Cross-Reference to Related Applications

This application is a Non-Provisional patent application of and claims benefit of U.S. Provisional Application Ser. No. 62/356,390 entitled "QUAD v-panel Assembly," and filed on June 29, 2016, which is incorporated herein by reference in its entirety.

Background

Wall panels are used in the construction of residential and commercial buildings to provide wall structures and support for roofing. Existing wall panel implementations may require on-site engineering and assembly, which can cause delay and increased cost in building construction. Furthermore, wall panel implementations may not provide enough strength to withstand forces due to seismic activity, wind, or other forces.

Summary

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other features, details, utilities, and advantages of the claimed subject matter will be apparent from the following more particular written Detailed Description of various implementations and implementations as further illustrated in the accompanying drawings and defined in the appended claims.

The present application discloses a standardized wall panel including a quad v- panel assembly. An implementation of a quad v-panel assembly disclosed herein includes a plurality of studs, v-brace studs, tracks, and apex plates. Brief Descriptions of the Drawings

FIG. 1 illustrates a schematic of an example quad v-panel assembly. FIG. 2 illustrates an example three-dimensional view of an example quad v- panel assembly.

FIG. 3 illustrates an example three-dimensional view of an example quad v- panel assembly with expanded views of a double apex plate connection.

FIG. 4 illustrates an example three-dimensional view of an example quad v- panel assembly with an expanded view of a center stud and horizontal track intersection area.

FIG. 5 illustrates the transfer of forces to an example quad v-panel assembly. FIG. 6 illustrates another schematic of an example quad v-panel assembly.

FIG. 7 illustrates example operations for making a quad v-panel assembly.

Detailed Descriptions

Wall panels are used in the construction of residential and commercial buildings to provide wall structures and support for roofing. Existing wall panel implementations may require on-site engineering and assembly, which can cause delay and increased cost in building construction. Furthermore, wall panel implementations may not provide enough strength to withstand forces due to seismic activity, wind, or other forces.

An implementation of a wall panel disclosed herein provides a quad v-panel assembly using standardized components. Furthermore, a method of manufacturing a quad v- panel assembly is described herein. The standardization of various components of the quad v- panel assembly and their arrangement in the quad v-panel assembly allows for manufacturing of the quad v-panel assembly using cold roll former machines. In the implementations disclosed herein, the lengths, depth, angles of connection, etc., are standardized. Such standardization reduces the need for repeated engineering design and analysis of the quad v- panel assemblies. Furthermore, the standardization also reduces the costs of manufacturing the quad v-panel assemblies. The quad v-panel assembly disclosed herein may be used in combination for wall structures in commercial and residential buildings that may provide improvements in strength and resistance to lateral forces due to high winds and/or seismic activity.

FIG. 1 illustrates a schematic of an example quad v-panel assembly 100. There are two profiles (e.g., profiles 180 and 182) of framing members used in the quad v-panel assembly, studs (e.g., profile 182) and tracks (e.g., profile 180). Studs and tracks are substantially similar as they both include a back-webbing portion 184 with walls extending substantially perpendicular from the back-webbing portion 184. The studs and tracks differ in that the studs include flanges that extend inward perpendicularly from the walls, and the tracks do not include these inward pointing flanges. As such, the track is "U" shaped and the stud is "U" shaped with flanges extended inward from the tips of the "U" shape. The quad v- panel assembly 100 includes exterior studs 102 and 104, interior studs 106 and 108, a center stud 110, v-brace studs, 112-126, a bottom track 128, a top track 130, and horizontal tracks 132 and 134 (also referred to as middle tracks), and truss assembly 140. The various components of the quad v-panel assembly 100 are connected to one another using fasteners such as bolts or screws and welding slots. Furthermore, the v-brace studs 112-126 are connected to the top track 130, the horizontal tracks 132 and 134 and the bottom track 128 using apex plates (e.g., apex plates 150-168), fasteners, and welding slots.

The exterior studs 102 and 104, interior studs 106 and 108, and the center stud 110 are substantially parallel to each other and are of a length that is substantially similar. Moreover, the exterior studs 102 and 104, interior studs 106 and 108, and the center stud 110 extend through slots of the top track 130 to form structural components of the truss assembly 140. The interior studs 106 and 108 and center stud 110 extend through pass through openings of the horizontal tracks 132 and 134.

