HARRINGTON WILLIAM J (US)
SOLOMON FRED L (US)
HARRINGTON WILLIAM J (US)
US3258889A | 1966-07-05 | |||
US3885008A | 1975-05-20 | |||
US4674253A | 1987-06-23 | |||
US3828502A | 1974-08-13 |
CLAIMS
What I claim is:
1. A building panel having structural integrity, comprising:
a peripheral frame including a top horizontal stud member, a bottom
horizontal stud member, a left vertical stud member, and a right vertical stud
member, wherein a first end portion of the top horizontal stud member joins to a
first end portion of left vertical stud member, a second end of the top horizontal stud
member joins to a first end portion of right vertical stud member, a first end portion
of the bottom horizontal stud member joins to a second end portion of left vertical
stud member, and a second end portion of the bottom horizontal stud member joins
to a second end of the right vertical stud member;
a foam formed at least within the peripheral frame, wherein the foam is
bonded to the peripheral frame, a first side of the foam defines an exterior surface of
the building panel, and a second side of the foam defines an interior surface of the
building panel; and
a mesh provided within the foam.
2. The building panel of claim 1, wherein the structural integrity of the building
panel is derived from the bonding of the foam to the peripheral frame.
3. The building panel of claim 1, wherein the foam comprises a thermoplastic
material or a thermoset material.
4. The building panel of claim 1, wherein the top horizontal stud member, the
bottom horizontal stud member, the right vertical stud member, and the left vertical
stud member are constructed from one of: metal, aluminum, wood, and plastic.
5. The building panel of claim 1, wherein the top horizontal stud member, the
bottom horizontal stud member, the right vertical stud member, and the left vertical
stud member are configured as one of: a convention stud, a c-shaped stud, and an
interlocking stud.
6. The building panel of claim 1, wherein a first side of the foam defines an
exterior surface of the building panel.
7. The building panel of claim 6, wherein a second side of the foam defines an
interior surface of the building panel.
8. The building panel of claim 7, wherein the foam and the mesh extends to the
outer boundary of the peripheral frame.
9. The building panel of claim 1, wherein at least one of the right vertical stud
member, the left vertical stud member, top horizontal stud member, and bottom
horizontal stud member is an interlocking stud operable to interlock with an
interlocking stud of an adjacent structural component.
10. An interlocking stud to guide to edge of a first building panel into a receiving
edge of another building comprising:
a base having a zigzag configuration;
a first side wall; and
a second side wall, wherein the first side wall and second side wall extends
from the edges of the base.
11. The interlocking stud of claim 10, wherein a structural component couples to
the interlocking stud within the first side wall and second side wall.
12. The interlocking stud of claim 11, wherein the interlocking stud is operable to
interlock with another interlocking stud having substantially the same configuration
as the base of the interlocking stud.
13. An improved modular building, said building comprising:
a first set of building panels defining a perimeter of the modular building,
wherein each of the building panels include a peripheral frame having a top
horizontal stud member, a bottom horizontal stud member, a left vertical stud
member, and a right vertical stud member, wherein a first end portion of the top
horizontal stud member joins to a first end portion of left vertical stud member, a
second end of the top horizontal stud member joins to a first end portion of right
vertical stud member, a first end portion of the bottom horizontal stud member joins
to a second end portion of left vertical stud member, and a second end portion of the
bottom horizontal stud member joins to a second end of the right vertical stud
member, and a foam formed at least within the peripheral frame, wherein the foam
is bonded to the peripheral frame, a first side of the foam defines an exterior surface
of the building panel, and a second side of the foam defines an interior surface of
the building panel, each of the building panels configured with an interlocking stud
as the left vertical stud member and the right vertical stud member for interlocking
with an adjacent building panel configured with an interlocking stud as the left
vertical stud member and the right vertical stud member; and
a covering supported by, and secured to, the set of building panels.
14. The improved modular building of claim 13, wherein the covering is
constructed from a second set of building panels.
15. The improved modular building of claim 13, further comprising a set of tracks,
wherein each track in the set of tracks includes a base portion, a first track sidewall,
and a second track sidewall and is anchored to a foundation of the modular building
with a set of anchors having a J-shape configuration comprising a round metal disc
affixed to the end of a bent steel rod.
16. The improved modular building of claim 15, wherein an anchor in the set of
anchors is inserted through a hole receptive in the base portion of a track in the set
of tracks into the foundation and a top portion of the anchor engages the base
portion of the track and the base portion of the track engages the foundation.
