Patio enclosure

Abstract

An enclosed structure, such as a patio enclosure, sunroom, or solarium, is attachable to the exterior wall of a building, has a high proportion of windows and a roof, and constructed from a framework of composite members and insulating wall panels, the panels and wall members being extruded from material having improved thermal characteristics and stability.

1 . A room structure for attachment to the exterior wall of a building mounted on a foundation adjacent to said wall, said room structure comprising an upright frame assembly having an upper end and formed by at least one enclosure wall and a roof structure extending between said exterior wall and the upper end of said frame assembly, said frame assembly including at least one vertically disposed support member, the improvement wherein 
 said support member comprises an assembly of an H-beam and a closure member,    each said support member and H-beam being comprised of a single piece of composite and having a like vertical height,    said H-beam being formed by a spacer wall and a pair of webs, the spacer wall extending between the webs and disposed inwardly and between the outer edges of the webs wherein to form a pair of outwardly open squared-C channels, and    said closure member being formed by a pair of sidewalls and a base wall, the sidewalls extending from opposite edges of the base wall wherein to form a squared-C cross-section, the closure member being snap-fittable in a friction fit into one of the squared-C channels of the H-beam to substantially close said channel and in a manner that the exterior base wall of the closure member and the edges of webs of the squared-C channel into which interfitted are substantially coplanar.    
   
   
       2 . The room structure according to  claim 1 , wherein the spacer wall of said H-shaped beam is centrally apertured, the aperture extending between the opposite ends of the beam.  
   
   
       3 . The room structure according to  claim 1 , wherein the H-shaped beam and C-shaped closure member are extruded from a composite PVC plastic.  
   
   
       4 . A beam structure for a patio enclosure, the beam structure comprising 
 a support member and a filler member, said members extending longitudinally and each of a generally constant cross-sectional shape,    said support member having a base wall, first and second walls disposed generally perpendicularly to the plane of said base wall, and outer end faces disposed parallel to the plane of said base wall, the first and second walls cooperating to define an outwardly open longitudinally extending channel sized to receive said filler member, and    said filler member having a base member and a pair of upstanding sidewalls adapted to frictionally engage and form a snug snap-fit engagement with a respective of said first and second walls, the base member and the outer end faces forming a generally continuous surface following said interfitment.    
   
   
       5 . The beam structure according to  claim 4  wherein 
 the support member comprises a generally H-shaped beam member and the channel thereof has a squared-C cross-section, and    the filler member has a squared-C cross-section.    
   
   
       6 . The beam structure according to  claim 4 , wherein at least one said member is injection molded from a polymeric material.  
   
   
       7 . The beam structure according to  claim 4 , wherein at least one said member is extruded from a synthetic wood composition.  
   
   
       8 . The beam structure according to  claim 4 , wherein 
 the H-shaped beam member has a pair of flange members, each forming a respective of said outer end faces, and    the exterior surfaces of the outer end faces and the exterior surface of the filler member are clad with vinyl cap stock.    
   
   
       9 . A modular wall for a patio enclosure formed as an add-on extension to an existing structure supported on the ground and having framing structure for at least one of a window or door, the modular wall comprising: 
 a longitudinally extending upper and lower track beam, the lower track beam being supported on the ground,    a pair of vertically extending corner posts, each post having an upper and lower end portion and an outwardly open channel extending between the end portions,    at least one vertically extending H-beam disposed between the corner posts and defining in combination with the corner posts a pair of laterally separated wall sections extending vertically between the track beams, the H-beam having upper and lower end portions and a pair of opposed outwardly open channels extending between the end portions thereof,    at least one said wall section comprising a lower and an upper cross-beam, and a lower and an upper wall panel, and said framing structure, wherein said cross-beams have opposite longitudinal ends and an outwardly open channel extending between the respective ends, said framing structure is disposed between said cross beams, said upper wall panel extends between the upper track and the upper cross-beam, and said lower wall panel extends between the lower cross-beam and the lower track member,    first means for positioning and securing the lower end portions to the lower track beam and the upper end portions to the upper track beam, wherein said track beams are disposed in generally parallel horizontal relation, said corner posts are secured and positioned at the opposite longitudinal ends of said lower and upper track beams, and the outwardly open channels of said H-beam and said corner posts are facing one another,    second means for enclosing the outwardly open channels of said H-beam and said corner posts wherein to cover said first means, at least in part, and    third means for positioning and securing the opposite longitudinal ends of said cross-beams to said H-beam and said corner post, wherein the outwardly open channels of the cross-beams, track members, corner posts and H-beam cooperate to form a channel for receiving the respective edges of the upper and lower wall panels.    
   
