WO2014133989A2 - Panneaux de construction en polystyrène expansé et assemblage, raccordement associés, et leur procédé de fabrication - Google Patents

Panneaux de construction en polystyrène expansé et assemblage, raccordement associés, et leur procédé de fabrication Download PDF

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Publication number
WO2014133989A2
WO2014133989A2 PCT/US2014/018154 US2014018154W WO2014133989A2 WO 2014133989 A2 WO2014133989 A2 WO 2014133989A2 US 2014018154 W US2014018154 W US 2014018154W WO 2014133989 A2 WO2014133989 A2 WO 2014133989A2
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WO
WIPO (PCT)
Prior art keywords
eps
panel
panels
structural
roof
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2014/018154
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English (en)
Other versions
WO2014133989A3 (fr
Inventor
David B. CAROLAN
M. Byron PHILIPS
Dalton BLEDSOE
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SOLID GREEN DEVELOPMENT LLC
Original Assignee
SOLID GREEN DEVELOPMENT LLC
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Filing date
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Application filed by SOLID GREEN DEVELOPMENT LLC filed Critical SOLID GREEN DEVELOPMENT LLC
Publication of WO2014133989A2 publication Critical patent/WO2014133989A2/fr
Publication of WO2014133989A3 publication Critical patent/WO2014133989A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • 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
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/28—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of other material
    • 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
    • E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
    • E04B1/165—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with elongated load-supporting parts, cast in situ
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
    • B26D1/01—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work
    • B26D1/12—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a cutting member moving about an axis
    • B26D1/14—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a cutting member moving about an axis with a circular cutting member, e.g. disc cutter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D3/00—Cutting work characterised by the nature of the cut made; Apparatus therefor
    • B26D3/06—Grooving involving removal of material from the surface of the work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F3/00—Severing by means other than cutting; Apparatus therefor
    • B26F3/06—Severing by using heat
    • B26F3/08—Severing by using heat with heated members
    • B26F3/12—Severing by using heat with heated members with heated wires
    • 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
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/026—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of plastic
    • 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
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
    • B26D1/0006—Cutting members therefor
    • B26D2001/0033—Cutting members therefor assembled from multiple blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
    • B26D1/0006—Cutting members therefor
    • B26D2001/006—Cutting members therefor the cutting blade having a special shape, e.g. a special outline, serrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D3/00—Cutting work characterised by the nature of the cut made; Apparatus therefor
    • B26D3/006—Cutting work characterised by the nature of the cut made; Apparatus therefor specially adapted for cutting blocs of plastic material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8652—Walls made by casting, pouring, or tamping in situ made in permanent forms with ties located in the joints of the forms
    • 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
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B2001/2481—Details of wall panels
    • 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
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E04B2001/249—Structures with a sloping roof
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16—Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/32—Floor structures wholly cast in situ with or without form units or reinforcements
    • E04B5/36—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor
    • E04B5/38—Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor with slab-shaped form units acting simultaneously as reinforcement; Form slabs with reinforcements extending laterally outside the element
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00—Adapting or protecting infrastructure or their operation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B30/00—Energy efficient heating, ventilation or air conditioning [HVAC]
    • Y02B30/90—Passive houses; Double facade technology

Definitions

  • the present invention relates generally to an apparatus and method for expanded polystyrene (EPS) building panels and associated assembly, connection, and tools, and in particular, energy efficient building systems using EPS panels made substantially of polystyrene or polystyrene-like material, assembly of EPS panels to form walls, flooring, and roof systems, and related assembly, connection and tools.
  • EPS expanded polystyrene
  • Energy efficiency reducing dependence on non-renewable resources, and reduction of carbon emissions has moved from social consciousness to being legislated in many parts of the world. With energy shortages, large demands on power girds caused by population increases and other factors, energy efficient buildings are needed. Residential and commercial buildings continue to be needed, and construction continues to address these building needs. Construction of energy efficient buildings could significantly lower energy demands on power grids, resulting in significant savings to energy consumers who occupy these energy efficient buildings. Many assume energy efficient buildings include solar, wind or some other form of renewable energy producing source that counters the energy demands of the building.
