Abstract
A ventilated structural panel comprising a first sheet, having a long axis defining a length and a perpendicular short axis defining a width, a plurality of spacing structural elements, fixedly attached to the first sheet such that the yield strength of the panel is greater than the individual yield strength of the first sheet, and the plurality of spacing structural elements being formed such that a plurality of unobstructed pathways are created for air to move from at least one edge of the panel to at least one of an opposite and an adjacent edge of the panel, wherein the first sheet is the only sheet in the panel.
Claims
1. A ventilated structural panel comprising: a first sheet, having a long axis defining a length and a perpendicular short axis defining a width; a plurality of spacing structural elements, fixedly attached to the first sheet such that the yield strength of the panel is greater than the individual yield strength of the first sheet; and the plurality of spacing structural elements being formed such that a plurality of unobstructed pathways are created for air to move from at least one edge of the panel to at least one of an opposite and an adjacent edge of the panel wherein the first sheet is the only sheet in the panel.
2. The ventilated structural panel in claim 1, wherein the first sheet is made of one of plywood, Oriented Strand Board, and medium-density fiberboard.
3. The ventilated structural panel in claim 2 wherein the first sheet is between 0.125 inches and 1.5 inches in thickness, not including the thickness of any spacing structural elements
4. The ventilated structural panel in claim 3 wherein each spacing structural element is (a) aligned parallel to other spacing structural elements of the panel, and (b) spaced apart from any adjacent spacing structural elements between 1 to 18 times a thickness of the each spacing structural element.
5. The ventilated structural panel in claim 4, wherein each spacing structural element is formed integrally with the first sheet.
6. The ventilated structural panel in claim 4, wherein each spacing structural element is rectangular shaped.
7. The ventilated structural panel in claim 4, wherein the surface of the first sheet has a plurality of through holes, the holes measuring between 0.0625 inches and 1.5 inches in diameter.
8. The ventilated structural panel in claim 4, wherein each spacing structural element measures between 0.25 inches and 1.50 inches in width.
9. The ventilated structural panel in claim 4, wherein each spacing structural element is equidistance from each adjacent spacing structural element of the panel.
10. The ventilated structural panel in claim 9, wherein a distance of between 5 and 16 times the width of each elongated member separates each elongated member from each neighboring elongated member of the same layer.
11. The ventilated structural panel in claim 9, further comprising the elongated members being comprised of one of wood, wood composite, plastic, a non-cellulose fibrous material, a combination of wood and plastic, and a combination of a cellulose material and one of a plastic material, a ferrous material, a non-cellulose fibrous material, and an other metallic material.
12. The ventilated structural panel in claim 11 further comprising at least three unobstructed pathways.
13. The ventilated structural panel in claim 12 wherein the plurality of spacing structural elements are arranged such that the panel has a unobstructed airflow of at least approximately 30% of an area of the panel.
14. The ventilated structural panel in claim 12 wherein a length of each of the plurality of spacing structural elements is equal to width of each of the plurality of spacing structural elements at least 2 inches.
15. The ventilated structural panel of claim 12 wherein the spacing structural elements are engineered matrix members.
16. The ventilated structural panel of claim 15 wherein the engineered matrix members are I beam shaped, having first and second flat sections joined by a transverse section having a width thinner that a width of each of the fist and second flat sections.
17. The ventilated structural panel of claim 15 wherein the engineered matrix members are truss shaped, having first and second flat sections joined by a truss web, the truss web being formed of a plurality of truss web supports, the truss web supports being one of diagonal supports, vertical supports, and both diagonal supports and vertical supports, where the truss web supports are one of cellulosic material, metallic material, and both cellulosic material and metallic material.