17. The improved modular building of claim 15, wherein the set of building panels
are inserted within the first track sidewalls and the second track sidewalls of the set
of tracks.
18. A system for securing a wall of a building to a foundation, comprising:
a track including a base portion, a first track sidewall, and a second track
sidewall; and
a set of anchors each having a J-shape configuration.
19. The system of claim 18, wherein each anchor in the set of anchors is inserted
through a hole receptive in the base portion of the track into the foundation and a
top portion of each of the anchors in the set of anchor engages the base portion of
the track and the base portion of the track engages the foundation.
20. The system of claim 18, wherein the building panel is inserted within the first
track sidewall and the second track sidewall of the track. |
POLY-BONDED FRAMED PANELS
BACKGROUND OF THE INVENTION
Field of the Invention:
[0001] The present invention relates to a building panel, method of
fabricating the building panel, and method of constructing a build employing the
building panel. More particularly, the present invention relates to a framed building
panel, method of fabricating the framed building panel, and method of constructing
a build employing the building panel, wherein the framed building panel has
increase structural integrity and is operable to construct a wall, roof, floor, ceiling,
room, and building.
Description of the Prior Art:
[0002] The construction industry is continuously attempting to find ways to
reduce the time, cost, and labor associated with the construction of a structure, such
as a building, wall, room, floor, ceiling and roof. Techniques used to reduce the
time, cost, and labor associated with the construction of a structure includes
prefabrication of various portions of a structure. Once the portion of the structure is
fabricated, it is then transported to the construction site for placement in its intended
location. One problem with such techniques is that the prefabricated portion of the
structure is constructed with conventional materials using the techniques that would
be used on the construction site. Another problem with these techniques is that the
prefabricated portion is subject to damage during its transportation to the
construction site.
[0003] These techniques typically also require that the structural integrity of
the prefabricated portion of the building is derived solely from the frame of the
prefabricated portion. In some instances, the structural integrity of the prefabricated
portion of the building and the building itself is further derived from the specific
way a prefabricated portion needs to be assembled with another portion of the
building using connections, fasteners, and other coupling mechanisms specific to
using the prefabricated portion.
[0004] Accordingly, there is a need for a building panel having structural
integrity, a method of fabricating the building panel having structural integrity, and
method of constructing a building employing the building panel. There is a need
for the building panel having structural integrity and the method of fabricating the
building panel having structural integrity, where the structural integrity is derived
from the bonding of the foam to vertically and horizontally aligned stud members.
There is a need for the vertically and horizontally aligned studs to form a frame.
There is a need for the foam to define an interior side of the building panel and an
exterior side of the building panel. There is a need for the building panel having
structural integrity to couple to another building panel having structural integrity.
There is a need for the building panel to interlock with an adjacent building panel
employing an interlocking stud. There is a need for the building panel to be held in
an upright position employing a track secured to a floor, such as with an anchor.
SUMMARY OF THE INVENTION
[0005] According to an embodiment of the present invention, a building
panel having structural integrity, a method of fabricating the building panel having
structural integrity, and method of constructing a building employing the building
panel are provided. The building panel is a one layer building panel that derives its
structural integrity from a foam forming the layer that bonds to horizontal and
vertical stud members. The vertical members can be provided at the edges of the
building panel. The horizontal members can be provided at the edges of the
building panel and together with the vertical member form a peripheral frame for
the building panel. The foam is bonded to the horizontal and vertical stud members
using above ambient temperatures and pressures. Building panels can be coupled to
one another to construct a structure, such as a room, floor, level and roof, using
vertical members at the edges having an interlocking capabilities. One or more
building panels can be inserted into one or more tracks secured to a floor to hold the
one or more building panels in an upright position.
[0006] According to an embodiment of the present invention, a building
panel having structural integrity is provided. The building panel includes a
peripheral frame having a top horizontal stud member, a bottom horizontal stud
member, a left vertical stud member, and a right vertical stud member. A first end
portion of the top horizontal stud member joins to a first end portion of left vertical
stud member, a second end of the top horizontal stud member joins to a first end
portion of right vertical stud member, a first end portion of the bottom horizontal
stud member joins to a second end portion of left vertical stud member, and a
second end portion of the bottom horizontal stud member joins to a second end of
the right vertical stud member. A foam is formed at least within the peripheral
frame, wherein the foam is bonded to the peripheral frame. A first side of the foam
defines an exterior surface of the building panel, and a second side of the foam
defines an interior surface of the building panel. Mesh is provided within the foam.
