Patent Grant
10465393
Not Applicable.
Not Applicable.
A. Field of the Invention
The present invention relates generally to apparatuses, systems and methods that are particularly configured to efficiently, safely and quickly install wall and roof panels onto a building. Specifically, the present invention relates to such apparatuses, systems and methods that allow persons to quickly prepare wall and roof panels for use as cladding on a building and to assist with more efficiently and safely installing the wall and roof panels onto the building. More specifically, the present invention relates to such apparatuses, systems and methods that allow the user to combine multiple panels together, position the combined panels onto the frame of the building and quickly, easily and safely attach the combined panels to the frame to form a wall or roof of the building.
B. Background
Metal cladding, which is the exterior wall and roof material installed on pre-engineered metal or steel buildings, is generally grouped into three categories, namely, exposed fastener panels, concealed fastener panels and standing seam. Metal cladding is typically machine formed through the use of roll-formers, sheet metal brakes or sheet metal folders from large coils of pre-coated sheet metal, typically ranging in thicknesses of 18 to 29 gauge, to construct the finished or installed shape of the metal panels, which typically range in width between two and four feet and may be of a wide rage of widths, with some panels be as long as forty feet or more. The typical, mechanical manufacturing method, which has been in use for several decades, produces a somewhat standardized appearance and profile for the metal panels. As a result, there are several primary styles of panels that are sold by the core group of metal building manufacturers in the United States and globally. While metal panels may have different profiles, nearly all of the different styles of panels are corrugated, meaning they comprise a series of ribs and valleys between the ribs, and they are specifically configured to provide the structural integrity that is necessary to resist the loads which are imposed on the building, weatherproof the building envelope and provide an aesthetic appeal for the building. Each metal panel and its associated corrugations from the forming process for a particular style of panel are designed to overlap and interlock or “corrugate” with each other to provide a continuous, repeatable and predictable pattern on the surface of the wall or roof.
The typical method that is utilized to install exterior metal cladding on a building is generally accomplished with a crew of three to five workers who install the metal panels from a position on the ground. The panels are received at the job site in stored bundles that usually comprise thirty to forty panels per bundle, with the panels in the bundle being pre-drilled for installation on a building. A metal panel is removed from the bundle of panels and carried by hand to the leading edge of the wall or roof structure. The metal panel is then lifted into place against the superstructure or frame of the building using a tethered clamp or by lifting the panels progressively vertical at an interval that is determined by the width of a single manufactured metal panel. After positioning the wall or roof panel on the frame, the user checks the panel for vertical and/or horizontal alignment, measures the panel for squareness and then secures the panel to the building's frame using screws or other mechanical fasteners that connect the wall or roof panels to the building's frame. The cladding for a building typically comprises the manufactured metal panels being installed over a thermal blanket insulation with laminated scrim or vinyl facing, or with a variety of other materials, such as gypsum wall board, exterior sheathing or the like.
As well known to persons skilled in the relevant art, the standard metal building superstructure frame is composed of a plurality of rigid frame members, typically referenced as posts for the walls and beams for the roof, with a plurality of horizontal girts spanning from between rigid frame members (posts) for the walls and a plurality of horizontal purlins spanning from between rigid frame members (beams) for the roof. For installation of wall panels, the metal panels are typically attached to the girts by installing a screw or other connector, as may be required or recommended by the manufacturer of the panel, through the panel into a girt. For installation of the roof panels, the metal panels are typically attached to the purlins by installing a screw or other connector, as may be required or recommended by the manufacturer of the panel, through the panel into a purlin.
As well known by persons who are skilled in the relevant art, the present apparatuses, systems and methods of installing panels, particularly metal panels on the superstructure/frame of a metal framed building, is known to be time consuming and inherently subject to errors with regard to the proper positioning and alignment of the panels. In particular, if the panels are not carefully positioned against the frame, the finished wall of panels can lack uniformity with regard to overhang distances and not have the desired squareness, which can result in saw-tooth panel edges on the squarely framed superstructure. In addition, the resulting wall or roof can have openings in the panels where apertures in a panel were not aligned with the metal girt or purlin to which the panel is attached.
Based on the consistency of the general configuration of the metal panels, from one style of panel to another, various types of tools, equipment, systems and methods have been developed to assist the workers with handling and installing the metal cladding on the frame of a building. Despite the existing apparatuses, systems and methods, what is needed is an improved apparatus, system and method for handling and installing panels on the frame of a building. More specifically what is needed is an improved apparatus, system and method for combining a plurality of separate wall or roof panels into a group of such panels, a process commonly referred to as “panelizing”, and for installing the panelized panels on the frame of a building, or more specifically on the girts or purlins (which are hereinafter collectively referred to as the “building's frame” or “frame”). An improved apparatus, system and method should be configured to allow the user to quickly, easily and efficiently panelize a plurality of panels so the panelized panels can be installed, in a predictable manner, on the building's frame. To accomplish this, the improved apparatus, system and method should be configured to ensure the panelized panels are put together in a substantially true, flat and level plane so the panels can be properly placed against a wall or roof portion of the frame. The new apparatus, system and method should be configured to improve accuracy with regard to maintaining squareness and overhang distances of the panels so as to eliminate the possibility of saw-tooth panel edges on a squarely framed building frame and holes in the finished wall or roof. Preferably, the new apparatus, system and method should be easy to use and relatively inexpensive to manufacture.
