US20170037621A1

US20170037621A1 - Composite building panels

Info

Publication number: US20170037621A1
Application number: US15/199,859
Authority: US
Inventors: Kevin E. Grenier; John E. Grenier
Original assignee: Individual
Current assignee: Individual
Priority date: 2015-06-30
Filing date: 2016-06-30
Publication date: 2017-02-09
Also published as: WO2017004465A1

Abstract

A composite, insulated, structural panel, that includes an exterior face comprising a length and a width, an opposing interior face comprising the length and the width, a foam core disposed between the exterior face and the interior face, and a first plurality of reinforcement ribs attached to the interior face and extending laterally along the width, and extending outwardly into the foam core.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 62/187,057 filed on Jun. 30, 2015, the entire contents of which are hereby incorporated by reference herein, for all purposes.

FIELD OF THE INVENTION

This invention relates to a composite building panel.

BACKGROUND OF THE INVENTION

Composite building materials have been used in construction industries for more than 50 years. The composite materials can be used to construct floors, walls, and ceilings in buildings. To have a composite building panel that can meet versatile needs, such as durability, low weight, impact resistance, design flexibility, high strength to weight ratio, heat resistance and insulation, sound damping and other insulation properties, weight bearing, etc, is desirable.
Prior art composite, insulated, structural panels typically utilize metal parts, such as wall fasteners, structural ribs, stand-offs, and the like, that extend through the thickness of the panel. Those metal parts effectively comprise thermal conduction pathways from the outer surface of the panel to the inner surface of the panel. Such thermal conduction pathways render those prior art panels very inefficient with respect to maintaining an interior building temperature.

SUMMARY OF THE INVENTION

A composite, insulated, structural panel, is disclosed. The composite, insulated, structural panel includes an exterior face comprising a length and a width, an opposing interior face comprising the length and the width, a foam core disposed between the exterior face and the interior face, and a first plurality of reinforcement ribs attached to the interior face and extending laterally along the width, and extending outwardly into the foam core, wherein in certain embodiments the first plurality of reinforcement ribs are formed from one or more metals. In these embodiments, however, none of the first plurality of reinforcement ribs extends from the interior face to the exterior face, thereby eliminating the metal thermal conduction pathways found in prior art composite panels.
A composite structural beam is disclosed. The composite structural beam includes a pair of interleaved brackets, and a foam core disposed between the pair of interleaved brackets.
A composite jamb stud is disclosed. The composite jamb stud includes a pair of interleaved brackets, in combination with a foam core disposed between the pair of interleaved brackets.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood from a reading of the following detailed description taken in conjunction with the drawings in which like reference designators are used to designate like elements, and in which:

FIG. 1 illustrates an isometric view of one embodiment of Applicants' composite panels 100;

FIG. 2 is a sectional view of the embodiment of Applicants' composite panels 100 illustrated in FIG. 1;

FIG. 3 illustrates a sectional view of one embodiment of a first composite panel 100A attaching to a second composite panel 100B;

FIG. 4 illustrates a sectional view of another embodiment of a first composite panel 100A attaching to a second composite panel 100B;

FIG. 5 illustrates an isometric view of another embodiment of Applicants' composite panels 500;

FIG. 6 is a sectional view of the embodiment of Applicants' composite panels 500 illustrated in FIG. 5;

FIG. 7 is a sectional view of one embodiment of a first composite panel 500A attaching to a second composite panel 500B;

FIG. 8 shows an isometric view of another embodiment of Applicants' composite panels 800;

FIG. 9A is a sectional view of the embodiment of Applicants' composite panels 800 illustrated in FIG. 8;

FIG. 9B is a sectional view of the embodiment of Applicants' composite panels 800 illustrated in FIG. 8 with a different embodiment of a reinforcement rib;

FIG. 9C is a sectional view of the embodiment of Applicants' composite panels 800 illustrated in FIG. 8 with another embodiment of a reinforcement rib;

FIG. 10A is a sectional view of one embodiment of a first composite panel 800A attaching to a second composite panel 800B;

FIG. 10B is a sectional view of another embodiment of a first composite panel 800A attaching to a second composite panel 800B;

FIG. 11 shows an isometric view of another embodiment of Applicants' composite panels 1100;

FIG. 12 is a sectional view of the embodiment of Applicants' composite panels 1100 illustrated in FIG. 11;

FIG. 13 is a sectional view of one embodiment of a first composite panel 1100A attaching to a second composite panel 1100B;

FIG. 14 shows an isometric view of another embodiment of Applicants' composite panels 1400;

FIG. 15 is a sectional view of the embodiment of Applicants' composite panels 1400 illustrated in FIG. 14;

FIG. 16 is a sectional view of one embodiment of a first composite panel 1400A attaching to a second composite panel 1400B;

FIGS. 17A and 17B show an isometric view of one embodiment of a jamb stud and a section view of the jamb stud;