[0007] In an embodiment of the present invention, the structural integrity of
the building panel is derived from the bonding of the foam to the peripheral frame.
[0008] In an embodiment of the present invention, the foam comprises a
thermoplastic material or a thermoset material.
[0009] In an embodiment of the present invention, the top horizontal stud
member, the bottom horizontal stud member, the right vertical stud member, and
the left vertical stud member are constructed from one of: metal, aluminum, wood,
and plastic.
[00010] In an embodiment of the present invention, the top horizontal stud
member, the bottom horizontal stud member, the right vertical stud member, and
the left vertical stud member are configured as one of: a convention stud, a c-shaped
stud, and an interlocking stud.
[00011] In an embodiment of the present invention, a first side of the foam
defines an exterior surface of the building panel and a second side of the foam
defines an interior surface of the building panel.
[00012] In an embodiment of the present invention, the foam and the mesh
extends to the outer boundary of the peripheral frame.
[00013] In an embodiment of the present invention, ate least one of the right
vertical stud member, the left vertical stud member, top horizontal stud member,
and bottom horizontal stud member is an interlocking stud operable to interlock
with an interlocking stud of an adjacent structural component.
[00014] According to an embodiment of the present invention, an interlocking
stud to guide to edge of a first building panel into a receiving edge of another
building is provided. The interlocking stud includes a base having a zigzag
configuration, a first side wall; and a second side wall, wherein the first side wall
and second side wall extends from the edges of the base.
[00015] In an embodiment of the present invention, a structural component
couples to the interlocking stud within the first side wall and second side wall.
[00016] In an embodiment of the present invention, the interlocking stud is
operable to interlock with another interlocking stud having substantially the same
configuration as the base of the interlocking stud.
[00017] According to an embodiment of the present invention, an improved
modular building is provided. The building includes a first set of building panels
defining a perimeter of the modular building, wherein each of the building panels
include a peripheral frame having a top horizontal stud member, a bottom
horizontal stud member, a left vertical stud member, and a right vertical stud
member. A first end portion of the top horizontal stud member joins to a first end
portion of left vertical stud member. A second end of the top horizontal stud
member joins to a first end portion of right vertical stud member. A first end portion
of the bottom horizontal stud member joins to a second end portion of left vertical
stud member. A second end portion of the bottom horizontal stud member joins to
a second end of the right vertical stud member. A foam formed at least within the
peripheral frame is bonded to the peripheral frame. A first side of the foam defines
an exterior surface of the building panel, and a second side of the foam defines an
interior surface of the building panel. Each of the building panels configured with
an interlocking stud as the left vertical stud member and the right vertical stud
member for interlocking with an adjacent building panel configured with an
interlocking stud as the left vertical stud member and the right vertical stud
member. A covering is supported by, and secured to, the set of building panels.
[00018] In an embodiment of the present invention, the covering is constructed
from a second set of building panels.
[00019] In an embodiment of the present invention, tracks includes a base
portion, a first track sidewall, and a second track sidewall and is anchored to a
foundation of the modular building with a set of anchors having a J-shape
configuration comprising a round metal disc affixed to the end of a bent steel rod.
[00020] In an embodiment of the present invention, an anchor is inserted
through a hole receptive in the base portion of a track into the foundation and a top
portion of the anchor engages the base portion of the track and the base portion of
the track engages the foundation.
[00021] According to an embodiment of the present invention, A system for
securing a wall of a building to a foundation is provided. The system includes a
track including a base portion, a first track sidewall, and a second track sidewall and
an anchor each having a J-shape configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
[00022] The above described features and advantages of the present
invention will be more fully appreciated with reference to the detailed description
and appended figures in which:
[00023] Figs. IA- IB depict exemplary diagrams of a building panel
having structural integrity according to an embodiment of the present invention;
[00024] Fig. 1C depicts an exemplary top view of a c-shaped stud with
foam and mesh according to an embodiment of the present invention;
[00025] Fig. 2 depicts an exemplary diagram of a building panel with a
diagonal stud member having structural integrity according to an embodiment of the
present invention;
[00026] Fig. 3 depicts an exemplary diagram of a building panel with an inner
vertical stud member having structural integrity according to an embodiment of the
present invention;
[00027] Fig. 4 depicts an exemplary diagram of an interlocking stud member
according to an embodiment of the present invention;
[00028] Fig. 5 depicts an exemplary diagram of an anchor and track according
to an embodiment of the present invention;
[00029] Fig. 6 depicts an exemplary flow chart of a method for constructing a
structure using a set of building panels according to an embodiment of the present
invention; and
[00030] Fig. 7 depicts an exemplary flow chart of a method of fabricating the
building panel shown in Fig. 1.