The apparatus, system and method for panelizing and installing the panelized wall and roof panels of the present invention provides the benefits and solves the problems that are identified above. That is to say, the present invention discloses a new apparatus, system and method of panelizing a plurality of panels into a combined group of panels, or panelized section, that can then be easily, safely and efficiently attached to the frame of a building to form the building's wall or roof cladding. The apparatus, system and method of panelizing and installing wall and roof panels of the present invention allows the user to quickly install wall and roof panels on a building, such as a metal framed building, in a manner which is much safer and more efficient than present systems and methods of installing panels on the frame of a building. The new apparatus, system and method of the present invention can be utilized with a wide variety of different types, sizes and configurations of panels and building frames and whether such panels are made out of metal or other materials. In the preferred configurations of the various aspects of the present invention, the new apparatus, system and method are easy to use and relatively inexpensive to manufacture.
With regard to the apparatus, system and method for panelizing and installing wall and roof panels, the present invention takes advantage of the fact that preformed corrugated panels are inherently formed into a series of continuous, repeatable, and known patterns that can be predictably combined together (i.e., so they can be panelized). This aspect of the present invention is comprised of two primary working assemblies with varying attachments, options, and appurtenances that are utilized to aid in the assembly and installation of exterior cladding. One of these working assemblies is configured as a layout table or jig, referred to herein as the panelizing assembly, having a support frame, alignment structure, rail tracks and a rolling cart. The other working assembly is a lifting assembly that is placed on the panelized section while it is on the panelizing assembly, attached to the panelized section and then utilized to raise the panelized section into place to form a wall or roof. To form the panelized sections, the ground or other working surface based panelizing assembly holds the individual metal panels on a true and flat level plane while allowing the panels to be placed square with the alignment structure, which has a plurality of interchangeable blocks or dies that are cooperatively configured to engage the corrugation of the metal panels. The rolling cart allows the user to easily distribute and position the panels on the alignment structure to form the panelized section. The panelized section can be installed in a fraction of the time and at a much lower effort than the traditional single panel hand lifting installation method that is currently in use to attach panels to the walls and roof of a structure.
Once the individual panels are distributed on the panelizing assembly, a lifting assembly is lowered to be positioned against the outward or upper surface of the panelized section, with it's profile-specific cap members against the panels, to create a ballasted squeeze against the corrugated panels that ensures the distance between all corrugations is consistent and accurate. The lifting assembly is attached to form the panelized array of panels, namely the panelized section, and then lifted by the use of aerial lifting equipment (such as a crane, boom truck, reach lift forklift or the like). Because the array of panels or panelized section is formed on a controlled layout table, namely the panelizing assembly, located on the ground or other working surface, the present apparatus, system and method will greatly enhance the accuracy for maintaining the squareness and overhang distances of the panels. As will be readily appreciated by persons who are skilled in the relevant art, this new assemblies will virtually eliminate the likelihood there will be saw-tooth panel edges on a squarely framed superstructure. The panelized section, attached to the lifting assembly, is then lifted into place by the crane, boom truck, reach lift forklift or other aerial lifting equipment. The new lifting assembly is configured to be rigid enough to support and maintain a flat, square, and consistent array of metal panels, in the form of the panelized section, through each axis of aerial rotation, from horizontal to vertical. Once the panelized array of wall or roof panels is lifted to the desired position on a wall or roof, the wall or roof installers will securely attach the corrugation of the trailing side of the new panelized section to the leading side of the last installed panelized section, verify that the leading edge of the newly added panelized section is within the allowed vertical tolerance and then secure the entire panelized section to the building's frame with screws or other mechanical fasteners (typically as may be recommended or required by the manufacturer of the panels).
The present invention, which includes the apparatus having multiple assemblies, the system and the intended method of use of the apparatus, will increase production, minimize exposure to job site injuries or falls and standardize the installation process with regard to the erection or installation of cladding materials onto the framed superstructure of a building, such as the metal panels which are typically utilized in metal building construction. The new apparatus for panelizing and installing the panelized section of wall or roof panels, which comprises the panelizing assembly, or layout table or jig, for forming a panelized section and the lifting assembly to lift the panelized section into place, allows the user to easily, quickly and efficiently combine a plurality of wall and roof panels into a panelized section that can be more quickly and safely installed on the building's superstructure utilizing overhead cranes, boom trucks, reach lift forklifts or like lifting equipment. Due to the benefits of the present invention, persons who are skilled in the relevant art will readily appreciate that the new apparatus, system and method that are disclosed herein will likely eliminate the need for workers to individually lift wall and roof panels by hand, as is presently done with regard to wall and roof panels.
In one embodiment of the present invention, the new apparatus for panelizing and installing a plurality of wall panels on the frame of a building generally comprises a panelizing assembly and a cooperatively configured lifting assembly. The panelizing assembly has a support frame and one or more panel alignment structures that are supported by the support frame. Each of the panel alignment structures are structured and arranged to receive a plurality of panels thereon and to position the panels into the panelized section. The lifting assembly has a support lift structure and one or more panel lifters that are attached to or integral with the support lift structure so as to be supported by the support lift structure. The support lift structure is structured and arranged to stiffen the lifting assembly so as to support the panelized section when it is being moved to the frame of the building and while being attached to the frame. Each of the panel lifters has a plurality of attachment mechanisms that are structured and arranged to engage the panels which are on the panelizing assembly so the plurality of panels can be formed into the panelized section. The attachment mechanisms also secure the lifting assembly to the panelized section so the panelized section may be lifted to the frame of the building. The panelizing assembly and the lifting assembly are cooperatively configured to squeeze the panelized section between the panel alignment structure of the panelizing assembly and the panel lifters of the lifting assembly.
