geometry of the collectors are dependent upon
the geometry of the connector to which they will be mated. Some
exemplary geometries are illustrated in FIGS. 2, 7, 19, 23, 27, 31,
and 35. As can be seen in these figures, the collectors can
optionally comprise rib(s) 226 (e.g., vertical, horizontal, and/or
diagonal (e.g., see FIG. 31)), to enhance the structural integrity
of the collector. It is also noted that the density of the ribs
(number of ribs per unit area), can be greater than the density of
the ribs in the panel (if the collector is separate) or in the
remainder of the panel (if the collector is integral). Diagonal
ribs, for example, can be used along with vertical ribs and
horizontal ribs in the area adjacent the panel engagement region,
e.g., see FIG. 31. In this embodiment vertical ribs and horizontal
ribs are employed throughout the side collector, with diagonal ribs
only located in the area adjacent the panel engagement region
(e.g., no diagonal ribs are used in the connector engagement
region).
[0074] Optionally, the side collector(s) and/or connectors can have
barrier elements to enable water, air, and/or bug infiltration
resistance. These barrier elements can comprise a ridge and a
valley, wherein the mating ridge and valley are rounded components.
For example, they can form greater than or equal to 40% of a
circle, specifically, greater than or equal to 50% (e.g., can form
a semicircle). Exemplary barrier elements are illustrated in FIGS.
31 and 32, wherein the barrier valley 242 on FIG. 31 is configured
to mate with the barrier ridge 244 on FIG. 32. As is illustrated,
the barrier valley 242 can be located on the connector engagement
region 222, adjacent to the panel engagement region 224, e.g., in
contact therewith.
[0075] As noted, the side collectors can be an integral part of the
panel (e.g., see FIG. 2), or a separate component (e.g., see FIG.
19), e.g., a side collector formed separate from the panel and
later attached to the panels (e.g., after manufacturing of the
panel is complete). Non-integral side collectors, such as tongue
and groove, base and cap, and standing seam side collectors are
advantageous in that panel sizes (e.g., length, width, height,
and/or thickness) are not limited by sizes that are already
produced because of cost issues associated with creating, testing,
and validating a new die system to produce the desired size. With
non-integral side collectors, any size and combination of panels
and/or sheets can be used, since the side collectors are produced
separate from the sheet and attached at a later time (e.g., at or
close to the job site). Additionally, different shape side
collectors can be used to attach different panels of a system
(e.g., roof) together. This enables the side collectors and
connectors to be customized for the particular location and desired
properties (e.g., to enhance structural integrity, sound dampening,
and/or light transmission, etc.) Non-integral side collectors are
additionally advantageous in that they essentially convert a
standard panel (e.g., a planar panel with no side collector) into a
modular panel. These side collectors can have a structure
configured to wrap around an edge of a panel, (e.g., a U-shape) and
be sized to receive the thickness(s) of the panel(s) to be fit
therein. These side collector(s) can be welded (e.g.,
ultrasonically and/or thermally), chemically attached (e.g.,
chemically bonded or glued), and/or mechanically attached (e.g.,
screwed, bolted, riveted, etc.) and/or otherwise affixed to the
panel(s).
[0076] As discussed above, the side collectors have a complementary
design to the connectors so as to enable mating thereof. In many
embodiments, these components can be snap-fit together. Hence, the
side collector 210 comprises an area that enables the connector to
readily move over the surface of the side collector, such that when
a force is exerted on the connector toward the side collector, the
sides 156 of the connector flex outward, away from the cavity 102
(see FIGS. 2-4). This enables the connector engagement region 222
to enter the cavity 102 until the flange 104 contacts the ledge
220, thereby allowing the sides 156 to move back toward the cavity
102.
[0077] Alternatively, in the various embodiments, if flexing of the
sides 156 of the connector is not possible and/or not desirable,
the connector can be disposed onto the collector by placing the
side collectors of two panes adjacent to one another. The connector
and collectors can be moved together (e.g., in the Z direction),
sliding the connector and collectors together (e.g., sliding the
connector engagement region 222 into the cavity 102).
[0078] When the collector is a separate element from the panel, it
comprises a panel engagement region 224 (see FIGS. 19, 23, 27, 31,
35, and 36). The height of the panel engagement region 224 is
sufficient to enable an end of a panel to be inserted therein
(e.g., is sized to receive the thickness(es) of the panel(s) to be
fit therein (see FIGS. 22 and 30)). Depending upon the design of
the collector, the receiving area 232 can be defined by the
connector engagement portion 222, arm(s) 230, and/or rib(s) 226.