18. The ventilated structural panel of claim 15, wherein the panel has a length of at least 24 feet.
19. The ventilated structural panel of claim 15, wherein the panel has a width of at least 16 feet.
20. The ventilated structural panel of claim 15, wherein the panel has a length at least 24 feet and a width of at least 16 feet.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0079] FIG. 1 is an exploded depiction of an embodiment of the panel;
[0080] FIG. 2 is plan view of an embodiment of the panel;
[0081] FIG. 3 is a plan view of an embodiment of the panel depicting the indented space and protruding segments;
[0082] FIG. 4 is a close-up iso view of an embodiment of the panel, depicting the indented space, protruding segments, and chamfered edges;
[0083] FIG. 5 is an iso view of the panel mounted on mounting elements;
[0084] FIG. 6 is an iso view of an embodiment of the panel utilizing plywood veneer as spacing structural elements, without showing the top sheet;
[0085] FIG. 7 is an iso view of an embodiment of the panel where the spacing structural elements are aligned diagonally, without showing the top sheet;
[0086] FIG. 8 is an iso view of an embodiment of the panel utilizing rectangular blocks as spacing structural elements, without showing the top sheet;
[0087] FIG. 9 is an iso view of an embodiment of the panel utilizing circular blocks as spacing structural elements, without showing the top sheet;
[0088] FIG. 10 is an iso view of an embodiment of the panel utilizing square blocks as spacing structural elements, without showing the top sheet;
[0089] FIG. 11 is a close-up iso view of an embodiment of the panel, depicting the indented space, protruding segments, and chamfered edges;
[0090] FIG. 12 is an iso view of an embodiment of the panel with perforations in one sheet, viewed from the underside;
[0091] FIGS. 13A and 13B are side views of two roof arrangements constructed with the panels;
[0092] FIG. 14 is a sectional view of a roof arrangement constructed with the panels for an unoccupied attic;
[0093] FIG. 15A is a sectional view of a roof arrangement constructed with the panels for an occupied attic;
[0094] FIG. 15B is a sectional view of a roof arrangement constructed with the panels for an unoccupied attic space, where some of the panels are perforated;
[0095] FIG. 16 is an iso view of a roof arrangement constructed using perforated and non-perforated panels;
[0096] FIG. 17 is a sectional view of a portion of a roof arrangement constructed using perforated and non-perforated panels;
[0097] FIG. 18 is a sectional view of a house showing a wall, floor, and roof constructed using the panels;
[0098] FIG. 19 is a sectional view of an insulated house showing a wall, floor, and roof constructed using the panels;
[0099] FIG. 20 is an exploded view of the portion indicated as portion A in FIG. 19;
[0100] FIGS. 20A and 20 B are iso-views of panels with a single layer of spacing structural elements, each having a portion of the top sheet cutaway to show detail;
[0101] FIG. 21 is an iso-view of a panel with a sheet having integrated spacing structural elements;
[0102] FIG. 22 is an iso-view of a panel with two sheets, each having integrated elongated members, with a portion of the top sheet cutaway to show detail;
[0103] FIG. 23 is an iso-view of a panel with two sheet, each having integrated elongated members with rectangular profiles;
[0104] FIG. 24 is an iso-view of a panel with two sheets, each having integrated elongated members with curved profiles;
[0105] FIG. 25 is an ISO view of a sheet having integrated elongated members and the plurality of perforations;
[0106] FIGS. 26A-26D are profile views of multiple examples of potential profiles of integrated elongated members.
[0107] FIG. 27 is an iso views of a panel comprised of a single layer of nesting elongated members.
[0108] FIG. 28 is an up close iso view of two elongated members with a notched attachment.
[0109] FIGS. 29-31 are an up close perceptive views of panels using three different embodiments of specialized shaped engineered matrix members, where the top sheet in each panel is not shown;
[0110] FIGS. 32-33 are close up perspective views of two additional embodiments of specialized shaped engineered matrix members.
DETAILED DESCRIPTION OF THE DRAWINGS
[0111] As seen in FIGS. 1 and 2, the panel 2 is comprised of a first sheet 4 and a second sheet 6 fixedly mated together via spacing structural elements 8. In one embodiment the spacing structural elements 8 are comprised of a first layer 10 and a second layer 12 of rectangular shaped elongated members 14, spaced apart from each other a predetermined spacing distance 16. The arrangement of elongated members 14 in the first layer 10 is perpendicular to the arrangement of elongated members 14 in the second layer 12, forming a matrix 17 of elongated members 14.