In a preferred configuration, each of the panel alignment structures has an alignment frame, a rail track having rail members that are attached to or integral with the alignment frame and a panel cart which is moveably engaged with the rail track so as to move from a panel cart area at a first side of the support frame to a second side of the support frame. The panel cart has a cart frame that is sized and configured to moveably support a bundle of panels. The user moves the bundle of panels between the first side and the second side of the support frame to position panels on the alignment frame. Each of the panel alignment structures has a plurality of panel positioning devices that are attached to or integral with the alignment frame and configured to extend above an upper surface of the alignment frame. Each of the panel positioning devices area sized and configured to hold a panel on the panelizing assembly. The panel positioning devices have a device profile that is sized and configured in corresponding relation to a panel profile of the panel so as to securely engage an inward/lower surface of the panel when the panel is placed on the alignment frame of the panel alignment structure. Each of the attachment mechanisms, which may be elongated cap members, have a profile that is also in corresponding relation, though opposite of the device profile, with the panel profile of the panel so as to securely engage an outward/upper surface of the panel. Each of the attachment mechanisms engage the panel opposite the inward/lower surface of the panel engaged by the panel positioning device when the lifting device is placed on the panel so as to squeeze the panel between the attachment mechanism of the lifting assembly and the panel positioning device of the panelizing assembly. The attachment mechanisms have one or more mounting apertures that are sized and positioned to be utilized to connect the attachment mechanism (i.e., the cap member) to the panel at the panel positioning device so as to secure the lifting assembly to the panelized section.
In one configuration, the support lift structure of the lifting assembly is pivotally attached to each of the panel lifters so as to allow the panelized section to pivot when the panelized section is lifted by the lifting assembly. A pivot locking device can be utilized to allow the user to selectively allow, limit and/or prevent pivoting of the panel lifters relative to the support lift structure. The support lift structure can comprise one or more trusses and one or more spreader frames, with each of the trusses being attached to or integral with one of the one or more panel lifters and each of the spreader frames being attached to or integral with the one or more trusses. The lifting assembly can have a plurality of panel lifters and a length adjusting mechanism associated with the support lift structure, with the length adjusting mechanism being structured and arranged to adjust the length of each of the one or more spreader frames so as change the position of one or more of the panel lifters relative to the other panel lifters.
In another embodiment of the present invention, the new system for panelizing and installing a plurality of wall panels on the frame of a building generally comprises the above described panelizing and lifting apparatus and the panels necessary to form the panelized section.
In yet another embodiment of the present invention, the new method for panelizing and installing a plurality of wall panels on the frame of a building generally comprises the steps of: (a) obtaining a panelizing and lifting apparatus having a panelizing assembly and a lifting assembly; (b) placing the panelizing assembly on a surface, with the panelizing assembly having a support frame supporting a plurality of panel alignment structures and each of the panel alignment structures having an alignment frame and a plurality of panel positioning devices on the alignment frame, each of the panel positioning devices positioned on the alignment frame so as to extend above an upper surface of the alignment frame, each of the panel positioning devices having a device profile; (c) placing a panel on the alignment frame in engagement with one or more of the panel positioning devices, the panel having been selected to form a panelized section comprising a plurality of such panels, with the panel having a panel profile, the device profile of each of the panel positioning devices configured in corresponding relation to the panel profile so as to engage an inward/lower surface of the panel; (d) moving the lifting assembly to be in engagement with an outward/upper surface of the panel, the lifting assembly comprising a support lift structure supporting a plurality of panel lifters, each of the panel lifters having a plurality of cap members, each of the cap members having a cap profile in corresponding relation to the panel profile of the panel; (e) positioning the cap members so as to be in alignment with panel positioning devices with the panel disposed between the cap members and the panel positioning devices; (f) attaching the lifting assembly to the panel while squeezing the panel between the lifting assembly and the panelizing assembly to allow the user to form the panelized section on the panelizing assembly using appropriately configured connectors; (g) lifting the lifting assembly and the panelized section off of the panelizing assembly; (h) moving the lifting assembly and the panelized section to a frame of the building and attaching the panelized section to the frame to form one of the wall or the roof of the building; and (i) disconnecting the lifting assembly from the panelized section. In a preferred configuration of the above method, each of the panel alignment structures further comprises a rail track that is associated with the alignment frame and a panel cart which is moveably engaged with the rail track an alignment frame. The method further comprising the step of positioning a bundle of panels on the panel cart, moving the panel cart on the rail track and removing the panel from the bundle of panels prior to panel placing step.
Accordingly, the primary objective of the present invention is to provide an improved apparatus, system and method for panelizing and installing wall and roof panels on the frame of a building that has the benefits described above and elsewhere herein and which overcomes the various limitations and problems that are associated with currently available apparatuses, systems and methods for handling and installing wall and roof panels on the frame of a building.
It is also a primary objective of the present invention to provide an improved apparatus, system and method for panelizing and installing wall and roof panels that can be utilized to easily, quickly and accurately panelize a plurality of wall or roof panels into a single array of panels that can then be lifted into position against the frame of a building so the users can more accurately, efficiently and safely install the panels on the building.
An important aspect of the present invention is that it provides a new apparatus, system and method for panelizing and installing wall and roof panels that achieves the goals of the above-described objectives.
Another important aspect of the present invention is that it provides an improved apparatus, system and method for panelizing and installing wall and roof panels on the superstructure frame of a building which comprises a panelizing assembly that is configured as a layout table or jig having a support frame, panel alignment structure, rail tracks and a rolling cart that are cooperatively configured to allow the user to quickly and accurately form a plurality of individual wall or roof panels into a panelized array of such panels for improved installation of the panels onto the frame of a building.
It is also an important aspect of the present invention to provide an improved apparatus, system and method for panelizing and installing wall and roof panels that comprises a lifting assembly which is structured and arranged to attach to a panelized section comprising an array of wall or roof panels to easily, quickly and safely lift and place the panelized array in position to install the panels on a frame of a building to form the walls or roof thereof.