FIGS. 18A and 18B illustrate an isometric view of another embodiment of a jamb stud and a sectional view of the jamb stud illustrated;

FIG. 19 shows an isometric view of an embodiment of a header beam;

FIG. 20 illustrates an isometric view of an assembly of the jamb stud illustrated in FIG. 17A and the header beam illustrated in FIG. 19; and

FIG. 21 is an isometric view of one embodiment of Applicants' composite beam.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This invention is described in preferred embodiments in the following description with reference to the Figures, in which like numbers represent the same or similar elements. Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
The described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are recited to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
In certain embodiments, Applicant's composite insulated structural panel comprises one or more materials on an exterior face, an integrated foam core and one or more structural ribs on an interior face, with some embodiments having structural ribs on an exterior face also.
In certain embodiments, both the interior ribs and the exterior face ribs (when used), can be made from a variety of materials, including but not limited to light gage steel or a fiber reinforced polymer material (fiberglass, carbon fiber, plastic). The ribs can be formed to various profiles, and are integrally bonded to the foam core. In certain embodiments, the ribs provide structural strength and stiffness for Applicant's composite panel, and the size, thickness, material and spacing of these ribs would vary depending on the span and loading requirements for a specific application.
The interior ribs are positioned to extend outwardly from an unclad/unsheathed foam surface of the panel, providing a stand-off space. This stand-off space accommodates the installation of utilities (electrical wiring and small water lines) to be installed after the panels have been erected when used in a building application. Holes through the ribs can be pre-drilled prior to panel manufacturing, or field drilled to allow the utilities to continue perpendicular to the ribs. An interior finish such as gypsum board (drywall), wood paneling, etc. can be installed by attaching directly to the interior ribs, if a finished surface is desired.
Applicant's composite panels are formed such that interior ribs are not in direct contact with the exterior surface of the panel, thereby eliminating a thermal link between the exterior face and the interior face of the panel. This provides an advantage for energy efficient building design.
In certain embodiments, the foam core can be manufactured from various materials, and with different thicknesses, depending on project needs and the amount of insulation value desired.
Thermal insulation is the reduction of heat transfer (the transfer of thermal energy between objects of differing temperature) between objects in thermal contact or in range of radiative influence. Thermal insulation can be achieved with specially engineered methods or processes, as well as with suitable object shapes and materials.
Heat flow is an inevitable consequence of contact between objects of differing temperature. Thermal insulation provides a region of insulation in which thermal conduction is reduced or thermal radiation is reflected rather than absorbed by the lower-temperature body.
The insulating capability of a material is measured with thermal conductivity (k). Low thermal conductivity is equivalent to high insulating capability (R-value). In thermal engineering, other important properties of insulating materials are product density (ρ) and specific heat capacity (c).
In certain embodiments, Applicant's foam core used in composite panels 100, 500, 800, and 1100, comprises a polyurethane foam formed in situ using a spray foam technique. Polyurethane was developed and used by the military in the 1940s and applied to airplanes. It wasn't until the 1970s that it started to be used as foam insulation.
In certain embodiments, Applicant's foam core comprises a closed cell foam. In certain embodiments, Applicant's spray foam system utilizes a chlorofluorocarbon blowing agent in a closed cell system.
Applicant utilizes various systems to apply the spray foam. In certain embodiments, Applicant utilizes a two component low pressure spray foam system. This is also known as a slow rise formula and often referred to as injection foam.
In certain embodiments, Applicant's foam core used in composite panels 100, 500, 800, and 1100, comprises a closed cell, polyisocyanurate foam formed in situ using a spray foam technique. The reaction of MDI and polyol takes place at higher temperatures compared with the reaction temperature for the manufacture of polyurethane foam.
At these elevated temperatures and in the presence of specific catalysts, a diisocyanate methylene diisocyanate (“MDI”) will first react with itself, producing a stiff, ring molecule, which is a reactive intermediate (a tri-isocyanate isocyanurate compound). Remaining MDI and the tri-isocyanate react with polyol to form a complex poly(urethane-isocyanurate) polymer, which is foamed in the presence of a suitable blowing agent.