For example, in FIG. 19, the receiving area 232 is defined by the
connector engagement portion 222 and arm 230. In FIG. 27, the panel
engagement region 224 has an arm 230, but the receiving area 232 is
defined by the connector engagement portion 222 and rib 226. In
FIGS. 31, 35, and 36, the receiving area 232 is defined by arms
230. In some designs, the arms 230 extend outward, e.g., from the
connector engaging area (see FIGS. 31, 34-39), e.g., such that the
panel engagement region comprises a body portion 262 which is
located adjacent to the connector engaging region (see FIGS. 31,
34, and 35) and arm(s) 230 extending from the body portion 262,
forming receiving area 232 for attachment onto an edge of a panel.
In other embodiments, the arms 230 are located in alignment with
the connector engaging region (see FIGS. 19, 23, and 27), e.g.,
such that the panel engagement region is located adjacent the
connector engaging region (e.g., the panel engagement region is
formed by the arms 230 (which may be multiwalled), and no body
portion).
[0079] Within the panel engagement region 224 can be energy
director(s) 228 extending into the receiving area 232. These energy
directors can be configured to engage an outer surface (e.g.,
surface 208) of the panel to which the collector will be attached.
The energy directors can aide in grasping and retaining the panel
in the receiving area 232 and/or can redirect energy received by
the collector and/or panel (e.g., during welding (e.g., ultrasonic
welding and/or thermal welding) together of the collector and
panel) into the ribs 198 of the panel. Therefore, desirably, some
or all of the energy directors 228 are located in the receiving
area 232 so as to align with vertical ribs (e.g., ribs extending in
the Y direction) in the panel when the panel is inserted into the
receiving area 232. The energy director(s) can be located on one or
both horizontal surfaces (surfaces extending in the X direction) in
the receiving area 232. To inhibit the arms from detaching from the
panel, and/or to avoid moisture, air, and/or insect infiltration,
an energy director can be located at the end of each arm 246.
Furthermore, it was discovered that the strongest bond between an
attachment member and a multiwall panel came about when an energy
director was positioned directly over a vertical rib in a multiwall
structure. Energy director(s) can be used on the vertical surface
when the panel has a closed end (e.g., is not open to the
individual ribs), and has horizontal ribs).
[0080] It was also discovered that using multiple energy directors
was advantageous because it increased the odds of having an energy
director over a rib in a multiwall panel without having to modify
the panel itself. The number of energy director(s) employed can be
different on each horizontal surface (and optionally the vertical
surface), and can vary depending upon the length of the horizontal
surfaces, the amount of vertical rib(s), if any, (and, if on the
vertical surface, the amount of horizontal ribs) in the panel,
and/or the amount of force that will be exerted onto the collector
and/or panel when they are assembled together. For example, in the
case of the multiwall panel, greater than or equal to 2 energy
directors are generally employed on each horizontal surface,
specifically, greater than or equal to 4, more specifically,
greater than or equal to 5, and yet more specifically, greater than
or equal to 8. Although any geometry can be employed for the energy
director 228, a generally triangular geometry is employed, e.g., a
right triangle extending into receiving area (such as from the
arm(s) 230). The height of the energy director (e.g., the distance
the energy director extends from arm 230 into receiving area 232)
can vary. Generally the height is less than or equal to 5 mm
(millimeters), specifically, 0.25 mm to 2 mm, more specifically,
0.5 to 1 mm.
[0081] The energy directors can be formed as an integral part of
the collector (i.e., an extension from arm 230, not an attachment
to arm 230). Furthermore, to enhance compatibility between the
collector and the panel, the energy director(s) can be formed from
the same type of material as the panel, or can be a composition
comprising the same type of material as the panel. For example if
the panel is a polycarbonate panel, the energy director(s) can be
polycarbonate, or a composition comprising polycarbonate, such as a
polycarbonate and ABS.
[0082] Not to be limited by theory, it is believed that the energy
directors pinpoint the energy of the vibrating ultrasonic horn to a
small area between the side collector and panel causing the energy
director to melt and subsequently fuse the side collector and panel
together with a strong chemical bond made from melted material.
Without the energy directors, the ultrasonic horn would vibrate,
heat, and compress a large unmelted side collector into the panel,
crushing a multiwall panel or creating a very weak bond with a
solid panel. In addition or alternative to the welding, the side
collectors 210 can also be attached to panel by chemical and/or
mechanical methods (e.g., gluing, chemical bonding, fastener(s),
and combinations comprising at least one of the foregoing).