[0112] As shown in FIG. 1, a first horizontal edge 18 and a second horizontal edge 20 of the first sheet 4 substantially align with a first horizontal edge 22 and a second horizontal edge 24 of the second sheet 6, respectfully. Similarly, a first vertical edge 26 and a second vertical edge 28 of the first sheet substantially align with a first vertical edge 30 and a second vertical edge 32 of the second sheet 6, respectfully. For sake of clarity, the second sheet 6, though present each embodiment depicted, is not shown in FIGS. 2, 3 and 6-10 below.
[0113] As shown in FIG. 3, the first 10 and the second layer 12 of elongated members 14 are indented a certain first distance 34 inward from the first horizontal edges 18, 22 of the first and the second sheet 4, 6. The first 10 and the second layer 12 of elongated members 14 correspondingly overlap the second horizontal edges 20, 24 of the first and the second sheet 4, 6 by the same first distance 34, creating first protruding segments 35. Similarly, the first 10 and the second layer 12 of elongated members 14 are indented a certain second distance 36 inward from the first vertical edges 26, 30 of the first and the second sheet 4, 6. Likewise, the first 10 and the second layer 12 of elongated members 14 correspondingly overlap the second vertical edges 28, 32 of the first and the second sheet 4, 6 by the same second distance 36, creating second protruding segments 37.
[0114] These matching indents and overlaps aid in fittingly mating a first panel 2 to a neighboring second panel 2 in a secure tongue in grove fashion. By providing corresponding indent and overlap on all four edges, a surface formed of multiple panels may be assembled faster, have increased strength and rigidity as a unit, and helps ensure a continued smooth panel surface. As in the embodiment shown, the first distance 34 of indent and overlap with respect to the horizontal edges can be of the same value as the second distance 36 of indent and overlap in the horizontal direction. It is to be noted that the indent and overlap have been exaggerated in FIG. 3, to show detail.
[0115] As shown in FIG. 4, a portion of the first protruding segments 35 that overlap the second horizontal edges 20, 24 of the first and the second sheet 4, 6, have a chamfered edge 38. These chamfered edges facilitate inserting the first protruding segments 35 of the first 10 and the second layer 12 of a first panel 2 into a second adjacent panel 2, and specifically into a space provided by the inward indent of the elongated members 14 the first distance 34 from first horizontal edges 18, 22 of the first 10 and the second layer 12 of the adjacent panel. The chamfer on the chamfered edge 38 would terminate between and from the second horizontal edges 20, 24 of the first and the second sheet 4, 6, and preferably would terminate approximately from the second horizontal edges 20, 24 of the first and the second sheet 4, 6.
[0116] In a like manner a portion of the second protruding segments 37 that overlap the second vertical edges 28, 32 of the first and the second sheet 4, 6, have a chamfered edge 38 [not shown]. These chamfered edges similarly facilitate inserting the second protruding segments 37 of the first 10 and the second layer 12 of a first panel 2 into a second adjacent panel 2, and specifically into the space provided by the inward indent of the elongated members 14 the second distance 36 from the first vertical edges 26, 30 of the first 10 and the second layer 12 of the adjacent panel. The chamfer on the chamfered edge 38 would terminate between and from the second vertical edges 28, 32 of the first and the second sheet 4, 6, and preferably would terminate approximately from the second vertical edges 28, 32 of the first and the second sheet 4, 6.
[0117] As shown in FIG. 5, the panel 2 may be mounted onto mounting elements 40 such as roofing rafters or trusses, flooring joists, or wall studs, just as normal plywood or OSB board would be mountedtwelve inches on center. Because of the panels' increased strength, they may be mounted to mounting elements 40 spaced father apart than a plywood or OSB board of the same thickness as the sum of the thickness of the first and second sheet of the panel would require under similar conditionsincluding allowing the panels to be mounted on mounting elements 40 spaced sixteen, twenty four, thirty six, forty two, forty eight, and ninety six inches apart on center.