Yet another important aspect of the present invention is that it provides an improved apparatus, system and method for panelizing and installing wall and roof panels which is relatively easy to use and inexpensive to manufacture.
As will be explained in greater detail by reference to the attached figures and the description of the preferred embodiments which follows, the above and other objects and aspects are accomplished or provided by the present invention. As set forth herein and will be readily appreciated by those skilled in the art, the present invention resides in the novel features of form, construction, mode of operation and combination of processes presently described and understood by the claims. The description of the invention which follows is presented for purposes of illustrating one or more of the preferred embodiments of the present invention and is not intended to be exhaustive or limiting of the invention. As will be readily understood and appreciated, the scope of the invention is only limited by the claims which follow after the discussion.
In the drawings which illustrate the preferred embodiments and the best modes presently contemplated for carrying out the present invention:
With reference to the figures where like elements have been given like numerical designations to facilitate the reader's understanding of the present invention, the preferred embodiments of the present invention are set forth in the text below. The enclosed figures are illustrative of one or more potential preferred embodiments and, therefore, are included to represent several different ways of configuring the present invention. Although specific components, materials, configurations and uses are illustrated, it should be understood that a number of variations to the components and to the configuration of those components described herein and shown in the accompanying figures can be made without changing the scope and function of the invention set forth herein. For instance, although the description and figures included herewith generally describe and show particular materials, shapes and configurations for the various components of the panelizing and lifting apparatus, system and method of the present invention and panels and buildings with which the apparatus, system and method may be utilized therewith, persons who are skilled in the art will readily appreciate that the present invention is not so limited. In addition, the exemplary embodiments of the present apparatus, system and method are shown and described with only those components which are required to disclose the present invention. It may be that some of the necessary elements for attaching and using the present invention are not shown or are not necessarily described below, but which are well known to persons skilled in the relevant art. As will be readily appreciated by such persons, the various elements of the present invention that are described below may take on any form consistent with forms that are readily realized by persons of ordinary skill in the art having knowledge of panels and buildings and other structures which use or can utilize such panels.
A panelizing and lifting apparatus that is configured pursuant to one or more embodiments of the present invention is shown generally as 5 in
With regard to the panelizing assembly 10, a wide variety of different types, sizes and configurations of panels 18 that can be panelized into a panelized section 22. An example of one type of prior art panel 18 that can be panelized by the panelizing assembly 10 of the present invention is shown in
A very common type of metal panel 18 that is utilized for the cladding that forms the metal walls 26 and roof 28 of a building 20 is a corrugated steel sheet having a plurality of spaced apart and parallel, alternating ribs 44 and valleys 46, as shown in
The panels 18 that can be utilized with the panelizing and lifting apparatus 5, system 14 and method 16 of the present invention can be, among others, of the type that are commonly known as exposed fastener, concealed fastener or standing seam panel installations. As well known to persons skilled in the art with regard to panels 18, particularly metal panels 18, exposed fastener panel installations result in the fasteners, such as self-drilling screws and the like, being visible and exposed to the environment. In use, the fasteners pass through the panels 18 to directly attach to the frame members, such as girts 48 and purlins 50, of the frame 24 of a typical building 20, as shown in
As set forth above, the panelizing and lifting apparatus 5, system 14 and method 16 of the present invention can be utilized with any type of panel 18 to form the panel 18 into the panelized section 22 that is then lifted in place against the girts 48 or purlins 50 of the building's frame 24, where the panelized section 22 is then attached to the frame 24 to form walls 26 or the roof 28. The assemblies 10/12, system 14 and method 16 can utilize any of the above or other panels 18, such that installation of the panels 18 (via panelized sections 22) to form walls 26 or a roof 28 will greatly benefit, with regard to accuracy, speed and safety, from the present inventions. For instance, blanket insulation, rigid board insulation, or other collateral materials can be joined to the panelized section 22 on the ground or other working surface 76 using the panelizing and lifting apparatus 5, system 14 and method 16 of the present invention to further gain the benefits of working from the ground or other surface 76 on the panelized support frame 72 to form the walls 26 and roof 28 of a building 20.
A typical metal building that can benefit from the new assemblies 10/12, system 14 and method 16 of the present invention has a base member 52 that rests on the foundation (not shown). A plurality vertical posts 54 connect to and extend upward from the base 52 to an eave strut 56 that defines the upper edge of the walls 26 of the building 20. One or more horizontally positioned girts 48 extend between and interconnect the posts 54. A plurality of beams 58 extend inward and slightly upward, for roofs 28 having a pitch (i.e., non-planar roofs 28), from the posts 54. The above description of the components and configuration of a building 20 that utilizes panels 18, particularly metal panels, is only an example of the components and configuration of a building 20 that is being utilized to describe the features and benefits of the present invention. The assemblies 10/12, system 14 and method 16 of the present invention can be utilized for any type of similarly configured building 20. As set forth in the Background, with regard to the prior art installation of panels 18 onto the walls 26 or roof 28 of a building, the panels 18 are individually placed against and attached to the base member 52, girts 48 and eave strut 56 to form the exterior cladding for the walls 26 and against and attached to the purlins 50 and eave strut 56 to form the exterior cladding for the roof 28. As set forth below, in the present invention a panelized section 22, comprising a plurality of panels 18, is placed against and attached to the same components in a manner that is faster, more accurate and safer.