This isocyanurate polymer has a relatively strong molecular structure, because of the combination of strong chemical bonds, the ring structure of isocyanurate and high cross link density, each contributing to the greater stiffness than found in comparable polyurethanes. The greater bond strength also means these are more difficult to break, and as a result a PIR foam is chemically and thermally more stable: breakdown of isocyanurate bonds is reported to start above 200° C., compared with urethane at 100 to 110° C.
Applicant's polyisocyanurate foam systems typically comprises an MDI/polyol ratio, also called its index (based on isocyanate/polyol stoichiometry to produce urethane alone), higher than 180. By comparison polyurethane indices are normally around 100. As the index increases material stiffness also increases.
In certain embodiments, greater stiffness, chemical and/or thermal stability are desirable in Applicant's composite panels 100 (FIG. 1), 500 (FIG. 5), 800 (FIG. 8), 1100 (FIG. 11), and 1400 (FIG. 14). In certain embodiments, the foam core 120 portion in Applicant's composite panels 100 (FIG. 1), 500 (FIG. 5), 800 (FIG. 8), 1100 (FIG. 11), and 1400 (FIG. 14) comprises a closed cell, polyisocyanurate foam.
The panels, when used in a building application, can be used for roofs, floors and walls. The wall panels can be designed as load-bearing, or non-load bearing.
Applicant's composite panels are formed such that interior ribs are not in direct contact with the exterior surface of the panel, thereby eliminating a thermal link between the exterior face and the interior face of the panel. This provides an advantage for energy efficient building design.
Applicant's composite panel design is efficient, taking advantage of a foam core as both insulation and a structural core material. Typical fiberglass batt insulation currently used in most buildings provides no structural value.
In a building application, the panels eliminate sub-framing (trusses, joists, purlins, girts, etc.) currently used with traditional construction. This will reduce construction material costs and labor costs by eliminating numerous pieces and speed up the construction process.
The typical connections of the panels to the supporting structure (or panel to panel connections) could be made on the interior of the structure, thus eliminating any possible water intrusion from screw holes on the exterior that extend through the panel, like that currently used for sandwich panels and SIPS panels. Moreover, the foam core provides better acoustics/sound control over typical construction using fiberglass batt insulation.
A first embodiment of Applicant's composite panel can be utilized as both a roof and wall panel. In certain embodiments, this first embodiment of Applicant's composite panel comprises an outer facing, but no inner facing. Referring now to FIG. 1, Applicant's composite panel 100 comprises an outerfacing 110 disposed over a foam core 120 with integral interior ribs creating a composite structural panel. Composite panel 100 comprises no inner facing. As those skilled in the art will appreciate, by “outer facing” Applicant means a surface of the composite panel intended for exterior use. By “inner facing,” Applicant means a surface of the composite panel not intended for exterior use.
Referring now to FIGS. 1, 2, 3, and 4, an exterior facing 110 comprises a metal deck profile or gage, including a standing seam deck common in the metal building industry. The target market and advantages would be: a) pre-engineered metal buildings; eliminating the roof purlins and wall girts, along with batt insulation currently used, and Type A panels would span directly to the buildings main frames; or b) any building where a metal panel exterior finish is desired.
In the illustrated embodiment of FIGS. 1 and 2, Applicant's composite panel 100 comprises a reinforcing rib in the form of channel 140 extending the entire length 102 of panel 100. Channel 140 comprises a pair of sides 141 and 144, wherein proximal portions 142 and 145 of sides 141 and 144, respectively, are disposed/molded within foam core 120. In certain embodiments, wherein those proximal portions 142 and 145 are formed to include textured surfaces for enhanced mechanical adhesion to form core 120. Distal portions 143 and 146 of sides 141 and 144, respectively, extend outwardly from surface 104 of foam core 120.
Referring again to FIG. 1, element 140 comprises a “U-shaped” channel that extends the entire length 102 of panel 100, and functions as a reinforcing rib for composite panel 100. Referring again to FIG. 2, floor 149 of the “U-shaped” channel 140 can be used as a stand-off rib. Stand-off ribs 130, 148, 158, 160, can be used to receive gypsum board, wood paneling, stucco, siding, veneer, and the like 149, by screws, nails or adhesive to the bottom surface of the ribs.
FIG. 1 illustrates reinforcing rib 140 as a “U-shaped” channel. This depiction should not be taken as limiting. In other embodiments, Applicant's reinforcing ribs can be formed from wood, metal, ceramic materials, and combinations thereof.
None of the reinforcing ribs 140 extend to, or outwardly from, metal/plastic surface 110. This being the case, none of the reinforcing ribs 140 can function as a thermal conduit transferring heat, in either direction, from surface 110 (FIGS. 1, 2) to surface 104 (FIG. 2), or vice versa.