  • EPS building materials have been used with insulated concrete forms (ICF), collectively referred to herein as energy efficient building materials.
  • ICF insulated concrete forms
  • These existing energy efficient building materials are generally formed by extrusion into a pre-made form or by cutting a block of EPS, for example, with a hot wire.
  • Existing energy efficient building materials are manufactured as a "one-size-fits almost none". In other words, these materials come in a single size, such as 4' x 8' x 12", and require extensive re-cutting and custom fitting at the assembly site. This re-cutting and custom fitting significantly increases labor costs and assembly time, thereby increasing the total cost of the final energy efficient structure or building.
  • EPS expanded polystyrene
  • Another object of the disclosed subject matter is to provide an EPS stem wall panel. Another object of the disclosed subject matter is to provide a mechanism to construct an EPS stem wall such that the EPS stem wall is level.
  • an energy efficient building system is assembled with panels made substantially of expanded polystyrene (EPS) that are pre-cut with a minimum amount of wasted EPS material.
  • EPS can include polystyrene, granite enhanced polystyrene, composites of polystyrene and other materials and/or any polystyrene-like material.
  • the panel has at least one chase for housing utility, telecommunications, electrical, and/or plumbing parts, such as cabling, conduit, ducting, and/or pipes, when the EPS material is removed from the chase.
  • the chase can be vertical, horizontal, and/or diagonal.
  • a support/alignment opening or chase in a panel receives material for supporting wall finish and/or for aligning multiple panels.
  • a column opening in the panel is created when EPS material is removed from the column area. This column opening, once created, can be filled with structural fill material, such as one or more of concrete, sand, compacted earth, plastic, wood, composite, steel, rebar or other supporting metal, or some other like material.
  • the panel can have at least one cut to form a lip.
  • the cut begins from an outer surface and traveling into the panel, at least until the cut breaches the column opening.
  • the cut deviates at the column opening from a straight line between the outer surface and the column opening or chase to form a lip.
  • the lip has abutting regions that compress together when the structural fill material is introduced to the column opening or chase.
  • Another cut creates a locking key system that can permit a reduction on thermal conductivity by reducing spaces between panels and/or abutting building structural components, can increase stability, and can assist with alignment.
  • the cut in the panel originates from the outer surface at one point to the outer surface at another location in a nonlinear path such that a gender neutral key shape is created.
  • a locking key system for one or more sides of a panel conforms to the key shape of one panel to an abutting panel and/or abutting building structural components.
  • One or more of the panels are suitable for walls, and walls that may have one or more voids cut for one or more windows, wherein said window void is operable to receive a window when the EPS is removed from the window void.
  • the panels are also suitable for walls having one or more doors, wherein the door void is operable to receive a door when the EPS is removed from the door void.
  • One or more of the panels is suitable for flooring.
  • One or more of the panels is suitable for a roof.
  • EPS material is used as insulation between the panel exterior surface and the panel interior surface, minimizing thermal conductivity. EPS material filling inserted into panel openings maximizes insulation quality.
  • an energy efficient roofing assembly for an energy efficient building consists of one or more roof panels made substantially from expanded polystyrene (EPS), pre-cut to meet specifications.
  • the roof panels have at least one thermal break on exterior of the panel, and one or more cuts to receive a rafter.
  • the panels also have at least one chase, and may have at least one recess to receive structural decking material.
  • Also on the panels is at least one track cut to receive a leg of a rim track, EPS insulation between exterior surfaces of the roof panel and interior surfaces of the roof panel, and EPS insulation between exterior nailing strip and fastener and interior surfaces.
  • Yet another object of the disclosed subject matter is to provide an EPS panel and assembly suitable for extending the structural integrity of various architectural embodiments of eve and cornice designs.
  • Yet another object of the disclosed subject matter is to provide tools a method for assembling a building incorporating the disclosed subject matter herein.
