CA2081651A1 - Modular prefabricated building panels - Google Patents
Modular prefabricated building panelsInfo
- Publication number
- CA2081651A1 CA2081651A1 CA 2081651 CA2081651A CA2081651A1 CA 2081651 A1 CA2081651 A1 CA 2081651A1 CA 2081651 CA2081651 CA 2081651 CA 2081651 A CA2081651 A CA 2081651A CA 2081651 A1 CA2081651 A1 CA 2081651A1
- Authority
- CA
- Canada
- Prior art keywords
- panel
- structural frame
- sheathing
- panels
- frame
- 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.)
- Abandoned
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
- E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
-
- 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
- E04C2/296—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 non-metallic or unspecified sheet-material
-
- 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
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
Abstract
ABSTRACT
Construction and use of a modular system of prefabricated building panels is described: in the system a structural frame of characteristically OSB (oriented strand board) or plywood is formed in jigs under compression, the integrity of the frame being assured by the rabbeting or dovetailing of all joints and the design of the supporting channels and l-struts, and by the gluing and nailing of all parts. In the preferred embodiment for load-bearing and insulating wall, floor and ceiling panels additional rigidity is provided by fire-retardant expanding foam insulation which hardens under pressure inside the frame. Electrical conduits are pre-set into the frame, which is offset from fastened interior and exterior sheathing boards so that the finished panel will mate in a rabbet joint with an identical panel; thus a series of such panels can be connected in the field with ease. In addition, the exterior sheathing of wall panels extends down to exactly cover the thickness of a joining floor member to prevent thermal loss and wind penetration; and a special comer wall panel has its dimensions reduced by the thickness of a joining wall member, so that the joint can be accommodated without compromising the horizontal modularity of the multiple identical-panel design.
Construction and use of a modular system of prefabricated building panels is described: in the system a structural frame of characteristically OSB (oriented strand board) or plywood is formed in jigs under compression, the integrity of the frame being assured by the rabbeting or dovetailing of all joints and the design of the supporting channels and l-struts, and by the gluing and nailing of all parts. In the preferred embodiment for load-bearing and insulating wall, floor and ceiling panels additional rigidity is provided by fire-retardant expanding foam insulation which hardens under pressure inside the frame. Electrical conduits are pre-set into the frame, which is offset from fastened interior and exterior sheathing boards so that the finished panel will mate in a rabbet joint with an identical panel; thus a series of such panels can be connected in the field with ease. In addition, the exterior sheathing of wall panels extends down to exactly cover the thickness of a joining floor member to prevent thermal loss and wind penetration; and a special comer wall panel has its dimensions reduced by the thickness of a joining wall member, so that the joint can be accommodated without compromising the horizontal modularity of the multiple identical-panel design.
Description
~ ~$1~
INTRODUCTION AND DESCRIPIION OF THE PRIOR ART
It has been suggested that the only things that the human race must of nece~sity concern itself with are buildings, children, and food; this may seem an exa~geration, but anyone who lives in a temperate or colder climate knows thnt buildings--and in particular housing--are of the first importance and critical for survival during long periods of the year. Any advance in the technology of building structures has a ripple effect throughout the society, and the invention and perfecting of prefabricated load-bearing panels for walls. ceilings and floors is arguably such an advance. Increasing numbers of companies ~re now providing various forms of such panels commercially. and it appears to be only a mattes of time before mainstream builders and home-buyers become aware of the financial savings--shon and long-tenn--to be gained by using such systems; a matter of time. and. of course. improvements: because the first panels to enter the market, while usable, lack certain features. The present invention provides several innovations which will allow easier. more accurate. faster. and hence more cost-effective erection of stronger and more stable structures.
The advantages of prefabricated panels--in particular those composed of foanl insulation injected between sandwiching layers of wood--over conventional framing techniques and other earlier panels has been explained in some detail in the preamble to Canadian Patent #1,287.96~, "Wall Panel With l~oam Insulation." Tisshlgton et al. 1991. and need not be repeated here in detail: these advantages include a degree of enhancement of insulating qualities and ease of erection. However certain problems with the design of the panels specified in the cited patenl are apparent. Because of the design of the bracing strut~s, loads will not necessarily be born equally throughout the area of the panel. Since the panels do not interlock. a separate spline connector is required. and must be fitted in the field. No provision is made for electrical connecting; therefore the inlegrity of the panel must be broken by drilling. or expensive t`ield work must be 20~165~
pert`ormed to wire around the panel. Finally, the connection between the vertical panels and floor does not provide adequate protection from thermal loss and wind movement~
and in storm situations wind penetration and separation may result in structural damage.
The present invention addresses and improves on all of these listed omissions insubstantial ways.
In sum, panels according to the invention are basically a structural frame between two flat boards, characteristically OSB (oriented strand board). The frame has a header channel along the top edge and a parallel footer channel along the bottom edge:
both channels have open edges oriented inwards. The exlerior of the frame is completed by an inset C-channel along one edge, and a corresponding parallel extended C-channel along the opposite edge; thus two panels cnn be rabbeted together along their interlocking edges with only adhesive and nails or screws to be applied in the field. Inside the frame, parallel with the edge C-channels. are l-struts. The web of the l-strut rabbets in the flanges of the l-strut and continues past these flanges to rabbet equally in the side plales of the footer and header channels, thus equally separating all these boards in a continuous linl; and mainlaining the structural integrity of the frame. and thus the panel, over its full length. Reintorcement spacers between the edge C-channel side-faces complete thestructural members. A panel so constructed is sufficiently strong to be used in some situations even without the extra rigidity provided by the insulation; however for most uses a foam such as expanding polyurethane. characteristically treated with a fire-retardant additive, will be injected and harden internally around the structure components.
As well, before the foam injection PVC pipe electrical leads and electrical boxes are placed internally in the panel, providing an integral electrical wiring grid between panel elements in Soth the horizontal and vertical planes: access is provided to the surt`ace facing the interior of the building.
- ln she standard wall panel provided in this inventicn, (as distinct from the 20~651 .
floor and ceiling panels), weather-proofing and additional structural characteristics are provided by having the external board face extending downwards to a depth equal to the floor thickness, creating a wind-proof connection between the wall panel and the floor structure. This principle is continued at the exterior corners of the building in the vertical plane: special corner parlels are pre-formed to have their vertical outer edge extending to overlap the vertical end of the adjoining corner wall. This provides completely sealed joints in both thè horizontal and vertical connections while maintaining the modular dimensions of the building and eliminating any requirement for cutting or retrofitting any of the panel elements. Finally, it is possible to construct insulated floor and roof panel elements of sufficient thickness to provide a fully insulated structure that can bear normal floor loads without major deflection over spans of up to sixteen feet. including cantilevers of four feet. while incorporating the improvements specified.
An object of the present invention is to provide an improved prefabricated building panel to be used for walls. floors. and ceilings of housing or other structures.
comprising a structural frame; reinforcing l-struts within said frame: an inner sheathing board fastened to the structural frame: and an outer sheathing board. fastened to the opposing side of the structural frarne parallel to the inner sheathing board.
A further object is to provide for such panels having electrical wiring conduits through the structural frame. access to the electrical wiring conduits through an access panel through the inner sheathing board. and insulation for heat or cold or sound or any combination thereof in the voids bounded by the structural frame and the sheathing boards: and in which all joints of the frame and of the l-struts are rabbeted. including dovetail rabbet joints, the purpose of the dovetailing being to assure strong bonding of ~hese joints during the compression and fastening of the structural frame in a jig.
A further object is to provide for such a panel in which the structural frame isgenerally a rectangular box in shape: in which the frame is considerably longer and wider 20~651 than it is thick; and in which the sheathing boards are generally rectangular and oriented parallel to the long and wide plane of the structural frame; and in which the electrical wiring conduits. when used. give access through ~he structural frame in the long or wide directions or both.