[0083] Bonding a separate side collector to a panel can comprise
inserting the edge of the panel into the receiving area of the side
collector until the edge contacts the vertical wall and/or the
panel cannot be inserted any further. Creating relative motion
between an ultrasonic welding horn and the arms of the side
collector so as to melt the energy director(s) and form a bond
between the arm and the panel surface.
[0084] To address thermal expansion of the panels, the side
collectors can have a joint side with an angled wall (e.g., angled
from the connector engagement region toward the receiving area)
such that, when assembled, the joint walls 254 form a joint (e.g.,
space 252) having a decreasing width from the base 258 toward the
connector engagement region 222 (see FIG. 36). In other words, the
joint wall can be non-perpendicular, as determined with respect to
the arm 230. The joint walls form a space having a converging
diameter from the base 258 toward the connector engagement region
222, and optionally all the way to the point 264 adjacent the end
of the joint wall 254 opposite the base 258. The size of the space
formed by the adjacent walls should be sufficient to enable the
thermal expansion of the panels to which the side collectors are
attached. Essentially, as the panels thermally expand, they would
exert a force on the side collectors, causing the side collectors
to move toward each other. As the side collectors move toward one
another, the width (as measured in the X direction), of the space
decreases. The space can have a width (as measured in the X
direction, and in the relaxed state (i.e., when no force is applied
due to thermally expanding panels)), at the base 258, of greater
than or equal to 1 mm, specifically, 2 mm to 10 mm, and more
specifically, 2.5 mm to 5 mm.
[0085] Alternatively, or in addition to the joint 252, a spacer 250
can be located between adjacent joint walls 254. The spacer can
comprise a flexible material that can be compressed by expanding
panels, e.g., a foam or elastomeric material (see FIG. 34). The
spacer can have a sufficient size and compressibility to allow for
the thermal expansion of the panels. For example, the spacer can
have a thickness (measured in the X direction and in the
non-compressed state) of greater than or equal to 1 mm,
specifically, 2 mm to 10 mm, and more specifically, 4 mm to 8
mm.
[0086] When the side collector is to be used with an alignment clip
that will not engage the outer surface of the side collector and/or
the connector, the side collector has an opening 212 to receive the
cross-member 24 of the clip 10 (e.g., see FIGS. 2, 31, and 36).
This opening is located in the joint wall 254 adjacent the
receiving area 232.
[0087] As is mentioned, a clip can optionally be employed with the
connector and collectors. Different types of clips are possible.
For example, the clip can be an alignment clip (e.g., see FIG. 1),
an engagement clip (e.g., see FIGS. 6 and 25), and/or a combination
clip (e.g., FIGS. 14, 17, 21, and 29). Hence, the clip can comprise
an alignment region that is designed to align the adjacent panels
such that when the panels are attached together, they are level.
For example, in FIG. 1, the clip 10 is illustrated as comprising a
cross-member 24 at one end of stem 22 and a base 18 at the other
end. The base 18 can have a foot 28, side(s) 12, 14, leg(s) 16,
area 20, support(s) 26, and/or tab(s) 32, e.g., the base can form a
"u" shape (e.g., with a side 14, leg 16, and arm 30 (see FIGS. 1
and 21), or with legs 16 and foot 28 (see FIG. 29)). The tab(s) 32
can help to provide space for the head of the fastener that can be
attached through the clip. For example, as is illustrated in FIGS.
1, 4, and 21, the base can comprise sides 12,14 (extending in the Y
directing away from the engagement) defining area 20 (which can be
hollow (see FIGS. 1) or solid (see FIG. 4)), with arm 30 extending
from the side 14 to leg 16 (which extends in the Y direction toward
the engagement). The foot 28 can extend away from stem 22 in one or
both direction, e.g., forming a L-shaped foot (see FIGS. 6 and 25)
or a T-shape (see FIGS. 1, 14, 17, 21, and 29), with the stem,
respectively. The T-shaped stem allows even alignment of the
assembled panels since both of the adjacent panels are held the
same distance from the support. However, the L-shaped foot only
extends along one panel and hence does not support the panels
evenly when assembled (e.g., the panels will be offset by the
thickness of the foot 28 and, if present, the tab 32).
[0088] When the clip 10 is assembled onto adjacent panels 200, 202
(see FIG. 4), side 12 is adjacent the first panel 200, while side
14 is adjacent the second panel 202. Arm 30 can be used to attach
the clip 10, and hence the panels 200,202, to a support 300 using
fastener(s) 302. Similarly, when an arm 30 is not present,
fastener(s) 302 can be attached to the support 300 through the foot
28 (see FIG. 15). Exemplary fasteners include a bolt, screw, nail,
rivet, nut, peg, glue, two-sided tape, as well as combinations
comprising at least one of the foregoing. Exemplary supports
include a beam (e.g., purlin, I-beam, rectangular beam, etc.),
piling, wall, a rafter, post, header, pillar, roof truss, as well
as combinations comprising at least one of the foregoing.