DETAILED DESCRIPTION OF THE INVENTION
[00031] The present invention is now described more fully hereinafter with
reference to the accompanying drawings that show embodiments of the present
invention. The present invention, however, may be embodied in many different
forms and should not be construed as limited to embodiments set forth herein.
Appropriately, these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the present invention.
[00032] According to an embodiment of the present invention, a building
panel having structural integrity, a method of fabricating the building panel having
structural integrity and method of constructing a building employing the building
panel are provided. The building panel is a one layer building panel that derives its
structural integrity from a foam forming the layer that bonds to horizontal and
vertical stud members. The vertical stud members can be provided at the edges of
the building panel. The horizontal stud members can be provided at the edges of
the building panel and together with the vertical stud member form a peripheral
frame for the building panel. The foam is bonded to the horizontal and vertical stud
members using temperatures and pressures above ambient. Building panels can be
coupled to one another to construct a structure, such as a room, floor, level and roof,
using vertical and horizontal stud members at the edges having an interlocking
capabilities. One or more building panels can be inserted into one or more tracks
secured to a floor to hold the one or more building panels in an upright position.
[00033] Exemplary diagrams of a building panel having structural integrity
according to an embodiment of the present invention are shown in Figs. IA- IB. In
the embodiment of Fig. IA, building panel 100 includes a top horizontal stud
member 102, a bottom horizontal stud member 104, a right vertical stud member
106, a left vertical stud member 108, and a foam member 110. The building panel
of Fig. IA includes an exterior panel side 112, an interior panel side 114, and a
mesh member 116 positioned within foam member 110 as shown Fig. IB. In the
Fig. IA embodiment of the present invention, the top horizontal stud member 102,
bottom horizontal stud member 104, right vertical stud member 106, and left
vertical stud member 108 can be constructed from one of metal, aluminum, wood
and plastic. In an embodiment of the present invention, a stud member, such as top
horizontal stud member 102, bottom horizontal stud member 104, right vertical stud
member 106, and/or left vertical stud member 108, can be configured as a
conventional stud, a c- shaped stud, an interlocking stud, or the like. In an
embodiment of the present invention, the foam member 110 forms around the c-
shaped stud members to provide increase structural integrity and mesh member 116
couples to c-shaped stud member as shown in Fig. 1C. In an embodiment of the
present invention, the mesh member 116 is provided within the foam member 110.
In an embodiment of the present invention, the mesh can span the extent of the
foam member 110 and couple to each of the top horizontal stud member 102,
bottom horizontal stud member 104, right vertical stud member 106, and left
vertical stud member 108. In an embodiment of the present invention, a set of mesh
members can be provided within the foam member 110 and extend from the top
horizontal stud member 102 to the bottom horizontal stud member 104. In an
embodiment of the present invention, a set of mesh members can be provided
within the foam member 110 and extend from the left vertical stud member 108 to
the right vertical stud member 106. The mesh member 116 can be configured from
materials including, but not limited to, aluminum, steal, copper, and plastic. In an
embodiment of the present invention, the mesh size can be from 2 Mesh to 325
Mesh which means the number of meshes per lineal inch of material. In an
embodiment of the present invention, the mesh size can be 5 Mesh to 300 Mesh. In
an embodiment of the present invention gauge of the mesh can be from 50 gauge to
10 gauge. In another embodiment, the mesh has a gauge ranging from 40 to 10. In
an embodiment of the present invention, the mesh has a gauge ranging from 30 to
15.
