Multipurpose structural panels for assembling structures

Abstract

The present invention is directed to a multi-purpose panel member that can be utilized as any surface or support beam within a structure. In one preferred embodiment, the panel can be monolithically extruded from aluminum. Also disclosed is a system for assembling a structure from the panels using a number of other components, also preferably extruded from aluminum.

Description

Claim of Priority ,

[0004]

[0001] This invention claims the benefit of U.S. Patent Application No. 17 / 221,061, filed Apr. 2, 2021, which is currently pending, under 35 U.S.C. § 119(e). The above U.S. patent application is based on a provisional patent application currently pending in the United States Patent and Trademark Office, namely Provisional Application No. 63 / 081,041, filed Sep. 21, 2020, and claims priority under 35 U.S.C. § 119(e) to the above provisional patent application. The above U.S. patent application is hereby incorporated by reference herein.

[0002] Furthermore, U.S. Patent Application No. 17 / 221,061 also claims the benefit of U.S. Provisional Patent Application No. 63 / 161,678, filed Mar. 16, 2021, under 35 U.S.C. § 119(e).

Technical Field

[0003] The present invention is directed to multi-purpose structural panels that can be used on any surface or support member within a building or structure. The present invention also provides a building system for assembling buildings and structures from the panel members of the present invention, the system including various other components to facilitate assembly. The present invention is also directed to systems and methods for assembling buildings and structures from prefabricated extruded alloy components.

Background Art

[0004] Structural Insulated Panels (also known as SIPs) are a relatively new building material consisting of a foam core and two layers of cladding, typically expanded polystyrene sandwiched between two thin metal veneers or oriented strand boards. While they offer some improvements over typical timber frame structures, several significant problems exist. One major issue is durability and corrosion resistance. Because the panels are bonded to each other, the layers tend to delaminate under adverse conditions. Also, SIPs can be difficult to route mechanical, electrical, or piping lines through because cutting them can reduce the panel's strength. SIPs also have inadequate fire safety ratings and require surrounding with separate products that have fire resistance ratings. [Overview of the Initiative] [Problems that the invention aims to solve]

[0005] Intermodal shipping containers have also been used as alloy-based structural systems. However, they tend to be difficult to work with and are manufactured in only a few standard sizes, limiting the options for building configurations created from these shipping containers. Therefore, the present invention offers significant improvements in these and other areas. [Means for solving the problem]

[0006] This invention relates to improvements in construction technology using the multi-purpose structural panel member of the present invention, as well as systems and methods for its use. The panel member of the present invention is primarily an improved rectangular profile for aluminum extrusion, which can be substantially used as any surface or support member within a building or structure. The panel can withstand loads in any direction and includes internal channels for insulation and ventilation. Thus, it can be used as a wall, ceiling, roof, structural support, beam, lintel, etc.

[0007] In one preferred embodiment, the panel is monolithically extruded from aluminum, for example, 6082 T6 aluminum alloy. However, other materials and construction methods may also be employed. For example, specific alloys can be customized based on the location or application of the structure, such as high corrosion resistance for marine environments or a low heat coefficient for environments with extreme temperatures. Non-metallic materials such as carbon fiber or basalt may also be suitable. The panel may also be assembled from multiple parts rather than being formed monolithically.

[0008] The panels can be sized to suit any desired building element, but the inventors determined that the optimal dimensions suitable for various building technologies are a rectangular profile approximately 4 inches (10.16 cm) thick x 24.5 inches (62.23 cm) wide. The length of the panels can also be made longer as desired, especially when the panels are extruded, but a maximum length of 60 feet (18.288 m) allows for the transport of panel members on roadways. The panels may include multiple internal channels of approximately 4 inches (10.16 cm) x 6 inches (15.24 cm), separated by a web connecting two faces of the panel. To facilitate extrusion, the wall thickness of the panel members may be uniform. The inventors determined that the 6082 T6 aluminum alloy requires only a uniform wall thickness of 1 / 8 inch (3.175 mm) to provide strength and load-bearing capacity against hurricanes, high wind speeds, snow, and earthquakes.