A further object is to provide for such a panel in which the sheathing boards are fastened to the structural frame in a manner so that a portion of the structural frame extends beyond the boards in the long or wide direction, and the long or wide direction of the panel is vertical when the panel is a wall panel: and an equivalent amount of lhe boards extend beyond the structural frame in the opposite direction, so that an identical second panel can be mated with standard fastening devices with a first panel: the extending portion of the structural frame of either of said panels being rabbeted between the extending portions of the sheathing boards of the other panel.
A further object is to provide for such a first panel in which the outer sheathing board extends farther than the inner sheathing board in either the long or wide dimension or both, the function of this extension being to cover the outside of a joining member where it joins the first panel. and so substantively minimize wind and thermal penetration.
A turther object is to provide for situations in which the panel is a corner wall panel and this extension occurs in the horizontal direction. so that the extending exterior sheathing board will exactly cover the external vertical surface of the joining wall member or panel: and further. where the joining wall member will join the corner wall panel in the midst of an internal surface of a building, that such surface may be composed of a series of approximately identical preformed panels of equal horizontal width. even where one of the panels is joined by a wall member.
A further object is to provide for such panels in which the insulation is an injected foarn. including polyurethane foam or the like. which expands and becomes 2~81S51 rigid, and in which the insulation has a high fire-retardallt capacity; and in which further the structural frame has been sprayed with a fire-retardant solution, so that the finished insuJated panel has a high fire-retardant capacity; and in which the rigidity of the injected insulation is a substantial contributing factor to the weight-bearing characteristics of the panel.
A further object is to provide for a method of constructing an integrated modular system of prefabricated building panels to be used for walls, floors, and ceilings of housing or other structures, comprising: designing a series of different sizes and thicknesses of panels to provide floors, ceilings. and walls and to provide for joins between floors, ceilings and walls (the panels bein~ modular. meaning regular multiple sizés of standard construction dimensions, and being interlocking, so that they can easily be joined in the field); forming a structural frarne in a jig for each type of panel required;
optionally including electrical wiring conduits and access: fastening each structural frame onto the appropriate interior sheathing board in a second jig; fastening the appropriate exterior sheathing board onto each type of structuMI frame while it is in the second jig:
spraying each completed panel with a fire and insect retardant solution; optionally, injecting insulation into the voids bounded by the structural frame and sheathing boards for each panel while the panel is held in a press: and testing each panel for dimensional accuracy.
A further object is to provide for such a method in which the structural frame is formed by placing the following components. generally all of oriented strand board or plywood or the like, in the jig frame under compression, the joints being fastened with waterproof adhesives and nailed together: characteristically in the following order: (i) a header channel. being a header base plate and then two parallel header facing plates; the facing plates defining the long and wide dimension of the fMme and the header base plate running at right angles between them. so as to form the header as a an inverted U-channel; the open t`ace of the U-channel opening towards the inside of the structural frame; (ii) two side channels. being U-channe~s constructed similar to the header channel (iii) side channel spacers, being members running at intervals between the facing plates of the side channels; (iii) I-struts. whose central "I" or web runs from the header base plate to a footer base plate, and whose parallel flanges are parallel to the header facing plates and run from them to a facing plates; and (iv) a footer channel, being a U-channel constructed similar to the header channel.
DETAILED DESCRlPI ION OF THE INVENTION
For this description, refer to the following diagrams, wherein like numerals refer to like parts:
Figure IA, invented wall panel, front elevation, partial cut-away view:
Figure IB, horizontal section of Figure IA along arrows "B";
Figure IC, vertical section of Figure IA along arrows "C";
Figure 2, structural frame of wall panel of Figure IA, including exterior sheathing board, partially exploded perspective view;
Figure 3, detail of structural t`rame of Figure 2, showing l-strut web rabbet joint in footer channel and facing plate dovetail; exploded perspective view:
Figure ~A. three invented wall panels joined as a wall; front elevation view: showing also floor in section elevation:
Figure ~B, rabbet joint between two mating wall panels of Figure ~A;
horizontal section through arrows "J";
Figure 5, joint between floor and wall panel of Figure ~A; section elevation along arrows "E";
Figure 6A, two standard invented wall panels and an invented corner wall panel joined as a wall, showing another wall joining at right angles: front elevation view9 showing the floor and second wall in section elevation;
, Figure 6B. invented corner wall panel, horizontal section view; and Figure 6C, corner joint between invented corner wall panel and joining wall of Figure 6A; horizontal section along arrows "G".
Re~erring first to Figure lA, modular wall panel indicated at 1~ can be seen to be structurally composed of exterior sheathing board 12; parallel interior sheathing board 14: footer channel indicated at 16, header channel indicated at 18 (best seen on Figure IC); I-struts indicated at 22; extending side channel indicated at 2~; inset side channel indicated at 26 (on Figure I B); and side channel spacers 30 (shown dotted on Figure IB). The invented wall panel 10 is designed to be structurally sound even without the addition of the foam insulation 40 shown on Figures IB and IC, which. when hardened in place, supplements the weight-bearing characteristics.
In addition to the structural elements. plastic IPVC) electrical conduits 34.
shown dotted within insulation ~0. and electrical connection box 36, opening through the interior sheathing board 14. allow quick and easy installation of electrical wiring (no~
shown).
The indicated elements will now be described in more detail: exterior sheathing 12 can be seen on Figures I A and I C to be extending distance indicate~ by arrow "F" downwards farther than interior sheathing 1~. This distance "F" is desi~ned as the thickness of an appropriate floor member. either a panel produced according to the invention (and which will be described below). or other common floor structure. Thus exterior sheathing 12 of panel 10 completely and accurately covers the exterior surface of the wall-floor joint to exclude wind and therrnal penetration. as can be seen on Figure S
(this and other salient points in Figure 5 will be explained in more detail below).
Turning to Figure 2. (where interior sheathing board 14 is not shown in order to afford a better view of the structural frame indicated at I 1,) footer channel 16 can be seen to ~e composed of footer base plate 15 and footer facing plates 17: header 20816~1 .
channel 18 is composed of header base plate 20 and header facing plates 19. Sidechannels 24 and 26 are mirror images of each other. and oriented similarly within the panel excepting only that 26 is inset within and 2~ extending beyond sheathing board 12.
Inset side channel 26 has inset side channel base plate 25 and two parallel inset side channel facing plates 27; similarly extending side channel 24 has inset side channel base plate 21 and two parallel inset side channel facing plates 23. The side channel facing plates 23 and 27 extend from the bottom of header channel 18 to the top of base channel 16. which is shown exploded downwards hl Figure 2 from its actual position above dotted Iines 13. The side channel base plates 25 and 21 extend from the top of header base plate 20 to the bottom footer base plate 15; in other words the side channel base plates 25 and 21 extend so as to completely cover the ends of the header 18 and footer 16 channels.
The l-struts 22 are composed of web 22A and l-strut flanges 22B. with the web 22A extending from header base pla~e 20 to footer base pla~e 15. and the l-strut flanges 22B extending from the bottom of header facing plates 19 to the top of footer channel facing plates 17. Characteristically there are two l-struts 22 as shown in Figure I A. in a four foot wide panel 10. Note on Figure I B how web 22A is rabbeted into flanges 22B at 22R. Note also on Figure 2. and in enlarged detail on Figure 3 at arrows indicated "R", how this l-strut web 22A is also rabbeted into rabbet grooves 17A an equal amount into footer ~acing plates 17 and footer base plate 15. Similarly (though not diagrammed) the l-strut web 22A rabbets into the header facing plates 19 and header base plate 20. Thus the header facing plates 19. the footer facing plates 17, and the intervening l-strut flanges 22B, all Iying in one plane. are induced to function as one structural unit by virtue of their being rabbeted together by the single member l-strut web 22A. Since the connecting base plates 20 and 15 are also rabbeted as just detailed, the integrity of this structural unit is extended to include the entire structural frame 11 indicated on Figure 2.