Further illustrated embodiment of FIGS. 1 and 2, Applicant's composite panel 100 comprises a “U-shaped” channel 150 extending the entire length 102 of panel 100. Reinforcing rib 150 comprises a pair of sides 151 and 154, wherein proximal portions 152 and 155 of sides 151 and 154, respectively, are disposed/molded within foam core 120. Distal portions 153 and 156 of sides 151 and 154, respectively, extend outwardly from surface 104 of foam core 120.
As shown in FIG. 1, distal portions 153 and 156 of legs 151 and 154, respectively, are formed to include an aperture extending therethrough. As further shown in FIGS. 1 and 2, electrical cabling and/or piping 159 can be routed through the apertures formed in legs 151 and 154.
FIGS. 1 and 2 show a single cable/pipe 159 extending through channel 150. FIGS. 1 and 2 should not be taken as limiting. In certain embodiments, reinforcing rib 150 is formed to include a plurality of aperture pairs formed therein along the length 102 of Applicant's composite panel 100.
Reinforcing rib 150 functions as a reinforcing rib for composite panel 100. In addition, as described herein above reinforcing rib 150 can also be used to fixture electrical cables, piping, and the like, to surface 104 of composite panel 100.
None of the reinforcing ribs 150 extend to, or outwardly from, metal/plastic surface 110. This being the case, none of the reinforcing ribs 150 can function as a thermal conduit transferring heat, in either direction, from surface 110 to surface 104, or vice versa.
As shown in FIG. 1, Applicant's composite panel 100 comprises a first panel connecting channel 130 disposed on a first side of composite panel 100 and extending throughout length 102 of panel 100. Applicant's composite panel 100 further comprises a second panel connecting channel 160 disposed on a second and opposing side of composite panel 100 and extending throughout width 102 of panel 100.
In the illustrated embodiment of FIG. 3, a first composite panel 100A is shown attached to a second composite panel 100B. A second attachment channel 160 of composite panel 100A is disposed against a first attachment channel 130 of composite panel 100B.
An attachment means 310 is shown interconnecting attachment channel 160 to attachment channel 130. The illustrated embodiment of FIG. 3 shows a single attachment means 310. FIG. 3 should not be taken as limiting. In certain embodiments, a plurality of attachment means 310 interconnect attachment channel 160 of composite panel 100A to attachment channel 130 of composite panel 100B.
FIG. 4 shows a first panel 100A attached to a second panel 100B as shown in FIG. 3. In addition, metal surface 110A and metal surface 110B are fastened together using a rolled seam 410.
Referring now to FIGS. 5, 6, and 7, Applicant's composite panel 500 comprises a foam core 120 in combination with a top sheathing layer 510. In certain embodiments, the foam core 120 is formed as an integral assembly with top sheathing layer 510 using a spray foam system. In other embodiments, foam core 120 is mechanically attached to top sheathing layer 510 using various attachment means including roofing nails, screws, and the like. In still other embodiments, foam core 120 is attached to top sheathing layer 510 using one or more adhesives.
Composite panel 500 further comprises one or more “U-shaped” channels 140 integrally molded into the foam core 120, and extending the entire length 502 of composite panel 500. Reinforcing rib 140 functions as a reinforcing rib for composite panel 500. In addition, as described herein above reinforcing rib 140 can also be used as a stand-off rib for attachment of various traditional surface materials, including without limitation gypsum board, stucco, siding, veneer, and the like.
As described hereinabove, reinforcing ribs 140 extend outwardly from surface 504. None of the reinforcing ribs 140 extend to, or outwardly from, sheathing 510. This being the case, none of the reinforcing ribs 140 can function as a thermal conduit transferring heat, in either direction, from surface 502 to surface 504, or vice versa.
Composite panel 500 further comprises one or more “U-shaped” channels 150 integrally molded into the foam core 120, and extending the entire length 502 of composite panel 500. Reinforcing rib 150 functions as a reinforcing rib for composite panel 500. In addition, as described herein above reinforcing rib 150 can also be used to fixture electrical cables, piping, and the like, to the “interior surface,” i.e. the non-sheathing side, of composite panel 500.
As described hereinabove, reinforcing ribs 150 extend outwardly from surface 504. None of the reinforcing ribs 150 extend to, or outwardly from, sheathing 510. This being the case, none of the reinforcing ribs 150 can function as a thermal conduit transferring heat, in either direction, from surface 502 to surface 504, or vice versa.
In the illustrated embodiment of FIG. 6, Applicant's composite panel 500 comprises reinforcing ribs 520A, 520B, and 520C, integrally molded into foam core 120, and extending the entire length 502 of composite panel 500. None of the reinforcing ribs 520A, 520B, and 520C, extend to, or outwardly from, surface 504 (FIG. 6). This being the case, none of the reinforcing ribs 520A, 520B, and 520C, can function as a thermal conduit transferring heat, in either direction, from surface 502 (FIG. 6) to surface 504 (FIG. 6), or vice versa.
In the illustrated embodiment of FIG. 7, a first composite panel 500A is shown attached to a second composite panel 500B. A second attachment channel 160 of composite panel 500A is disposed adjacent a first attachment channel 130 of composite panel 500B.