[00034] In the Fig. IA embodiment of the present invention, top horizontal
stud member 102 and bottom horizontal stud member 104 are axially aligned and
positioned at the upper and lower periphery of building panel 100 to form the top
and bottom of building panel 100. In an embodiment of the present invention, top
horizontal stud member 102 and bottom horizontal stud member 104 are axially
align and positioned at a predetermined distance from one another. In the Fig. IA
embodiment of the present invention, right vertical stud member 106 and left
vertical stud member 108 are axially aligned and positioned at the left and right
periphery of building panel 100 to form the left side and right side of building panel
100. In an embodiment of the present invention, left vertical stud member 108 and
right vertical stud member 106 are axially aligned and positioned at a predetermined
distance from one another. In an embodiment of the present invention, the vertical
stud members 106 and 108 extend the height of the building panel 100 and the
horizontal stud members 102 and 104 extend the length of the building panel 100.
In an embodiment of the present invention, the vertical stud members 106 and 108
of building panel 100 are configured to interlock with a vertical stud member of an
adjacent building panel 100 to form a wall or room. In an embodiment of the
present invention, the horizontal stud members 102 and 104 are configured to
interlock with the interlocking stud members of building panels used to form a
ceiling, roof, or floor of a structure. The building panel can be secured to a floor
member to hold the building panel in an upright position by methods including, but
not limited to, slots in the foundation or direct fixation with screws, welds or
adhesives.
[00035] In the Fig. IA embodiment of the present invention, the top horizontal
stud member 102, bottom horizontal stud member 104, right vertical stud member
106, and left vertical stud member 108 form a frame around panel member 110. In
the Fig. IA embodiment of the present invention, a first end portion of the top
horizontal stud member 102 squarely abuts a first end portion of left vertical stud
member 108. In the Fig. IA embodiment of the present invention, a second end of
the top horizontal stud member 102 squarely abuts a first end portion of right
vertical stud member 106. In the Fig. IA embodiment of the present invention, a
first end portion of the bottom horizontal stud member 104 squarely abuts a second
end portion of left vertical stud member 108. In the Fig. IA embodiment of the
present invention, a second end portion of the bottom horizontal stud member 104
squarely abuts a second end of right vertical stud member 106. In an embodiment
of the present invention, the members can be coupled, such as by screws, welding,
adhesive and bolts, at the points of abutment to further provide structural integrity.
[00036] In the Fig. IA embodiment of the present invention, panel member
110 extends and bonds to the inner side of each of the top horizontal stud member
102, bottom horizontal stud member 104, right vertical stud member 106, and left
vertical stud member 108. In the Fig. IA embodiment of the present invention, the
thickness of the panel member 110 is substantially the same as the width of the top
horizontal stud member 102, bottom horizontal stud member 104, right vertical stud
member 106, and left vertical stud member 108. The front side and back side of the
foam member 110 defines the exterior and interior of building panel 100. In an
embodiment of the present invention, building panel 100 conforms to chapter 26 of
the International building code for requirements including, but not limited to, flame
spread and smoke spread.
[00037] In an embodiment of the present invention, panel member 110 extends
to the outer side of each of the top horizontal stud member 102, bottom horizontal
stud member 104, right vertical stud member 106, and left vertical stud member
108 and bonds to the back, front, and inner sides of each of the top horizontal stud
member 102, bottom horizontal stud member 104, right vertical stud member 106,
and left vertical stud member 108. In an embodiment of the present invention, the
panel member 110 thickness extends beyond the width of each of the top horizontal
stud member 102, bottom horizontal stud member 104, right vertical stud member
106, and left vertical stud member 108. In an embodiment of the present invention,
the front side and back side of the foam member 110 defines the exterior and
interior of building panel 100 as well as the exterior and interior of a wall, roof, or
ceiling for a structure constructed with building panel 100.
[00038] An exemplary embodiment of the building panel 100 of Figs. IA - IB
is shown in Fig. 2 with a diagonal stud member. In the Fig 2 embodiment of the
present invention, diagonal stud member 202 can be constructed from one of metal,
aluminum, wood and plastic. In the Fig. 2 embodiment of the present invention, a
first end portion of the diagonal stud member 202 abuts to a second end portion of
the top horizontal stud member 102 and a first end portion of right vertical stud
member 106. In the Fig. 2 embodiment of the present invention, a second end
portion of the diagonal stud member 202 abuts a first end portion of the bottom
horizontal stud member 104 squarely and second end portion of left vertical stud
member 108. In the Fig. 2 embodiment of the present invention, panel member 110
extends and bonds to the inner side of each of the top horizontal stud member 102,
bottom horizontal stud member 104, right vertical stud member 106, and left
vertical stud member 108 as well as the right and left side of diagonal stud member
202. In an embodiment of the present invention, the members can be coupled at the
points of abutment to further provide structural integrity.