The panelizing section 22, which comprises a plurality of joined panels 18, takes advantage of the fact that the panels 18 which are utilized for cladding for a building 20 are corrugated, to various degrees, so that the leading edge of one panel 18 is placed in interlocking relation with the trailing edge of another panel 18. In a typical prior art wall or roof installation for certain panels (i.e., exposed fastener panels), a first panel 18 is removed from a bundle of panels 19 (as shown in
As described in more detail below, the panelizing assembly 10 of the present invention is structured and arranged to allow the user to create a panelized section 22 on the ground or other surface where the panels 28 can be more quickly and accurately joined together. The lifting assembly 12 allows the user to lift the panelized section 22 into place against the frame 24 of the building 20 as an entire unit or array of panels 18. Once lifted in place, a first panelized section 22 is joined to the frame 24 in the manner which is appropriate for the type of panels 18 (such as exposed fastener panels, concealed fastener panels, standing seam panels and the like). The second panelized section 22 is then formed, lifted into place with the lifting assembly 12 and then the second panelized section 22 is attached to the first panelized section 22, with the aligned edges of the two panelized sections 22 in overlapping or other joined relation, and to the frame 24 of the building 20. This process repeated until the entire wall 26 or roof 28, or desired portions thereof, are covered with panels 18 (via the panelized sections 22). For purposes of describing the various attributes and benefits of the present invention, each panelized section 22 has a first or leading side 60 (which is the side that is in the cladding/sheeting direction), a second or trailing side 62, a first or upper end 64 (with upward being the upper edge of a wall panel and the up-slope edge of a roof panel), a second or lower end 66, an outward or upper surface 68 and an inward or lower surface 70 (with the terms “outward or upper” and “inward or lower” having the same meaning as set forth above), as shown in
The panelizing assembly 10, shown in
Together, the support frame 72 and panel alignment structures 74 define a first side 78, second side 80, first end 82 and second end 84 of the new panelizing assembly 10, as best shown in
The support frame 72 comprises one or more support frame members 86 that are sized and configured to support the panel alignment structures 74, panels 18 and a panelized section 22, as shown in
To accomplish the various desired objectives of the present invention, a preferred configuration of the support frame 72 has a plurality of surface support members 88 that are attached to or integral with the lower surface 89 of support frame 72, which in the embodiments shown in the figures, is the lower of the support frame members 86, so as to extend downwardly therefrom (i.e., towards the surface 76), as best shown in
The support frame 72 of the panelizing assembly 10 of the present invention also has one or more, preferably a plurality of, frame lifting devices 90 (shown in
As set forth above, the new panelizing assembly 10 has one or more panel alignment structures 74 that are structurally associated with the support frame 72 such that the support frame 72 supports the panel alignment structures 74 above the surface 76, as shown in
As best shown in
Although the alignment frame 92 may be integral with the support frame 72 or fixedly attached to the support frame 72, by welding, rivets or other appropriate mechanisms, in the preferred embodiment the alignment frame 92 is removably attached to the support frame 72 to allow the user to separate the panel alignment structure 94 from the support frame 72 for ease of moving and storing the panelizing assembly 10 and to allow the user to adjust spacing between the panel alignment structures 94 to accommodate different lengths of panels 18 and for two-tone color transitions and/or the locations of skylights and/or other wall or roof accessories. In one configuration, the support frame 72 and each of the panel alignment structures 74 have a plurality of cooperatively configured and arranged frame mounting apertures, shown as 112 on the support frame 72 and as 114 on the panel alignment structures 74 in
As set forth above, each of the panel alignment structures 74 have a rail track 96 that is attached to, integral with or otherwise supportedly associated with the alignment frame 92, as best shown in
The panel cart 100, which moves along the rail track 96, has a panel cart frame 120 that is sized and configured to receive a bundle of panels 19 on the upper surface 122 thereof, with the panel frame 120 and upper surface 122 best shown in
In a preferred embodiment of the panelizing assembly 10, the panel alignment structures 74 have cart stop members 104 at each of the opposing ends 106/108 of the alignment frame 92 to prevent the panel cart 100 from going beyond the ends 106/108 of the alignment frame 92, which are at the sides 78/80 of the support frame 72, as shown in
To allow the user to easily, quickly and accurately align the panels 18 into the desired panelized section 22, the panelizing assembly 10 also includes a plurality of panel positioning devices 110 on the panel alignment structures 74 and, in a preferred embodiment, the panel cart 100, as shown in
With regard to the exemplary corrugated panel 18 shown in
In a preferred configuration, the placement of the panel positioning devices 110 is such that the spacing between adjacent panel positioning devices 110 will result in each panel 18 being engaged by two or more panel positioning devices 110 on the same panel alignment structure 74 to ensure that the panels 18 stay properly aligned. In addition, each of the panel alignment structures 74 will have panel positioning devices 110 that are aligned with the panel positioning devices 110 on the other panel alignment structures 74. More specifically, the panel alignment structures 74 are cooperatively configured such that the panel positioning devices 110 of each panel alignment structure 74 are aligned with the panel positioning devices 110 of the other panel alignment structures 74. For instance, with regard to the exemplary panelizing assembly 10 shown in the figures, the panel positioning devices 110 on the panel alignment structures 74a/74b/74c are positioned at the same location along the length of the longitudinal frame members 94a/94b of the alignment frame 92. With the panel positioning devices 110 aligned, the panel 18 will extend over the panel alignment structures 74a/74b/74c to engage the panel positioning devices 110 to align the entire length, from first end 36 to second end 38, of the panel 18 to ensure that the formed panelized section 22 is true, straight and accurate so that it can placed on the frame 24 of a building 20 and be joined to an adjacent panelized section 22 to form a wall 26 or the roof 28 of the building 20.
