Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
  • E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
  • E04C2/22—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics reinforced
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
  • E04B1/14—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
  • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
  • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
  • E04B1/78—Heat insulating elements
  • E04B1/80—Heat insulating elements slab-shaped
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
  • E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
  • E04C2/205—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B60—VEHICLES IN GENERAL
  • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
  • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
  • B60R13/08—Insulating elements, e.g. for sound insulation

Definitions

• the present invention relates in general to construction materials and, more particularly, to residential and commercial building panels containing insulating foam and support members extending partially through the insulating foam.
• One alternative building approach involves the use of hollow sectional forms, which are put together in the shape of the exterior wall.
• the hollow forms are filled with concrete and then disassembled when the concrete sets, leaving a concrete wall.
• the concrete wall is long-lasting and strong against the elements, but the forms are generally expensive to setup.
• FIG. 1 shows exemplary prior art I-beam metal strut 12 between foam blocks 14.
• the I-beam metal strut 12 is continuous across foam block 14, at least through portions of the metal struts and, consequently, is thermally conductive through the continuous metal areas . Since I-beams 12 go completely through foam, blocks 14, heat and cold will conduct from one side to the other side of the wall structure. In the summer, I-beam 12 conducts heat from the exterior to the interior of the building. In the winter, I-beam 12 conducts cold from the exterior to the interior of the building. In any case, the I-beam construction decreases the thermal insulation property of the building panels .
• the present invention is a building panel for residential and commercial construction comprising a plurality of insulating blocks connected together by adhesive.
• a plurality of support members are disposed on opposite sides of the insulting blocks for providing structural support .
• Each support member has a head portion in contact with a surface of the insulating block and a stem portion extending into the insulating block and having a length less than a width of the insulating block so that a thermal conduction path of the support members is discontinuous across the insulating blocks .
• the present invention is a building panel comprising an insulating material having a width.
• a plurality of support members is disposed in the insulating material for providing structural support.
• Each support member has a thermal conduction path that is less than the width of the insulating material .
• the present invention is a building panel comprising an insulating material having- a width.
• a plurality of support members is disposed, in the insulating material for providing structural support.
• the support members have a thermal conduction path that is discontinuous across the width of the insulating material .
• the present invention is a method of making a building panel comprising the steps of providing an insulating material having a width, and disposing a plurality of support members into the insulating material for providing structural support.
• the support members have a thermal conduction path that is discontinuous across the width of the insulating material.
• the present invention is a building structure, comprising a frame having a plurality of columns and a plurality of building panels disposed between the columns of the frame.
• Each building panel includes an insulating material having a width, and a plurality of support members disposed in the insulating material for providing structural support.
• the support members have a thermal conduction path that is discontinuous across the width of the insulating material .
• FIG. 1 illustrates a known wall panel with I-beam strut disposed completely through the panel
• FIG. 3 illustrates a ⁇ T"-shaped. support member
• FIG. 4 illustrates the "T"-shaped support member with multiple cut-outs
• FIG. 5 illustrates the W T"-shaped support member with alternate cut-outs
• FIG. 6 illustrates the "T"-shaped support member for insertion into the foam-filled panel
• FIG. 7 illustrates the "T"-shaped support member for insertion into a recess of foam-filled panel
• FIG. 8 illustrates an "L"-shaped support member for insertion into a recess of the foam-filled panel
• FIG. 9 illustrates a cut-away of the foam-filled panel with the "T"-shaped support member installed
• FIGs. lOa-lOf illustrate a top view of the foam- filled panel with different arrangements of support members
• FIG. 11 illustrates the foam-filled panel with support members installed in horizontal and vertical positions
• FIGs. 12a-12b illustrate alternate shapes for the foam-filled panel with support members
• FIG. 13 illustrates the use of foam-filled panels in high-rise buildings between frame columns.
• the pre-manufactured panels can be made in a controlled environment, such as a manufacturing facility, shipped to the construction site, and then assembled together to form the walls and roof of the building.
• the pre- manufactured panels stand strong against adverse environmental conditions, such as wind, rain, snow, hurricane, flood, and earthquake.
• the wall and roof panels are easy to assemble into the complete building structure on the job site.
• the wall and roof panels of the present invention provide improved insulation, i.e., higher R-value insulation factor, as compared to the prior art.
• an architect or builder will design and layout the building structure.
• the building may be a home, office, industrial, hotel, or commercial structure of any size and shape and as tall as the local building codes permit.
• the building designer will specify a blueprint of the building, including dimensions for the walls and roof .