[0118] Turning to FIG. 6, a plurality of plywood veneer strips 42 may also function as the elongated members 14. In such an embodiment, each elongated structural element 14 may be made up of a plurality of plywood veneer strips 42, ranging from two to ten inch plywood veneer strips 42 per elongated structural element 14, and preferably six inch plywood veneer strips 42 per elongated structural element 14.
[0119] As shown in FIG. 7, the matrix 17 of elongated members 14 may be arranged diagonally with respect to the horizontal 18, 20, 22, 24 and vertical 26, 28, 30, 32 edges of the first and the second sheet 4, 6. In this embodiment, the elongated members 14 of the first layer 10 may be arranged at an angle of between 30 and 60 with respect to the first horizontal edge 18 of the first sheet 4, and preferably at an angle of 45 with respect to the first horizontal edge 18 of the first sheet 4. The elongated members 14 of the second layer 12 may also be arranged at an angle of between 30 and 60 with respect to the first horizontal edge 18 of the first sheet 4, and preferably at an angle of 45 with respect to the first horizontal edge 18 of the first sheet 4.
[0120] As shown in FIGS. 8 through 10, the spacing structural elements 8 may also be comprised of blocks 44 being preferably rectangular 46, circular 48, or square 50 in shape. Though according to tests, panels 2 utilizing blocks 44 as the spacing structural elements 8 increased the strength of a comparable plywood board by only half as much as panels 2 utilizing elongated members 14 as the spacing structural elements 8, panels utilizing blocks 44 as the spacing structural elements 8 offer an increased assortment of paths that a pipe, tube, wire, or other insert 52 may be run through the panel 2, especially if the insert has dimensions approaching one half the spacing between the first and second sheet 4,6.
[0121] As shown in FIGS. 8 and 9 the blocks 44 would also preferably be indented a first and second distance 34, 36, and similarly have first and second protruding segments 35, 37, correspondingly overlapping their respective edges the same first and second distances 34, 36.
[0122] As shown in FIG. 8, the blocks 44 could also be aligned diagonally with respect to the horizontal 18, 20, 22, 24 and vertical 26, 28, 30, 32 edges of the first and the second sheet 4, 6. In this embodiment, the blocks 44 may be arranged at an angle of between 30 and 60 with respect to the first horizontal edge 18 of the first sheet 4, and preferably at an angle of 45 with respect to the first horizontal edge 18 of the first sheet 4.
[0123] As shown in FIG. 11, the protruding segments 35, 37 of the blocks 44 would similarly be provided with a chamfered edge 38, to assist in inserting the protruding segments 35, 37 of the blocks of a first panel 2 into the space provided by the blocks 44 of an adjacent second panel 2 indented at least as much as the distance the protruding segments 35, 37 protrude past the edge of the first and the second sheet 4, 6.
[0124] Turning to FIG. 12, a perforated panel 2 with a perforated first sheet 4 is shown. The perforations 46 are arranged in a matrix type arrangement and facilitate the passage of air from the outside of the perforated panel 2, through the perforated first sheet 4, via the plurality of perforations 46 into the interior of the perforated panel 2. The perforations 46 are through holes of between 1/16 inches and inches in diameter, and preferably between inches and 1 inch in diameter, and most preferably between inches and inches in diameter. The matrix arrangement may be staggered, with each hole spaced between 4 and 12 diameters from adjacent holes. Additionally, a layer of screening 80 (not shown) may be attached to the inner surface of the perforated first sheet 4. The perforated panel 2 is constructed in a similar manner to the non-perforated panel 2, with the exception of perforating or using a perforated first sheet 4, and the perforated panel 2 may be used in the same manner as the non-perforated panel 2.
