WO2007021867A1 - Poly-bonded framed panels - Google Patents

Poly-bonded framed panels Download PDF

Info

Publication number
WO2007021867A1
WO2007021867A1 PCT/US2006/031258 US2006031258W WO2007021867A1 WO 2007021867 A1 WO2007021867 A1 WO 2007021867A1 US 2006031258 W US2006031258 W US 2006031258W WO 2007021867 A1 WO2007021867 A1 WO 2007021867A1
Authority
WO
WIPO (PCT)
Prior art keywords
stud member
building
building panel
foam
vertical stud
Prior art date
Application number
PCT/US2006/031258
Other languages
French (fr)
Inventor
Fred L. Solomon
William J. Harrington
Original Assignee
Platinum Advanced Technologies, Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from US11/201,156 external-priority patent/US7621101B2/en
Application filed by Platinum Advanced Technologies, Inc. filed Critical Platinum Advanced Technologies, Inc.
Priority to CA002660456A priority Critical patent/CA2660456A1/en
Publication of WO2007021867A1 publication Critical patent/WO2007021867A1/en

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
    • E04C2/30—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
    • 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
    • E04C2/386—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 frame of unreconstituted or laminated wood
    • 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
    • E04C2/388—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 frame of other materials, e.g. fibres, plastics

Definitions

  • the present invention relates to a building panel, method of
  • the present invention relates to a framed building
  • prefabricated portion is subject to damage during its transportation to the
  • the prefabricated portion of the building is derived solely from the frame of the
  • the structural integrity of the prefabricated portion In some instances, the structural integrity of the prefabricated portion.
  • an upright position employing a track secured to a floor, such as with an anchor.
  • the building panel is a one layer building panel that derives its
  • the vertical members can be provided at the edges of the vertical members.
  • the horizontal members can be provided at the edges of the
  • the foam is bonded to the horizontal and vertical stud members
  • Building panels can be coupled to
  • a structure such as a room, floor, level and roof
  • building panels can be inserted into one or more tracks secured to a floor to hold the
  • a building in an upright position.
  • the building panel having structural integrity is provided.
  • the building panel includes a
  • peripheral frame having a top horizontal stud member, a bottom horizontal stud
  • top horizontal stud member joins to a first end portion of left vertical
  • a second end of the top horizontal stud member joins to a first end
  • stud member joins to a second end portion of left vertical stud member, and a
  • a foam is formed at least within the peripheral
  • the building panel is derived from the bonding of the foam to the peripheral frame.
  • the foam comprises a
  • thermoplastic material or a thermoset material.
  • the bottom horizontal stud member, the right vertical stud member, and the left vertical stud member are constructed from one of: metal, aluminum, wood,
  • the top horizontal stud In an embodiment of the present invention, the top horizontal stud
  • the left vertical stud member are configured as one of: a convention stud, a c-shaped
  • the interlocking stud is
  • a first end portion of the top horizontal stud member joins to a first end
  • a first end portion of right vertical stud member joins to a first end portion of right vertical stud member.
  • a second end portion of the bottom horizontal stud member joins to
  • a foam formed at least within the
  • peripheral frame is bonded to the peripheral frame.
  • a first side of the foam defines
  • a covering is supported by, and secured to, the set of building panels.
  • the covering is constructed
  • tracks includes a base
  • foundation of the modular building with a set of anchors including, but not limited
  • anchor bolts or other similar methods.
  • an anchor is inserted
  • portion of the anchor engages the base portion of the track and the base portion of
  • the track engages the foundation.
  • the system includes a
  • track including a base portion, a first track sidewall, and a second track sidewall and
  • FIG. IA- IB depict exemplary diagrams of a building panel having
  • FIG. 1C depicts an exemplary top view of a c-shaped stud with foam
  • FIG. 2 depicts an exemplary diagram of a building panel with a
  • FIG. 3 depicts an exemplary diagram of a building panel with an inner
  • FIG. 4 depicts an exemplary diagram of an anchor and track according
  • FIG. 5 depicts an exemplary flow chart of a method for constructing a
  • Fig. 6 depicts an exemplary flow chart of a method of fabricating the
  • the building panel is a one layer building panel that derives its
  • the vertical stud members can be provided at the edges of the building panel.