• the designer selects wall and roof panels to conform to the building blueprint, i.e., the walls and roof are made with a plurality of building panels assembled together according to the design.
• the panels can be round, rectangle, triangle, curved, polygon, or any other convenient shape.
• the selected panels are connected together on the job site to form, the walls and roof of the building.
• the building panels can be stacked on-end with appropriate support for multi-story structures.
• FIG. 2 illustrates a portion of building structure 20 with two building panels or sections 22 connected together at joint 26.
• Building panels are each made with one or more insulating blocks 28.
• the insulating blocks 28 may be made with expanded polystyrene (EPS) foam formed in 48-inch blocks.
• EPS expanded polystyrene
• the blocks 28 can have other lengths and be made with fiberglass, paper, or any other thermally insulating material .
• the height of each insulating block depends on the building design, typically ranging from 8-10 feet.
• the thickness of the insulating blocks ranges from 4-8 inches. In other embodiments, the insulating blocks may range from 2 to 12 inches in thickness.
• a plurality of insulating blocks 28 are interconnected to run the length of the wall.
• Adjacent insulating blocks 28 are held together with an adhesive, e.g., urethane glue.
• Building panel 22 may have side end caps 34 for support and protection of the foam block.
• Building panel 22 may also have top and bottom end caps (not shown) .
• the top cap is a metal angle or "L"-shaped brace running along the top perimeter of panel 22, contacting the top and sides of the insulating blocks.
• the bottom cap is a metal angle or n L"-shaped brace running along the bottom perimeter of panel 22, contacting the bottom and sides of the insulating blocks.
• the bottom cap may be formed in or attached to the foundation of the building structure to aid in aligning the walls and to meet hurricane and earthquake standards .
• Support members or struts 30 are inserted into insulating blocks 28 to provide structural support and withstand the environmental elements, e.g., wind, rain, and snow.
• the building panels 22 are also resistant to water, mold, mildew, insects, fire, hurricanes, and earthquakes.
• Support members 30 and insulating blocks 28 compliment one another to provide a strong yet thermally isolating building panel.
• Support member 30 can be made from a variety of materials capable of providing structural support with the insulating block, such materials including metal (steel, aluminum or composite metal), ceramic, concrete, fiberglass, graphite, wood, plastic, cardboard, rubber, and composites of such materials .
• support members 30 are formed in the shape of a U T" and run the height of the wall, from top to bottom.
• the stem of support member 30 extends partially into the insulating block 28 but does not extend completely through the insulating block.
• the support members 30 are installed on opposite sides of panel 22, in an alternating pattern and offset or staggered with respect to the adjacent support members on the other side of the building panels, as shown in FIG. 2.
• the support members are about 12-18 inches apart on center of each member, and about 24-36 inches apart on each side of the building panel.
• panel 22 provides several advantages for building construction.
• the building panels can be made off- site, in a controlled environment such as a manufacturing facility, and then transported to and assembled at the building site.
• the off-site manufacturing provides cost saving efficiencies in terms of accessibility to mass production equipment, sheltered work environment, and ready access to raw materials.
• the building panels can be formed to any size and shape in accordance with the building design.
• the panels can be straight, curved, angled, etc.
• the insulating blocks 28 provide exceptional insulation properties against the outside elements. Each inch, of thickness of the insulating block yields about R-4 insulation factor. A 6-inch thick foam panel would provide about R-24 value of insulation.
• the support members 30 provide structural strength to panel 22. With support members 30, an 8-foot by 8-foot by 6-inch section of panel 22 can withstand in excess of 27,000 lbs. of total axial loading directed against surface 32.
• the support struts in the foam blocks are continuous through the panel, see exemplary I-beam 12 in FIG. 1.
• the continuous metal structure of I-beam 12 through foam block 14 provides a continuous thermal conduction path from the interior surface to the exterior surface that reduces the R-value insulation factor of the prior art panel .
• An important feature of building panel 22 is its thermal non-conductivity properties in combination with the structural strength it provides.
• the thermal non-conductivity property of panel 22 arises from the fact the support members extend only partially through the building panel . As seen in FIG. 2, each support member 30, on both sides of panel 22, stops in the interior portion of the insulating block 28 and does not extend completely through from the interior surface to the exterior surface of the building panel. In one embodiment, the support member extends about half way through the insulating block. In a 6-inch insulating block, the "T" support member extends about 3 inches into the insulating block.
• Support members 30 are typically made with metal and as such have high thermal conductive properties . The support members 30 inherently exhibit a thermal conduction path through the metal.