An attachment means 310 is shown interconnecting attachment channel 160 to attachment channel 130. The illustrated embodiment of FIG. 7 shows a single attachment means 310. FIG. 7 should not be taken as limiting. In certain embodiments, a plurality of attachment means 310 interconnect attachment channel 160 of composite panel 500A to attachment channel 130 of composite panel 500B.
Referring now to FIG. 8, Applicant's composite panel 800 comprises a foam core 120 in combination with one or more “U-shaped” channels 140A (FIG. 9A), “C-shaped” channels 140B (FIG. 9B), or “Z-shaped” channels 140C (FIG. 9C), integrally molded into the foam core 120, and extending the entire length 802 of composite panel 800. Applicant's composite foam panel 800 further comprises one or more “U-shaped” channels 150 integrally molded into the foam core 120, and extending the entire length 802 of composite panel 800. Applicant's composite panel 800 comprises no metal/plastic surface 110, and no sheathing layer 510. Rather, material covering surface 902 (FIG. 9A) of Applicant's composite panel 800 is “field installed.”
Reinforcing rib 140 functions as a reinforcing rib for composite panel 800. In addition, as described herein above reinforcing rib 140 can also be used as a stand-off rib for attachment of various traditional surface materials, including without limitation, stucco, siding, veneer, and the like.
As described hereinabove, reinforcing ribs 140A (FIG. 9A), 140B (FIG. 9B), and 140C (FIG. 9C) extend outwardly from surface 904. None of the reinforcing ribs 140A-140C extend to, or outwardly from, top foam surface 902 (FIGS. 9A-9C). This being the case, none of the reinforcing ribs 140A-140C can function as a thermal conduit transferring heat, in either direction, from surface 902 to surface 904, or vice versa.
Composite panel 800 further comprises one or more “U-shaped” channels 150 integrally molded into the foam core 120. Reinforcing rib 150 functions as a reinforcing rib for composite panel 800. In addition, as described herein above reinforcing rib 150 can also be used to fixture electrical cables, piping, and the like, to the “interior surface,” i.e. the non-sheathing side, of composite panel 500.
As described hereinabove, reinforcing ribs 150 extend outwardly from surface 904. None of the reinforcing ribs 150 extend to, or outwardly from, surface 902. This being the case, none of the reinforcing ribs 150 can function as a thermal conduit transferring heat, in either direction, from surface 902 to surface 904, or vice versa.
In the illustrated embodiment of FIGS. 8 and 9A-9C, Applicant's composite panel 800 comprises reinforcing ribs 520A, 520B, and 520C, integrally molded into foam core 120 (FIGS. 9A and 9B). In some embodiments, Applicant's composite panel 800 comprises “Z-shaped” reinforcing ribs 522A, 522B, and 522C (FIG. 9C). None of the reinforcing ribs 520A, 520B, and 520C, extend to, or outwardly from, surface 902 (FIGS. 9A and 9B). None of the reinforcing ribs 522A, 522B, and 522C, extend to, or outwardly from, surface 902 (FIG. 9C). This being the case, none of the reinforcing ribs 520A, 520B, 520C, 522A, 522B, and 522C can function as a thermal conduit transferring heat, in either direction, from surface 902 to surface 904, or vice versa.
In the illustrated embodiment of FIG. 10A, a first composite panel 800A is shown attached to a second composite panel 800B. A second attachment channel 160 of composite panel 800A is disposed adjacent a first attachment channel 130 of composite panel 800B.
In the illustrated embodiment of FIG. 10B, a first composite panel 800A is shown attached to a second composite panel 800B. A “C-shaped” second attachment channel 160B of composite panel 800A is disposed adjacent a “C-shaped” first attachment channel 130B of composite panel 800B.
An attachment means 310 is shown interconnecting attachment channel 160 to attachment channel 130. The illustrated embodiment of FIG. 3 shows a single attachment means 310. FIG. 3 should not be taken as limiting. In certain embodiments, a plurality of attachment means 310 interconnect attachment channel 160 of composite panel 800A to attachment channel 130 of composite panel 800B.
In certain embodiments, Applicant's composite panel 100 (FIGS. 1, 2, 3, 4) can be used as a roof panel. In certain embodiments, composite panel 100 can be designed and manufactured with a radius/curved roof if that profile is desired.
Applicant's composite panel 500 (FIGS. 5, 6, 7) can be used in virtually any building type. Composite panel 500 is a variation of the current industry SIPS panels, with the exception that composite panel 500 panel comprises sheathing on the exterior face only, and comprises the stand-off ribs on the interior surface only.
For both Applicant's composite panel 100 and composite panel 500, various roofing materials (asphalt shingles, built-up roofing, tiles, etc.) can be installed. When used for walls, various traditional surface materials (stucco, siding, veneer, etc.) can be used.
Applicant's composite panel 800 is similar to the composite panel 500, except the exterior face sheathing is field installed after the panels are erected. This provides flexibility in design and construction, and a reduced shipping cost over the composite panel 500. In certain embodiments, Applicant's composite panel 800 can also be used for interior wall or partitions, providing an increased acoustic value and potential savings in construction time over conventional construction of these types of walls.