With regard to the panel alignment structures 74, the panel positioning devices 110 are integral with or attached to the upper surface 116 of the alignment frame 92. In one embodiment, the panel positioning devices 110 are integral or fixedly attached to the longitudinal frame members 94a/94b of the alignment frame 92 such that the panel alignment structures 74 are to be utilized with a particular configuration of panel 18 having a panel profile 47. Although limiting, this type of configuration may work well for persons who primarily install one or only a few different types of panels 18. In a preferred embodiment, however, each panel positioning device 110 is removably, but securely, attached to the alignment frame 92 (normally the longitudinal frame members 94a/94b thereof) so the user may have a single set of panel alignment structures 74 and be able to replace the panel positioning devices 110 as necessary for the device profile 126 to be the same as the panel profile 47 of the panels 18. In a preferred configuration, bolts, screws or other such connectors are utilized to removably attach the panel positioning devices 110 to the longitudinal frame members 94a/94b of alignment frame 92 of each of the panel alignment structures 74 that make up panelizing assembly 10.
As shown in the figures, the panel positioning devices 110 are configured in pairs such that the first longitudinal frame member 94a and the second longitudinal frame member 94b of an alignment frame 92 will each have a correspondingly positioned panel positioning device 110 and the panel positioning devices 110 on each of the alignment frames 92 that make up support frame 72 will also be correspondingly positioned so the panel positioning devices 110 are transversely aligned across the panel lifting apparatus 10. This will ensure that each panel 18 is aligned with the other panels 18 that are placed on the panel alignment structures 74 when forming a panelized section 22.
In the embodiment shown in the figures, panel positioning devices 110 are also utilized on the panel cart 110, as shown in
As will be readily appreciated by persons who are skilled in the art, the panel positioning devices 110 can be made out of a wide variety of different types of material, including metal, plastic, composite, rubber and the like. If the panel positioning devices 110 are integral to the alignment frame 92, it is likely that the panel positioning devices 110 will be made out of metal. In practice, however, the use of metal panel positioning devices 110 have been found to dent the panels 18. In a preferred embodiment, the panel positioning devices 110 are made of a material that is selected so it will not damage the panels 18 when they are placed on the panel alignment structures 74 or the panel cart 100. In one embodiment, the panel positioning devices 110 are made out of polyurethane or the like, with the panel positioning device 110 being shaped and configured to the desired device profile 126 (i.e., in corresponding relation with the panel profile 47 of the panels 18 that will make up the panelized section 22).
In a preferred embodiment, the panel positioning devices 110 are also configured to assist the user with connecting two adjacent panels 18 together in the manner suggested by the manufacturer of the panels 18 or as otherwise may be desired. A common manner of connecting the first side 32 of one panel 18 to the second side 34 of the previously positioned panel 18 (i.e., the first side 32 of panel 18b to the second side 34 of panel 18a) is to drive a self-drilling screw or other connector through the overlapping or otherwise joining portion, shown as 164 in
As set forth above, the present invention also includes a panel lifting assembly 12 that is structured and arranged to engage the panelized section 22 formed by the panelizing assembly 10 described above. Typically, the new lifting assembly 12 will be placed in position against the panelized section 22 (as shown in
The lifting assembly 12 of the present invention generally comprises one or more, typically a plurality of, specially configured panel lifters 130 and a support lift structure 132, as shown in
In the embodiment shown in the figures, the lifting assembly 12 has three elongated panel lifters 130, shown in
The lifter frame 134 of each panel lifter 130 is structured and arranged to extend substantially between the first side 60 and the second side 62 of the panelized section 22, as best shown in
As set forth above, each panel lifter 130 of the lifting assembly 12 has a plurality of cap members 136 that are integral with or attached to the lifter frame 134 so as to extend below the lower surface 148 of the lifter frame 134 and engage the panelized section 22 on the panelizing assembly 10 so the panelized section 22 can be lifted into place against the frame 24 of a building 20. Each of the cap members 136 have a cap body 152, with a first end 154 and second end 156, that is sized and configured with a cap profile 158, as best shown in
With each cap member 136 placed in corresponding position with a panel positioning device 110 and the lifting assembly 12 placed on and secured to the panels 18 that will form the panelized section 22 while the panels 18 are on the panelizing assembly 10, the plurality of cap members 136 and panel positioning devices 110 will tightly squeeze the various panels 18 between the lifting assembly 12 and the panelizing assembly 10 to securely hold the panels 18 that will form the panelized section 22 together so the user can easily, quickly and accurately form the panelized section 22. Once all of the cap members 136 are secured to the panelized section 22, as set forth in detail below, the lifting assembly 12 can raise the panelized section 22 off of the panelizing assembly 10 and lift the panelized section 22 into position against the frame 24 of a building 20.
In a preferred configuration, the cap members 136 are made out of steel or other stiff, strong metal with a cap profile 158 that matches the portion of the panel profile 47 of the panel 18 (i.e., the ribs 44 or valleys 46). Alternatively, the cap members 136 can be made out of other materials that are sufficiently stiff and strong to accomplish the objectives of the present invention. In a preferred configuration, each of the cap members 136 has a liner 166 that covers the lower surface 162 of the cap body 152, as shown in
To secure the panel lifters 130 of the lifting assembly 12 to the panel 18 that make up a panelized section 22, the various cap members 136 should have a cap spacing 168 that corresponds to a device spacing 170 of panel positioning devices 110, as shown in
In a preferred configuration, each of the cap members 136 are removably attached to the lower surface 148 of the lifter frame 134, such as the platform 150 shown in the figures, with a bolt, screw or like connector. Being removably attached to the lifer frame 134 allows the user to selectively position the cap members 136 along the length of the lifter frame 134 so the cap members 136 will be in alignment with the portion of the panel 18 (i.e., the ribs 44) over which it will be placed and the panel positioning device 110 under the same portion of the panel 18. This configuration will allow an installation company to have one or more sets of panel lifters 130 that can be utilized with a wide range of different types of panels 18 having different panel profiles 47. In an alternative embodiment, the panel lifters 130 can be manufactured for a particular panel profile 47 of a panel 18 and the cap members 136 can be integral with or fixedly attached to the lifter frame 134. In this configuration, the manufacturer of the panels 18 can supply one or more sets of panel lifters 130, with the cap members 136 that are configured and positioned to match the panel profile 47 of the panels 18, to the installers so the installation company can utilize those panel lifters 130 with their lifting assembly 12 to help form and lift panelized sections 22.