[0125] Turning to FIGS. 13A and 13B, two panel roofing arrangements are shown. FIG. 13A shows a panel arrangement suited for unfinished attics and non-living spaces. The panels 2, 2 are arranged so that neither the first nor the second sheets 4, 4, 6 of the panels 2, 2 opposite the ridge meet, leaving an interior ridge gap 48 and an exterior ridge gap. The ridge will be capped with a ridge vent 52. The bottommost terminal edges 56 of the panels 2, 2 will be include a screen 54, insect block 58, or other permeable occlusion, arranged to allow air passage into the interior of the panels 2, 2, but hinder insect entry. FIG. 13B shows a panel arrangement suited for finished attics and living spaces. The panels 2, 2 are arranged so that the first sheets 4, 4 of the panels 2, 2 opposite the ridge meet, forming a solid interior ridge 50, but the second sheets 6 of the panels 2, 2 opposite the ridge meet do not meet, leaving an exterior ridge gap. The ridge will be capped with a ridge vent 52, and the bottommost terminal edges 56 of the panels 2, 2 will be likewise permeably occluded.
[0126] As shown in FIG. 14, a panel arrangement for an unoccupied attic is demonstrated. Panels 2, 2 are arranged on trusses and rafters 60 so as to leave an interior ridge gap 48 and an exterior ridge gap, as described in FIG. 13A. The ridge is capped by a ridge vent 52. Warm, moist air 62 from the interior of the house is exhausted through the ridge vent, via the interior ridge gap 48 and exterior ridge gap. The panels are installed with the permeably occluded 54, 58 terminal edges 56 adjacent to openings in soffits or lower fascia (not shown). Cooler air 64 enters through the permeably occluded 54, 58 terminal edges 56, travels through the interior of the panels 2, 2, absorbing heat from the first and the second sheets 4, 4, 6 and mixing with warm moist air entering through perforations 46, and exits through the ridge vent 52, via the exterior ridge gap.
[0127] As shown in FIG. 15A, a panel arrangement for an occupied attic or directly roofed living space is demonstrated. Panels 2, 2 are arranged on trusses and rafters 60 so as to leave an only an exterior ridge gap, as described in FIG. 13B. The ridge is capped by a ridge vent 52. Warm, moist air 62 progresses from the interior of the house through insulation 65 and transfers its heat and moisture to the insulation 65 and first sheets 4, 4 of the panels 2, 2. The panels are installed with the permeably occluded 54, 58 terminal edges 56 adjacent to openings in soffits or lower fascia (not shown). Cooler air 64 enters through the permeably occluded 54, 58 terminal edges 56, travels through the interior of the panels 2, 2, absorbing heat from the first and the second sheets 4, 4, 6 and exits warm air 62 through the ridge vent 52, via the exterior ridge gap. The upper terminal edges 56 forming the upper ridge gaps in each embodiment may also be permeably occluded 54, 58.
[0128] As shown in FIG. 15B a panel arrangement for an unoccupied attic space, using perforated panels is demonstrated. The perforated panels 2 are arranged such that the perforated first sheet faces the interior of the building, allowing warm air 62 to directly enter into the interior of the panel matrix through the perforations 46, from multiple locations in the attic space. Because of the increased ventilation due to the perforations 46 in the perforated panels 2, the panels may be arranged either with or without an interior ridge gap 48. It is envisioned that a ridge vent 52 will be used to cap an exterior ridge gap (not shown) to allow the exhaust of warm air 64 out of the panel matrix, and in combination may be used with one or more gabled vents (not shown).
[0129] As shown in FIGS. 16 and 17, the perforated panels 2 and non-perforated panels 2 may be used in conjunction in a roofing construction arrangement. In one embodiment, the perforated panels 2 are arranged in the top one or more rows of the roof sheathing and the non-perforated panels 2 are arranged in the bottom one or more rows of roof sheathing. The inner first sheets 4 of the upper rows of panels 2 normally lack abutting insulation 65, allowing warm moist air to more freely enter perforations 46. The inner first sheets 4 of the lower rows of panels 2 normally have abutting insulation 65, diminishing air transfer rates through perforations 46, and therefore would normally have non-perforated first sheets 4. It is to be appreciated that sheeting arrangements of all perforated panels 2, all non-perforated panels 2, or any combination of perforated and non-perforated panels 2 2, would still fall in the scope of this invention.