Applicant's composite panels 1100 (FIGS. 11, 12, 13) and 1400 (FIGS. 14, 15, 16) are designed for roof applications where a traditional tile roof appearance is desired. These panels provide the advantage of light weight, and will speed up construction by eliminating most if not all of the wood framing (trusses, etc.) used in current traditional construction. Use of composite panels 1100 and 1400 also reduces the labor of installing the roof tiles, and could virtually eliminate the roof leak potential that current installation procedures create (nailing through the roofing paper).
Referring now to FIGS. 11, 12, and 13, Applicant's composite panel 1100 comprises a foam core 120 in combination with a top concrete layer 1110. In certain embodiments, the foam core 120 is formed as an integral assembly with top concrete layer 1110, using Applicant's spray foam system. In other embodiments, foam core 120 is mechanically attached to concrete layer 1110 using various attachment means including nails, screws, and the like. In still other embodiments, foam core 120 is attached to concrete layer 1110 using one or more adhesives.
In the illustrated embodiments of FIGS. 11, 12, and 13, Applicant's composite panel 1100 further comprises a plurality of roof tiles 1120 attached to the concrete layer 1110. In certain embodiments, the plurality of roof tiles 1120 are “field installed” after installation of the composite panels 1100.
Composite panel 1100 further comprises one or more “U-shaped” channels 140 integrally molded into the foam core 120, and extend the entire length 1102 of composite panel 1100. Reinforcing rib 140 functions as a reinforcing rib for composite panel 1100. In addition, as described herein above reinforcing rib 140 can also be used as a stand-off rib for attachment of various traditional surface materials, including without limitation stucco, siding, veneer, and the like.
Reinforcing ribs 140 extend outwardly from surface 1204 (FIG. 12). None of the reinforcing ribs 140 extend to, or outwardly from, surface 1202. This being the case, none of the reinforcing ribs 140 can function as a thermal conduit transferring heat, in either direction, from surface 1202 to surface 1204, or vice versa.
Composite panel 1100 further comprises one or more “U-shaped” channels 150 integrally molded into the foam core 120, and extend the entire length 1102 of composite panel 1100. Reinforcing rib 150 functions as a reinforcing rib for composite panel 1100. In addition, as described herein above reinforcing rib 150 can also be used to fixture electrical cables, piping, and the like, to surface 1204 of composite panel 500.
Reinforcing ribs 150 extend outwardly from surface 1204. None of the reinforcing ribs 150 extend to, or outwardly from, surface 1202. This being the case, none of the reinforcing ribs 150 can function as a thermal conduit transferring heat, in either direction, from surface 1202 to surface 1204, or vice versa.
In the illustrated embodiment of FIG. 12, Applicant's composite panel 1100 comprises reinforcing ribs 520A, 520B, and 520C, integrally molded into foam core 120, and extend the entire length 1102 of composite panel 1100. None of the reinforcing ribs 520A, 520B, and 520C, extend to, or outwardly from, surface 1204 (FIG. 12). This being the case, none of the reinforcing ribs 520A, 520B, and 520C, can function as a thermal conduit transferring heat, in either direction, from surface 1202 (FIG. 9) to surface 1204 (FIG. 9), or vice versa.
Referring now to FIGS. 14, 15, and 16, Applicant's composite panel 1400 comprises a foam core 120 in combination with a top concrete layer 1510, molded to appear like concrete roof tiles, slate shingles, wood shake shingles, or any similar roofing material. In certain embodiments, the foam core 120 is formed as an integral assembly with top concrete layer 1510 using Applicant's spray foam system. In other embodiments, foam core 120 is mechanically attached to concrete layer 1510 using various attachment means including nails, screws, and the like. In still other embodiments, foam core 120 is attached to concrete layer 1510 using one or more adhesives.
In the illustrated embodiments of FIGS. 14, 15, and 16, Applicant's composite panel 1400 further comprises a plurality of slate tiles 1410 attached to the concrete layer 1510. The basic concept for this panel is that the concrete surface is molded to look like a shingle/slate/wood shake roof and that there is no field installing of those type of materials. If field install shingles are preferable than the user could use panel 500 or 800. In certain embodiments, the plurality of slate tiles 1410 are “field installed” after installation of the composite panels 1400.
Composite panel 1400 further comprises one or more “U-shaped” channels 140 integrally molded into the foam core 120, and extend the entire length 1402 of composite panel 1400. Reinforcing rib 140 functions as a reinforcing rib for composite panel 1400. In addition, as described herein above reinforcing rib 140 can also be used as a stand-off rib for attachment of various traditional surface materials, including without limitation stucco, siding, veneer, and the like.
