Granted Patent B1

US 12,650,017 · App. 18/630,876 · Granted Jun 9, 2026

Inventors: Alexis Xavier Rivas (Gardena, CA); Craig Derian (Gardena, CA)

Assignee: Cover Technologies, Inc.

E04C2/384E04C2/284E04C2/3405E04C2/46E04C2/50E04C2/52E04C2002/004E04C2002/3488

Abstract

Claims (317)

1 . A panel system comprising:

a first wall panel, in a set of wall panels, comprising:

a left column element:

configured to carry vertical loads through a left side of the wall panel; and

defining a left gasket relief extending vertically along the left column element;

a right column element:

configured to carry vertical loads through a right side of the wall panel;

a footer element:

extending between the left column element and the right column element; and

defining a lower vertical wall datum configured to seat on a vertical floor datum of a floor panel to vertically locate the wall panel relative to the floor panel;

a header element:

extending between the left column element and the right column element above the footer element;

an insulative element:

extending between the left column element, the right column element, the header element, and the footer element;

a left flange:

extending rearward from the left column element;

laterally offset from the left gasket relief;

configured to mate to a second right flange of a second wall panel installed adjacent the wall panel, via a series of clinch connections; and

defining a left lateral wall datum configured to laterally locate the first wall panel relative to the second wall panel; and

a left return flange:

configured to stiffen the left flange; and

extending laterally from the left flange opposite the second wall panel; and

a gasket:

located along the left gasket relief; and

configured to compress between the left gasket relief of the first wall panel and a second right column element of a second wall panel during installation of the series of clinch connections.

2 . The panel system of claim 1 :

further comprising a second wall panel, in a set of wall panels, comprising:

second left column element:

configured to carry vertical loads through a second left side of the second wall panel;

a second right column element:

configured to carry vertical loads through a second right side of the second wall panel;

a second footer element:

extending between the second left column element and the second right column element; and

defining a second lower vertical wall datum configured to seat on the vertical floor datum surface of the floor panel to vertically locate the second wall panel relative to the floor panel;

a second header element:

extending between the left column element and the right column element above the footer element;

a second insulative element:

extending between the second left column element, the right column element, the second header element, and the second footer element;

a second exterior façade panel:

extending across outer faces of the second left column element, the second right column element, the second footer element, and the second header element;

the second right flange:

extending rearward from the second right column element opposite the exterior façade panel;

configured to mate to the first left flange of the first wall panel via the series of clinch connections; and

defining a right lateral wall datum configured to laterally locate the second wall panel relative to the first wall panel; and

a second right return flange:

configured to stiffen the second right flange; and

extending laterally from the second right flange opposite the first wall panel; and

wherein the first wall panel and the second wall panel are assemblable into a section of the wall via the series of clinch connections configured to:

mate the left lateral wall datum of the first wall panel the right lateral wall datum of the second wall panel;

compress the gasket between the left column element of the first wall panel and the second right column element of the second wall panel; and

form an interlock securing the first left flange to the second right flange.

3 . The panel system of claim 2 :

further comprising a moisture barrier flap:

to overlap a junction between the first wall panel and the second side of a second wall panel to prevent ingress of moisture.

4 . The panel system of claim 1 :

wherein the first wall panel further comprises:

a lower flange extending rearward from the footer element defining:

the lower vertical wall datum configured to seat against the vertical floor datum of the floor panel to locate the wall panel relative to the floor panel; and

a surface for a series of clinch connections to a flange of the floor panel;

further comprising the floor panel comprising:

a bottom inner panel;

an insulation layer arranged below the bottom inner panel;

a bottom outer panel defining a foundation mount configured to interface with a foundation structure;

a first joist coupled to the bottom inner panel;

a second joist:

laterally offset from the first joist; and

coupled to the bottom inner panel;

a lateral flange:

coupled to the bottom inner panel;

extending upwardly from a second edge of the bottom inner panel; and

configured to fasten to a second floor panel via a series of clinch connections;

a vertical flange:

defining the vertical floor datum configured to vertically locate and support a lower vertical wall datum of a wall panel arranged over the floor panel; and

wherein the first wall panel and the floor panel are assemblable via the series of clinch connections configured to:

mate the lower vertical wall datum of the first wall panel to the vertical floor datum of the floor panel; and

form an interlock securing the lower flange of the first wall panel to the vertical flange of the floor panel.