The v-brace studs 112-126 are of a length that is substantially similar. The angles between the v-brace studs 112-126 and the top track 130, the horizontal tracks 132 and 134, and the bottom track 128 are standardized. For example, the angles between v-brace stud 112 and bottom track 128, v-brace stud 118 and horizontal track 132, and v-brace stud 122 and the top track 130 may be substantially similar. In example implementations, the angle between the exterior stud 102 and the v-brace stud 112 is between 30 degrees and 80 degrees. The v-brace studs are each connected to their respective apex plates using one fastener (e.g., a hinge connection) and welding slots. The use of one fastener allows the v-brace studs to rotate when under force and transfer these forces to the structural column of the system. In alternative implementations, more than one fastener may be used to secure the v-brace stud with an apex plate.

The horizontal tracks 132 and 134 (e.g., two middle tracks) are positioned back to back (e.g., web to web), which is referred to as double horizontal bracing. The horizontal tracks 132 and 134, the top track 130 and the bottom track 128 are connected to the exterior studs 102 and 104, the interior studs 106 and 108 and the center stud 110 using fasteners and/or welding slots. Similarly, the bottom chord 144 (e.g., a track) of the truss assembly 140 and the top track 130 may form a double horizontal brace.

The truss assembly 140 of the quad v-panel assembly 100 includes a top chord

142, a bottom chord 144, and a plurality of interior braces 146. The truss assembly 140 uses the exterior studs 102 and 104, interior studs 106 and 108, and the center stud 110 as support structure for the truss assembly 140. As such, the bottom chord 144 and the top track 130 include pass through openings through which the interior studs 106 and 108 pass. In implementations, the top chord 142 and the bottom chord 144 may be tracks. The plurality of interior braces 146 may be studs that are connected to the top chord 142 and the bottom chord 144 using apex plates, fasteners, and welding slots. Furthermore, the interior studs 106 and

108 may be connected to the top chord 142 using abutment plates (e.g., abutment plate 148), fasteners, and welding slots.

Apex plates are connected to their respective tracks and studs (excluding the v- brace studs) using at least two fasteners and welding slots on each track or stud. For example, the apex plate 156 is connected to interior stud 106 with two fasteners 170 and welding slots

172.

Each of the studs and tracks may include pass through holes or openings that may be utilized for electrical wiring or other components of a building containing one or more Quad v-panel assembly 100. These holes are illustrated below with respect to FIG. 3.

Each track, stud, and apex plate may be formed from galvanized steel such as cold rolled galvanized steel using cold roller machines and presses. For example, for manufacturing a v-brace stud, a roll of galvanized cold steel is cut to a predetermined length equaling the length of a v-brace stud. Subsequently, the cut length of the cold rolled steel is formed into the shape of a v-brace stud. Pass through holes or openings, pilot holes for fasteners, and welding slots may be punched, cut, or etched into the cut length of galvanized cold steel before or after forming the v-brace stud.

In some example implementations, the truss assembly 140 includes truss hangers for attaching floor/and or ceiling trusses. For example, a truss hanger may be attached to or be formed as a part of the abutment plate 148. The truss hanger is configured to a floor and/or celling truss that extends in the z-direction and attaches to another truss hanger of another quad v-panel or other structure. For example, a top chord of a floor/ceiling trust may be attached the trust hanger at abutment plate 148, and a bottom chord of a floor/ceiling truss may be attached to a trust hanger at apex plate 176. Other trust hangers may be attached to or formed as a part of other plates such as apex plates 174, 178, etc. FIG. 2 illustrates an example three-dimensional view of an example quad v- panel assembly 200. The quad v-panel assembly 200 includes a number of studs, tracks, and apex plates as described above with respect to FIG. 1. As can be seen in FIG. 2, the quad v- panel assembly 200 includes apex plates on the reverse side of the quad v-panel assembly. The quad v-panel assembly 200 includes four v-panels (e.g., "quad" v-panel assembly 200). For example, the quad v-panel assembly 200 includes a v-panel 202 that includes a portion of an exterior stud 204, v-brace studs 206 and 208 (e.g., two v-brace studs per v-panel), a portion of an interior stud 210, a portion of a bottom track 212, a portion of a middle track 214, and an interior center stud 216. The various components are connected using apex plates. For example, an apex plate 218 is used to connect the v-brace studs 206 and 208 to the interior stud 210 and the middle track 214. The various components may be connected to the apex plates using fasteners and/or welds (e.g., via welding slots). In some example implementations, the v-brace studs are connected to the apex plates using a single fastener (and sometimes welds), thus allowing the v-brace studs to pivot with respect to the apex plates and other components. For example, the v-brace studs 206 and 208 are connected to the apex plate 218 using fasteners (e.g., nuts/bolts) that allow the v-brace studs 206 and 208 to pivot with respect to the apex plate 218, the middle track 214 and the interior stud 210.