[0089] In order to prevent the panels 200,202 from being unlevel
due to the presence of the fastener 302, the side(s) 12,14, and/or
leg(s) 16 have a length "l", and/or the solid area 20 has a
thickness, that is greater than or equal to the height "h" that the
fastener head 304 extends from the linear portion 22 toward the
panels. If there is a difference in the thickness of the panels (in
the Y direction), the side(s) 12,14, and/or leg(s) 16 have a length
"l", and/or the solid area 20 has a thickness (as is appropriate),
to compensate for the difference in the panels' thicknesses, such
that, when the panels, connector, and clip are assembled together,
the outer surface 208 of the panels are level with one another;
they are aligned. In other words, the side(s) 12,14, and/or leg(s)
16 have different length "l", and/or the solid area 20 has a
different thickness, wherein the difference in the length/thickness
is equal to the difference in the panels' thicknesses.
[0090] Further structural integrity can be attained in the clip via
the use of an optional extension from the leg(s) 16 and/or sides
12,14, e.g., support 26. Lateral extension(s) 26 (e.g., see FIGS.
1, 14, 17, 21, and 29) can be employed with the various embodiments
of the clip, wherein the lateral extension(s) can extend toward
and/or away from the adjacent panel to which the clip is connected.
For example, the lateral extension(s) can extend toward and/or away
from the stem 22 (in the X direction). These extension(s) can
provide support to the panel as well as can inhibit air, water,
and/or insect infiltration.
[0091] At the end of the stem 22 opposite the foot 28 is an
engagement that can be located in an opening in the side collector
and/or can contact a surface of the side collector. Exemplary
engagements include a cross-member 24 (see FIGS. 1, 21, and 29),
wing(s) 36 (see FIGS. 6, 14, 17, and 25), and/or receiver 40 (see
FIGS. 14, 17, and 21). In various embodiments, the engagement can
have a generally T-shape (e.g., the cross-member 24 is located
perpendicular to the stem 22), and/or can be arcuate (e.g.,
extending from the stem 22 in a manner complementary to the shape
of the side collector outer surface 214); such as wing(s) 36.
Hence, the engagement can be configured to be located in an opening
in the side collector (see FIGS. 3 and 4, opening 212 in side
collector 210), or can, when assembled, be located between the side
collector (e.g., the outer surface 214) and the connector (e.g.,
the inner surface 122) (see FIG. 26, wing(s) 36 contacting surface
(slide region) 214). When the engagement is configured to be
located in the opening 212, the stem has a length that is less than
the height of the receiving area (e.g., both measured in the Y
direction). In other words, the stem has a length that is less than
the thickness of the panel that will be received in the receiving
area 232.
[0092] The cross-member 24 can extend out from the stem 22 in the
"X" plane (e.g., see FIGS. 1, 21, and 29), in one or both
directions (e.g., positive and negative) and the distance in each
direction can be the same or different. Similarly, one or more
wings can extend from the stem 22 along the "X" plane, in one or
both directions, with the length of the wings being the same or
different (see FIGS. 6, 17, 21, and 25). Larger wing widths provide
higher wind loads. The desired width of the wings (e.g., from the
end of one wing to the end of the other wing), is therefore
dependent upon the intended application and desired structural
integrity. Wing spans of up to and exceeding 50 mm can be employed,
specifically spans of 5 mm to 40 mm, and more specifically spans of
10 mm to 30 mm.
[0093] With respect to the angle at which the cross member (and
wings) extend from the stem 22, it is also determined based upon
desired structural integrity and the desired shape of the side
collector to which the clip will connect. The cross-members can
extend from the stem at an angle .theta. of 85.degree. to
95.degree., with an angle of 90.degree. desirable to enable higher
loadings. An angle .theta. of more than 90.degree. reduces load
potential while an angle .theta. of less than 90 inhibits assembly
of the panels and the clip, and can make it not possible to
assemble. The wings are generally curved and extend from the stem
at an angle .theta. of 100.degree. to 155.degree., specifically,
35.degree. to 75.degree., and more specifically, 40.degree. to
50.degree.. For example, clips having an angle .theta. of
90.degree. have a loading capacity of 100 pounds per square foot
(psf), while at an angle of 135.degree., the clip (comprising the
same material and thickness), has a loading capacity of less than
80 psf.