[00039] An exemplary embodiment of the building panel 100 of Figs. IA - IB
is shown in Fig. 3 with an inner vertical stud member. In the Fig. 3 embodiment of
the present invention, an inner vertical stud member 302 can be constructed from
one of metal, aluminum, wood and plastic. In the Fig. 3 embodiment of the present
invention, a fist end portion of an inner vertical stud member 302 squarely abuts the
top horizontal stud member 102 and a second end of the inner vertical stud member
302 squarely abut the bottom horizontal stud member 104. In the Fig. 3
embodiment of the present invention, panel member 110 extends and bonds to the
inner side of each of the top horizontal stud member 102, bottom horizontal stud
member 104, right vertical stud member 106, and left vertical stud member 108 as
well as the right and left side of inner vertical stud member 106. In an embodiment
of the present invention, the members can be coupled at the points of abutment to
further provide structural integrity. In an embodiment of the present invention,
inner stud members can be configured to define openings for doors, windows, and
the like.
[00040] An exemplary top view of an interlocking stud member is shown in
Fig. 4. In the Fig. 4 embodiment of the present invention, interlocking stud member
400 is configured to have a zigzag-shaped cross section including a base with a
zigzag shape 402 and two sidewalls 404a-404b extending from the edges of the
base 402. As would be appreciated by those of ordinary skill in the art, however,
the configuration is not limited to the illustration in Fig. 4, but instead can be of any
configuration that guides the edge of one panel into a receiving edge of another
panel. In the Fig. 4 embodiment of the present invention, the zigzag-shaped cross
section at the first side of the stud member 400 can interlock with a zigzag-shaped
cross section of an adjacent stud member 400 having the same configuration to
create walls, ceilings, roofs and floors of a structure. The interlocking stud member
400 can be used when constructing a wall including, but not limited to, a
conventional wall structure, modular wall structure, building panel 100, and the
like.
[00041] An exemplary side view of an anchor and track is shown in Fig. 5. In
the Fig. 5 embodiment of the present invention, the track 500 has a C-shaped
configuration having a base and two sidewalls projecting upward from the base,
which can be secured to a floor at the side of base opposite the sidewalls using one
or more anchors 502. In an embodiment of the present invention, the track 500 can
be used to hold one or more wall structures, such as a building panel 100, in an
upright position between the sidewalls. The track 500 can be constructed from one
of metal, aluminum, and the like. In an embodiment of the present invention, the
track can be secured to a floor using one or a combination of screws, bolts, welds,
anchors, adhesive, and the like. In the Fig. 5 embodiment of the present invention,
an anchor 502 has a J-shaped configuration, which can be inserted through a hole in
the base (not shown) of the track 500 into a floor in order to secure the track 500 to
the floor's surface. In an embodiment of the present invention, the track can be
secured to a floor using one or a combination of screws, four bolts, molds, anchors
and the like. The anchor 502 can be constructed from one of metal, steel, and the
like. In an embodiment of the present invention, the floor is pre-dried concrete and
the base of the track 500 meets with a pre-dried concrete floor. Once the concrete
dries, the track 500 and anchor 502 are securely fastened to the concrete floor.
[00042] An exemplary flow chart of a method of constructing a structure using
the building panels, anchor and track, and interlocking stud member is shown in
Fig. 6. The type of structure includes, but are not limited to, a wall, roof, room,
home, commercial building, strip mall, cold storage facility, and apartment
building. The method begins with step 600. In step 600, a set of tracks is
positioned in a configuration to define the outer boundaries of a building. In step,
602, anchors are inserted through holes in the tracks and into the floor that the
tracks sit on. In an embodiment of the present invention, the floor is concrete. In
step 604.; the walls of the structure are constructed. In the Fig. 6 embodiment of the
present invention, construction of a wall includes, inserting a set of building panels
within the sidewalls of the track and interlocking the interlocking stud members of
adjacent building panels. To inserting a building panel within the sidewalls of the
track, the building panel can be lifted over the sidewalls of the track. Interlocking
the interlocking stud of the building panel to the interlocking stud of an adjacent
building panel is performed prior to inserting the building panel into the track. The
interlocking of interlocking studs and insertion of interlocked building panels into
the track secures the interlocked building panels to one another in an upright
position. A ceiling constructed from the building panels can be secured to a wall
constructed of the ceiling panels employing an eave lock, wherein the eave lock has
a base portion and a pair of sidewall, each sidewall being angled away from the
base portion.