[0009] Another aspect of the present invention involves employing the panels of the present invention together with various other components to create a system in which buildings can be assembled rather than constructed in the conventional manner. In detail, the panel members include male and female interlocking components, which are not critical but facilitate the alignment of the panel members. Tracks can be used to fasten the panel members to a base and to each other to form ceiling, floor, and roof structures. Frame elements can be used to cover the ends of the panel members, thereby creating flat surfaces on the edges of the panel members, which facilitate openings for door posts or windows.

[0010] In one preferred embodiment, the panel is substantially hollow or has channels within it, making it adaptable to various applications. For example, the channels can be used to pass mechanical lines, electrical lines, or piping lines. Furthermore, the channels may be used as ducts for air conditioning. This not only contributes to more efficient construction but also allows the structure to be efficiently heated or cooled by harmonizing the air within the panel. Part of the reason for this is that the conduction of heat from one side of the panel to the other (and therefore the heat loss or heat gain from one side of the panel to the other) can be regulated by harmonizing the air within the panel. Such a structure can substantially eliminate the need for suspended ceiling structures due to space-saving designs. It will be understood that the channels can also house or act as conduits for various future housing technologies.

[0011] In yet another embodiment, the channels may be configured to collect, transport, and / or store rainwater. When the panels of the present invention are used as roofing components, apertures may be selectively created to facilitate the introduction of rainwater into the channels. Channels in the roofing components may also be positioned to communicate with channels in other paneling components, such as walls or ceilings, to facilitate the transport and / or storage of collected rainwater.

[0012] Another feature of the present invention is its ability to create electromagnetically shielded buildings by using aluminum panels on all surfaces of the building. This can be beneficial in certain scenarios, such as when it may be desirable to prevent radio frequency transmissions from entering or leaving a building. On the other hand, the present invention can also block radio transmissions between different rooms within the same building. In this scenario, a wired mesh network or similar may be desirable to facilitate coverage of WiFi signals, cellular signals, and other signals throughout the building.

[0013] Another feature of the present invention is the ability to utilize specific panels in a conductive manner. While the use of panels for conducting main voltages (e.g., 100-240V) should be carried out with utmost care, the transmission of low-voltage electricity is relatively easy to achieve and poses fewer safety concerns. Thus, various low-voltage electronic devices can receive power simply by making contact with the surface of the panel. This facilitates the placement of household items such as air conditioning thermostats, smoke detectors, security alarm panels and sensors, cameras, and other items including but not limited to internet-connected and / or "Internet of Things" devices. Furthermore, the aluminum panels themselves can be used as transducers to determine the temperature within a building more precisely and efficiently. As is well known, the resistivity of aluminum changes with temperature fluctuations. Therefore, by monitoring fluctuations in the low-voltage current applied across the panels, each aluminum panel can be used as a temperature sensor. Thus, the temperature of each room within a building can be monitored with a much better granularity than is currently possible. Furthermore, "a smart air conditioning system allows for the direction of cooled or heated air as needed, for example, by opening or closing the air vents in a specific room. It will be understood that the use of the panel as a sensor and / or transducer is not strictly limited to its use as a temperature sensor."

[0014] The panel members of the present invention are not limited to use in buildings or enclosures, but can be used as substantially any structural member. Accordingly, bridges and other spans can be quickly assembled from the system of the present invention. The present invention can be found particularly suitable when temporary and / or reusable structural members are desired, such as pedestrian bridges, scaffolding for event venues, or, in some cases, structural pool covers that provide additional floor space to hotels.

[0015] Another advantage of the present invention is that building components can be sold by weight rather than by quantity. Given that all components of the system can be made from extruded aluminum, the total mass of aluminum required to assemble any structure can be calculated from the known quantities of components needed for that structure. Thus, the material cost for constructing a particular structure can be easily estimated.

[0016] These and other objects, features and advantages of the present invention will become more apparent when considering the drawings and embodiments for carrying out the invention.