5 . The panel system of claim 1 :

wherein the first wall panel further comprises:

a lower flange extending rearward from the footer element defining:

a lower vertical wall datum configured to seat against a floor datum of the floor panel to locate the wall panel relative to the floor panel; and

a first set of fastener bores;

further comprising the floor panel comprising:

a bottom inner panel;

an insulation layer arranged below the bottom inner panel;

a bottom outer panel defining a foundation mount configured to interface with a foundation structure;

a first joist coupled to the bottom inner panel;

a second joist:

laterally offset from the first joist; and

coupled to the bottom inner panel;

a lateral flange:

coupled to the bottom inner panel; and

extending upwardly from a second edge of the bottom inner panel; and

a vertical flange:

defining a vertical floor datum configured to vertically locate and support a lower vertical wall datum of a wall panel arranged over the floor panel; and

defining a second set of fastener bores; and

wherein the first wall panel and the floor panel are assemblable via a series of fasteners configured to:

install within the first set of fastener bores and the second set of fastener bores; and

mate the lower vertical wall datum of the first wall to the vertical floor datum of the floor panel.

6 . The panel system of claim 5 , wherein, during installation, a tapered pin inserts within a first fastener bore of the first series of fastener bores and a second fastener bore of the second series of fastener bores to position the first wall relative to the floor panel.

7 . The panel system of claim 1 :

wherein the first wall panel further comprises:

a header element:

comprising a top plate defining an upper vertical wall datum configured to seat on a roof datum surface of a roof panel to vertically locate the roof panel relative to the first wall panel; and

extending between the left column element and the right column element;

further comprising the roof panel comprising:

an inner panel:

defining a first inner panel edge configured to rest on the top plate of the first wall panel;

an insulation layer extending above the inner panel;

a moisture barrier:

arranged above the insulation layer; and

extending across an exterior surface of the roof panel;

a first joist:

coupled to and extending below the inner panel; and

offset from a first edge of the inner panel;

a second joist:

coupled to and extending below the inner panel;

laterally offset from the first joist; and

offset from a second edge of the inner panel opposite the first edge of the inner panel;

a flange:

coupled to the inner panel;

extending upwardly from the second edge of the inner panel; and

configured to fasten to a second roof panel via a series of clinch connections; and

a gutter mount:

extending outwardly from the first edge of the roof panel; and

configured to locate a gutter over the top plate of the first wall panel; and

wherein the first wall panel and the roof panel are assemblable via a joist bracket:

defining a first surface coupled to the first joist via a first series of fasteners; and

defining a second surface coupled to the header of the first wall panel via a second series of fasteners.

8 . The system of claim 1 , wherein the insulative element:

defines a cast-in-place within an interior panel volume formed by the left column element, the right column element, the footer, and the header; and

is configured to carry shear loads through the first wall panel.

9 . The system of claim 1 , wherein the insulator element:

defines a pre-cast material exhibiting a geometry fitting within an interior panel volume formed by the left column element, the right column element, the footer, and the header; and

is configured to carry shear loads through the first wall panel.

10 . The panel system of claim 1 , wherein the first wall panel further comprises:

a central column element:

arranged between the left column element and the right column element; and

defining a panel relief extending between the footer element to the header element and configured to house electrical and plumbing elements.

11 . The panel system of claim 1 :

wherein the wall panel further comprises:

an exterior façade mount extending between the left column element and the right column element; and

further comprising an exterior façade panel:

configured to install onto the exterior façade mount of the first wall panel; and

defining a prefinished exterior surface.

12 . The panel system of claim 1 :

wherein the first wall panel further comprises:

an interior wall hanger defining a track along an interior surface of the first wall panel; and

further comprising an interior finish panel:

configured to install onto the interior wall hanger of the first wall panel; and

comprising a prefinished interior surface.