Each end 154/156 of the elongated cap members 136 have one or more mounting apertures 172, best shown in
In the embodiments shown in the figures, the lifting assembly 12 also comprises a sliding connector plate 174 associated with each of the mounting apertures 172 of the cap members 136, as best shown in
The above describes utilizing screws, bolts or other connectors to with the cap members 136 to attach the panel lifters 130 to the outward/upper surface 40 of the panels 18 that form the panelized section 22 to allow the lifting assembly 12 to attach to and lift the panelized section 22. As will be readily appreciated by persons who are skilled in the art, a wide variety of other attachment mechanisms, other than the cap members 136, can be utilized to removably, but securely, attach the panel lifters 130 to the panels 18 that make up the panelized section 22. The attachment mechanisms can comprise mechanical fasteners, magnets, vacuum systems or the like that are structured and arranged to securely attach the lifting assembly 12 to the panelized section 22 so the panelized section 22 can be raised off of the panelizing assembly 10 and lifted into position against the frame 24 of a building 20 to form the walls 26 and/or roof 28 of the building 20. The use and configuration these, and other, panel attachment mechanisms are generally well known to persons skilled in the art.
The support lift structure 132, which is integral with or attached to the panel lifters 130 of the lifting assembly 12 is utilized to raise the panel lifters 130 and the attached panelized section 22 off of the panelizing assembly 10, lift the panelized section 22 into place against the frame 24 of a building 20 and then lower the lifting assembly 12 back to the panelizing assembly 10 and position the panel lifters 130 on the next set of panels 18 that will form a panelized section 22. The support lift structure 132 generally comprises one or more trusses 176 and one or more spreader frames 178, as shown in
Each of the trusses 176 have a plurality of truss frame members 180 that are structured and arranged to support the lifting assembly 12 and a panelized section 22 as they are raised from the panelizing apparatus and lifted into position against the frame 24 of a building 20. Each of the truss frame members 180 has two or more horizontal frame members 180a, one or more vertical frame members 180b interconnecting the horizontal frame members 180a and a plurality of angled frame members 180c that interconnect the horizontal frame members 180a and/or the vertical frame members 180b. In the embodiment shown in the figures, there is one vertical frame member 180b at or near the center of the trusses 176. As will be readily appreciated by persons who are skilled in the art, the trusses 176 will be doing the primary work when moving a panelized section 22. As such, the frame members 180 of the trusses 176 need to be made out of materials and structured and arranged to be sufficiently strong and stiff to accomplish the objectives of raising the lifting assembly 12 and panelized section 22 off of the panelizing assembly 10 and placing the panelized section 22 in position against the frame 24. In one embodiment, the truss frame members 180 are made out of tubular steel or aluminum and fixedly joined together to form the truss 176. A variety of other types of frame members and materials can also be utilized for the trusses 176.
As shown in
In a preferred configuration, the pivot mechanisms 182 are operatively connected to a pivot locking device 184, best shown in
As best shown in
As set forth above, the support lift structure 132 also has one or more, typically a plurality of, spreader frames 178 that are structured and arranged to interconnect the trusses 176 and provide the necessary rigidity to the support lift structure 132 so the lifting assembly 12 can lift and position the panelized section 22 to its position against the frame 24. The spreader frames 178 each have a plurality of spreader frame members 188 that are structured and arranged and made out of materials to provide a rigid spreader frame 178 that allows the lifting assembly 12 to be safely lifted and moved by aerial lifting equipment, such as a crane or the like, and to maintain the square or rectangular shape of the panelized section 22 as the panelized section 22 is being moved and positioned against the frame 24 to form the walls 26 and/or roof 28 of the building 20. The spreader frame 178 should be sufficiently rigid to hold the trusses 176 in position relative to each other and to prevent the panelized section 22 from flexing or otherwise moving in an undesirable manner. For use when forming a wall 26, it may only be necessary to utilize two spreader frames 178 should be sufficient. For use when forming the roof 28, it may be beneficial to utilize three spreader frames 178 to provide additional stiffening.
In one embodiment, the spreader frames 178 are a fixed length and the trusses 176 are fixedly attached to or integral with the spreader frames 178. As will be readily appreciated by persons skilled in the art, however, this will be very limiting with regard to the size and configuration of the panelized section 22 with which the lifting assembly 12 can be safely and effectively utilized. In a preferred configuration, the lifting assembly 12 has a length adjusting mechanism 190, as shown in
The system 14 for panelizing and installing panels 18 of the present invention comprises the panelizing assembly 10 and lifting assembly 12 described above. In addition, as shown in the diagram of
Once the panels 18 for the panelized section 18 are in place, the lifting assembly 12 is lowered onto the outward/upper surface 40 of the panels 18. More specifically, an aerial lifting machine 200, such as a crane or the like, is attached to the support lift structure 132 of the lifting assembly 12 and the lifting assembly 12 is positioned on the panels 18 such that the cap members 136 supported by the panel lifters 130 are positioned in corresponding relation to the panel positioning devices 110 under the panels 18. With the cap members 136 having a cap profile 156 in corresponding relation to the panel profile 47 (but opposite the device profile 126 of the panel positioning devices 110), the panels 18 will be pressed between the lifting assembly 12 and the panelizing assembly 10. The user assembles the panelized section 22 and attaches the lifting assembly 12 to the panelized section 22 by inserting connectors, such as screws or the like, through properly positioned mounting apertures 172 near the ends 154/156 of the cap members 136. The trusses 176 and spreader frame 178 of the support lift structure 132 support the panel lifters 130 and maintain the shape of the panelized section 22 as the aerial lifting machine 200 raises the panelized section 22 off of the panelizing assembly 10 and raises the panelized section 22 into place against the frame 24 of a building 20 to form the walls 26 or roof 28 thereof. Because the trusses 176 are pivotally attached to the panel lifters 130 the panelized section 22 can be pivoted into the desired position for the wall 26 or roof 28. One or more pivot locking devices 184 allow the user to allow free pivoting, controlled pivoting or no pivoting of the panel lifters 130 and, therefore, the panelized section 22. Latches 186 help hold the panelized section 22 in place against the frame 24, particularly for the walls 26, while the users secure the panelized section 22 to the frame 24. Once the panelized section 22 is attached, or at least sufficiently attached, the lifting assembly 12 is disconnected and lowered back down by the aerial lifting machine 200 to attach to another group of panels 18.