  • Fig. 1 shows a top down view of one embodiment of an expanded polystyrene (EPS) panel
  • Fig. 2 shows a top down view of one embodiment of an EPS panel having a corner
  • Fig. 3 shows a perspective view of one embodiment of an EPS panel
  • Fig. 4 shows a perspective view of one embodiment of roofing EPS panels
  • Fig. 5 shows a cut-away perspective view of one embodiment of an EPS panel using concrete to create a beam and vertical column that might also include structural steel, rebar, or other material for additional structural support;
  • Fig. 6 shows a perspective view of one embodiment of assembling several EPS panels to form a wall
  • Fig. 7 shows a perspective view of one embodiment of assembling a stem wall and flooring
  • Fig. 8 shows a perspective view of one embodiment of an alignment cradle for EPS panels
  • Fig. 9 shows a cross sectional top down view of one embodiment of EPS panel demonstrating cuts
  • Figs. 10a and 10b show a cross sectional top-down view of side panel and corner elements of the disclosed subject matter
  • Fig. 11 shows a cross sectional side view of the roof, soffit, and side wall junction
  • Figs. 12a and 12b show a different cross sectional side view of the EPS panels
  • Fig. 13 shows an alternate embodiment of the embodiment shown in Fig. 11, depicting a cross sectional side view of the roof, soffit/eve, and side wall junction;
  • Fig. 14 shows a blade system for use in manufacturing a building disclosed herein.
  • like elements should be understood to represent like elements, whether reference labels are present or not on some versions of a repeated element, for simplicity.
  • a building is made of expanded polystyrene (EPS) panels, with at least one of the EPS panels having an exterior surface.
  • EPS expanded polystyrene
  • EPS can include polystyrene, granite enhanced polystyrene, composite polystyrene and other building material, and material resistant to thermal transfer.
  • the EPS panels are pre-cut to specifications.
  • Fig. 1 shows a top down view of one embodiment of an expanded polystyrene (EPS) panel 112. While EPS panels are suitable for walls, flooring, and/or roofing, the EPS panel 112 shown in Fig. 1 is for a wall. At an end of the EPS panel 112, a receiving opening 102 for receiving a key lock spoil from a column or chase or structural component is shown.
  • a chase 106 is operable to receive utility, telecommunications, electrical, and/or plumbing components, such as cabling, conduit, ducting, pipes, and the like, when the EPS is removed from the chase 106.
  • the chase 106 can be vertical, horizontal, or diagonal.
  • a "mushroom" shaped lock cut is created for support when structural fill material is introduced.
  • the chase can also be described as a support/alignment opening 106 and is operable to receive structural fill material for alignment purposes and support.
  • a column opening 110 is created when EPS is removed from the column area.
  • the column opening 110 is operable to receive structural fill material when the EPS is removed from the column opening 110 area.
  • a wall panel 112 can be a stem wall.
  • a stem wall is designed to be set at least partially below grade.
  • the stem wall EPS panel 112 also can contain the locking key receptacle.
  • the mushroom cut 108 is particularly useful in the stem wall when concrete or similar heavy structural material is used to improve the stability of the panel.
  • the EPS removed from the support/alignment opening 106 can be used to connect multiple stem wall EPS panels 112 together, similar to that for other EPS wall panels 112.
  • Each end of the EPS panels 112 has a locking key receptacle.
  • the locking key receptacle could receive one or more structural fill materials.
  • the locking key shape will mirror the shape of the structural fill material, for example the "claw-like" cut out for a steel brace 902 and 904 of Fig. 9.
  • the "mushroom" shaped cuts 108 between some of the column openings 110 This type of cut maintains more of the EPS panels' inherent structural support than making a straight cut from one column cut to the next.
  • At least one cut begins from an outer surface of a panel 112 and traveling into the panel 112 at least until the cut breaches the column opening 110 or alternatively chase 106.
  • the cut then deviates from a straight line between the outer surface and the column opening 110 or chase 106 to form a lip having abutting regions.
  • the abutting regions compress together when the structural fill material is introduced into the column opening 110 or chase 106.
  • at least one cut originates from an outer surface of a panel 112 at one point to an outer surface of the panel 112 at another location in a nonlinear path such that a key shape is created.
  • a locking key system for one or more sides of a panel 112 conforms to the key shape of the panel 112 to an abutting panel 112, alternatively to a cut-out portion from the column opening 110, or structural material.
  • Fig. 2 shows a top down view of one embodiment of an EPS panel having a corner.