~t ~ou~ ~ aL~o noted that other joints within this frame are also rabbeted or dovetailed 208~651 and contribute to the strength of the whole: side channel base plates 25 and 21 are dovetailed with their respective side channel facing plates 27 and 23 and also with header and footer facing plates 19 and 17; this is best seen on Figure 2 and exploded detail Figure 3, where such a dovetail joint surface is numbered at 17D. As well. header and footer channel base plates 20 and 15 are rabbeted with their respective facing plates 19 and 17; and finally, channel spacers 30 are dovetailed into side channel facing plates 27 and 23, as best seen on Figure lB. Particularly by this means the structural integrity of the entire panel 10 is maintained even without the addition of the foam 40.
Field installation of multiple panels 10 is perforrned as follows: for this exp!anation, existence of a floor surface, such as floor panel 39 from Figure 5. is assumed; first, standard sill connector plate ~4 on Figures S and 4A, characteristically a wooden 2" by 4" member, is fastened to the upper face of the floor 39 to provide a firm structural locking and sealing connection between the wall panel 10 and the horizontal face. (Note on Figure S how connector plate ~4 fits snugly into the cavity defined by sheathing boards 12 and 1~ and footer base plate 15: the dimensions of panel 10 are designed for this purpose). When panels indicated at IOA and IOB on Figure 4A are erected side by side overtop standard connector plate ~4 and slid together, their extending and inset portions mate, as seen best in Figure ~B. which is a section as indicated on Figure ~A as arrows J. Exterior shenthing board 12 of panel IOA covers side channel facing plate 23 of panel IOB. and side channel base plate 21 of panel IOB is snugged up against side channel base plate 25 of panel IOA. The panels form one integrated system.
All the joints are sealed with silicone or the like at mating. and screwed or nailed. as indicated by fasteners ~6, to assure weather-proof connection. Any number of panels 10 such a~s IOA, IOB. IOC and so on can be mated to form a wall of any length.
The join of extending exterior sheathing board 12 over the outside of the joint of panel lOB with floor panel 39 is detailed in Figure 5. which is a section elevalion 208165~
, .
>f this joint along arrows indicated at "E" on Figure 4A. Note how distance indicated by arrow "F" is the full thickness of the floor panel indicated at 39. and how exterior sheathing 12 extends down exactly to be flush with the lower sh~'athing ~2 of floor panel 39. so that corner ~1 is a perfectly square joint. Note also how standard connector plate 4~. characteristically a field-installed 2" by 4" wooden member, provides a firm locking and sealing connection as described previously. It will be appreciated that the degree of overlap and structural integrity of this wall-floor corner joint makes it highly impervious ~o wind penetration, allowing for the use of this modular system in high-wind storm risk zones Foundation indicated at 90 is shown for interest: many different foundation configurations are possible, and panicularly in high-risk storm zones others will be in use: all known ones are compatible with this system.
A special wall panel, indicated at IOX on Figures 6A, 6B, and 6C, is prefabricated for easy modular mating of corners. As will be most easily seen onhorizontal section Figure 6B through such a panel, exterior sheathing 12 is lel`t the same width as on standard panels 10. a distance indicated by arrow 80 on Figure 6B. but the rest of the panel IOX is reduced in width by an amount equal to the thickness of a standard panel 10. as indicated by arrow 81. so that a panel such as that indicated IOD on Fi~ures 6A and 6C will mate evenly when placed at ri~ht angles to make a corner joint.
Thus the extending ponion of sheathing 12 of special corner panel IOX exactly covers the end of panel IOD. providing exactly the same type of overlap protection against thermal loss and wind and water penetration as previously explained for the floor-to-wall connection. Trim strip 70, seen on Figure 6C. may if desired be field installed to finish the joint. Again a standard connector plate 4~. this time oriented vertically. is used to nail or screw the joined panels. As seen on Figure 6B. narrower panel IOX may if desired have only a single l-strut 22.
Finally. it is within the scope of the invention to provide for such 208~651 .
interlocking and structurally integral panels specially designed for floors and roofs: since characteristically the only differences from thè detailed wall panels 10 described are the thickness, (which is ideally 41/4" or 61/4" for wall panels; 61/2 for floor panels, and 51/2 for roof panels, in order to configure with existing construction practice), these units are not diagrammed. Note that these thicknesses are variable without changing the essential aspects of the invention. As well, it may not be necessary to include electrical wiring in all floor and roof panels; and the join of the top of a wall panel to the bottom of a ceiling or ceiling panel may require a bevelled connector plate (not diagrammed). Otherwise, the mating of the floor and roof panels is essentially the same as described for wall panels.
Note also that window and door openings may be factory cut with rough framing in place, so that the continuity of the electrical grid is maintained. Special sizes of panels may be ordered with such windows and doors pre-cut, to maintain the modularity of the system and its congruence with multiples of common construction dimensions. This grid can even be pre-fabricated to line up vertically in multi-lloor structures, extending through the intervening horizontal floor panels. Or doors and windows can be cut from the panels in the field and framed and reinforced on site. with care being taken not to interrupt the electrical grid. The header channel 18. indicated previously on Figures IA. IC. and 2. forrns the upper (approximately 10%) vertical portion of the panel 10 and is of sufficient strength and depth to accommodate window and door openings of standard dimensions. (Window and door options are not diagrammed).
The standard wall panel 10 is factory formed by placing the components in a jig frarne under compression. the joints being fastened with waterproof adhesives and nailed together. With reference to ~igure 2. the order of assembly is characteristically as follows: header base plate 20 is placed in a jig (jig is not diagrammed), then header facing plates 19, side channels 24 and 26. I-struts 22 and footer channel 16. Electrical 208~51 connection box 36 and electrical conduits 34 are then inserted into the pre-drilled frame, connected and sealed with silicone. The whole frame is then held in the jig until the setting of the adhesives is complete, thus maintaining the dimensional accuracy of the structu}al frame.
Interior sheathing board 14 (not shown on Figure 2, but appearing on Figures IA, B, C, and other later Figures) is then placed in a second jig fixture. fitted with appropriate spacers to assure the proper offsets and positioning of the structural frame which is then placed in the jig, fastened with adhesives and nailed to the inner face of the sheathing board 14.
Exterior sheathing board 12, which may be of plywood, oriented strand board or a pre-finished decorative composition, is then placed in the jig, adjusted to the proper offsets and fastened to the structural frame as previously described.
The completed structure is then held in the jig under compression until the setting of the fastenings is complete. Following the completion of the fabrication process.
the panel elements are sprayed with a liquid borax solution. to provide a flre and termite retardant capacity to the wood-based components. The foam insulation mixture is then injected (characteristically using a low pressure frothing method) into the voids bounded by the structural frame elements and the sheathing boards 1~ and 12, with the panel 10 being held irl a press to contain the pressures exened from within by the expansion of the foam mixture. (Press and borax spraying are not shown diagramatically).
Note that the dovetailing of the rabbetting of the side base plates 25 and 21 into the side facing plates 27 and 23 and header and footer tacing plates 19 and 17. as previously explained and partially diagrammed on Figures I B. 2. and 3, assures that the expansion pressures of the foam will strengthen these rabbet joints as they cure.
The foam insulation is norsnally an expanded two part polyurethane plastic with a calcium based additive component to add a high fire retardant capacity to the 20816~
toam. When t`ully cured the foam has a density of approximately 1.5 Ib. per cubic foot.
and a thermal resistance factor of R-6 per inch of thickness. The finished panels characteristically have a thermal resistance factor of R-30, R-40, or R-45 for wall, ceiling, or floor panels respectively.