In some example implementations, an angle between two respective v-brace studs may be a predetermined angle between twenty (20) and one-hundred and sixty (160) degrees from each other. For example, an angle 220 may be from about 20 degrees to about 160 degrees. In some example implementations, an angle between a v-brace stud and a horizontal track may be a predetermined angle from about ten (10) degrees to about eighty (80) degrees. For example, an angle 226 between the v-brace stud 224 and a horizontal track 228, may be from about 10 degrees to about 80 degrees.

FIG. 3 illustrates an example three-dimensional view of an example quad v- panel assembly 300 with expanded views (e.g., view A and view B) of a double apex plate connection 306. View A illustrates the double apex plate connection 306 from the perspective of arrow 302. View B illustrates the double apex plate connection 306 from the perspective of arrow 304.

Referring now to View A, the double apex plate connection 306 includes apex plates 310 and 360. The apex plate 310 is connected to v-brace studs 312 using single fasteners 320 for each v-brace stud 312. The apex plate 310 is connected to an interior stud 330 and horizontal tracks 332 and 334 with two fasteners 320. Likewise, the apex plate 360 is connected to v-brace studs 314 using single fasteners for each v-brace stud 314. Thus, the v- brace studs are pivotally attached to the apex plates. Thus, when forces are applied to the v- panel assembly, the v-brace studs 314 may flex and pivot under the forces and transfer the forces throughout the v-panel assembly. In some example implementations, the v-braced studs are further attached to the apex plates with welds using welding slots. For example, the v-brace studs 314 are attached to the apex plate 360 using welds and welding slots (such as welding slots 322). Other components (e.g., various tracks and studs of the v-panel assembly 300) may be connected the various apex plates using welds and welding slots.

The apex plate 360 is connected to the interior stud 330 and horizontal tracks 332 and 334 with two fasteners. It should be understood that the apex plates may be attached to studs and tracks using more than two fasteners. It should be understood that other apex plates of the quad v-panel assembly 300, such as apex plate 348, are configured similarly to apex plates 310 and 360. Similarly, apex plates on the reverse side of the quad v-panel assembly 300 are configured similarly to the apex plates 310 and 360.

The horizontal tracks 332 and 334 are contiguous pieces that are attached to both exterior studs 336 and 338. Furthermore, the interior stud 330 is a contiguous piece that is attached to both a bottom track 340 and top track 342. As such, the horizontal tracks 332 and 334 include punch out openings through which the interior stud 330 passes through. The horizontal tracks 332 and 334 are attached to the interior stud 330 using fasteners 320 and welding slots 322.

In this particular implementation, the studs, tracks, and apex plates of the quad v-panel assembly are roll formed from a 14-gauge galvanized steel roll using specialized roll formers. Such roll formers may be communicatively connected to a machine that is configured to receive a macro file with instructions for cutting the steel roll at predetermined distance and at predetermined angle so that is can be roll formed to generate the various components of the quad v-panel assembly. Furthermore, such a roll former machine is also configured to receive instructions from the macro file regarding placement, punching, etching or cutting of pilot holes for fasteners, welding slots, and pass through openings. The pilot holes and the welding slots allow the chords to be placed in a specialized assembly jig to be connected to the braces.

Furthermore, the standardization of the pilot holes, weld welding slots, and pass through openings also enables computerized robotic welding of the studs, tracks, and apex plates. Such welded connections increase the overall strength of the quad v-panel assembly 300 as the welded connections are stronger than light gauge material, thus eliminating failure at the point of connection between the studs, tracks, and apex plates. Additionally, the welded connections do not loosen like mechanical fasteners, thus adding strength to the quad v-panel assembly 300.