[0017] For a complete understanding of the nature of the present invention, please refer to the following embodiments for carrying out the invention, as interpreted in conjunction with the accompanying drawings. [Brief explanation of the drawing]

[0018] [Figure 1] Perspective view of a panel member according to one embodiment of the present invention [Figure 2] Front isometric view of the panel member shown in Figure 1. [Figure 3] Perspective view of a corner bracket according to one embodiment of the present invention. [Figure 4] Front isometric view of the corner bracket shown in Figure 3. [Figure 5] Perspective view of a corner bracket according to another embodiment of the present invention [Figure 6] Front isometric view of the corner bracket shown in Figure 6. [Figure 7] Perspective view of a truck according to one embodiment of the present invention. [Figure 8] Perspective view of a frame according to an embodiment of the present invention [Figure 9] Perspective view of a pair of building plates according to an embodiment of the present invention [Figure 10] Perspective view of a reinforcing insert according to an embodiment of the present invention [Figure 11] [[ID=I0]]Partial cutaway perspective view showing various components assembled by the system of the present invention[[ID=II]] [Figure 12] Partial cutaway perspective view showing various components assembled by the system of the present invention [Figure 13] Partial cutaway perspective view showing various components assembled by the system of the present invention [Figure 14] Partial cutaway perspective view showing various components assembled by the system of the present invention[[ID=I0]] [Figure 15] Partial cutaway perspective view showing various components assembled by the system of the present invention [Figure 16] Partial cutaway perspective view showing various components assembled by the system of the present invention [Figure 17] Detailed partial cutaway perspective view showing various components assembled by the system of the present invention [Figure 18] Detailed cutaway perspective view showing various components assembled by the system of the present invention [Figure 19] Detailed partial cutaway perspective view showing various components assembled by the system of the present invention [Figure 20] Detailed partial cutaway perspective view showing various components assembled by the system of the present invention [[ID=I9]] [Figure 21] Partial cutaway perspective view showing various components assembled by the system of the present invention [Figure 21A] Exploded view of FIG. 20 [Figure 22] Partial cutaway perspective view showing various components assembled by the system of the present invention [Figure 23] Partial cutaway perspective view showing various components assembled by the system of the present invention [Figure 24] Partial cutaway perspective view showing various components assembled by the system of the present invention [Figure 25] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 26] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 27] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 28] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 29] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 30] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 31] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 32] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 33] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 34] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 35] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 35A] Detailed view of the embodiment shown in Figure 35 [Figure 35B] Detailed view of the embodiment shown in Figure 35 [Figure 35C] Detailed view of the embodiment shown in Figure 35 [Figure 35D] Detailed view of the embodiment shown in Figure 35 [Figure 36] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 37] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 38]Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 39] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 40] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 41] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 42] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 43] Perspective view of multiple parts according to one embodiment of the present invention [Figure 44] Partial cutaway perspective view showing various parts assembled by the system of the present invention. [Figure 45] Cross-sectional view of two panel members according to another embodiment of the present invention [Figure 46] Perspective view of the panel member according to the embodiment shown in Figure 45. [Figure 47] Perspective view of a truck according to another embodiment of the present invention [Figure 48] Cross-sectional view of a truck, shown in Figure 47. [Figure 49] Perspective view of a truck according to yet another embodiment of the present invention [Figure 50] Cross-sectional view of a truck, shown in Figure 49. [Figure 51] A partially constructed structure using panel members according to one embodiment of the present invention. [Figure 52] Perspective view of a gusset plate according to one embodiment of the present invention [Figure 53] A perspective detail view showing the use of gusset plates adjacent to two panel members according to one embodiment of the present invention. [Figure 54] Perspective view of an insertion plate according to one embodiment of the present invention. [Figure 55] Cross-sectional view of the insertion plate shown in Figure 54. [Figure 56]This is a perspective view showing an insertion plate placed within a channel of a panel member according to one embodiment of the present invention, where the panel member is shown as partially transparent to aid in disclosure. [Figure 57] Front isometric view of a panel according to another embodiment of the present invention [Figure 58] Perspective view of the panel according to the embodiment shown in Figure 57. [Figure 59] Front isometric view of a truck according to another embodiment of the present invention [Figure 60] Front isometric view of a truck according to yet another embodiment of the present invention [Modes for carrying out the invention]

[0019] Throughout the drawings, the same reference number refers to the same part.