  • the panel 112 in Fig. 2 is suitable for a wall, and has a corner 202 with an EPS "key lock" 204 made from the column opening shown in Fig. 1.
  • the "key lock” may be made with abutting structural material.
  • the corner 202 is shown to accommodate two of the EPS panels at a 90 degree angle, and allow EPS pieces cut for structural materials to be used assembled at 90 degree angles.
  • EPS panels 112 create a system of reducing thermal conductivity, since the panel exterior surfaces and panel interior surfaces lack protrusions that extend from the exterior surface through to the interior surface, and lack protrusions that extend from the exterior or interior surface continuously to another protrusion on the opposing exterior or interior surface.
  • the panels 112 When the locking key system of one panel 112 is inserted into the locking key system of another panel 112 to form a wall, the panels 112 additionally have a top opening that is operable to receive structural fill material.
  • two or more panels can connect a wall panel to a floor panel, a wall panel to a roof panel, and so on.
  • the top reinforcing member When the top opening of a panel 112 is substantially filled with structural fill material and at least one top reinforcing member, the top reinforcing member may be coupled to the column reinforcing member, wherein the column void and the top opening are filled with structural fill material substantially simultaneously.
  • the column void and/or the top opening may be lined with a substantially waterproof lining prior to filling with the structural material.
  • a top plate may be coupled to the structural fill material in the top opening immediately after the fill is inserted into the top opening.
  • the panel assemblies or combinations described herein may be coupled to the roof assemblies described below and shown in embodiments in figures 11 and 13.
  • Fig. 3 shows a perspective view of one embodiment of an EPS panel.
  • the column openings and chases are shown with the EPS column removed.
  • the purpose of the column openings and chases are generally to provide a void where a structural material can be inserted to provide additional structural support and alignment. For example, concrete could be poured into the void and allowed to cure. In another example, metal support beams/poles could be inserted. It is important to note that not all column opening or chase EPS will need to be removed and the number necessary, if any, is dictated by the particular building being erected. For example, a one story single residence home would require fewer of the column opening and chase EPS to be removed than a two story single residence home because the structural support required by each is different.
  • HEC horizontal electrical chases
  • VEC vertical electrical chases
  • EPS panel horizontal electrical chases
  • utility, telecommunications, electrical, and/or plumbing components such as cable, fiber, conduit, pipes, and the like.
  • Fig. 3 one embodiment is shown having a horizontal chase 304 suitable for a utility component.
  • electrical chases it should be noted that the HECs and VECs are not limited to electrical wiring and could accommodate almost anything that needs to be routed in a building, such as, but not limited to, utility and/or plumbing components like conduit, electrical wiring, fiber optics, telephone cabling, general cabling, piping, plumbing, and the like.
  • the EPS material has been removed from two of the fir strip cuts and fir strips 302 have been inserted.
  • the structural members for nailing or fir strips 302 can be used to provide an easy way to mount wall coverings, cabinets, sheetrock, trim work, moldings, fascia, ceiling and roof coverings, or other material to the EPS panel.
  • certain panels can have voids cut for one or more windows, wherein the window voids are operable to receive windows when the EPS is removed from the window voids.
  • a door void can be cut into an EPS panel to receive a door when the EPS is removed from the door void.
  • a window buck may be coupled to the sides of a window void after the EPS is removed from the wall panel, and a door buck may be coupled to the sides of a door void after EPS is removed from the wall.
  • window and door voids are usually on a wall panel, they can also be on a roofing panel, such as for a sky light or attic door, or on a flooring panel, such as for a basement trap door, or some other similar window or door opening on a floor.
  • Fig. 4 shows a perspective view of one embodiment of roofing EPS panels.
  • one or more roof panels 402 made substantially from EPS, pre-cut to meet specifications, have at least one thermal break on an exterior of the panel, and one or more cuts to receive a rafter 404.
  • the roof panel 402 may have at least one chase, and may have at least one recess to receive structural decking material.
  • At least one track cut on a roofing panel is cut to receive a leg of a rim track.
  • EPS insulation between exterior surfaces of the roof panel and interior surfaces of the roof panel, and EPS insulation between exterior nailing strip and fastener and interior surfaces is present.