The method 16 of panelizing and installing panels 18 of the present invention generally comprises the following steps: (1) moving a panelizing assembly 10 to the desired position using a moving machine 202; (2) placing the support frame 72 of the panelizing assembly 10 on a surface 76 near a frame 24 that will define the walls 26 and/or roof 28 of a building 20; (3) positioning the one or more panel alignment structures 74 on the support frame 72 for the panels 18 that will be utilized to form a panelized section 22; (4) securing the panel alignment structures 74 to the support structure 72, with each panel alignment structure 74 having an alignment frame 92 with panel positioning devices 110 located thereon for the panels 18; (5) placing a bundle of panels 19 on a panel cart 100 located at a panel cart area 128 of the panel alignment structure 74 at or near a first side 78 of the support structure 72; (6) moving the panel cart 100 on a rail track 96 that is associated with the alignment frame 92 toward the second side 80 of the support structure 72; (7) removing a panel 18 from the panel cart 100; (8) placing the panel 18 on panel positioning devices 110 on the alignment frame 92, with the panel positioning devices 110 having a device profile configured in corresponding relation with a panel profile 47 of the panels 18 so as to align the panels 18 to form the panelized section 22 and to hold the panels 18 in place on the panel alignment structure 74; (9) lowering a lifting assembly 12 to the panels 18 on the panelizing structure 10 using an aerial lifting machine 200 attached to a support lift structure 132 supporting one or more panel lifters 130 that each have a plurality of cap members 136 on a lower surface 148 thereof; (10) positioning the panel lifters 130 on the panels 18 with the cap members 136 in corresponding relation to the panel positioning devices 110 under the panels 18, with the cap members 136 having a cap profile 156 in corresponding relation to the panel profile 47 (opposite the device profile 126 of the panel positioning devices 110) so the panels 18 will be pressed between the lifting assembly 12 and the panelizing assembly 10; (11) attaching the lifting assembly 12 to the panels 18 and forming the panelized section 22, by joining the overlapping or joining portions 164, using screws or other connectors placed through mounting apertures 172 in the cap members 136; (12) raising the lifting assembly 12 and panelized section 22 off of the panelizing assembly 10 with the aerial lifting machine 200 to position the panelized section at the frame 24 of the building 20: (13) attaching the panelized section 22 to the frame 24 to form a wall 26 or roof 28 of the building 20; and (14) disconnecting the lifting assembly 12 from the panelized section 22. After disconnecting the lifting assembly 12, the user will typically move the lifting assembly 12 back to the panelizing assembly 10 to either attach to and form another panelized section 22 for the wall 26 or roof 28 or place the lifting assembly 12 on the panelizing assembly 10 to store these assemblies 10/12 for later use.
In one of the preferred configurations of the present invention, the panelizing assembly 10 and the lifting assembly 12 can be disassembled and stored together in an apparatus bundle 204, as shown in
While there are shown and described herein specific forms of the invention, it will be readily apparent to those skilled in the art that the invention is not so limited, but is susceptible to various modifications and rearrangements in design and materials without departing from the spirit and scope of the invention. In particular, it should be noted that the present invention is subject to modification with regard to any dimensional relationships set forth herein and modifications in assembly, materials, size, shape and use. For instance, there are numerous components described herein that can be replaced with equivalent functioning components to accomplish the objectives of the present invention.
This patent application claims priority to U.S. Provisional Patent Application No. 62/607,920 filed Dec. 20, 2017.
| Number | Name | Date | Kind |
|---|---|---|---|
| 2496571 | Wagner | Feb 1950 | A |
| 2847755 | Mummert | Aug 1958 | A |
| 3333322 | Toffolon | Aug 1967 | A |
| 3673675 | Eggert, Jr. | Jul 1972 | A |
| 3866300 | Bell | Feb 1975 | A |
| 3934386 | Al Haj Issa | Jan 1976 | A |
| 4123879 | Blodee | Nov 1978 | A |
| 4257158 | Casutt | Mar 1981 | A |
| 4348797 | Hutchison | Sep 1982 | A |
| 4452587 | Laws | Jun 1984 | A |
| 4637540 | Fujita | Jan 1987 | A |
| 5095673 | Ward | Mar 1992 | A |
| 6467236 | Schlegel | Oct 2002 | B1 |
| 8316605 | Oberg | Nov 2012 | B2 |
| 20030154614 | Rice | Aug 2003 | A1 |
| 20080083183 | Rymell | Apr 2008 | A1 |
| 20100229367 | Franklin | Sep 2010 | A1 |
| Number | Date | Country | |
|---|---|---|---|
| 62607920 | Dec 2017 | US |