Reinforcing ribs 140 extend outwardly from surface 1504 (FIG. 15). None of the reinforcing ribs 140 extend to, or outwardly from, surface 1502. This being the case, none of the reinforcing ribs 140 can function as a thermal conduit transferring heat, in either direction, from surface 1502 to surface 1504, or vice versa.
Composite panel 1400 further comprises one or more “U-shaped” channels 150 integrally molded into the foam core 120, and extending the entire length 1402 of composite panel 1100. Reinforcing rib 150 functions as a reinforcing rib for composite panel 1400. In addition, as described herein above reinforcing rib 150 can also be used to fixture electrical cables, piping, and the like, to surface 1504 of composite panel 1400.
Reinforcing ribs 150 extend outwardly from surface 1504. None of the reinforcing ribs 150 extend to, or outwardly from, surface 1502. This being the case, none of the reinforcing ribs 150 can function as a thermal conduit transferring heat, in either direction, from surface 1502 to surface 1504, or vice versa.
In the illustrated embodiment of FIG. 15, Applicant's composite panel 1400 comprises reinforcing ribs 520A, 520B, and 520C, integrally molded into foam core 12, and extending the entire length 1402 of composite panel 1400. None of the reinforcing ribs 520A, 520B, and 520C, extend to, or outwardly from, surface 1504. This being the case, none of the reinforcing ribs 520A, 520B, and 520C, can function as a thermal conduit transferring heat, in either direction, from surface 1502 to surface 1504, or vice versa.
Miscellaneous pieces such as jambs and headers at openings, corners, sills, headers and trimmers at roof openings, and the like are designed, detailed and provided as part of a complete system. All of Applicant's composite assemblies, including composite roof panels, composite wall panels, and such miscellaneous assemblies, all implement the same concept: namely, no thermal link, accommodating utilities through the stand-off space, and providing ribs (flush or stand-off) for attachment of other materials.
Referring now to FIGS. 17A and 17B, Applicant's jam stud 1700 comprises interlaced “L-shaped” studs 1710A and 1710B. As shown in FIG. 17A, interlaced L-shaped studs 1710A and 1710B define a substantially enclosed space. Foam core 120 is disposed within that substantially enclosed space.
In certain embodiments, the foam core 120 is formed as an integral assembly with interlaced L-shaped studs 1710A and 1710B using Applicant's spray foam system. In other embodiments, foam core 120 is mechanically attached to interlaced L-shaped studs 1710A and 1710B using various attachment means including nails, screws, and the like. In still other embodiments, foam core 120 is attached to interlaced L-shaped studs 1710A and 1710B using one or more adhesives.
Referring now to FIGS. 18A and 18B, Applicant's assembly 1800 comprises jamb stud 1700 (FIGS. 17A, 17B) in combination with jack stud 1810. Jack stud 1810 comprises housing 1820 which defines two substantially enclosed spaces, namely substantially enclosed space 1822 and substantially enclosed space 1824.
Referring now to FIG. 19, Applicant's header beam 1900 comprises interlaced “U-shaped” brackets 1910A and 1910B to form a substantially enclosed space.
Foam core 120 is disposed within that substantially enclosed space. In certain embodiments, the foam core 120 is formed the substantially enclosed space as an integral assembly with interleaved “U-shaped” brackets 1910A and 1910B using Applicant's spray foam system. In other embodiments, foam core 120 is mechanically attached to interleaved “U-shaped” brackets 1910A and 1910B using various attachment means including nails, screws, and the like. In still other embodiments, foam core 120 is attached to interleaved “U-shaped” brackets 1910A and 1910B using one or more adhesives.
Referring now to FIG. 21, Applicant's composite beam 2100 comprises a first reinforcing rib 2110 disposed around a portion of foam core 120, in combination with a second reinforcing rib disposed within foam core 120. In certain embodiments, both the first reinforcing rib and the second reinforcing rib extend the entire length 2102 of header 2100.
In certain embodiments, foam core 120, comprising an embedded reinforcing rib 2120, is formed as an integral assembly with U-shaped bracket 2110. In other embodiments, foam core 120, comprising an embedded reinforcing rib 2120, is mechanically attached to U-shaped backed 2110 using various attachment means including nails, screws, and the like. In still other embodiments, foam core 120, comprising an embedded reinforcing rib 2120, is attached to U-shaped backed 2110 using one or more adhesives.
In the illustrated embodiment of FIG. 20, Applicant's assembly 2000 comprises jam stud 1700, in combination with jack stud 1800, and header 1900. Further in the illustrated embodiment of FIG. 20, header 1900 is attached to jam stud 1700 using brackets 2010 and 2020. In an alternative embodiment, Applicant's assembly 2000 comprises jamb stud 1700, in combination with jack stud 1800, and header 2100.
While the preferred embodiments of the present invention have been illustrated in detail, it should be apparent that modifications and adaptations to those embodiments may occur to one skilled in the art without departing from the scope of the present invention.