• the foam portion of panel 22 has high thermal insulation properties .
• the support members 30 do not extend all the way from the interior surface to the exterior surface of panel 22, there is no channel of high thermal conductivity from the interior surface to the exterior surface in the body of the building panel.
• the thermal conduction path associated with the support members is discontinuous through panel 22 as the insulating material blocks the thermal transfer at the point where the support member stops in the interior of the insulating block 28.
• thermal transfer through panel 22 is not completely eliminated with the use of support members 30 as insulating blocks 28 are not perfect thermal isolators.
• the high thermal transfer associated with the metal support members is certainly discontinuous across the wall panel 22 and as such significantly improves its R-value insulation factor for the wall panel as a whole.
• the structural strength of building panel 22 arises from the arrangement of the support members 30 in the insulating blocks 28.
• Each w T"-shaped support member 30 has a head portion parallel to and in contact with the interior and exterior surfaces of panel 22.
• the stem of the ⁇ X T" -shaped support member extends into the insulating block 28.
• the W T"- shaped support members 30 are positioned on opposite sides of panel 22, in an alternating pattern and offset or staggered with respect to the adjacent support members on the opposite side of the building panel.
• the embedded stem of support members 30, arranged as shown in FIG. 2, increases the structural strength of panel 22.
• the support member 30 is shown in FIG. 3 having head portion 40 and stem portion 42.
• the support member is formed from a rolled sheet of steel that is bent to the desired "T" shape.
• the steel is 20 gauge thickness, although other gauge steel could be used as well.
• the V ⁇ T" r -shape of the support member is formed using a sheet metal bending machine and process. At about 1 inch into the width of the steel plate a first 180° bend is made at point 44, commonly known as a "double-hem.” At another 2 inches into the width of the steel plate a second 180° bend is made at point 46. At another 1 inch into the width of the steel plate a third bend at 90° is made at point 48. The steel plate is cut at about 3 inches past point 48 to form stem 42.
• the double-hem ⁇ T"-shaped support member 30 having head portion 40 width of 2 inches, stem portion 42 of 3 inches, and a length the same as the height of panel 22, i.e., 8-10 feet.
• the head portion 40 can range from 2-4 inches and the stem portion 42 can range from 1-6 inches.
• FIG. 6 illustrates in cross-section groove or slot 58 cut into a side surface of insulating blocks 28 from the bottom to the top of panel 22.
• the groove 58 is about 3 inches deep into the insulating block.
• An adhesive 60 such as urethane glue is disposed into groove 58.
• a groove 58 is cut into insulating blocks 28 of panel 22 for each support member 30.
• the stem portion 42 of support members 30 are then inserted into the groove 58 until the head portion 40 contacts the surface of insulating block 28, The stem portion 42 cures with adhesive 60 and forms a secure union between support member 30 and insulating block 28.
• a shallow trench or recess 76 is cut into insulating block 28 to sufficient depth to contain head portion 72.
• a groove 78 cut into a side surface of insulating blocks 28 from the bottom to the top of panel 22. For- a 6-inch thick insulating block, the groove 78 is cut about 3 inches deep into the insulating block.
• An adhesive 80 such as urethane glue is disposed into groove 78.
• a groove 78 is cut into insulating blocks 28 of panel 22 for each support member 30.
• the stem portion 74 of support members 70 are then inserted into the grooves 78 until the top surface of head portion 74 is co- planar with the side surface of insulating blocks 28.
• the recessed head portion provides a flush surface for panel 22.
• FIG. 9 shows a cut-away of insulating block 28 with support member 30 in place. Note that the cut-outs or openings 56 in the support member 30 also improve the adhesive of the stem portion to the insulating block 28. Alternately, the stems portions can be textured, roughened, corrugated, or partially punched for better adhesion in groove 58 to the insulating block.
• FIGs. lOa-lOf illustrate alternate embodiments of the support members . Each figure is a cross-sectional view of panel 22.
• FIG. 10a shows "U"-shaped support members 90 disposed in insulating block 28 extending the height of panel 22.
• the ⁇ U"-shaped support members 90 are formed by making two 90° bends in the sheet of steel.
• the "U"-shaped support member 90 has a head portion and two stem portions extending partially into insulating block 28, but does not extend all the way through from the interior surface to the exterior surface of panel 22. Accordingly, the thermal conduction path through panel 22, attributed to the metal support members, is discontinuous.
• the support members 90 are installed on opposite sides of panel 22, in an alternating pattern and offset or staggered with respect to the adjacent support members on the other side of the building panel.