After the fabrication process, each panel is tested for dimensional accuracy, and the connecting faces are sanded and cleaned to ensure firm and complete connection and sealing during erection at the construction site. Panels are marked for installation orientation before leaving the factory. and are available in a range of standard widths and heights, to conform with standard construction practice and so ensure simple planning and construction of the buildings formed from the prefabricated panel units.
The foregoing is by example only, and the scope of the invention should be limited only by the appended claims.
INTRODUCTION AND DESCRIPIION OF THE PRIOR ART
It has been suggested that the only things that the human race must of nece~sity concern itself with are buildings, children, and food; this may seem an exa~geration, but anyone who lives in a temperate or colder climate knows thnt buildings--and in particular housing--are of the first importance and critical for survival during long periods of the year. Any advance in the technology of building structures has a ripple effect throughout the society, and the invention and perfecting of prefabricated load-bearing panels for walls. ceilings and floors is arguably such an advance. Increasing numbers of companies ~re now providing various forms of such panels commercially. and it appears to be only a mattes of time before mainstream builders and home-buyers become aware of the financial savings--shon and long-tenn--to be gained by using such systems; a matter of time. and. of course. improvements: because the first panels to enter the market, while usable, lack certain features. The present invention provides several innovations which will allow easier. more accurate. faster. and hence more cost-effective erection of stronger and more stable structures.
The advantages of prefabricated panels--in particular those composed of foanl insulation injected between sandwiching layers of wood--over conventional framing techniques and other earlier panels has been explained in some detail in the preamble to Canadian Patent #1,287.96~, "Wall Panel With l~oam Insulation." Tisshlgton et al. 1991. and need not be repeated here in detail: these advantages include a degree of enhancement of insulating qualities and ease of erection. However certain problems with the design of the panels specified in the cited patenl are apparent. Because of the design of the bracing strut~s, loads will not necessarily be born equally throughout the area of the panel. Since the panels do not interlock. a separate spline connector is required. and must be fitted in the field. No provision is made for electrical connecting; therefore the inlegrity of the panel must be broken by drilling. or expensive t`ield work must be 20~165~
pert`ormed to wire around the panel. Finally, the connection between the vertical panels and floor does not provide adequate protection from thermal loss and wind movement~
and in storm situations wind penetration and separation may result in structural damage.
The present invention addresses and improves on all of these listed omissions insubstantial ways.
In sum, panels according to the invention are basically a structural frame between two flat boards, characteristically OSB (oriented strand board). The frame has a header channel along the top edge and a parallel footer channel along the bottom edge:
both channels have open edges oriented inwards. The exlerior of the frame is completed by an inset C-channel along one edge, and a corresponding parallel extended C-channel along the opposite edge; thus two panels cnn be rabbeted together along their interlocking edges with only adhesive and nails or screws to be applied in the field. Inside the frame, parallel with the edge C-channels. are l-struts. The web of the l-strut rabbets in the flanges of the l-strut and continues past these flanges to rabbet equally in the side plales of the footer and header channels, thus equally separating all these boards in a continuous linl; and mainlaining the structural integrity of the frame. and thus the panel, over its full length. Reintorcement spacers between the edge C-channel side-faces complete thestructural members. A panel so constructed is sufficiently strong to be used in some situations even without the extra rigidity provided by the insulation; however for most uses a foam such as expanding polyurethane. characteristically treated with a fire-retardant additive, will be injected and harden internally around the structure components.
As well, before the foam injection PVC pipe electrical leads and electrical boxes are placed internally in the panel, providing an integral electrical wiring grid between panel elements in Soth the horizontal and vertical planes: access is provided to the surt`ace facing the interior of the building.
- ln she standard wall panel provided in this inventicn, (as distinct from the 20~651 .
floor and ceiling panels), weather-proofing and additional structural characteristics are provided by having the external board face extending downwards to a depth equal to the floor thickness, creating a wind-proof connection between the wall panel and the floor structure. This principle is continued at the exterior corners of the building in the vertical plane: special corner parlels are pre-formed to have their vertical outer edge extending to overlap the vertical end of the adjoining corner wall. This provides completely sealed joints in both thè horizontal and vertical connections while maintaining the modular dimensions of the building and eliminating any requirement for cutting or retrofitting any of the panel elements. Finally, it is possible to construct insulated floor and roof panel elements of sufficient thickness to provide a fully insulated structure that can bear normal floor loads without major deflection over spans of up to sixteen feet. including cantilevers of four feet. while incorporating the improvements specified.
An object of the present invention is to provide an improved prefabricated building panel to be used for walls. floors. and ceilings of housing or other structures.
comprising a structural frame; reinforcing l-struts within said frame: an inner sheathing board fastened to the structural frame: and an outer sheathing board. fastened to the opposing side of the structural frarne parallel to the inner sheathing board.
A further object is to provide for such panels having electrical wiring conduits through the structural frame. access to the electrical wiring conduits through an access panel through the inner sheathing board. and insulation for heat or cold or sound or any combination thereof in the voids bounded by the structural frame and the sheathing boards: and in which all joints of the frame and of the l-struts are rabbeted. including dovetail rabbet joints, the purpose of the dovetailing being to assure strong bonding of ~hese joints during the compression and fastening of the structural frame in a jig.
A further object is to provide for such a panel in which the structural frame isgenerally a rectangular box in shape: in which the frame is considerably longer and wider 20~651 than it is thick; and in which the sheathing boards are generally rectangular and oriented parallel to the long and wide plane of the structural frame; and in which the electrical wiring conduits. when used. give access through ~he structural frame in the long or wide directions or both.
A further object is to provide for such a panel in which the sheathing boards are fastened to the structural frame in a manner so that a portion of the structural frame extends beyond the boards in the long or wide direction, and the long or wide direction of the panel is vertical when the panel is a wall panel: and an equivalent amount of lhe boards extend beyond the structural frame in the opposite direction, so that an identical second panel can be mated with standard fastening devices with a first panel: the extending portion of the structural frame of either of said panels being rabbeted between the extending portions of the sheathing boards of the other panel.
A further object is to provide for such a first panel in which the outer sheathing board extends farther than the inner sheathing board in either the long or wide dimension or both, the function of this extension being to cover the outside of a joining member where it joins the first panel. and so substantively minimize wind and thermal penetration.
A turther object is to provide for situations in which the panel is a corner wall panel and this extension occurs in the horizontal direction. so that the extending exterior sheathing board will exactly cover the external vertical surface of the joining wall member or panel: and further. where the joining wall member will join the corner wall panel in the midst of an internal surface of a building, that such surface may be composed of a series of approximately identical preformed panels of equal horizontal width. even where one of the panels is joined by a wall member.
A further object is to provide for such panels in which the insulation is an injected foarn. including polyurethane foam or the like. which expands and becomes 2~81S51 rigid, and in which the insulation has a high fire-retardallt capacity; and in which further the structural frame has been sprayed with a fire-retardant solution, so that the finished insuJated panel has a high fire-retardant capacity; and in which the rigidity of the injected insulation is a substantial contributing factor to the weight-bearing characteristics of the panel.
A further object is to provide for a method of constructing an integrated modular system of prefabricated building panels to be used for walls, floors, and ceilings of housing or other structures, comprising: designing a series of different sizes and thicknesses of panels to provide floors, ceilings. and walls and to provide for joins between floors, ceilings and walls (the panels bein~ modular. meaning regular multiple sizés of standard construction dimensions, and being interlocking, so that they can easily be joined in the field); forming a structural frarne in a jig for each type of panel required;
optionally including electrical wiring conduits and access: fastening each structural frame onto the appropriate interior sheathing board in a second jig; fastening the appropriate exterior sheathing board onto each type of structuMI frame while it is in the second jig:
spraying each completed panel with a fire and insect retardant solution; optionally, injecting insulation into the voids bounded by the structural frame and sheathing boards for each panel while the panel is held in a press: and testing each panel for dimensional accuracy.