[00043] An exemplary flow chart of a method of fabricating the building panel
of Fig. 1 is shown in Fig. 7. The method begins in step 700. In step 700, a
peripheral frame of stud members is placed in a mold press. In an embodiment of
the present invention, the mold press includes an enclosure having a top panel,
sidewalls and a bottom panel. In an embodiment of the present invention, a mesh
is coupled to the peripheral frame. In an embodiment of the present invention, a
mesh is suspended within the peripheral frame. In step 702, the top panel is placed
on, and secured to the sidewalls. In an embodiment of the present invention, the top
panel is secured to the sidewalls with sufficient strength to sustain pressures
achieved by the mold press.
[00044] In one embodiment, the studs and/or mesh can be surface treated for
improved bonding. Surface treatment can be effected by any of the several
techniques known in the art, such as corona discharge, plasma treatment, ozone
treatment, sand blasting, brush tumbling, and the like. Preferably, surface treatment
is effected by grinding with an abrasive wheel. As will be appreciated by those of
ordinary skill in the art, the effect of the surface treatment can vary based on the
type of material used to fabricate the stud and/or mesh. For example, a metal stud
can be subjected to sand blasting in order to increase the adhesion between the
metal stud and the foam material.
[00045] In an alternate embodiment, a metal stud can be pretreated with a
plasma thermal spray coating thus taking advantage of the ability of plasma
technology to excite gas atoms and molecules into transient and nonequilibiϊum
conditions. An enclosed vacuum chamber can be used to excite the gas molecules
by subjecting the gas mixture to an electrified field of radio frequency (rf) energy.
In the alternative, the plasma technology can be performed under atmospheric
pressure and ambient temperature, without the use of vacuum equipment. The
oxygen functionalities created on the surfaces are chemically reactive and
permanent and allow the foam material to form a covalent bond to the modified
surface.
[00046] In step 704, a foam is injected and distributed consistently into the
mold press. In an embodiment of the present invention, the foam is injected within,
and bonded to, the peripheral frame. In an embodiment of the present invention, the
foam is injected within, over, and bonded to, the frame. In an embodiment of the
present invention, the foam has a thickness substantial equivalent to the thickness of
the stud members of the peripheral frame. In an embodiment of the present
invention, the foam has a thickness to substantially cover the stud members of the
peripheral frame.
[00047J In the Fig. 7 embodiment of the present invention, the press can be
maintained above-ambient pressure, where the pressure is directly related to the
density of the foam. In an embodiment of the present invention, the density of the
foam can be based on the specific application that the building panel is going to be
used. Any suitable temperature and pressure can be provided that allows the
reaction to proceed. For example, the temperature may range from about 32°F to
about 18O 0 F. In one embodiment, the reaction temperature is about 75 0 F to about
170 0 F. In another embodiment, the reaction occurs at a temperature of about 75 0 F
to about 150 0 F. In yet another embodiment, the reaction occurs at a temperature of
about 80 0 F to about 85 0 F. The pressure may range from about 1 psi to about 15 psi.
In one embodiment of the present invention, the pressure is about 3 psi to about 10
psi. In another embodiment of the present invention, the reaction occurs under a
pressure of about 5 psi to about 7 psi.
[00048] The foam can be any suitable foam material that is capable of being
injected and distributed consistently within the peripheral frame. For example, the
foam material may be a thermoset material or a thermoplastic material. The foam
may include, but is not limited to, polystyrene, polyurethane, polyurea,
polyisocyanurate, and the like. In one embodiment, the material is a molded
expanded polystyrene foam. In another embodiment, the material is an extruded
expanded polystyrene foam.
[00049] In still another embodiment, polyurethane foam is used. The
polyurethane foam may be a single-component polyurethane, where the main
components (isocyanate and a hydroxy-terminated component) are stored together
as a blended mix, accompanied by a blowing agent in liquid form, and catalyzed to
cure when exposed to moisture in the air. On release from their pressurized
container, the two main components react chemically, and the heat from this
reaction causes the blowing agent to convert into a gas and expand to form the
cellular structure of the foam. When the reaction is complete, the gas is trapped
within the material. In two-component polyurethane, the same two main
ingredients and appropriate catalysts are kept apart until application. The chemical
reaction when they are combined is much faster than with one-component foam.