• the support members are about 12-18 inches apart on center of each member.
• the "U"-shaped support member 90 can also be recessed into insulating block 28 as described in FIG. 7.
• FIG. 10b shows w T"-shaped support members 100 disposed in insulating block 28 extending the height of panel 22. Opposing "T"-shaped support members 100 are directly opposite one another, but still do not extend all the way through from the interior surface to the exterior surface of panel 22. In the embodiment of FIG. 10b, there is a break or gap between opposing ⁇ T" support members 100, the space being filled with foam to block the thermal conduction path from the interior surface to the exterior surface of panel 22. Accordingly, the thermal conduction path through panel 22, attributed to the metal support members, is discontinuous.
• FIG. 10c illustrates the "T"-shaped support members 100 of FIG.
• FIG. 1Od shows straight support members 110 embedded within the interior of insulating material 108.
• the panel 22 can be made by creating a form of the outline of the building panel .
• the support members 110 are placed into the form, and the form is filled with the insulating material 108, e.g., paper, foam, or fiberglass.
• the insulating material 108 is mixed with an adhesive to create a semi-fluid mixture that surrounds and encases the support members 110 as the form is filled.
• the panel forms are removed, leaving panel 22.
• the support members 110 do not extend all the way through from the interior surface to the exterior surface of panel 22. In the embodiment of FIG. 1Od, there is a break or gap on either end of the support member 110 before the interior and exterior surfaces of panel 22.
• the space of the gap is filled with the insulating material 108 to block the thermal conduction path from the interior surface to the exterior surface of panel 22 , Accordingly, the thermal conduction path through panel 22, attributed to the metal support members, is discontinuous .
• FIG. 1Oe shows straight support members 110 in combination with "T"-shaped support members 112 embedded within the interior of insulating material 108.
• the panel 22 can be made by creating a form of the outline of the building panel.
• the support members 110 and 112 are placed into the form, and the form is filled with the insulating material 108 in its semi-fluid state to surround and encase the support members 110 and 112 as the form is filled.
• the panel forms are removed, leaving panel 22.
• the support members 110 and 112 do not extend all the way through from the interior surface to the exterior surface of panel 22, which blocks the thermal conduction path from the interior surface to the exterior surface of panel 22.
• FIG. 1Of shows angled support members 114 embedded within the interior of insulating material 108.
• panel 22 can be made by creating a form of the outline of the building panel. The support members 114 are placed into the form, and the form is filled with the insulating material 108. The insulating material 108 is mixed with an adhesive to create a semi-fluid mixture that surrounds and encases the support members 114 as the form is filled. When the insulating material hardens, the panel forms are removed, leaving panel 22. The support members 114 do not extend all the way through from the interior surface to the exterior surface of panel 22.
• the curtain wall panel has an exterior surface that can be covered with mesh, sto, dinsglass, and an exposure surface such as stucco, granite, brick, or slate.
• the interior surface of the curtain wall panel has sheet rock and decorative covering such as paint or wall paper.
• Curtain wall panel 22 can be formed with horizontal and vertical conduits or air channels or chases to run electric wire and plumbing pipes .
• foam-filled panel 22 can be formed within another panel that acts as the curtain wall panel.
• the electric and plumbing lines can be placed in gaps between the curtain wall panel and the inner foam-filled panel 22.
• Panels like 22 have applications in many other industries, such as aircraft fuselage, automobile bodies, and marine hulls.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Structural Engineering (AREA)
• Civil Engineering (AREA)
• Physics & Mathematics (AREA)
• Life Sciences & Earth Sciences (AREA)
• Electromagnetism (AREA)
• Wood Science & Technology (AREA)
• Acoustics & Sound (AREA)
• Building Environments (AREA)
• Laminated Bodies (AREA)
• Panels For Use In Building Construction (AREA)
• Curtains And Furnishings For Windows Or Doors (AREA)

Applications Claiming Priority (2)

Publications (2)

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• 2007
  • 2007-01-25 EP EP07717411.8A patent/EP1994238A4/de not_active Withdrawn
  • 2007-01-25 WO PCT/US2007/061051 patent/WO2007106613A2/en not_active Ceased
  • 2007-01-25 US US11/626,991 patent/US20070227086A1/en not_active Abandoned
  • 2007-01-25 CA CA2641755A patent/CA2641755C/en not_active Expired - Fee Related
  • 2007-01-25 CN CNA200780002551XA patent/CN101460686A/zh active Pending

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