A further object is to provide for such a method in which the structural frame is formed by placing the following components. generally all of oriented strand board or plywood or the like, in the jig frame under compression, the joints being fastened with waterproof adhesives and nailed together: characteristically in the following order: (i) a header channel. being a header base plate and then two parallel header facing plates; the facing plates defining the long and wide dimension of the fMme and the header base plate running at right angles between them. so as to form the header as a an inverted U-channel; the open t`ace of the U-channel opening towards the inside of the structural frame; (ii) two side channels. being U-channe~s constructed similar to the header channel (iii) side channel spacers, being members running at intervals between the facing plates of the side channels; (iii) I-struts. whose central "I" or web runs from the header base plate to a footer base plate, and whose parallel flanges are parallel to the header facing plates and run from them to a facing plates; and (iv) a footer channel, being a U-channel constructed similar to the header channel.
DETAILED DESCRlPI ION OF THE INVENTION
For this description, refer to the following diagrams, wherein like numerals refer to like parts:
Figure IA, invented wall panel, front elevation, partial cut-away view:
Figure IB, horizontal section of Figure IA along arrows "B";
Figure IC, vertical section of Figure IA along arrows "C";
Figure 2, structural frame of wall panel of Figure IA, including exterior sheathing board, partially exploded perspective view;
Figure 3, detail of structural t`rame of Figure 2, showing l-strut web rabbet joint in footer channel and facing plate dovetail; exploded perspective view:
Figure ~A. three invented wall panels joined as a wall; front elevation view: showing also floor in section elevation:
Figure ~B, rabbet joint between two mating wall panels of Figure ~A;
horizontal section through arrows "J";
Figure 5, joint between floor and wall panel of Figure ~A; section elevation along arrows "E";
Figure 6A, two standard invented wall panels and an invented corner wall panel joined as a wall, showing another wall joining at right angles: front elevation view9 showing the floor and second wall in section elevation;
, Figure 6B. invented corner wall panel, horizontal section view; and Figure 6C, corner joint between invented corner wall panel and joining wall of Figure 6A; horizontal section along arrows "G".
Re~erring first to Figure lA, modular wall panel indicated at 1~ can be seen to be structurally composed of exterior sheathing board 12; parallel interior sheathing board 14: footer channel indicated at 16, header channel indicated at 18 (best seen on Figure IC); I-struts indicated at 22; extending side channel indicated at 2~; inset side channel indicated at 26 (on Figure I B); and side channel spacers 30 (shown dotted on Figure IB). The invented wall panel 10 is designed to be structurally sound even without the addition of the foam insulation 40 shown on Figures IB and IC, which. when hardened in place, supplements the weight-bearing characteristics.
In addition to the structural elements. plastic IPVC) electrical conduits 34.
shown dotted within insulation ~0. and electrical connection box 36, opening through the interior sheathing board 14. allow quick and easy installation of electrical wiring (no~
shown).
The indicated elements will now be described in more detail: exterior sheathing 12 can be seen on Figures I A and I C to be extending distance indicate~ by arrow "F" downwards farther than interior sheathing 1~. This distance "F" is desi~ned as the thickness of an appropriate floor member. either a panel produced according to the invention (and which will be described below). or other common floor structure. Thus exterior sheathing 12 of panel 10 completely and accurately covers the exterior surface of the wall-floor joint to exclude wind and therrnal penetration. as can be seen on Figure S
(this and other salient points in Figure 5 will be explained in more detail below).
Turning to Figure 2. (where interior sheathing board 14 is not shown in order to afford a better view of the structural frame indicated at I 1,) footer channel 16 can be seen to ~e composed of footer base plate 15 and footer facing plates 17: header 20816~1 .
channel 18 is composed of header base plate 20 and header facing plates 19. Sidechannels 24 and 26 are mirror images of each other. and oriented similarly within the panel excepting only that 26 is inset within and 2~ extending beyond sheathing board 12.
Inset side channel 26 has inset side channel base plate 25 and two parallel inset side channel facing plates 27; similarly extending side channel 24 has inset side channel base plate 21 and two parallel inset side channel facing plates 23. The side channel facing plates 23 and 27 extend from the bottom of header channel 18 to the top of base channel 16. which is shown exploded downwards hl Figure 2 from its actual position above dotted Iines 13. The side channel base plates 25 and 21 extend from the top of header base plate 20 to the bottom footer base plate 15; in other words the side channel base plates 25 and 21 extend so as to completely cover the ends of the header 18 and footer 16 channels.
The l-struts 22 are composed of web 22A and l-strut flanges 22B. with the web 22A extending from header base pla~e 20 to footer base pla~e 15. and the l-strut flanges 22B extending from the bottom of header facing plates 19 to the top of footer channel facing plates 17. Characteristically there are two l-struts 22 as shown in Figure I A. in a four foot wide panel 10. Note on Figure I B how web 22A is rabbeted into flanges 22B at 22R. Note also on Figure 2. and in enlarged detail on Figure 3 at arrows indicated "R", how this l-strut web 22A is also rabbeted into rabbet grooves 17A an equal amount into footer ~acing plates 17 and footer base plate 15. Similarly (though not diagrammed) the l-strut web 22A rabbets into the header facing plates 19 and header base plate 20. Thus the header facing plates 19. the footer facing plates 17, and the intervening l-strut flanges 22B, all Iying in one plane. are induced to function as one structural unit by virtue of their being rabbeted together by the single member l-strut web 22A. Since the connecting base plates 20 and 15 are also rabbeted as just detailed, the integrity of this structural unit is extended to include the entire structural frame 11 indicated on Figure 2.
~t ~ou~ ~ aL~o noted that other joints within this frame are also rabbeted or dovetailed 208~651 and contribute to the strength of the whole: side channel base plates 25 and 21 are dovetailed with their respective side channel facing plates 27 and 23 and also with header and footer facing plates 19 and 17; this is best seen on Figure 2 and exploded detail Figure 3, where such a dovetail joint surface is numbered at 17D. As well. header and footer channel base plates 20 and 15 are rabbeted with their respective facing plates 19 and 17; and finally, channel spacers 30 are dovetailed into side channel facing plates 27 and 23, as best seen on Figure lB. Particularly by this means the structural integrity of the entire panel 10 is maintained even without the addition of the foam 40.
Field installation of multiple panels 10 is perforrned as follows: for this exp!anation, existence of a floor surface, such as floor panel 39 from Figure 5. is assumed; first, standard sill connector plate ~4 on Figures S and 4A, characteristically a wooden 2" by 4" member, is fastened to the upper face of the floor 39 to provide a firm structural locking and sealing connection between the wall panel 10 and the horizontal face. (Note on Figure S how connector plate ~4 fits snugly into the cavity defined by sheathing boards 12 and 1~ and footer base plate 15: the dimensions of panel 10 are designed for this purpose). When panels indicated at IOA and IOB on Figure 4A are erected side by side overtop standard connector plate ~4 and slid together, their extending and inset portions mate, as seen best in Figure ~B. which is a section as indicated on Figure ~A as arrows J. Exterior shenthing board 12 of panel IOA covers side channel facing plate 23 of panel IOB. and side channel base plate 21 of panel IOB is snugged up against side channel base plate 25 of panel IOA. The panels form one integrated system.