Claims

We claim:

1. A composite, insulated, structural panel, comprising:

an exterior face comprising a length and a width;

an opposing interior face comprising said length and said width;

a foam core disposed between said exterior face and said interior face;

a first plurality of reinforcement ribs attached to said interior face and extending laterally along said width, and extending outwardly into said foam core.

2. The composite, insulated, structural panel of claim 1, wherein:

said first plurality of reinforcement ribs are formed from one or more metals;

none of said first plurality of reinforcement ribs extends from said interior face to said exterior face.

3. The composite, insulated, structural panel of claim 1, wherein said one or more first plurality of reinforcement ribs comprise a U-shape.

4. The composite, insulated, structural panel of claim 1, wherein said one or more first plurality of reinforcement ribs comprise a C-shape.

5. The composite, insulated, structural panel of claim 1, wherein said one or more first plurality of reinforcement ribs comprise a Z-shape.

6. The composite, insulated, structural panel of claim 1, further comprising:

a first stand-off rib disposed adjacent a first end, and extending laterally along said width, wherein a portion of said first stand-off extends outwardly from said interior face;

a second stand-off rib disposed adjacent a second end, and extending laterally along said width, wherein a portion of said second stand-off extends outwardly from said interior face;

wherein:

a first composite, insulated, structural panel can be attached to a second composite, insulated, structural panel by attaching a first stand-off rib disposed in said first composite, insulated, structural panel to a second stand-off rib disposed in said second composite, insulated, structural panel.

7. The composite, insulated, structural panel of claim 1, further comprising:

a second plurality of reinforcement ribs attached to said exterior face and extending laterally along said width, and extending outwardly into said foam core.

8. The composite, insulated, structural panel of claim 7, wherein:

said second plurality of reinforcement ribs are formed from one or more metals;

none of said second plurality of reinforcement ribs extends from said exterior surface face to said interior face; and

none of said first plurality of reinforcement ribs contacts any of said second plurality of reinforcement ribs.

9. The composite, insulated, structural panel of claim 7, wherein said one or more second plurality of reinforcement ribs comprise a U-shape.

10. The composite, insulated, structural panel of claim 7, wherein said one or more first plurality of reinforcement ribs comprise a C-shape.

11. The composite, insulated, structural panel of claim 7, wherein said one or more first plurality of reinforcement ribs comprise a Z-shape.

12. The composite, insulated, structural panel of claim 1, wherein:

a top surface of said foam core comprises said exterior face; and

an opposing bottom surface of said foam core comprises said interior face.

13. The composite, insulated, structural panel of claim 1, further comprising:

a sheathing material disposed over a top surface of said foam core;

wherein said sheathing material comprises said exterior face.

14. The composite, insulated, structural panel of claim 13, wherein said sheathing material comprises metal.

15. The composite, insulated, structural panel of claim 13, wherein said sheathing material comprises a plurality of clay tiles.

16. The composite, insulated, structural panel of claim 13, wherein said sheathing material comprises concrete.

17. The composite, insulated, structural panel of claim 16, wherein said sheathing material comprises foamed concrete.

18. The composite, insulated, structural panel of claim 13, wherein said sheathing material comprises a plurality of shingles.

19. The composite, insulated, structural panel of claim 13, wherein said sheathing material comprises fiber reinforced polymer.

20. The composite, insulated, structural panel of claim 13, wherein said sheathing material comprises fiberglass reinforced polymer.

21. The composite, insulated, structural panel of claim 1, wherein said foam core comprises:

a plurality of closed cells; and

a chlorofluorocarbon gas disposed in each of said plurality of closed cells.

22. The composite, insulated, structural panel of claim 15, wherein said foam comprises a closed cell polyurethane foam.

23. The composite, insulated, structural panel of claim 15, wherein said foam comprises a closed cell polyisocyanaurate foam.

24. The composite, insulated, structural panel of claim 15, wherein said foam comprises a closed cell polystyrene foam.

25. The composite, insulated, structural panel of claim 15, wherein said foam comprises a closed cell neoprene foam.

26. The composite, insulated, structural panel of claim 15, wherein said foam comprises a closed cell polyethylene foam.

27. A composite structural beam, comprising:

a pair of interleaved brackets;

a foam core disposed between said pair of interleaved brackets.

28. The composite structural beam of claim 27, wherein said foam core comprises:

a plurality of closed cells; and

a chlorofluorocarbon gas disposed in each of said plurality of closed cells.

29. The composite structural beam of claim 27, wherein said foam comprises a closed cell polyurethane foam.

30. The composite structural beam of claim 27, wherein said foam comprises a closed cell polyisocyanaurate foam.

31. The composite structural beam of claim 27, wherein said foam comprises a closed cell polystyrene foam.

32. The composite structural beam of claim 27, wherein said foam comprises a closed cell neoprene foam.

33. The composite structural beam of claim 22, wherein said foam comprises a closed cell polyethylene foam.

34. A composite jamb stud, comprising:

a pair of interleaved brackets;

a foam core disposed between said pair of interleaved brackets.

35. The composite jamb stud of claim 34, wherein said foam core comprises:

a plurality of closed cells; and

a chlorofluorocarbon gas disposed in each of said plurality of closed cells.

36. The composite jamb stud of claim 34, wherein said foam comprises a closed cell polyurethane foam.

37. The composite jamb stud of claim 34, wherein said foam comprises a closed cell polyisocyanaurate foam.

38. The composite jamb stud of claim 34, wherein said foam comprises a closed cell polystyrene foam.

39. The composite jamb stud of claim 34, wherein said foam comprises a closed cell neoprene foam.

40. The composite jamb stud of claim 34, wherein said foam comprises a closed cell polyethylene foam.