  • a structural roof beam 406 supports the roof panels.
  • the structural decking material may include at least one web of a rafter. Also, the structural decking material may extend to the end of the soffit/eve. A structural decking material recess allows for the additional thickness of the structural decking material such that the roof retains a uniform surface. The recess may be altered to accommodate varying thickness of the structural decking material. Further discussion regarding the roof panels and roof assembly are discussed below and demonstrated in Figures 11 and 13.
  • Fig. 5 shows a cut-away perspective view of one embodiment of an EPS panel using concrete to create a beam and vertical column that might also include structural steel, rebar, or other material for additional structural support.
  • the panel 112 in Fig. 5 is shown having vertical structural support 502, as well as lateral/horizontal structural support 504. While in this embodiment, both vertical 502 and horizontal 504 structural support members are shown, it is understood that panels 112 in this embodiment have only vertical or only horizontal structural support members.
  • the mushroom cuts 108 in Fig. 1 can be seen more clearly here as providing support and/or alignment as the voids and protrusions created by the cuts fit tightly with the structural fill material.
  • the cuts can be made using a hot wire system, a blade system (as shown in Fig. 14), or some other similar method.
  • the creation of the EPS panels 112 and/or the cutting of the EPS panels 112 can be performed at a location other than the final installation location.
  • Fig. 6 shows a perspective view of one embodiment of one way to assemble several EPS panels to form a wall.
  • the EPS panels are shown being assembled about a particular type of alternative structural support member or structural framing member 602.
  • the structural framing member 602 pictured here is one embodiment utilizing structural steel and a "stacked" EPS panel in a 4-3-3 application 608.
  • a 4-3-3 application 608 means that a 4', 3' and 3' panel is being utilized to achieve a wall assembly reaching 10' in height.
  • Many standard and nonstandard height walls can be constructed from different combinations of one, three, and four foot tall EPS panels. It is important to note that regardless of which combination of EPS panels are used, the VECs, HECs, and fir/nailers cuts align.
  • a horizontal utility chase 604 and a vertical utility/structural member chase 610 are present, as well as a lateral/horizontal structural framing member 606.
  • a chase 612 to accommodate a structural nailing member is shown in Fig. 6.
  • at least one chase is created in an EPS panel.
  • the EPS panel has an exterior surface.
  • the chase can receive one or more of cabling, conduit, ducting, and pipes when EPS is removed from the chase.
  • the chase can be vertical, horizontal, and/or diagonal.
  • At least one support/alignment opening is created, wherein the support/alignment opening is operable to receive a material for supporting wall finish and/or for aligning multiple panels, as shown in the embodiment in Fig. 6.
  • the panels described herein are suitable for walls, flooring, and roofing of a building.
  • a system of reducing thermal conductivity between an exterior panel surface and an interior panel surface is created using EPS material as insulation and filling into panel openings.
  • a top opening into a top of the EPS panel is created and is operable to receive structural fill material.
  • EPS material can be removed from the support/alignment opening to create a support/alignment void, and material can be inserted into the support/alignment void for supporting wall finish and/or aligning the panels.
  • One or more voids may be cut for windows to receive a window when the EPS is removed from the window void, and for doors, wherein the door void is operable to receive a door when the EPS is removed from the door void.
  • Fig. 7 shows a perspective view of one embodiment of assembling a stem wall and flooring.
  • This figure shows a complete stem wall 112 made from stem wall EPS panels and structural materials laid across the tops of the stem wall EPS panels to create an insulated EPS deck structure 704 for placing/mounting floor EPS panels.
  • the floor EPS panels are capable of receiving lightweight concrete or other flooring or sub-flooring materials 702.
  • Fig. 7 shows EPS corners 202 of wall panel embodiment as stem wall.
  • a structural floor joist 706 supports assembly of the flooring or sub-flooring materials 702 and the EPS deck 704.
  • Fig. 8 shows a perspective view of one embodiment of an alignment cradle for EPS panels.
  • a standard concrete form material 802 is shown in Fig. 8, to hold the alignment cradle 806.
  • the alignment cradle 806 holds an EPS panel.
