Structural panel chase connection manufacture method

Abstract

Structural Panel Chase Connection Manufacture Methods are the embedded frame solution to the problems associated with providing access for services, such as plumbing or electrical chases with high precision and accuracy. Connecting two or more panels in any direction using the embedded frame method becomes easy yet incredibly strong without requiring special tools for assembly or disassembly, so that components can be flat packed and stored when not in use. Flexible and variable these Structural Panel Chase Connection Manufacture Methods can accommodate a wide variety of dimensional configuration, not limited to only panel, post and beam configurations and can be manufactured using any available flat building materials.

Claims

1. A method of assembling a laminate panel, comprising: preparing a side material, said side material comprising a first flat base sheet, a second flat base sheet and a plurality of strips between said first flat base sheet and said second flat base sheet, said strips extending from a first side of said first and said second sheet to a second side opposite said first side of said first and said second sheet, and a channel being between adjacent ones of said strips, each said channel extending from said first side of said first sheet and said second sheet to said second side of said first sheet and said second sheet; cutting said side material into a first stile and a second stile; placing said first stile and said second stile in a spaced relationship, each said stile having a first end portion and a second end portion; placing a first rail and a second rail, each said rail having a first surface and a second surface opposite said first surface, said first rail being between said first end portions of said first stile and said second stile and said second rail being between said second end portions of said first stile and said second stile; said first stile, said second stile said first rail and said second rail forming a perimeter of said panel and defining a space; placing a first additional member in said space, said first additional member extending from said first stile to said second stile, and placing a second additional member in said space, said second additional member extending from first stile to said second stile, placing a first surface material over said first surfaces of said first stile, said second stile, said first rail and said second rail, placing a second surface material over said second surfaces of said first stile, said second stile, said first rail and said second rail to form said panel.

2. The method of claim 1, further comprising: placing a connection block having a hole drilled therein into one of said channels, said connection block configured for use in connection of adjacent panels.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

(2) FIGS. 1A-1C illustrate exemplary embodiments for a lamination of materials together to create the structural panel with chase voids (FIG. 1 C.4) in accordance with the present enclosure;

(3) FIGS. 2A-2D illustrate additional embodiments for cutting panels into strips (FIG. 2 A) and using as framing material inside empty of filled (filled not shown) panel configuration in accordance with the present enclosure;

(4) FIG. 3A-3C illustrate details of connection point (FIG. 3 A.4) without and with connection block (FIG. 3 B) insert with zoomed-in cutaway view.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(5) Related art consists of four sets of drawings.

(6) FIGS. 1A-1C illustrate exemplary embodiments for a lamination of materials together to create the structural panel with chase voids (FIG. 1) in accordance with the present enclosure. FIG. 1A depicts the flat base material (1) on which the (FIG. 1B) sub material (2) is placed with channel spaces between. FIG. 1C demonstrates the top layer of flat material (3) which is applied prior to press lamination of all components. The interior material is oriented perpendicular to create high precision channels (4) in the base material (which will be sliced into framing material).

(7) FIGS. 2A-2D illustrate additional embodiments for cutting panels into strips and using as framing material inside empty or filled panel configuration in accordance with the present enclosure. This set of drawings depict the use of the strips cut from full panel (FIG. 1C) to create frame material with high precision channels to create an interior frame in a flat panel configuration. FIG. 2A represents two stiles left and right of a frame. FIG. 2B shows completed stile and rail frame. FIG. 2C shows how service chases (5) can be installed and FIG. 2D shows how exterior surface material (6) can be laminated to the result (filled or voids inside panel).

(8) FIG. 3A-3C illustrate details of connection point without and with block insert. Set of drawings show the high precision receptacles used as connection points, joining multiple panels in a side by side configuration using connecting blocks. FIG. 3A zooms-in on the detail of the high precision connection point seen as a rectangular hole left open (4). FIG. 3B details the connection block (7) shown which fills the open rectangle hole and this version is pre-drilled with a tension connection hole (8) for running a rod or cable through which can be tightened and secured for extra strength in temporary conditions. Tension can be released for rapid disassembly. Block shown in FIG. 3C is set up for straight in-line assembly of successively joined panels. The dotted line midway of the block (9) indicates that one-half of the block would be inside the vacant opening (4) and the other half, otherwise exposed, would be inserted into the adjoining panel vacancy for connecting the two panels together. FIG. 3C also depicts the laminated materials used to create a full finished panel. From left to right would be the surface material (6), the base material (1), with the sub material (2) in the middle, followed by closing base material (3) and another surface material (6). Other blocks can come in different shapes and sizes to accommodate connecting and securing at any angle, for example L-shaped blocks for 45-degree angles.