[0020] While the entire construction system of the present invention will be disclosed in detail, it is worthwhile to first describe the various individual components of the system. Referring to Figures 1 and 2, preferred embodiments of a panel member or panel 10 are shown. The panel 10 is preferably formed monolithically by extrusion or the like, but it may also be possible to assemble the panel 10 from multiple parts. The panel 10 includes two opposing faces 12 supported by a plurality of webs 15. The faces 12 also define the long edge 1 of the profile of the panel 10. The panel 10 also includes a convex member 13 and a concave member 14 that define the short edge 2 of the profile of the panel 10. The convex member 13 and the concave member 14 also serve to facilitate interlocking relationships between consecutive adjacent panel members 10 when used, for example, in the construction of walls, floors, or ceilings. It will be understood that the exact shape of the convex member 13 and the concave member 14 is not important as long as the interlocking relationships can be facilitated. In the figures, they are shown as simple shapes. The web 15 defines, at least partially, a plurality of channels 11 that extend longitudinally along the panel 10 and terminate at open ends 16 at each end of the panel 10. The panel 10 may also include a plurality of mounting apertures 17 positioned at desired locations, which can be arranged to align with other mounting apertures on various components of the system of the present invention, as further described below.

[0021] Moving to Figures 3-6, two corner brackets 20, 20' are shown, which may be used with one embodiment of the present invention, but are not required or necessary. As can be seen, the corner brackets 20, 20' are essentially channels 21, 21' surrounded by convex members 23, 23' and concave members 24, 24' positioned on a surface to facilitate the adjacency of panels 10 at angles other than 0 (i.e., not linear). A relatively standard corner angle in building construction is 90°, which is shown in Figures 3 and 4. As can be seen, the convex members 23 and concave members 24 are orthogonal to each other, thereby facilitating the adjacency of continuous panel members 10 at a 90° angle. However, the adjacency angle can also be substantially adapted as shown in Figures 5 and 6.

[0022] Figure 7 shows a track 30 according to a preferred embodiment of the present invention. The track includes a channel 33 at least partially defined by two webs 31, and an outer flange 32. By inserting the panel member 10 into the channel 33, alignment and fastening can be facilitated when constructing walls, floors, or ceilings. In this regard, by aligning the mounting aperture 35 with the mounting aperture 17 of the panel member (as shown in Figure 1), fastening the panel 10 to the track 30 can be facilitated.

[0023] Moving on to Figure 8, a frame 40 according to a preferred embodiment of the present invention is shown. The frame 40 can function as an end cap when needed, such as when forming a frame for a window opening using the panel 10. Thus it includes a channel 42 at least partially defined by a web 41 and is distinguished from a track by the absence of an outer flange. The frame 40 may also include a plurality of mounting apertures 43, which facilitate fastening to the panel 10.

[0024] Figure 9 shows a ridge plate 50 for facilitating the adjacency of panel members along the ridge of a gable roof. Figure 10 shows an insert 60 which is essentially an enclosed channel or box beam, and by inserting this insert 60 into the channel 11 of the panel 10, structural reinforcement can be provided to the panel 10, for example, when the panel 10 is used as a support beam or girder. The insert 60 can also be used to increase the safety margin for a freestanding span or cantilever configuration of the panel 10.