  • a pin 804 assists adjustment of an alignment cradle 806 for an EPS wall panel.
  • the alignment cradle can be made of various materials, but in one embodiment, the alignment cradle 806 is metal.
  • An adjustment mechanism 808 adjusts the height
  • Fig. 9 shows a cross sectional top down view of one embodiment of EPS panel and cuts.
  • a void to receive legs 902 of structural fill material in an EPS panel is shown in Fig. 9.
  • a void to receive web 904 of structural fill material is shown.
  • the void created by cuts 902 and 904 are considered one void to receive structural fill material.
  • Voids created by cuts 902 and 904 may be on any side of the panel.
  • voids 902 and 904 are cut out in one path entering one face of the EPS panel, creating a void to receive structural fill material and exiting in a place other than the entry location is understood.
  • Fig. 12b shows a different view of the voids 902, 904 or cut out paths.
  • cut out paths or voids 902, 904 can be created using such methods as a hot wire method, a blade system method, or other similar methods.
  • a blade system is used that operates as an "edge router" to manufacture the cut. It is understood that this cut can be made on an EPS panel on top, bottom, sides, and on a roof and/or floor.
  • FIGs. 10a and 10b show a cross sectional top-down view of side panel and corner elements of the disclosed subject matter.
  • a vertical chase 1040 is suitable for utilities and/or structural fill, in one embodiment.
  • Chase 1042 is a chase or column opening suitable for structural fill.
  • Chases 1040 and 1042 can accommodate wiring, piping, tubing, or the like and make installation of the same significantly easier.
  • These chases 1040 and 1042 can also accommodate structural support members such as rebar or structural anchors.
  • openings 1046 accommodate interior drywall nailers, however, in alternate embodiments, openings 1046 could be changed to accommodate larger structural members.
  • a void 1044 created from an interior of an EPS wall panel can receive structural members or nailing members and can be recessed from interior plane of a wall panel to provide a thermal break, resulting in minimizing thermal conductivity.
  • openings 1044 can accommodate exterior finish structures and wall cap braces as well as metal or other structural studs or structural fill 1048.
  • Fig. 11 is one embodiment depicting a cross sectional side view of the roof, soffit/eve, and side wall junction.
  • An alternative or complimentary embodiment is shown. More specifically, this cross sectional side view accentuates several of the unique features of this particular embodiment.
  • An EPS starter roof panel 1102 recessed from a standard EPS roof panel exterior plane is operable to receive structural decking 1122 as needed for structural requirements.
  • Panel thickness includes structural roof framing member 1114 height and distance beyond in one solid panel.
  • An EPS fill piece 1104 provides a thermal break for metal structural ledger support.
  • An EPS wall panel 1106 is shown wherein panel thickness includes vertical wall structural member width and distance beyond in one solid panel.
  • a vertical structural nailing member 1108 and a vertical structural member 1110 are shown.
  • a top horizontal structural member 1112 and a structural roof framing member 1114 are shown in Fig. 11.
  • a fastening screw 1116 ties roof decking material 1122, structural nailing member 1121, EPS panel 1102 and roof framing member 1114 together.
  • a standard material ledger and/or fascia material 1118 is also shown.
  • An EPS void or cut 1120 can receive a roof nailing member or structural nailing member 1121.
  • Structural decking material 1122 is shown on Fig. 11.
  • An EPS wall cap 1123 provides a thermal break for transition from wall to roof structures.
  • a standard EPS roof panel 1124 and a standard angle clip 1126 per engineering specifications is shown.
  • this figure depicts how all external and internal surfaces (e.g. surfaces which are outside of the structure in the weather and elements as well as those surfaces on the inside of the conditioned space) encompass a thermal break and are insulated from thermal transfer, with the exception of inconsequential bridging through screws 1116 from exterior to interior and interior to exterior surfaces and environments.
  • screws 1116 are the only thermally conductivity path from the external elements to the interior, or the converse.
  • metal structural members are insulated by EPS material from thermal transfer.
  • structural nailing strip and fastener are also insulated from thermal transfer by EPS material. Therefore there are no direct thermal pathways of consequence for thermal transfer between exterior and interior surfaces and environments.