13 . The panel system of claim 1 :

further comprising a fenestration panel comprising:

a third left column element:

configured to carry vertical loads through a left side of the fenestration panel;

a third right column element:

configured to carry vertical loads through a right side of the fenestration panel;

a fenestration element:

arranged between the left column and the right column; and

defining a panel of glass;

a third header element:

extending between the third left column element and the third right column element above the footer element; and

arranged above the fenestration element;

a third right flange:

extending rearward from the third right column element;

configured to mate to the first left flange of the first wall panel via the series of clinch connections; and

defining a right lateral fenestration datum configured to laterally locate the fenestration panel relative to the first wall panel; and

a third right return flange:

configured to stiffen the second right flange; and

extending laterally from the second right flange opposite the first wall panel; and

wherein the first wall panel and the fenestration panel are assemblable into a section of the wall via a series of clinch connections configured to:

mate the left lateral wall datum of the first wall panel to the right lateral fenestration datum of the fenestration panel; and

form an interlock securing the first left flange to the third right flange.

14 . A panel system comprising:

a first wall panel, in a set of wall panels, comprising:

a left column element:

configured to carry vertical loads through a left side of the wall panel; and

defining a left gasket relief extending vertically along the left column element;

a right column element:

configured to carry vertical loads through a right side of the wall panel;

a lower vertical wall datum:

configured to seat on a vertical floor datum surface of a floor panel to vertically locate the wall panel relative to the floor panel;

a header element:

extending between the left column element and the right column element above the floor panel;

an insulative element:

extending between the left column element, the right column element, the header element, and the footer element;

an exterior façade panel:

defining a prefinished exterior surface; and

extending across outer faces of the left column element, the right column element, the footer element, and the header element; and

a left flange:

extending rearward from the left column element opposite the exterior façade panel;

laterally offset from the left gasket relief;

configured to mate to a second right flange of a second wall panel installed adjacent the wall panel, via a series of clinch connections; and

defining a left lateral wall datum configured to laterally locate the first wall panel relative to the second wall panel; and

a gasket:

located along the left gasket relief; and

configured to compress between the left gasket relief of the first wall panel and a second right column element of a second wall panel during installation of the series of clinch connections.

15 . The panel system of claim 14 :

further comprising a second wall panel, in a set of wall panels, comprising:

a second left column element:

configured to carry vertical loads through a second left side of the second wall panel;

a second right column element:

configured to carry vertical loads through a second right side of the second wall panel;

a second footer element:

extending between the second left column element and the second right column element; and

defining a second lower vertical wall datum configured to seat on the vertical floor datum surface of the floor panel to vertically locate the second wall panel relative to the floor panel;

a second insulative element:

extending between the second left column element, the right column element, the second header element, and the second footer element; and

the second right flange:

extending rearward from the second right column element opposite the exterior façade panel;

configured to mate to the first left flange of the first wall panel via the series of clinch connections; and

defining a right lateral wall datum configured to laterally locate the second wall panel relative to the first wall panel; and

wherein the first wall panel and the second wall panel are assemblable into a section of the wall via the series of clinch connections configured to:

mate the left lateral wall datum of the first wall panel to the right lateral wall datum of the second wall panel;

compress the gasket between the left column element of the first wall panel and the second right column element of the second wall panel; and

press material of the first left flange into the second right flange to secure the first left flange to the second right flange.

16 . The panel system of claim 14 :

wherein the first wall panel further comprises:

lower flange extending rearward from the footer element defining:

a lower vertical wall datum configured to seat against a floor datum of the floor panel to locate the wall panel relative to the floor panel; and

a surface for a series of clinch connections to a floor panel flange floor panel;

further comprising the floor panel comprising:

a bottom inner panel;

an insulation layer arranged below the bottom inner panel;

a bottom outer panel defining a foundation mount configured to interface with a foundation structure;

a first joist coupled to the bottom inner panel;

a second joist:

laterally offset from the first joist; and

coupled to the bottom inner panel;

a lateral flange:

coupled to the bottom inner panel;

extending upwardly from a second edge of the bottom inner panel; and

configured to fasten to a second floor panel via a series of clinch connections; and

a vertical flange:

defining a vertical floor datum configured to vertically locate and support a lower vertical wall datum of the first wall panel arranged over the floor panel; and

wherein the first wall panel and the floor panel are assemblable via the series of clinch connections configured to:

mate the lower vertical wall datum of the first wall panel to the vertical floor datum of the floor panel; and

form an interlock securing the lower flange of the first wall panel to the vertical flange of the floor panel.