[0025] Having described some of the individual components, we can now discuss the interoperability of the components. Referring to Figures 11-16, we can see detailed views of several parts of an assembly created using the components described above. In each figure, multiple panels 10, tracks 30, and frames 40 are arranged in various configurations on top of a base 500 for a structure such as a house or building. As can be seen, the panels are used to form various exterior and interior walls, ceilings, upper floors, and roofs of the building. The tracks 30 are used to fasten the panels 10 to the base 500 and to each other when joining two panels to form a connection between the ceiling / floor or roof and the wall. The frames 40 function as "end caps" when forming window frames. Otherwise, the presence of recesses 14 and protrusions 13 on the panels 10 would prevent the internal opening of the window from being a uniformly flat surface.

[0026] In Figure 11, multiple tracks 30 are fastened to a base 500 and are used to support multiple panel members 10 in a vertical orientation for use as wall members. In Figure 12, two panel members can be seen in a "T" configuration, which indicates that the panel members can also be used as columns and support beams. Also in Figure 12, the panels 10 are arranged to form a window by suspending one panel 10 as a lintel across two other panels 10 that function as columns. It can also be seen that a frame 40 is fastened inside the window to prepare a flat surface for the installation of the window and / or window frame.

[0027] Figure 13 shows multiple tracks 30 fastened to the top of multiple vertically oriented panel members 10. In this regard, the structure is prepared for the addition of a second floor or a flat roof. Figure 14 shows horizontally oriented panel members 10 to be used as the ceiling of the first floor and the floor of the second floor. As will be disclosed in more detail below, the horizontal panel members 10 are fastened to the tracks 30 by fasteners such as self-drilling screws, bolts, or rivets inserted through the outer flange 32. In Figure 15, it can be seen that the walls of the second floor are formed by installing another vertically oriented panel member 10' on the tracks 30. It can also be seen that the horizontally oriented panel members 10 can be cantilevered to the outside of the structure and can function as a sunshade or balcony. Finally, in Figure 16, it can be seen that yet another panel member 10 is installed in an angled configuration, thereby forming a apex or gable roof. The above panel members 10 are fastened to the vertically oriented panel members via the tracks 30.

[0028] Figures 17 and 18 show detailed diagrams of a corner configuration according to one embodiment of the present invention. Figure 17 shows the interconnection between two adjacent panels 10 via a 90° corner bracket 20 and an interlocking interface between the convex member 13 and concave member 14 of the associated panel 10 and the convex member 23 and concave member 24 of the corner bracket 20. Figure 18 shows multiple tracks 30 fastened to a base 500 via fasteners 600 passing through an outer flange 32. In certain scenarios, it may be desirable to use steel fasteners to penetrate a concrete base. However, if the tracks 30 are made of aluminum, galvanic corrosion may occur over time. Therefore, electrical contact between the fasteners 600 and the tracks 30 can be avoided by insulating the fasteners 600 from the tracks 30 using neoprene gaskets or washers. Furthermore, the panels 10 are secured to the tracks 30 by arranging the multiple fasteners 600 so that they pass through the corresponding mounting apertures of the tracks 30 and the panels 10, respectively.

[0029] Figures 19 and 20 provide detailed diagrams of the system of the present invention used to construct a multi-story building. Thus, multiple panels 10 are used to construct walls, as well as the ceiling of the first floor and the floor of the second floor. The panels 10 that function as ceilings / floors are sandwiched between two tracks 30 positioned on the panels 10 that function as walls. In this scenario, fasteners 600 are positioned through the outer flanges 32 of the tracks into the panels that function as floors. In this way, the panels 10 that function as floors can be securely held in place. In certain embodiments, since the panels 10 may not have properly positioned mounting apertures, it may be desirable to use self-tapping screws, bolts, or rivets for this purpose.

[0030] Figures 21 and 21A show the partially completed structure in both its constructed and unfolded forms for further illustration. Also, as can be seen, a gable roof is formed by the adjacent placement of multiple panel members 10. Therefore, two ridge plates 50 are employed to facilitate the connection of each panel 10 at the roof ridge.