[0094] The length of the clip (i.e., in the Z direction) is also
dependent upon desired structural integrity (e.g., wind load
resistance). When maximum wind load resistance is desired, the clip
length is equal to the length of the panel. When less resistance is
needed, the clip can have a length that is less than or equal to
50% of the length of the panel, specifically less than or equal to
25% of the length of the panel, and more specifically, less than or
equal to 10% of the length of the panel. For example, the clip
length can be less than or equal to 24 inches (61 centimeters
(cm)), specifically, less than or equal to 12 inches (30.5 cm),
more specifically, less than or equal to 6 inches (15.2 cm), yet
more specifically, less than or equal to 3 inches (7.6 cm), and
even less than or equal to 2 inches (5.1 cm).
[0095] In addition to the cross-member(s) 24 and/or wing(s) 36, the
engagement can further comprise flange(s) 38. The flange(s) are
configured to receive a portion of the connector and/or fastener(s)
(e.g., to receive protrusion 120 into region 42 defined by
flange(s) 38; see FIGS. 20 and 21; and/or to receive fastener 302
(see FIGS. 14 and 15)). Therefore, the flange(s) 38 can optionally
be threaded, and/or comprise an adhesive or bonding agent, e.g., to
facilitate retention between the clip and the connector. In
addition to the flange, support structure 40 may extend outward
from the flange and to the wing to provide additional structural
integrity to the flange (see FIGS. 14 and 17). The geometry of the
support structure is preferably complementary (e.g., the negative)
of the geometry of the portion of the connector and/or collector to
which it will be adjacent when assembled.
[0096] The stem 22 extends from a base 18 (e.g., from the foot 28)
to the engagement. Therefore, if the engagement is configured to be
located in the opening 212, the stem 22 will have a length that is
less than the thickness of the panel, while if the engagement is
configured to physically contact the surface 214 of the side
collector, the stem 22 will have a length that is greater than or
equal to the thickness of the panel (measured in the Y plane).
[0097] Referring to FIG. 37, this figure is intended to show that
the above configurations can be reversed such that the connector is
the male element and the side collectors form the female element to
enable mating of these components. In this exemplary embodiment,
when the side collectors are assembled together, the joint walls
274 form the cavity 272. As with the other embodiments, any
complementary mating engagement can be employed, such as snap-fit,
tongue-and-groove, etc. The connector can further be attached to
one or both of the side collectors with a fastener 302. As can be
seen from the figure, this arrangement enables a small profile
since there is a minimum amount of connector and no side collector,
extending away from the panels. The distance that the support 166
of the side collector extends away from the side collector 210 is
dependent upon the size of the panels and the clips. For example,
the support 166 can have a thickness (measured in the Y direction),
that is less than or equal to 30% of the thickness of the panel
(measured in the Y direction), specifically, less than or equal to
20%, and even less than or equal to 10%. In some embodiments, the
support has a thickness of less than or equal to 40 mm,
specifically, less than or equal to 30 mm, and more specifically,
less than or equal to 20 mm, and even less than or equal to 10
mm.
[0098] Referring to FIGS. 38 and 39, exemplary embodiments
illustrating connector assemblies that use the side collectors to
hold the panels together without the need for connectors. In these
embodiments, mating pairs of side collectors have complementary
geometries (e.g., snap-fig (FIG. 38), or tongue-and-groove (FIG.
39)). In these embodiments, the side collectors do not have mirror
geometries with each other (e.g., as is illustrated in many of the
other figures. They have complementary, mating geometries that
enable the two side collectors to fixedly mate (e.g., to hold
together so as separate only when intentionally disassembled). In
many embodiments, of these side collectors, and even of the above
connector/side collector groups, the elements permanently mate
(e.g., once the elements are assembled they cannot be disassembled
without breaking one or more of the components).
[0099] The connector, side collector, and clip can, independent of
the other elements, comprise any material that gives the desired
properties (e.g., light transmission, insulation, strength,
durability, and/or impact resistance, etc.). For example, they can
each, independently comprise a metal (e.g., aluminum), a polymeric
material (e.g., acrylic, polycarbonate, etc.), or combinations
comprising at least one of the foregoing. Panels, side collectors,
and/or connectors can optionally, independently, be solid or hollow
(e.g., multiwall, for example comprising support structures, such
as ribs). If the ribs are present, the density, configuration
(straight, angled, parallel, perpendicular, etc.) of the ribs, is
merely dependent upon the desired structural integrity and
transmissivity of the particular element. For the side collectors
and connectors, the ribs can have a thickness of up to 1 mm,
specifically, 0.25 to 0.75 mm, and more specifically, 0.35 to 0.6
mm. In some embodiments, the diagonal ribs have a greater thickness
than the parallel and/or perpendicular ribs (wherein parallel and
perpendicular are determined in relation to the X direction).