Curing is chemical, requires no air or moisture, and is independent of the
surrounding environment. As an alternative, polyiscyanurate foam may be used for
improved fire-resistance and higher R- values as compared to polyurethane foam.
[00050] In yet another embodiment, the foam material includes polyurea
linkages and may be prepared by reacting an isocyanate with an amine-terminated
component. Whether the foam includes urethane or urethane linkages, the foam
may be the result of a one-shot method or a prepolymer method. Those of ordinary
skill in the art will appreciate that the different methods have advantages and
disadvantages depending on the application.
[00051] Any isocyanate available to one of ordinary skill in the art is suitable
for use according to the invention. Isocyanates for use with the present invention
include aliphatic, cycloaliphatic, araliphatic, aromatic, any derivatives thereof, and
combinations of these compounds having two or more isocyanate (NCO) groups per
molecule. Suitable isocyanate-containing components include diisocyanates having
the generic structure: O=C=N-R-N=C=O, where R is preferably a cyclic, aromatic,
or linear or branched hydrocarbon moiety containing from about 1 to about 20
carbon atoms.
[00052] Suitable hydroxy-terminated components include, but are not limited
to, polyols including polyether polyols, polycaprolactone polyols, polyester polyols,
polycarbonate polyols, hydrocarbon polyols, and mixtures thereof. Both saturated
and unsaturated polyols are suitable for use with the present invention. Non-
limiting examples of amine-terminated compounds for use with the present
invention include amine-terminated hydrocarbons, amine-terminated polyethers,
amine-terminated polyesters, amine-terminated polycarbonates, amine-terminated
polycaprolactones, and mixtures thereof. The amine-terminated segments may be
in the form of a primary amine (NH 2 ) or a secondary amine (NHR).
[00053] If the prepolymer method is used to form a polyurethane or polyurea-
based material, the curing agent may include hydroxy-terminated curing agents,
amine-terminated curing agents, and mixtures thereof. For example, any of the
hydroxy-terminated compounds or amine-terminated compounds discussed above
are also suitable for use as a curative.
[00054] As known to those of ordinary skill in the art, aliphatic or saturated
components, i.e., components that do not include C=C or aromatic rings, produce
foam materials that are less susceptible to ultraviolet light. As such, in one
embodiment (when applicable), the foam includes only aliphatic components to
result in a non-yellowing product. This embodiment is especially useful when the
panels are intended to be left unpainted once installed.
[00055] Foaming of the material of the invention may occur through the
addition of at least one physical or chemical blowing or foaming agent. Suitable
blowing or foaming agents include, but are not limited to, organic blowing agents,
such as azobisformamide; azobisisobutyronitrile; diazoaminobenzene;
N,N-dimethyl-N,N-dinitrosoterephthalamide;
N,N-dinitrosopentamethylene-tetramine; benzenesulfonyl-hydrazide; benzene- 1,3-
disulfonyl hydrazide; diphenylsulfon-3-3, disulfonyl hydrazide; 4,4'-oxybis benzene
sulfonyl hydrazide; p-toluene sulfonyl semicarbizide; barium azodicarboxylate;
butylamine nitrile; nitroureas; trihydrazino triazine; phenyl-methyl-uranthan;
p-sulfonhydrazide; peroxides; and inorganic blowing agents such as ammonium
bicarbonate and sodium bicarbonate.
[00056] In another embodiment, the material is foamed forcing a pressurized
gas, such as nitrogen or carbon dioxide, into the polymerizing mixture. In another
embodiment, the material is foamed by blending microspheres with the composition
either during or before the molding process. Polymeric, ceramic, metal, and glass
microspheres are useful in the invention, and may be solid or hollow and filled or
unfilled.
[00057] The foamed material may be closed-cell or open-cell, however, as
known to those of ordinary skill in the art, a closed-cell foam material forms a
hydrophobic top skin. As such, if the material of the invention is initially an open-
cell foam, a subsequent sealant is preferred to add hydrophobicity to the cured
material.
[00058] In step 706, the top panel of the mold press is removed. In step 708,
the building panel is removed from the mold press.
[00059] While specific embodiments of the present invention have been
illustrated and described, it will be understood by those having ordinary skill in the
art that changes can be made to those embodiments without departing from the
spirit and scope of the invention.
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