Referring now to View B, the double apex plate connection is illustrated with apex plates 310 and 360. As can be seen the horizontal tracks 332 and 334 include punch out openings 344 that may be utilized for electrical wiring or other structural components for buildings. The horizontal tracks 332 and 334 include pass through openings through which the interior stud 330 extends.

FIG. 4 illustrates an example three-dimensional view of an example quad v- panel assembly 400 with an expanded view (e.g., View A) of a center stud and horizontal track intersection area. View A illustrates the crossing from a perspective of arrow 410.

Horizontal tracks 402 and 404 include pass through openings such that a center stud 406 may pass through the horizontal tracks 402 and 404. The center stud 406 is attached to the horizontal tracks 402 and 404 using fasteners (not shown) inserted through pilot holes 420.

FIG. 5 illustrates the transfer of forces to an example quad v-panel assembly 500. A lateral force 502, is acting on the quad v-panel assembly 500. Example lateral forces include forces due wind, seismic activity, etc. As the lateral force 502 acts upon the quad v- panel assembly, the quad v-panel assembly may shift to the right (illustrated by dotted lines 510 and 514) and the force may be transferred through various parts of the quad v-panel assembly 500. For example, due to the lateral force 502, a v-brace stud 504 may buckle or flex out to a position illustrated by the dotted line 506. Similarly, a v-brace stud 512 may bend or buckle to a position illustrated by dotted line 514. It should be understood that the dotted lines 510, 506, and 514 are for illustrative purposes and the amount of shifting, flexing, or buckling may be more or less drastic than the dotted lines. Other v-brace studs 516 and 518 may be stretched lengthwise due to the lateral force 502 Thus, the v-brace studs 504 provide compression strength when under lateral force 502, and the v-brace studs 516 and 518 provide tension strength when under lateral force 502. Due to the forces acting upon the apex plates, the apex plates may rotate. For example, due to the lateral force 502, an apex plate 520 may rotate in a direction illustrated by arrow 522.

The combination of stretching v-brace studs, buckling v-brace studs, and rotating apex plates provides enhanced strength characteristics to the quad v-panel assembly 500. The structure of the quad v-panel assembly allows for the quad v-panel assembly to withstand significant and changing forces. It should be noted that the quad v-panel assembly 500 would provide similar strength features due to a lateral force opposite lateral force 502. Thus, the quad v-panel assembly 500 provides tension and compression strength features in a number of directions.

FIG. 6 illustrates a schematic of an example quad v-panel assembly 600 connected to posts 602 and 604. The schematic illustrates various connection components that may be used to connect the quad v-panel assembly between the posts 602 and 604. In implementations one or more quad v-panels 600 may be connected using posts or columns. In other implementations, the quad v-panels 600 may be directly connected to one another. The posts 602 and 604 may be structural columns that form interior structural components of buildings. The structural columns may be positioned at standardized distances from each other, at corners of rooms, at corners of floors, etc.

FIG. 7 illustrates example operations 700 for manufacturing the quad v-panel assembly disclosed herein. Specifically, FIG. 7 illustrates the various operations 700 of an automated implementation of manufacturing quad v-panel assemblies disclosed herein. An operation 702 receives a macro file at a roll former machine used to generate the components of the quad v-panel assemblies. In one implementation, such macro file may be received from a software application that generates the macro file based on an architectural drawing. At operation 704, steel rolls are positioned in the roll formers. At operation 706, the roll formers interpret the instructions from the macro file to roll form the studs for the quad v-panel assembly. At operation 708, the roll formers interpret the instructions from the macro file to roll form the tracks for the quad v-panel assembly. Similarly, operation 710 roll forms the apex plates (and abutment plates for the truss assembly) for the quad v-panel assembly as per the instructions from the macro file. In operation 712, brace studs for the truss assembly are roll formed. Also, at operation 712 pilot holes are punched in the studs, tracks, apex plates, and abutment plates, whereas at an operation 714 welding slots are cut as per the instructions from the macro file. Once various parts are configured, at an operation 716, the parts are assembled to configure the quad v-panel assembly. An operation 718 determines if more quad v-panel assemblies are needed to be made and repeats one or more of the above operations as necessary.

The above specification, examples, and data provide a complete description of the structure and use of exemplary embodiments of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. Furthermore, structural features of the different embodiments may be combined in yet another embodiment without departing from the recited claims. Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the scope of the invention. The implementations described above and other implementations are within the scope of the following claims.