17 . The panel system of claim 14 :

wherein the first wall panel further comprises:

a lower flange extending rearward from the footer element defining:

a lower vertical wall datum configured to seat against a floor datum of the floor panel to locate the wall panel relative to the floor panel; and

a first set of fastener bores;

further comprising the floor panel comprising:

a bottom inner panel;

an insulation layer arranged below the bottom inner panel;

a bottom outer panel defining a foundation mount configured to interface with a foundation structure;

a first joist coupled to the bottom inner panel;

a second joist:

laterally offset from the first joist; and

coupled to the bottom inner panel;

a lateral flange:

coupled to the bottom inner panel;

extending upwardly from a second edge of the bottom inner panel; and

a vertical flange:

defining a vertical floor datum configured to vertically locate and support a lower vertical wall datum of a wall panel arranged over the floor panel; and

defining a second set of fastener bores; and

wherein the first wall panel and the floor panel are assemblable via a series of fasteners configured to:

install within the first set of fastener bores and the second set of fastener bores; and

mate the lower vertical wall datum of the first wall to the vertical floor datum of the floor panel.

18 . The panel system of claim 17 wherein, during installation, a tapered pin inserts within a first fastener bore of the first series of fastener bores and a second fastener bore of the second series of fastener bores to position the first wall relative to the floor panel.

19 . The panel system of claim 14 :

wherein the first wall panel further comprises:

a header element:

comprising a top plate defining an upper vertical wall datum configured to seat on a roof datum surface of a roof panel to vertically locate the roof panel relative to the first wall panel; and

extending between the left column element and the right column element;

further comprising the roof panel comprising:

an inner panel:

defining a first inner panel edge configured to locate on the top plate of first wall panel;

an insulation layer extending above the inner panel;

a moisture barrier:

arranged above the insulation layer; and

extending across an exterior surface of the roof panel;

a first joist:

coupled to and extending below the inner panel; and

offset from a first edge of the inner panel;

a second joist:

coupled to and extending below the inner panel;

laterally offset from the first joist; and

offset from a second edge of the inner panel opposite the first edge of the inner panel;

a flange:

coupled to the inner panel;

extending upwardly from the second edge of the inner panel; and

configured to fasten to a second roof panel via a series of clinch connections;

a gutter mount:

extending outwardly from the first edge of the roof panel; and

configured to locate a gutter over the top plate of the first wall panel; and

wherein the first wall panel and the roof panel are assemblable via a joist bracket:

defining a first surface coupled to the first joist via a first series of fasteners; and

defining a second surface coupled to the header of the first wall panel via a second series of fasteners.

20 . A panel system comprising:

a first wall panel, in a set of wall panels, comprising:

a left column element:

configured to carry vertical loads through a left side of the wall panel; and

defining a left gasket relief extending vertically along the left column element;

a right column element:

configured to carry vertical loads through a right side of the wall panel;

a lower vertical wall datum:

configured to seat on a vertical floor datum surface of a floor panel to vertically locate the wall panel relative to the floor panel;

a header element:

extending between the left column element and the right column element above the floor panel;

an insulative element:

extending between the left column element, the right column element, the header element, and the footer element;

a left flange:

extending rearward from the left column element opposite the exterior façade panel;

laterally offset from the left gasket relief;

configured to mate to a second right flange of a second wall panel installed adjacent the wall panel, via a series of clinch connections; and

defining a left lateral wall datum configured to laterally locate the first wall panel relative to the second wall panel;

an exterior façade mount:

extending between the left column element and the right column element along an exterior surface of the first wall panel; and

an interior wall hanger:

defining a track along an interior surface of the first wall panel; and

an interior finish panel:

configured to install onto the interior wall hanger of the first wall panel; and

comprising a prefinished interior surface; and

an exterior façade panel:

configured to install onto the exterior façade mount of the first wall panel; and

defining a prefinished exterior surface.

Assignments (1)

Continuity (4)

References Cited (15)