   
       10 . The modular wall according to  claim 9 , and further wherein 
 the second means comprises a filler beam of predetermined cross-section, which filler beam is frictionally interfit in a snug-fit into the respective channel to form an exterior surface that appears to be unitary.    
   
   
       11 . The modular wall according to  claim 10 , and further wherein the upper and lower track beams, the corner posts, the H-beam, the cross-beams, and the filler beam are extruded or injection molded from a synthetic wood PVC composition.  
   
   
       12 . The modular wall according to  claim 11 , and further wherein the exterior surfaces of said beams are selectively clad with vinyl cap stock.  
   
   
       13 . A wall joint for a patio enclosure, which enclosure is formed as an add-on extension to an existing structure, supported on the ground, and has framing structure for at least one of a window or door, the wall joint comprising: 
 a first pair of longitudinally extending upper and lower track beams and a second pair of longitudinally extending upper and lower track beams, the first pair of track beams being disposed at a right angle to the second pair of track beams, and each said lower track beam being supported on the ground,    a vertically extending corner post, said post having a lower and upper end portion and forming outwardly open first and second channels, the channels being disposed at right angles to one another,    a vertically extending first and second wall section, each said wall section including upper and lower end portions that are juxtaposable with and extend along a respective pair of said lower and upper track beams, said first wall section having a first vertical edge that is juxtaposable with the first channel of said corner post and at least one framing structure, and said second wall section having a second vertical edge that is juxtaposable with the second channel of said corner post and at least one framing structure,    first means for securing and positioning the lower end portion of said corner post and said lower track beams to said support wherein the first and second channels are juxtaposed with a respective end of one and the other of said lower track beams,    second means for securing and positioning the upper end portion of said corner post to said upper track beams,    third means for enclosing the outwardly open first and second channels of said corner post wherein to cover each said first and second means, at least in part, and    fourth means for connecting the wall sections to the track beams and said corner post.    
   
   
       14 . An extruded article, said article produced by extruding a cellulosic inorganic filled plastic composite, the composite consisting of a bound together mixture of polyvinyl chloride, a cellulosic material, selected from sawdust, finely pulverized dried wood, and wood flour, baking flour, and a binder.  
   
   
       15 . The extruded article of  claim 14 , said article extending longitudinally about a geometrical axis and formed by a cross-section including a base member, and a pair of webs, the webs extending from the base member and forming an outwardly open channel.  
   
   
       16 . The extruded article of  claim 15 , wherein the article is H-shaped and defines a pair of oppositely facing outwardly open channels.  
   
   
       17 . The extruded article of  claim 15 , wherein the article is C-shaped.  
   
   
       18 . The extruded article of  claim 15 , wherein the article is box shaped and includes a central aperture extending between the opposite end of the article.  
   
   
       19 . A kit for constructing an enclosure to the exterior wall of an existing structure, said kit comprising: 
 a plurality of wall panels of predetermined height, width, and thickness,    framing structure, such as for mounting an assembly of at least one window or door, as required,    a plurality of elongated track beams, the track beams forming upper and lower end caps of front and side walls formed by the kit and each having a central track,    a plurality of vertical uprights of H-shaped cross section, the H-beam forming two opposed outwardly opening C-shaped channels,    a plurality of C-shaped cross-beams, the cross-beam having an outwardly open C-shaped channel,    a plurality of corner posts of generally square cross section and forming two outwardly opening channels of squared-C cross-section,    means for positioning and securing the wall panels, framing structure, track beams, H-beams, C-shaped cross-beams, and corner posts to one another and the support structure, and    a plurality of closure members of squared-C cross-section, the closure members being snap-fittable into a respective C-shaped channel provided in the H-beam and corner post, wherein to close the channel and form a unitary appearing exterior.    
   
   
       20 . The kit according to  claim 19 , wherein the track beams, H-beam, corner-post, C-shaped cross-beam, and closure members of the kit are extruded or injection molded of a composite PVC, with predetermined exterior surfaces of each clad with a protective surface of vinyl.