[0130] Turning now to FIGS. 18 and 19, the panels may be likewise used in wall sheathing and flooring. As shown in FIG. 18, a panel 2, 2 may be attached to a wall joist/wall stud 66 and floor joist 68, in a similar manner as traditional sheeting materials. As with roofing embodiments, the terminal edges 56 will include permeable occlusions 54, 58. In one embodiment, a terminal gap 74, facilitated by joist spacing elements 72, here proximate to the ceiling joists 70, provides a passageway for air to inter and exit the interior of the panels 2, 2.
[0131] In the embodiment shown in FIG. 19, a panel 2, 2 is attached to an insulated 65 wall joist/ wall stud and a floor joist 68, with siding 76 attached to the exterior sheet of the panels 2, 2. The flooring panel 2, 2 contains a layer of screening 80 between the first layer 10 and the second layer 12 of elongated members 14. Cool air 64 enters the panel 2, 2 interior by passing through a lower terminal gap 74, facilitated by joist spacing elements 72, then through the permeably occluded 54, 58 lower terminal edge 56, moves up through the interior of the panel 2, 2 absorbing heat and moisture from the first and the second sheets 4, 4, 6, and exits warm air 62 through the permeably occluded 54, 58 upper terminal edge 56, and out an upper terminal gap 74. The air flow may be channeled by one or more first channeling component 78, and as shown in FIG. 20, one ore more second channeling components 82. The first and the second channeling components may be decorative as well as functional, and serve additionally as housing trim.
[0132] FIG. 20 shows a close up of the upper section of FIG. 19, indicated as portion A, showing in detail the upper terminal gap, and the first and the second channeling components 78, 82.
[0133] Turning to FIGS. 21 and 22. A first sheet 4A of a panel 2A with integrated spacing structural elements 8A is shown. The spacing structural elements 8A may take the form of, for example, integrated blocks 44A (not shown) or integrated elongated members 14A. In panels 2A employing integrated elongated members 14A, the integrated elongated members 14A generally run horizontally on a first sheet 4A and will generally run vertically on a second sheet 6A.
[0134] Turning to FIGS. 23, 24, and 26A-D, the profiles of the integrated elongated members are generally either rectangular 100, square 101, or curved 102, or some combination of each, depending upon the application requirements, each providing a plurality of parallel, unobstructed, contiguous pathways 5. As shown in FIG. 26, for example, the integrated elongated members may have flat tops 104, flat sides 106, and angled edges 108, and/or curved tops 110, curved sides 112, and rounded edges 114 or chamfered edges 116. Additionally the sides maybe perpendicular where they intersect the top and/or the interior surface of the sheet 4A, 6A, or at a non-perpendicular angle.
[0135] As shown in FIG. 25, similar to panels 2 described above, a first sheet 4A and/or second sheet 6A of panels 2A with integrated elongated members 14A may also possess perforations 46A, and may be used in similar embodiments as those described in paragraphs above.
[0136] Turning to FIG. 27, a panel 2A comprised of a first and a second sheet 4A, 6A, each having integrated elongated members 14A. In this embodiment, the integrated members 14A on the first sheet 4A are arranged parallel to the integrated members 14A on the second sheet 6A. This arrangement allows the integrated members 14A on the first sheet 4A to be nested within the spacing distance 16 separating the integrated members 14A on the second sheet 6A from one another, when the first and the second sheet 4A, 6A are brought together to form the panel 2A. In the same way, this allows the integrated members 14A on the second sheet 6A to be nested within the spacing distance 16 separating the integrated members 14A on the first sheet 4A from one another. The integrated members 14 A on the first sheet 4A would attach directly to the interior surface of the second sheet 6A in this embodiment. The parallel unobstructed continuous pathways 5 for air would be defined by the interior surface of the first and second sheets 4A, 6A and their respective integrated members 14A, similar to a other single layer embodiments, as compared to being defined by the interior surface of one of the first sheet and second sheet 4A, 6A, and at least three separate elongated members 14, 14A, as in multiple layer embodiments.