[0031] Figure 22 shows a partially completed structure utilizing a membrane 100 between consecutive panels 10. In one preferred embodiment, the membrane 100 is self-adhesive and water-resistant. Therefore, the system of the present invention can be employed when resistance to water intrusion is a concern, particularly in the construction of roofs. As can be seen, by applying the membrane 100 to the interconnection of any two consecutive panels 10, it can be ensured that water does not seep into the gap formed therein. This figure also shows that the panel members 10 can be used in a cantilever configuration to form awnings and balconies. In particular, between adjacent panels 10, caulking may be used in addition to or instead of the membrane 100.

[0032] Figures 23-28 show how conventional interior and exterior finishes can be used in combination with this system by applying them to the upper part of the panel members 10. Non-limiting examples of exterior finishes include: covering materials, house wrap / mesh, and stucco (Figure 23); rigid insulation, fiberglass mesh, and stucco (Figure 24); or covering materials, high-density polyethylene paper, and siding (Figure 25). Non-limiting examples of interior finishes include: drywall and paint (Figure 26); cement board and stucco (Figure 27); and substrate strips, cement board, and wall tiles (Figure 28).

[0033] Figures 29–34 illustrate how conventional roof and floor finishes can be used in combination with this system. Non-limiting examples of such roof finishes include: rigid insulation, covering materials, and TPO (Figure 29); rigid insulation, moisture barrier, and metal tiles (Figure 30); or rigid insulation, plywood, and asphalt shingles (Figure 31). Non-limiting examples of floor finishes include: building paper / mesh and tile flooring (Figure 32); plastic barrier, foam pad, and laminated wood (Figure 33); or subfloor strips, foam pad, and hardwood (Figure 34).

[0034] Figures 35-35D illustrate how conventional mechanical lines, electrical lines, and piping lines can be integrated with the present invention. In particular, water pipes 1000 and electrical conduits 2000 can be easily routed through channels 11 within panel 10. Furthermore, channels 11 can be used as air conditioning ducts 300, as shown in Figure 35B.

[0035] Figures 36-41 show various insulation options that can be applied to the surface of the panel or placed within the channels 11 of the panel 10. Figure 36 shows a pre-molded or pre-cut insulation material 3000, such as foam, which can be slid into the channels 11 during construction. Figure 37 shows a spray insulation material 4000 that can be applied to the face 12 of the panel 10. Figure 38 shows an injection-molded foam insulation material 5000 that can be used within the channels 11 where electrical lines or piping lines are utilized. Figures 40 and 41 show that insulation can be added on-site through the open ends 16 of the panel 10.

[0036] Figures 42 and 44 provide schematic diagrams of a method for more efficiently routing cooled air from an air conditioning unit through channels 11 in a panel 10. Figure 43 shows additional components to facilitate this purpose. As can be seen, the connector 330 and elbow 320 can be used to route cooled air from the air conditioning unit 6000 into one or more channels 11 and between channels 11 in a continuous panel. This can also be done by simply providing apertures in the track 30 (and the ends of the panel 10) to facilitate airflow between the continuous panel 10 and the track 30, but this may hinder the construction of the entire structure. The elbow 320 and connector 330 allow such advantages to be implemented after construction. A discharge grille 310 can also be used to introduce cooled air into the room through a wall panel 10 or ceiling panel 10.

[0037] Moving on to Figures 45 and 46, another embodiment of the panel 10' is illustrated. This embodiment is particularly suitable for use of the panel 10' as a roofing member. As can be seen, the panel member 10' includes the same structure as in the embodiment described above, which includes opposing faces 12' separated by a plurality of webs 15', the plurality of webs 15' defining a channel 11' that traverses at least partially the open end 16' of the panel 10'. The panel 10' also includes a convex member 13' and a concave member 14'. This additional structure in this embodiment is a flanged extension 19 that traverses the length of the panel 10. Each flanged extension 19 includes a flange that extends inward toward the panel 10'. As can be seen in Figure 45, when two panels 10' are adjacent to each other, the flanged extensions 19 abut each other. Then, by positioning the caps 200 surrounding the flange portions of the flanged extensions around both flanged extensions 19, the two panels 10' can be locked together to form a waterproof seal. In this configuration, the assembly closely resembles the typical crimped structure of existing metal roofs. This embodiment of the present invention avoids the need for additional waterproofing steps such as membranes and caulking when using panels 10' as roofing components.