All the joints are sealed with silicone or the like at mating. and screwed or nailed. as indicated by fasteners ~6, to assure weather-proof connection. Any number of panels 10 such a~s IOA, IOB. IOC and so on can be mated to form a wall of any length.
The join of extending exterior sheathing board 12 over the outside of the joint of panel lOB with floor panel 39 is detailed in Figure 5. which is a section elevalion 208165~
, .
>f this joint along arrows indicated at "E" on Figure 4A. Note how distance indicated by arrow "F" is the full thickness of the floor panel indicated at 39. and how exterior sheathing 12 extends down exactly to be flush with the lower sh~'athing ~2 of floor panel 39. so that corner ~1 is a perfectly square joint. Note also how standard connector plate 4~. characteristically a field-installed 2" by 4" wooden member, provides a firm locking and sealing connection as described previously. It will be appreciated that the degree of overlap and structural integrity of this wall-floor corner joint makes it highly impervious ~o wind penetration, allowing for the use of this modular system in high-wind storm risk zones Foundation indicated at 90 is shown for interest: many different foundation configurations are possible, and panicularly in high-risk storm zones others will be in use: all known ones are compatible with this system.
A special wall panel, indicated at IOX on Figures 6A, 6B, and 6C, is prefabricated for easy modular mating of corners. As will be most easily seen onhorizontal section Figure 6B through such a panel, exterior sheathing 12 is lel`t the same width as on standard panels 10. a distance indicated by arrow 80 on Figure 6B. but the rest of the panel IOX is reduced in width by an amount equal to the thickness of a standard panel 10. as indicated by arrow 81. so that a panel such as that indicated IOD on Fi~ures 6A and 6C will mate evenly when placed at ri~ht angles to make a corner joint.
Thus the extending ponion of sheathing 12 of special corner panel IOX exactly covers the end of panel IOD. providing exactly the same type of overlap protection against thermal loss and wind and water penetration as previously explained for the floor-to-wall connection. Trim strip 70, seen on Figure 6C. may if desired be field installed to finish the joint. Again a standard connector plate 4~. this time oriented vertically. is used to nail or screw the joined panels. As seen on Figure 6B. narrower panel IOX may if desired have only a single l-strut 22.
Finally. it is within the scope of the invention to provide for such 208~651 .
interlocking and structurally integral panels specially designed for floors and roofs: since characteristically the only differences from thè detailed wall panels 10 described are the thickness, (which is ideally 41/4" or 61/4" for wall panels; 61/2 for floor panels, and 51/2 for roof panels, in order to configure with existing construction practice), these units are not diagrammed. Note that these thicknesses are variable without changing the essential aspects of the invention. As well, it may not be necessary to include electrical wiring in all floor and roof panels; and the join of the top of a wall panel to the bottom of a ceiling or ceiling panel may require a bevelled connector plate (not diagrammed). Otherwise, the mating of the floor and roof panels is essentially the same as described for wall panels.
Note also that window and door openings may be factory cut with rough framing in place, so that the continuity of the electrical grid is maintained. Special sizes of panels may be ordered with such windows and doors pre-cut, to maintain the modularity of the system and its congruence with multiples of common construction dimensions. This grid can even be pre-fabricated to line up vertically in multi-lloor structures, extending through the intervening horizontal floor panels. Or doors and windows can be cut from the panels in the field and framed and reinforced on site. with care being taken not to interrupt the electrical grid. The header channel 18. indicated previously on Figures IA. IC. and 2. forrns the upper (approximately 10%) vertical portion of the panel 10 and is of sufficient strength and depth to accommodate window and door openings of standard dimensions. (Window and door options are not diagrammed).
The standard wall panel 10 is factory formed by placing the components in a jig frarne under compression. the joints being fastened with waterproof adhesives and nailed together. With reference to ~igure 2. the order of assembly is characteristically as follows: header base plate 20 is placed in a jig (jig is not diagrammed), then header facing plates 19, side channels 24 and 26. I-struts 22 and footer channel 16. Electrical 208~51 connection box 36 and electrical conduits 34 are then inserted into the pre-drilled frame, connected and sealed with silicone. The whole frame is then held in the jig until the setting of the adhesives is complete, thus maintaining the dimensional accuracy of the structu}al frame.
Interior sheathing board 14 (not shown on Figure 2, but appearing on Figures IA, B, C, and other later Figures) is then placed in a second jig fixture. fitted with appropriate spacers to assure the proper offsets and positioning of the structural frame which is then placed in the jig, fastened with adhesives and nailed to the inner face of the sheathing board 14.
Exterior sheathing board 12, which may be of plywood, oriented strand board or a pre-finished decorative composition, is then placed in the jig, adjusted to the proper offsets and fastened to the structural frame as previously described.
The completed structure is then held in the jig under compression until the setting of the fastenings is complete. Following the completion of the fabrication process.
the panel elements are sprayed with a liquid borax solution. to provide a flre and termite retardant capacity to the wood-based components. The foam insulation mixture is then injected (characteristically using a low pressure frothing method) into the voids bounded by the structural frame elements and the sheathing boards 1~ and 12, with the panel 10 being held irl a press to contain the pressures exened from within by the expansion of the foam mixture. (Press and borax spraying are not shown diagramatically).
Note that the dovetailing of the rabbetting of the side base plates 25 and 21 into the side facing plates 27 and 23 and header and footer tacing plates 19 and 17. as previously explained and partially diagrammed on Figures I B. 2. and 3, assures that the expansion pressures of the foam will strengthen these rabbet joints as they cure.
The foam insulation is norsnally an expanded two part polyurethane plastic with a calcium based additive component to add a high fire retardant capacity to the 20816~
toam. When t`ully cured the foam has a density of approximately 1.5 Ib. per cubic foot.
and a thermal resistance factor of R-6 per inch of thickness. The finished panels characteristically have a thermal resistance factor of R-30, R-40, or R-45 for wall, ceiling, or floor panels respectively.
After the fabrication process, each panel is tested for dimensional accuracy, and the connecting faces are sanded and cleaned to ensure firm and complete connection and sealing during erection at the construction site. Panels are marked for installation orientation before leaving the factory. and are available in a range of standard widths and heights, to conform with standard construction practice and so ensure simple planning and construction of the buildings formed from the prefabricated panel units.
The foregoing is by example only, and the scope of the invention should be limited only by the appended claims.
Claims (26)
1. An improved prefabricated building panel to be used for walls, floors, and ceilings of housing or other structures, comprising:
(a) a structural frame;
(b) reinforcing I-struts within said frame:
(c) an inner sheathing board, fastened to the structural frame;
and (d) an outer sheathing board, fastened to the opposing side of the structural frame parallel to the inner sheathing board.
(a) a structural frame;
(b) reinforcing I-struts within said frame:
(c) an inner sheathing board, fastened to the structural frame;
and (d) an outer sheathing board, fastened to the opposing side of the structural frame parallel to the inner sheathing board.
2. A panel as in Claim 1, and having (e) electrical wiring conduits through the structural frame.
3. A panel as in Claim 1, and having (f) access to the electrical wiring conduits through an access panel through the inner sheathing board.
4. A panel as in Claim 1, and having (g) insulation for heat or cold or sound or any combination thereof in the voids bounded by the structural frame and the sheathing boards.
5. A panel as in Claim 1. all joints of said frame and of said I-struts being rabbeted.
6. A panel as in Claim 5, in which one or more of the rabbetted joints in the structural frame are dovetailed joints.
7. A panel as in Claim 1 in which the structural frame is generally a rectangular box in shape and is formed from separate pieces which are rabbeted together to improve the strength of the joints; and in which the frame is considerably longer and wider than it is thick; and in which said sheathing boards are generally rectangular and oriented parallel to the long and wide plane of the structural frame; and in which the electrical wiring conduits, when used, give access through the structural frame in said long or wide directions or both.