[0137] In a related embodiment, integrated elongated members 14A of a first and second sheet 4A, 6A could be arranged parallel such that, instead of nesting within respective spacing distances 16 in the posing sheets 4A, 6A, as shown in FIG. 27, the parallel elongated members 14A of each sheet 4A, 6A could stack substantially directly on top of one another along the full length of the elongated members 14 A (not shown). This would create parallel unobstructed continuous pathways 5 for air that would be two elongated members 14A high, and defined by for elongated members 14 A, two from each of the first and the second sheet 4A, 6A, and the interior surface of both the first sheet 4A and the second sheet, 6A.
[0138] Turning to FIG. 28, a panel 2 is shown wherein the respective elongated members 14 of the first and the second sheets 4A, 6A interacts with one another at their point of attachment in a notch/recess fashion. At the point where a first elongated member 14 contacts a second elongated member 14, one or both of the first and the second elongated member 14 is provided with a notch 118. In the case where only one of the first nor the second elongated member is provided with a notch 118 at their point of interaction, this allows either the first or second elongated member 14 to recess into the notch 118 on the opposed elongated member 14. Or, in the case that both the first and second elongated members 14 are provided with opposing notches 118 at the point of interaction, this allows each elongated member to recess into the notches 118 provided on the opposed elongated member 14. While this notch/recess arrangement creates a potentially stronger bond amongst the elongated members 14 and therefore the panel 2 as a whole, at the same time this decreases the size of the parallel, contiguous, unobstructed pathways 5 for air within the panel 2.
[0139] Additional embodiments of the elongated matrix members 14 are envisioned.
[0140] In their simplest form, an elongated matrix member 14 is a stick or extrusion with a square or rectangular cross section and a length equal to a parallel axis of the sheet 4, 6 to which it is attached. The elongated matrix members 14 are ideally in cross section, but, as mentioned above, can be larger (2 or greater) or smaller ( or smaller) as required for the application. The elongated matrix members 14 are preferably attached to at least one sheet 4, 6 and to one another where multiple layers of elongated matrix members 14 intersect, in order to transfer shear stresses, though the elongated matrix members 14 may have one or more locations where they intersect that they are not attached, in order to increase flexibility of the overall panel, as may be required in certain situations.
[0141] Additionally, engineered matrix members 120 can be utilized and manufactured from a variety of materials, like organic, wood, cellulose or other fibrous materials, plastics, metals or other materials that can be shaped or extruded, and can be formed into the square or rectangular cross sectional shapes discussed previously, or formed into one of many specialized shapes.
[0142] Specialized shaped engineered matrix members 120 will preferably have a first flat section 122 with a rectangular outer face, an opposed second flat section 124 with a rectangular outer face, and transverse section 126 connecting an inner face of the first flat section 122 to an inner face of the second flat section 124. The outer face of at least one of the first and the second flat section 122, 124 will preferably be attached to at least one of a sheet 4, 6 and an outer face of a first or a second flat section 122, 124 of an additional specialized shaped engineered matrix member 120 disposed in an adjacent layer. The range of shapes and structures of the specialized shaped engineered matrix members 120 will vary mainly based upon the design of the transverse section 126.
[0143] In a first embodiment of specialized shaped engineered matrix members 120, I beam shaped members 125 are formed by the first and second flat sections 122, 124 of engineered matrix members 120 being joined by a relatively thin and elongate transverse section 126. The thin elongate transverse section 126 and the inner faces of the first and the second flat sections 122, 124 define two narrow channels, one on each side of the thin elongate transverse section. These narrow channels act to increase the size of parallel, contiguous, unobstructed pathways 5 for air to pass between two adjacent I beam shaped members 125 of a common layer, as compared to similarly spaced elongated members 14 with a square or rectangular cross section.