Diagonal ribs are ribs that are neither parallel nor perpendicular.
In other words diagonal ribs not parallel or perpendicular to the
panel outer surface when the element (collector or connector) is
attached to the panel. Diagonal ribs provide improved stiffness in
all directions compared to vertical and horizontal ribs. Ribs,
particularly diagonal ribs, can be used to tune the degree of
stiffness (e.g., flexibility of the elements). Desirably, the
connector engagement region of the side collector is stiff (rigid
such that it does not flex or bend when being assembled with the
connector), while the connector has flexible sides 156 to enable it
to be assembled over the side collector.
[0100] Similarly the panels can be solid, hollow, or a combination
thereof (e.g., can be multiwall panels wherein cavities of the
panels are hollow and may optionally be filled, e.g., comprise a
fluid (such as gas, liquid and/or gel)), depending on the desired
properties of the structure (e.g., soundproof, heat transmission,
light transmission, weight, etc.). For example, the panels can
optionally be arranged so that there is a space between adjacent
stacked panels (e.g., see FIGS. 15 and 18) or without space between
the adjacent stacked panels (e.g., see FIG. 12), and the panels can
be solid, hollow, and/or filled (with a fluid such as a liquid,
gel, and/or gas), with a variety of rib configurations (e.g., see
FIGS. 12, 15, and 18).
[0101] If multiwall panels are used, any number of layers or sheets
can be used, with any combination of support structures being
contemplated for use. Owing to the connector assemblies (e.g., to
the separate side collectors), one can choose a panel having any
desired thickness, structure (multiwall or solid), color,
width/length, and shape, and adapt its edges to bear edge
connectors having the desired attachment structure, and affix it to
other panels having edge connectors with complementary attachment
structure. Standard panel thicknesses are 4, 4.5, 6, 8, 10, 16, 20,
25, 32, 35, 40, 45 and 50 mm, and further, different varieties of
multiwall panels are available, generally having 2 to 10 layers,
specifically, 2 to 6 layers (e.g., with 1 to 5 cells across the
panel thickness). Also, the cavities can have a variety of internal
structures (rectangular passages, triangular passages, etc.).
Furthermore, conceivably, due to the flexibility attained with the
side collectors, radically different panels (e.g., a 4 mm solid
panel and a 32 mm multiwall panel) can be fit together, so long as
the panels were each fit with side collectors having complementary
attachment structures.
[0102] Once the side collector is attached to the panel (or if it
is integral) assembly of the panels with the connector assembly can
comprise inserting a clip into the side collector (e.g., where it
engages the rectangular cut out). In other words, sliding the
cross-member into the opening in the side collector. The clip can
then be fastened to the support. A second panel, with side
collector attached, can be slid up against the first panel so that
the two touch or are in close proximity and so that the side
collector of the second panel engages the clip. Finally, the
connector is attached to the extended legs of the side collectors
(i.e., to the connector engagement region) to secure everything
together.
[0103] The connector(s), collectors, and clips can be formed using
various techniques, such as extrusion (e.g., a metal/plastic
co-extrusion, a plastic coextrusion with a caplayer (e.g., for
ultraviolet protection, and so forth)). The metal/plastic
co-extrusion could be used to attain enhanced rigidity to withstand
very high forces like hurricane force winds. The metal could be
incorporated in the area(s) of the plastic. For example, referring
to FIG. 31, the metal 260 could be coextruded with the plastic to
provide enhanced structural integrity to the arms 230, opening 212,
and/or part or all of the joint side of the collector (e.g., from
the bottom to the opening 212). In some embodiments, the metal is
coextruded in the area of one or both arms, and/or along the base
258, and/or along the joint wall 254. The metal can extend up the
joint wall 254 along the entire body portion, and/or from the base
258 up to and/or through the opening 212 (if present). In some
embodiments, the metal is coextruded along the base and joint wall,
but not along the arms.
[0104] An advantage of the present method is that bonding secondary
elements (e.g., collectors) to either multiwall or solid sheet
products relying on adhesive systems are messy and have an
extensive manual element. Ultrasonic welding techniques employed in
the past resulted in poor bond strength and/or crushed multiwall
panels. Other mechanical fastening or heat welding techniques
resulted in surface blemishes or other unsightly marks on the
materials surface. The technique disclosed herein includes a
bonding technique which provides for an intimate bond between
similar materials making up the panel and the attachment. The use
of the energy directors can facilitate the bond between the
attachment elements (the side collector and the panel, the
connector and the side collector, etc. (e.g., standing seam leg,
tongue or groove attachment, snap attachment, etc)). It was
discovered that the inclusion of these energy directors enables the
use of ultrasonic welding without crushing the multiwall panel or
creating a weak bond between two flat polymer surfaces.