8. A panel as in Claim 7, in which the sheathing boards are fastened to the structural frame in a manner so that a portion of the structural frame extends beyond the boards in the long or wide direction, and said long or wide direction of the panel is vertical when the panel is a wall panel; and an equivalent amount of the boards extend beyond the structural frame in the opposite direction, whereby an identical second panel can be mated with a first panel; the extending portion of the structural frame of either of said panels being rabbeted between the extending portions of the sheathing boards of the other panel.
9. A panel as in Claim 8, in which said panels are mated with standard fastening devices so that a secure bond is obtained between said first and second panels.
10. A panel as in Claim 7, in which the outer sheathing board extends farther than the inner sheathing board in either the long or wide dimension or both. the function of said extension being to cover the outside of a joining member where it joins the panel, and so substantively minimize wind and thermal penetration.
11. A panel as in Claim 10, in which the panel is a wall panel and said extension occurs at the bottom of the panel so as to cover the thickness of a floor member joining said wall panel; in which the amount of the extension is as much as or more than the thickness of the floor member.
12. A panel as in Claim 11, in which the bottom of the structural frame is higher than the inner and outer sheathing boards by an amount equivalent to the thickness of a standard connector sill plate. so that when installed on top of the connector sill plate the interior sheathing board extends down to the bottom of the sill plate and the exterior sheathing board extends down to below the bottom of the sill plate.
13. A panel as in Claim 10, in which the panel is a corner wall panel and said extension occurs in the horizontal direction, to at least cover the thickness of a wall member joining said wall panel.
14. A panel as in Claim 13, in which the joining wall member is of known thickness and the wall panel is preformed to have its inner sheathing board and structural frame reduced in horizontal extent by an amount equal to said thickness, so that (a) the extending exterior sheathing board will exactly cover the external vertical surface of the joining wall member: and (b) where the joining wall member will join said corner wall panel in the midst of an internal surface of a building, such surface may be composed of a series of approximately identical preformed panels of equal horizontal width, even where one of the panels is joined by a wall member.
15. A panel as in Claim 4, in which the insulation is an injected foam which expands and becomes rigid.
16. A panel as in Claim 15, in which the insulation has a high fire-retardant capacity; and in which further the structural frame has been sprayed with a fire-retardant solution, so that the finished insulated panel has a high fire-retardant capacity.
17. A panel as in Claim 15. in which The insulation is heat or cold insulation of polyurethane foam or the like which is injected and becomes rigid when it expands and hardens.
18. A panel as in Claim 1, in which the panel is a floor panel constructed of materials and in such a manner as to allow it to carry normal loads found in housing situations over a 16-foot clear span, and to carry such loads on a 4-foot cantilever without additional support; such method of construction to include that said 1-struts have a central "I" or web that runs between opposing parallel members of the structural frame. with parallel flanges of the I-struts running parallel to the sheathing boards; and with all of the joints between the I-strut web and I-strut flanges and between said flanges and said structural frame being rabbeted.
19. A panel as in Claim 17, in which the rigidity of the injected insulation is a substantial contributing factor to the weight-bearing characteristics of the panel.
20. A method of constructing an integrated modular system of prefabricated building panels to be used for walls, floors, and ceilings of housing or other structures, comprising:
(a) designing a series of different sizes and thicknesses of panels to provide floors, ceilings. and walls and to provide for joins between floors.
ceilings and walls; said panels being modular. meaning regular multiple sizes of standard construction dimensions, and being interlocking, so that they can easily be joined in the field; each panel being comprised of a structural frame, an interior and an exterior sheathing board, optional electrical wiring conduits, optional electrical wiring access through the sheathing boards. and optional insulation inside the structural frame;
(b) forming a structural frame in a jig for each type of panel required; optionally including electrical wiring conduits and access:
(c) fastening each structural frame onto the appropriate interior sheathing board in a second jig:
;
(d) fastening the appropriate exterior sheathing board onto each type of structural frame while it is in the second jig;
(e) spraying each completed panel with a fire and insect retardant solution:
(f) optionally, injecting insulation into the voids bounded by the structural frame and sheathing boards for each panel while said panel is held in a press;
(g) testing each panel for dimensional accuracy.
(a) designing a series of different sizes and thicknesses of panels to provide floors, ceilings. and walls and to provide for joins between floors.
ceilings and walls; said panels being modular. meaning regular multiple sizes of standard construction dimensions, and being interlocking, so that they can easily be joined in the field; each panel being comprised of a structural frame, an interior and an exterior sheathing board, optional electrical wiring conduits, optional electrical wiring access through the sheathing boards. and optional insulation inside the structural frame;
(b) forming a structural frame in a jig for each type of panel required; optionally including electrical wiring conduits and access:
(c) fastening each structural frame onto the appropriate interior sheathing board in a second jig:
;
(d) fastening the appropriate exterior sheathing board onto each type of structural frame while it is in the second jig;
(e) spraying each completed panel with a fire and insect retardant solution:
(f) optionally, injecting insulation into the voids bounded by the structural frame and sheathing boards for each panel while said panel is held in a press;
(g) testing each panel for dimensional accuracy.
21. A method as in Claim 20, in which the insulation injected as described in section (f) has an additive giving it a high fire retardant capacity, so that together with the spraying specified in part (e) the finished panel has a high fire retardant capacity.
22. A method as in Claim 20, in which the structural frame is generally a rectangular box in shape and is formed from separate pieces which are rabbetedtogether to improve the strength of the joints; and in which the frame is considerably longer and wider than it is thick; and in which said sheathing boards are generally rectangular and oriented parallel to the long and wide plane; and in which the electrical wiring conduits, when used, give access through the structural frame in the long or wide directions or both; and in which the structural frame is formed in part (b) by placing the following components, generally all of oriented strand board or plywood or the like. in the jig frame under compression, the joints being fastened with waterproof adhesives and nailed together; characteristically in the following order:
(i) a header channel, being a header base plate and then two parallel header facing plates; the facing plates defining the long and wide dimension of the frame and the header base plate running at right angles between them, so as to form the header as a an inverted U-channel; the open face of the U-channel opening towards the inside of the structural frame;
(ii) two side channels, being U-channels constructed similar to the header channel and facing inwards like the header channel, at right angles to and joining the ends of the header channel;
(iii) side channel spacers, being members running at intervals between the facing plates of the side channels:
(iii) I-struts, whose central "I" or web runs from the header base plate to a footer base plate, and whose parallel flanges are parallel to the header facing plates and run from them to a facing plates; and (iv) a footer channel. being a U-channel constructed similar to the header channel running parallel to the header channel; the open face of the U likewise opening inwards.
(i) a header channel, being a header base plate and then two parallel header facing plates; the facing plates defining the long and wide dimension of the frame and the header base plate running at right angles between them, so as to form the header as a an inverted U-channel; the open face of the U-channel opening towards the inside of the structural frame;
(ii) two side channels, being U-channels constructed similar to the header channel and facing inwards like the header channel, at right angles to and joining the ends of the header channel;
(iii) side channel spacers, being members running at intervals between the facing plates of the side channels:
(iii) I-struts, whose central "I" or web runs from the header base plate to a footer base plate, and whose parallel flanges are parallel to the header facing plates and run from them to a facing plates; and (iv) a footer channel. being a U-channel constructed similar to the header channel running parallel to the header channel; the open face of the U likewise opening inwards.
23. A method as in Claim 22. in which the rabbet joints within the side U-channels specified in part (ii), and between base plates of said channels and the header and footer facing plates, are dovetail joints; and in which similarly the rabbet joints between the side channel spacers and side channel facing plates are dovetail joints:
the purpose of the dovetailing of said dovetail joints being to assure strong bonding of said joints during the compression and fastening in the jig.
the purpose of the dovetailing of said dovetail joints being to assure strong bonding of said joints during the compression and fastening in the jig.