[0144] Additionally, the thin elongate transverse sections 126 in the I beam shaped members 125 may be solid or perforated. The perforated I beam shaped members 125 offer the benefit of enhanced cross ventilation performance and increase the interior cabling options of the panels, as the perforations 128 provide additional pathways 129 for air and/or cables to pass through the panel 2, and through the very I beam shaped members 125. Either perforated or solid, the I beam shaped members 125 offer the benefit of being easily extruded and utilized in a panel 2.
[0145] Turning to FIG. 30, in a second embodiment of specialized shaped engineered matrix members 120, truss shaped members 130 are constructed by the first and second flat sections 122, 124 of engineered matrix members 120 being joined by a truss web 132 transverse section 126. The truss web 132 is formed of a plurality of truss web supports 134 that can be both diagonal supports of the same or varying angles, and vertical supports. The truss web supports 134 will normally be of approximately an equal width as that of the first and the second flat sections 122, 124.
[0146] In a first embodiment of truss shaped members 130, the truss web 126 is comprised of a plurality of diagonal truss web supports 134 that form a continuous series of triangles down the length of the truss shaped member 130. That is, except for terminal ends of the truss shaped members, at each intersection of a diagonal truss web support 134 with the inner face of the first and the second flat sections 122, 124, another diagonal truss will also intersect the same inner face of the first and the second flat sections 122, 124 at an adjacent location. Such adjacent intersections form a triangulated parallel chord truss. The truss web supports 134 can be comprised of folded or formed material, and similar to the perforated I beam shaped members 125, the truss shaped members 130 to facilitate additional air flow and additional pathways for running cables and pipes through the panels 2, especially with the additional pathways diagonally and orthogonally through the specialized shaped engineered matrix members 120.
[0147] Turning to FIG. 31, in a second embodiment of truss shaped members 130, the intersection of the diagonal truss web supports 134 with the inner face of the first and the second flat sections 122, 124 can be spaced either a fixed or varying distance from one another. These skip truss shaped members 136 are similar to the truss shaped members 130, but because they have less truss web supports 134, they are less costly to manufacture and fabricate and offer increased size and angles of pathways through the panels 2 and the specialized shaped engineered matrix members 120, while still retaining much of the superior strength qualities of the truss shaped members 130.
[0148] Turning to FIG. 32, in a third embodiment of specialized shaped engineered matrix members 120, honeycomb shaped members 138 are constructed by the first and second flat sections 122, 124 of engineered matrix members 120 being joined by a honeycomb web 140 transverse section 126. The honeycomb web 140 is formed by a plurality of honeycomb or other repeating open geometric shapes connected to one another, and arranged such that an axis of opening B-B is disposed perpendicular to a long axis A-A. Similar to the perforated I beam shaped members 125 and the truss shaped members 130, the honeycomb web 140 of the honeycomb shaped members 138 facilitates additional air flow and additional pathways 129 for running cables and pipes through the panels 2, especially with the additional pathways diagonally and orthogonally through the specialized shaped engineered matrix members 120.
[0149] Turning to FIG. 33, in a fourth embodiment of specialized shaped engineered matrix members 120, corrugated shaped members 142 are constructed by the first and second flat sections 122, 124 of engineered matrix members 120 being joined by a corrugated or sinusoidal type curved web 144 transverse section 126. The peaks and the troughs of the corrugated web 144 attach to the inner faces of the first and second flat sections 122, and curving a path in-between. The curved shape of the corrugated web 144 provides a different profile and potentially wider pathways 129 for air flow and running cables, as compared to the truss shaped members 130.
[0150] The specialized shaped engineered matrix members 120 may be used in all situations as the rectangular shaped elongate members 14. The specialized shaped engineered matrix members 120 may be formed in a separate process and later attached to the sheets 4,6, or, similar to the integrated elongated members 14A, the specialized shaped engineered matrix members 120 may be formed, in whole or part, together with the sheets 4A, 6A. Panels 2 may be constructed out of all non-engineered spacing structural elements 8, all engineered matrix members 120, or some combination of each.