[0038] Figures 47 and 48 show alternative embodiments of track 30' that can be used to facilitate the construction of a gable roof. As can be seen, the web 31' is angled with respect to the outer flange 32'. Thus, when a panel member 10 or 10' is positioned at an angle for use in a gable roof, this panel member 10 or 10' can be coplanar with respect to the outer flange 32', thereby facilitating better fastening.

[0039] Figures 49 and 50 show yet another embodiment of the track 30'', which includes two outer flanges 32'' projecting vertically from each of the two webs 31''. This embodiment of the track 30'' is suitable for certain installation scenarios, such as when an interior wall is used to support a ceiling. The wall can be inserted into the channel between the two webs 31'', while a ceiling panel can be secured to each of the two flanges 32''.

[0040] Figure 51 shows a partially completed structure, where panel 10 is used in a vertically oriented configuration to support a relatively long span between panels that function as columns. For the purpose of supporting the disclosure in the context of Figure 51, vertically oriented panels are denoted by 10' and horizontally oriented panels by 10''. Vertically oriented panels 10' can also be said to support loads within the plane of the panel, while horizontally oriented panels 10'' can be said to support loads outside the plane of the panel. It will be understood that the bending strength of a panel is much greater near its short edge than at its long edge. Therefore, vertically oriented panels 10' can withstand much larger loads than horizontally oriented panels 10'' when cantilevered, suspended between two or more points, or otherwise discontinuously supported. Panels 10 that function as columns are configured to support axial loads.

[0041] Figure 51 also shows a configuration in which a pointed roof is supported using vertically oriented panel members 10'. Referring further to Figures 52 and 53, a gusset plate 70 can be used to facilitate an angled, vertically oriented connection between panel members 10 and 10'. The gusset plate 70 may include a mounting aperture 71 for supporting the use of bolts or other fasteners.

[0042] Figures 54 and 55 show an insertion plate 80 according to one embodiment of the present invention. This insertion plate includes two webs 81 that at least partially define an internal channel 83. Two flanges 82 protrude from the outside of the insertion plate 80. As shown, the flanges 82 are perpendicular to the webs 81, but they may be positioned at any desired angle. Now moving to Figure 56, we can see that the insertion plate 80 is designed to be inserted into the channel 11 of the panel member 10. The length of the insertion plate 80 between the two webs 81 must be configured and dimensioned to correspond to the channel 11. In the most preferred embodiment, this is approximately 4 inches (10.16 cm) square (as already disclosed). Thus, as can be seen here, the insertion plate 80 can be used in a similar manner to tracks 30, 30', and 30'' in any scenario where it is more desirable to position the webs within the panel 10. This may be for aesthetic purposes, for waterproofing, or for other reasons. Furthermore, the insertion plates 80 may also be useful for installation in cases where a track member extending the entire length may not be suitable, such as when some of the channels 11 of the panel member 10 are used as mechanical conduits, electrical conduits, or piping conduits, or for various other purposes. Using multiple insertion plates 80 of the size of a single channel may be preferable to cutting the track 30 to the desired size.

[0043] Moving to Figures 57 and 58, yet another embodiment of panel 10'''' is shown, which includes projections or protrusions 3 along the inner surface of the panel. The protrusions 3 provide additional material for the fasteners to grip, thereby reducing the total number of fasteners per panel required to secure and hold panel 10''''. The protrusions 3 can take substantially any size, dimensions, or arrangement desirable for that purpose. In the illustrated embodiment, the protrusions 3 are positioned approximately 1 / 2 inch (1.27 cm) from the side of each panel 10'''' and have a thickness of approximately 1 / 4 inch (0.635 cm). The protrusions 3 may extend along the entire length of the panel or may be trimmed to a desired length. Referring particularly to Figure 58, visual markers 4 may be provided on the outer surface to assist the user in the precise placement of the fasteners.