[0105] The various connectors, collectors, and assemblies disclosed
herein address the issue of needing expensive aluminum extrusions
for connectors. The present assemblies provide enough strength to
withstand hurricane force (200 mph) winds with the use of plastic
connector and collectors, (or the side collectors when no connector
is used). The combination of the profile structure and the clips
that connects the panels to support (e.g., rafter, etc.) has been
modeled to provide enough strength to withstand these high
loads.
[0106] Additionally, with the separate side collectors, substantial
reduction in shipping costs can be attained. Since the panels do
not include the side collectors, they can be packaged in a much
smaller area, thereby allowing shipping of greater than or equal to
40% more product in the same space, with greater than or equal to
50% believe possible.
[0107] In one embodiment, a connector assembly can comprise: a
connector and a pair of side collectors. Each side collector can
comprise a connector engagement region having a size and geometry
to mate with the connector so as to hold ends of two adjacent
panels together, and a panel engagement region comprising a
receiving area having an energy director extending into the
receiving area, and having a size to attach onto an edge of the
panel.
[0108] In another embodiment, a connector assembly can comprise: a
first side collector, comprising a first panel engagement region
comprising a first receiving area that has a size to attach onto an
edge of a first panel; and a second side collector, comprising a
second panel engagement region comprising a second receiving area
that has a size to attach onto an edge of a second panel. The first
side collector and second side collector can be configured to
directly mate with each other to hold to panels together.
[0109] In yet another embodiment, a connector assembly can
comprise: a pair of side collectors, and a connector having a
support and an extension protruding therefrom. Each side collector
can comprise a cavity that when assembled with the other side
collector forms a connector engagement region, and a panel
engagement region comprising a receiving area having a size to
attach onto an edge of the panel. The extension and the cavity can
have a size and shape to enable the extension to be inserted into
the cavity so as to hold ends of two adjacent panels together. The
connector can be further configured to be attached to each side
collector with a fastener.
[0110] In an embodiment, a connector can comprise: two cavities
defined by flexible walls, wherein each of the cavities has a
geometry and is configured to mate with connector engagement
regions from a pair of side collectors; and a header located
between the two cavities. The cavities can enable two sets of
panels to be stacked and connected with the connector.
[0111] In an embodiment, a side collector comprises: a connector
engagement region comprising head having a size and geometry to
mate with a panel connector; and a panel engagement region
comprising a receiving area having an energy director extending
into the receiving area, and having a size to attach onto an end of
a panel.
[0112] In the various embodiments: (i) the connector assembly can
further comprise a clip, wherein the clip has a base that can be
attached to a support, an engagement, and a stem extending
therebetween; wherein the panel engagement region further comprises
an opening in a joint wall on a side of the panel engagement region
opposite the receiving area, wherein the opening is configured to
receive the engagement; and/or (ii) the connector assembly can
further comprise a clip, wherein the clip has a base that can be
attached to a support, an engagement, and a stem extending
therebetween; wherein the base comprises elements that, when
assembled with the connector, collector, and panels, the panels
will be level; and/or (iii) the connector assembly can further
comprise a clip, wherein the clip has a base that can be attached
to a support, an engagement, and a stem extending therebetween;
wherein the base comprises a "U" shaped section formed by a side
and a leg, and wherein the side and leg have a length that is
greater than a height of a fastener head, and an area extending
from the side, away from the leg to another side; and/or (iv) the
connector assembly can further comprise a clip, wherein the clip
has a base that can be attached to a support, an engagement, and a
stem extending therebetween; wherein the base comprises a "U"
shaped section formed by a foot connected to the stem and extending
perpendicular thereto, and legs extending from the foot in a Y
direction toward the engagement, and wherein the legs have a length
that is greater than a height of a fastener head; and/or (v) the
connector assembly can further comprise a clip, wherein the clip
has a base that can be attached to a support, an engagement, and a
stem extending therebetween; wherein the engagement has threaded
flanges, and wherein the engagement has a complementary geometry to
be disposed between the connector and the collector; and/or (vi)
the receiving area can be defined by comprises an arm extending
from a wall, and wherein arm comprises a plurality of the energy
directors, and wherein one of the energy directors is located at
the end of the arm away from the connector engagement region;
and/or (vii) the connector assembly can further comprise a second
arm extending from an opposite end of the wall to define the
receiving area, wherein the second arm comprises a plurality of the
energy directors, and wherein the energy directors extending from