  • screws 1116 do not have a direct thermally conductive pathway between exterior and interior surfaces and environments.
  • the starter roof panel EPS 1102 is provided.
  • the top of the starter roof panel is recessed to receive structural decking material 1122.
  • the structural decking material 1122 may then extend to the end of the soffit/eve.
  • the recess allows for the additional thickness of the structural decking material 1122 such that the roof retains a uniform surface.
  • the thickness of the structural decking material 1122 can vary. Depending on the requirements or specifications to support the particular soffit/eve chosen by the end user, the recess may be altered to accommodate the thickness of the structural decking material 1122.
  • the addition of the structural decking material 1122 provides significant strength and rigidity to the soffit/eve.
  • Figs. 12a and 12b show a different cross sectional side view of the disclosed subject matter.
  • an EPS wall panel 1108 connects to an EPS starter roof panel 1102 and a standard roof panel 1124.
  • An EPS void 1120 is created and operable to receive structural fill. These EPS voids 1120 accommodate structural nailing member and fasteners, for example.
  • the recess or difference 1210 between EPS starter roof panel 1102 and standard roof panel 1124 to accommodate the structural decking material is shown.
  • An EPS void 1212 is created to receive a leg of a rim track.
  • Fig. 12b one can see the EPS starter roof panel 1204 angled downward at an interior plane 1216 of an EPS starter roof panel 1204 and joined flush at a "seat" 1214 to the top of EPS wall panel 1202.
  • the seat 1214 is cut in the EPS starter roof panel 1204.
  • a portion of the EPS starter roof panel 1204 can be trimmed so that the overall assembled dimensions of EPS roof starter panel 1204 and EPS wall panel 1202 can be adjusted to accommodate various architectural designs and dimensions of the disclosed subject matter can be a reduced size panel. This reduced size makes trimming on site significantly easier and quicker, reducing construction labor cost of the building.
  • the starter roof panel 1204 could be 24" wide x 8.5" thick, but other dimensions could be employed without departing from the teachings herein. It is important to understand that the thickness is also dictated by the decking requirements or specifications. In another example, the thickness could be 7.75" to accommodate 1.25" thick decking to maintain a flush roof deck plane to receive a roofing material covering) x 25.3" long. Also, the length is dictated by the roof pitch vs. the eve length to maximize efficiency of material and/or structural requirements or specifications. Again, these dimensions are merely examples and are not intended to limit or otherwise restrict the disclosure.
  • a different view of a void to receive legs 902 of structural fill material in an EPS panel as shown in Fig. 9 is on the EPS wall panel 1202.
  • a different view of a void to receive web 904 of structural fill material is shown.
  • Fig. 13 shows an alternate embodiment of the embodiment shown in Fig. 11, depicting a cross sectional side view of the roof, soffit/eve, and side wall junction.
  • An EPS standard wall panel 1302 is shown having a vertical structural member centered in the panel.
  • a vertical structural member 1110 is also shown.
  • a top structural member 1112 is assembled using a cut as described in Fig. 9.
  • a standard ledger, fascia and eve materials 1118 are shown, similar to those shown in Fig. 11.
  • Standard fasteners 1310 for fascia material and fastening screws 1312 for connecting standard ledger material to structural rim track 1326 are shown.
  • Decorative soffit/eve finish material 1314, standard fastening screws 1316, and structural roof decking material 1318 are shown.
  • An EPS wall cap 1320 provides a thermal break from an exterior ledger to an interior rim track 1326.
  • a standard EPS roof panel 1124 and a structural roof framing member 1114 are also shown.
  • An EPS void or cut 1120 of Fig. 11 can receive a roof nailing member or structural nailing member.
  • Fig. 13 differs in one way from Fig. 11 by eliminating the EPS fill piece 1104 of Fig. 11.
  • the EPS fill piece 1104 in Fig. 11 provides a thermal break for metal structural ledger support decking material.
  • Fig. 14 shows a blade system used in the method of manufacturing a building as described herein.
  • a blade system can be used to create at least one chase in an EPS panel for receiving cabling, conduit, ducting, pipes, and the like, when the EPS is removed from the chase.