[0044] Referring to Figures 59 and 60, further embodiments of tracks 30''' and 30'''' are shown, respectively. Each track 30''', 30'''' includes additional flanges 32''', 32'''' compared to the previously disclosed embodiments to more structurally securely fasten panels within the channels 33''', 33'''' of the tracks 30''', 30''''. This is due to the fact that fasteners can be driven into both flanges 32''', 32'''' rather than relying on a single flange as previously disclosed. Figure 59 shows a “T”-shaped track 30''' capable of accommodating three panels in each of the three channels 33''''. Figure 60 shows an “L”-shaped track 30'''' capable of accommodating two panels. Tracks 30''', 30'''' can be dimensionally and configured to suit any orientation or load-bearing capacity. For example, the flanges 32''', 32'''' can be lengthened to provide additional support.

[0045] Numerous modifications, alterations, and changes are possible in detail to the embodiments of the present invention described above, but all matters in the above description and all matters shown in the accompanying drawings are intended to be interpreted as illustrative rather than restrictive. Accordingly, the scope of the present invention shall be determined by the appended claims and their legal equivalents. [Explanation of Symbols]

[0046] 1 Long edge of the panel profile 2 Panel profile short edge 3 protrusions 4. Visual Markers 10, 10', 10'', 10'''' panel, panel component 11. Multiple channels 12, 12' side 13, 13' Panel convex member, protrusion 14, 14' panel concave member, recess 15, 15' Panel Web 16, 16' open end 17 Panel mounting aperture 19 Flanged extension section 20, 20' corner bracket 21,21' Channel 23,23' Convex member of corner bracket 24,24' Corner bracket concave member 30, 30', 30'', 30'''', 30'''' Track 31, 31', 31'' Track Web 32, 32', 32'', 32'''', 32'''' outer flange 33, 33''', 33'''' Track Channels 35. Mounting aperture for trucks 40 frames 41-frame web 42-frame channel 43 Frame mounting aperture Plate for 50 buildings 60 Inserts 70 Gusset Plates 71 Mounting Aperture 80 Insertion Plate 81 Insertion plate web 82 Flange of insertion plate 83 Internal Channels 100 membranes 200 Conduit 300 Air conditioning duct 310 Air vent grille 320 Elbow 330 connector 500 base 600 fasteners 1000 water pipes 2000 Conduit 3000 insulation material 4000 Spray Insulation 5000 Injection-molded foam insulation 6000 Air Conditioning Units

Claims

1. It is a multi-purpose structural construction panel: A monolithic panel component comprising two opposing surfaces separated by multiple webs; A convex member and a concave member configured in correspondence; and, At least one flanged extension, which extends inward toward the panel member and is configured to receive a cap; Equipped with, The two opposing surfaces, together with the convex and concave members, surround the rectangular profile of the panel member. The plurality of webs extend longitudinally along the panel member and define, at least partially, a plurality of channels adjacent to the open end of the panel member. A multi-purpose structural construction panel, wherein the cap is sized and configured to secure the panel member to another adjacent panel member, with a configuration that is at least partially water-resistant.

2. The panel according to claim 1, wherein the panel member is constructed of extruded aluminum.

3. The panel according to claim 1, wherein the panel member is made of AA6082 T6 aluminum alloy.

4. The panel according to claim 1, wherein the correspondingly configured convex member and concave member are sized and configured to interlock when one panel member is placed adjacent to another panel member.

5. The panel according to claim 1, further comprising a plurality of mounting apertures on each of the two opposing surfaces.

6. The panel according to claim 1, wherein the thickness of the surface, the web, and the convex and concave members is approximately 0.125 inches (3.175 mm).

7. The panel according to claim 1, wherein the distance between the two opposing surfaces is approximately 4.00 inches (10.16 cm).

8. The panel according to claim 1, wherein the distance between the convex member and the concave member is approximately 24.5 inches (62.23 cm).

9. The panel according to claim 1, further comprising at least one projection disposed on the inside of the panel member.

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