the second arm are staggered with respect to the energy directors
extending from the first arm, except for an optional energy
director located at the end of the second arm opposite the wall;
and/or (viii) the receiving area can be defined by a wall with arms
extending therefrom, wherein the arms can each have an energy
director protruding into the receiving area from an end of the arm
(e.g., the end of the arm opposite the wall); and/or (ix) on a side
of the side collector opposite the receiving area is a joint wall,
wherein the joint wall can be non-perpendicular as determined with
respect to an arm of the receiving area, such that, when two
complementary side collectors are assembled together, a thermal
expansion space is formed between adjacent joint walls; and/or (x)
on a side of the side collector opposite the receiving area is a
joint wall, wherein when two complementary side collectors are
assembled together, a thermal expansion space is formed between
adjacent joint walls, and wherein the connector assembly further
comprises a spacer located in the thermal expansion space; and/or
(xi) the panel engagement region can further comprise a body
portion located between the receiving area and the connector
engagement region, and wherein the body portion comprises diagonal
ribs; and/or (xii) the connector can be permanently mated to a pair
of side collectors; and/or (xiii) a pair of complementary side
collectors can be permanently mated together; and/or (xiv) the
first side collector and the second side collector can have a
mating geometry selected from the group consisting of tongue and
groove, and snap-fit; and/or (xv) the connector and a pair of side
collectors can have a mating geometry selected from the group
consisting of tongue and groove, and snap-fit; and/or (xvi) the
first side collector can further comprise a first wall with two
first arms extending therefrom to define the first receiving area
and first energy directors extending from the first arms into the
first receiving area, and the second side collector can further
comprise a second wall with two second arms extending therefrom to
define the second receiving area and second energy directors
extending from the second arms into the second receiving area;
and/or (xvii) the first side collector and the second side
collector can have complementary openings configured to receive an
engagement of a clip that is configured to secure the first side
collector and the second side collector to a support (e.g., the
engagement can extend from an end of a stem that has a length that
is less than a height of the first receiving area); and/or (xviii)
the extension (e.g., connector male extension) and the cavity
(e.g., the side collector female cavity) can form a mating geometry
selected from the group consisting of tongue and groove, and
snap-fit; and/or (xix) the support (e.g., connector support) can
have a thickness of less than or equal to 20 mm (e.g., as measured
in the Y direction); and/or (xx) the connector can further comprise
a first slot on a side of the connector and between the cavities,
wherein the first slot has a size and geometry to receive and end
of a panel without a side collector; and/or (xxi) the connector can
further comprise a second slot on another side of the connector
opposite the first slot and between the cavities, wherein the
second slot has a size and geometry to receive and end of another
panel without a side collector; and/or (xxii) the header (e.g., the
header of the connector) can be configured to receive a fastener
that attaches the connector to flanges of a clip that is configured
(e.g., designed) to secure the connector to a support structure
with a fastener. The panel assemblies can comprise any of the above
side collectors, and/or connectors, and/or clips.
[0113] All ranges disclosed herein are inclusive of the endpoints,
and the endpoints are independently combinable with each other
(e.g., ranges of "up to 25 wt. %, or, more specifically, 5 wt. % to
20 wt. %", is inclusive of the endpoints and all intermediate
values of the ranges of "5 wt. % to 25 wt. %," etc.). "Combination"
is inclusive of blends, mixtures, alloys, reaction products, and
the like. Furthermore, the terms "first," "second," and the like,
herein do not denote any order, quantity, or importance, but rather
are used to denote one element from another. The terms "a" and "an"
and "the" herein do not denote a limitation of quantity, and are to
be construed to cover both the singular and the plural, unless
otherwise indicated herein or clearly contradicted by context. The
suffix "(s)" as used herein is intended to include both the
singular and the plural of the term that it modifies, thereby
including one or more of that term (e.g., the film(s) includes one
or more films). Reference throughout the specification to "one
embodiment", "another embodiment", "an embodiment", and so forth,
means that a particular element (e.g., feature, structure, and/or
characteristic) described in connection with the embodiment is
included in at least one embodiment described herein, and may or
may not be present in other embodiments. In addition, it is to be
understood that the described elements may be combined in any
suitable manner in the various embodiments.
[0114] While particular embodiments have been described,
alternatives, modifications, variations, improvements, and
substantial equivalents that are or may be presently unforeseen may
arise to applicants or others skilled in the art. Accordingly, the
appended claims as filed and as they may be amended are intended to
embrace all such alternatives, modifications variations,
improvements, and substantial equivalents.
* * * * *