  • the chase can be vertical, horizontal, and/or diagonal and may be found on any side of a panel.
  • the blade system can also be used to create at least one support/alignment opening which is operable to receive a material for supporting wall finish and/or for aligning multiple panels.
  • the blade system can be used to create at least one column opening in a column area of the EPS panel. The column opening is operable to receive structural fill material when the EPS is removed from the column area.
  • the blade system can be used for cutting from an exterior surface into the EPS panel at least until the cut path breaches the column opening, wherein the cut deviates from a straight line between the exterior surface and the column opening to form a lip.
  • the lip can have abutting regions that compress together when the structural fill material is introduced.
  • the blade system can be used to create at least one cut originating from an outer surface at one point to an outer surface at another location in a nonlinear path such that a key shape is created.
  • a locking key system is created for one or more sides of a panel, wherein the locking key system conforms to the key shape of one panel to an abutting panel or structural material.
  • different size blades such as a small blade 1402, a medium blade 1404, and/or a larger blade 1406 having blade edges suitable for cutting EPS material are stacked on top of each other on a standard motor shaft 1408.
  • the blades 1402, 1404, 1406 can be dado blades or other types of blades.
  • This blade system can have different size blades can be stacked and secured on motor shaft 1408 mounted to a standard router table to create different contour cuts on EPS panels. When the blade system is mounted on a "router table", the panel can be moved across the table while blade 1402, 1404, 1406 is spinning to make the cut.

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  • Architecture (AREA)
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  • Forests & Forestry (AREA)
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  • Building Environments (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)

Abstract

L'invention concerne un appareil et un procédé destinés à des panneaux de construction en polystyrène expansé (EPS) et leur assemblage, leur raccord et leurs outils associés, et en particulier, des systèmes de construction à bon rendement énergétique utilisant des panneaux EPS constitués sensiblement de matériau en polystyrène ou de type polystyrène, l'assemblage de panneaux EPS pour former des murs, un sol et des systèmes de toiture, et leur assemblage, leur raccordement et leurs outils correspondants. De multiples panneaux EPS prédécoupés selon les cahiers des charges permettent un temps d'assemblage minimisé pour une toiture, des murs, un sol, et ont un système de clé de verrouillage et un matériau de remplissage EPS dans des ouvertures pour maximiser la qualité d'isolation et réduire la conductivité thermique. Certains panneaux EPS ont des ouvertures ou saignées de colonne, créées lorsque la colonne ou saignée EPS prédécoupée est retirée, pour recevoir un matériau de remplissage structurel. Certains panneaux EPS sont des saignées verticales, horizontales et/ou diagonales pour recevoir des composants utilitaires, d'électricité et/ou de plomberie. Certains panneaux EPS ont des découpes de tasseaux/fond de clouage pour recevoir des bandes de tasseaux/fond de clouage après retrait du matériau EPS, permettant à des bandeaux et autres revêtements muraux d'être fixés aux panneaux.
PCT/US2014/018154 2013-02-26 2014-02-25 Panneaux de construction en polystyrène expansé et assemblage, raccordement associés, et leur procédé de fabrication Ceased WO2014133989A2 (fr)

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US61/769,279 2013-02-26

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WO2020183206A1 (fr) 2019-03-14 2020-09-17 Mester Qualitas Kft. Coffrage permanent, structure de construction et procédé de création d'une structure de construction

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US5561953A (en) * 1994-12-01 1996-10-08 Rotter; Martin J. Contoured ventilation system for metal roofs
US6209284B1 (en) * 1999-03-01 2001-04-03 William H. Porter Asymmetric structural insulated panels for use in 2X stick construction
US20070163197A1 (en) * 2005-12-27 2007-07-19 William Payne Method and system for constructing pre-fabricated building
US8151539B2 (en) * 2007-08-10 2012-04-10 Constructions Systems Australia Pty Ltd Panel building system
US20100095621A1 (en) * 2008-10-20 2010-04-22 Green-Source Products Llc High performance insulated structural panel
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WO2020183206A1 (fr) 2019-03-14 2020-09-17 Mester Qualitas Kft. Coffrage permanent, structure de construction et procédé de création d'une structure de construction

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