24. A method as in Claim 22, in which a first standard wall panel is formed as follows: the interior and exterior sheathing boards are formed so that the exterior sheathing board is formed to extend downwards farther than the internalsheathing board by the amount of the thickness of a floor member where said standard wall panel will be installed, so as to substantively minimize wind and thermal penetration at the joint between said wall panel and the floor member: and in which said structural frame is offset within said sheathing boards horizontally. so that one side channel extends beyond the edge of said sheathing boards. and the opposing side channel is inset within said sheathing boards by an equal amount; so that an identical second standard wall panel can be mated by rabbeting along a vertical edge and finally fastening by known means so that a secure bond is obtained between said first and second panels.
25. A method as in Claim 24, in which a standard corner wall panel is formed with the horizontal dimension of the interior sheathing board being reduced. as measured from the edge adjoining and parallel to the extending side channel, by an amount equivalent to the thickness of a standard wall panel, and the side channel along this edge is inset by an amount equivalent to the thickness of a standard connector plate such as a wood two-by-four; so that a joining standard wall panel can be joined to a standard corner wall panel within the same horizontal distance as the width of a standard wall panel; and also so that if this joint occurs as an exterior edge of a building, wind and thermal penetration are substantively minimized at said joint.
26. A method as in Claim 22, in which a first standard floor panel is formed as follows: said structural frame is offset within said sheathing boards horizontally, so that one side channel extends beyond the edge of said sheathing boards. and the opposing side channel is inset within said sheathing boards by an equal amount so that an identical second standard floor panel can be rabbeted along one edge; and expanding foam insulation is injected into the voids defined by the structural frame and the sheathing boards: and the said standard floor panel is constructed of materials and in such a manner as to allow it to carry normal loads found in housing situations over a 16-foot clear span, and to carry such loads on a 4-foot cantilever without additional support.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2081651 CA2081651A1 (en) | 1992-10-28 | 1992-10-28 | Modular prefabricated building panels |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2081651 CA2081651A1 (en) | 1992-10-28 | 1992-10-28 | Modular prefabricated building panels |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2081651A1 true CA2081651A1 (en) | 1994-04-29 |
Family
ID=4150609
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2081651 Abandoned CA2081651A1 (en) | 1992-10-28 | 1992-10-28 | Modular prefabricated building panels |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2081651A1 (en) |
Cited By (14)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2003027413A1 (en) * | 2001-09-26 | 2003-04-03 | Dow Global Technologies Inc. | Method and system for providing conduit and boxes in a closed wall system |
| GB2391027A (en) * | 2002-07-18 | 2004-01-28 | Wynn Peter Holloway | Modular building panels with composite I beams |
| GB2441603A (en) * | 2006-04-21 | 2008-03-12 | Kingspan Holdings | Structural insulated panel |
| WO2010040921A1 (en) * | 2008-10-10 | 2010-04-15 | Arcelormittal Construction France | Composite panel for a wall and method for making same |
| WO2011033289A1 (en) * | 2009-09-17 | 2011-03-24 | William Ronald Arrowsmith | A building panel assembly |
| WO2015042665A1 (en) * | 2013-09-26 | 2015-04-02 | Aussib Groups Pty Ltd | Building panels – systems components & methods |
| GB2542199A (en) * | 2015-09-14 | 2017-03-15 | Fabulo Ltd | Multifunctional panel system |
| US9702152B2 (en) | 2011-06-17 | 2017-07-11 | Basf Se | Prefabricated wall assembly having an outer foam layer |
| US10801197B2 (en) | 2015-01-19 | 2020-10-13 | Basf Se | Wall assembly having a spacer |
| GB202110374D0 (en) | 2021-07-19 | 2021-09-01 | Cds Group Services Ltd | Decorative panel |
| US11118347B2 (en) | 2011-06-17 | 2021-09-14 | Basf Se | High performance wall assembly |
| AU2019206115B2 (en) * | 2011-09-01 | 2021-09-30 | Ninderry Developments Pty Ltd | An insulated wall panel system with cable support |
| WO2022169471A1 (en) * | 2020-02-07 | 2022-08-11 | Mw Enterprises Llc | Machine walls |
| US11541625B2 (en) | 2015-01-19 | 2023-01-03 | Basf Se | Wall assembly |
-
1992
- 1992-10-28 CA CA 2081651 patent/CA2081651A1/en not_active Abandoned
Cited By (23)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2003027413A1 (en) * | 2001-09-26 | 2003-04-03 | Dow Global Technologies Inc. | Method and system for providing conduit and boxes in a closed wall system |
| GB2391027A (en) * | 2002-07-18 | 2004-01-28 | Wynn Peter Holloway | Modular building panels with composite I beams |
| GB2391027B (en) * | 2002-07-18 | 2006-07-19 | Wynn Peter Holloway | A building panel |
| GB2441603B (en) * | 2006-04-21 | 2011-03-02 | Kingspan Holdings | A structural insulated panel |
| GB2441603A (en) * | 2006-04-21 | 2008-03-12 | Kingspan Holdings | Structural insulated panel |
| US8833023B2 (en) | 2008-10-10 | 2014-09-16 | Arcelormittal Construction France | Composite panel for a wall and method for making same |
| FR2937064A1 (en) * | 2008-10-10 | 2010-04-16 | Arcelormittal France | COMPOSITE PANEL FOR WALL AND METHOD OF MANUFACTURE. |
| CN102209820A (en) * | 2008-10-10 | 2011-10-05 | 法国阿塞洛米塔尔建筑公司 | Composite panel for a wall and method for making same |
| RU2485259C2 (en) * | 2008-10-10 | 2013-06-20 | Арселормитталь Констрюксьон Франс | Laminated panel for wall and method of its manufacturing |
| WO2010040921A1 (en) * | 2008-10-10 | 2010-04-15 | Arcelormittal Construction France | Composite panel for a wall and method for making same |
| WO2011033289A1 (en) * | 2009-09-17 | 2011-03-24 | William Ronald Arrowsmith | A building panel assembly |
| US9702152B2 (en) | 2011-06-17 | 2017-07-11 | Basf Se | Prefabricated wall assembly having an outer foam layer |
| US11118347B2 (en) | 2011-06-17 | 2021-09-14 | Basf Se | High performance wall assembly |
| US11131089B2 (en) | 2011-06-17 | 2021-09-28 | Basf Se | High performace wall assembly |
| AU2019206115B2 (en) * | 2011-09-01 | 2021-09-30 | Ninderry Developments Pty Ltd | An insulated wall panel system with cable support |
| US20160237683A1 (en) * | 2013-09-26 | 2016-08-18 | Aussib Groups Pty Ltd | Building Panels - Systems Components & Methods |
| WO2015042665A1 (en) * | 2013-09-26 | 2015-04-02 | Aussib Groups Pty Ltd | Building panels – systems components & methods |
| US10801197B2 (en) | 2015-01-19 | 2020-10-13 | Basf Se | Wall assembly having a spacer |
| US11541625B2 (en) | 2015-01-19 | 2023-01-03 | Basf Se | Wall assembly |
| GB2542199A (en) * | 2015-09-14 | 2017-03-15 | Fabulo Ltd | Multifunctional panel system |
| WO2022169471A1 (en) * | 2020-02-07 | 2022-08-11 | Mw Enterprises Llc | Machine walls |
| GB202110374D0 (en) | 2021-07-19 | 2021-09-01 | Cds Group Services Ltd | Decorative panel |
| GB2609031A (en) | 2021-07-19 | 2023-01-25 | Cds Group Services Ltd | Decorative panel |
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