  • the horizontal stud members can be provided at the edges of
  • the foam is bonded to the horizontal and vertical stud
  • Building panels can be
  • a structure such as a room, floor, level and roof
  • One or more building panels can be inserted into one or more tracks
  • FIGS. 1A-1B are shown in Figs. 1A-1B.
  • building panel 100 includes a top horizontal stud
  • the building panel 106 a left vertical stud member 108, and a foam member 110.
  • Fig. IA includes an exterior panel side 112, an interior panel side 114, and a
  • bottom horizontal stud member 104 right vertical stud member 106, and left
  • vertical stud member 108 can be constructed from one of metal, aluminum, wood
  • a stud member such as top
  • horizontal stud member 102 bottom horizontal stud member 104, right vertical stud member 106, and/or left vertical stud member 108, can be configured as a
  • the mesh member 116 is provided within the foam member 110.
  • the mesh can span the extent of the
  • foam member 110 and couple to each of the top horizontal stud member 102,
  • bottom horizontal stud member 104 right vertical stud member 106, and left
  • a set of mesh members can be provided
  • the mesh member 116 can be configured from materials including,
  • the mesh size can be from 2 Mesh to 325 Mesh which means the
  • the mesh size can be 5 Mesh to 300 Mesh. In an embodiment of the
  • gauge of the mesh can be from 50 gauge to 10 gauge. In another embodiment, the mesh has a gauge ranging from 40 to 10. In an embodiment of the
  • the mesh has a gauge ranging from 30 to 15.
  • fiber can be made from any material that strengthens the impact level of the panel
  • the material can be, but is not limited to, Fiberglass, Aramid, Carbon
  • square yard of the fiber can range from 12 oz. to 300 oz. In an embodiment of the
  • the weight per square yard of the fibber can range from 12 oz. to
  • the fiber can range from 75 oz. to 200 oz. In an embodiment of the present
  • the weight per square yard of the fibber can range from 125 oz. to 300
  • surface can be 0, +/-5, +/-10, +/-15, +/-30, +/-45, +/-60 and +/-90 degrees or any
  • the fiber layers can be either stitch bonded or woven together to
  • right vertical stud member 106 right vertical stud member 106 and left
  • vertical stud member 108 are axially aligned and positioned at the left and right
  • building panel 100 periphery of building panel 100 to form the left side and right side of building panel
  • left vertical stud member 108 and
  • right vertical stud member 106 are axially aligned and positioned at a predetermined
  • stud members 106 and 108 extend the height of the building panel 100 and the
  • horizontal stud members 102 and 104 extend the length of the building panel 100.
  • the vertical stud members 106 and 108 are identical to each other.
  • building panel 100 are configured to interlock with a vertical stud member of an
  • the horizontal stud members 102 and 104 are configured to
  • the building panel can be secured to a floor
  • stud member 102, bottom horizontal stud member 104, right vertical stud member 106, and left vertical stud member 108 form a frame around panel member 110.
  • horizontal stud member 102 squarely abuts a first end portion of left vertical stud
  • top horizontal stud member 102 squarely abuts a first end portion of right
  • first end portion of the bottom horizontal stud member 104 squarely abuts a second
  • the members can be coupled, such as by screws, welding,
  • thickness of the panel member 110 is substantially the same as the width of the top
  • foam member 110 defines the exterior and interior of building panel 100.
  • building panel 100 conforms to chapter 26 of the International building code for requirements including, but not limited to, flame
  • panel member 110 extends
  • panel member 110 thickness extends beyond the width of each of the top horizontal
  • building panel 100 as well as the exterior and interior of a wall, roof, or
  • FIG. 1 An exemplary embodiment of the building panel 100 of Figs. IA - IB
  • diagonal stud member 202 can be constructed from one of metal
  • first end portion of the diagonal stud member 202 abuts to a second end portion of
  • horizontal stud member 104 squarely and second end portion of left vertical stud
  • panel member 110 In the Fig. 2 embodiment of the present invention, panel member 110
  • the members can be coupled at the
  • an inner vertical stud member 302 can be constructed from
  • a fist end portion of an inner vertical stud member 302 squarely abuts the
  • panel member 110 extends and bonds to the
  • the members can be coupled at the points of abutment to further provide structural integrity.
  • the members can be coupled at the points of abutment to further provide structural integrity.
  • inner stud members can be configured to define openings for doors, windows, and
  • FIG. 4 An exemplary side view of an anchor and track is shown in Fig. 4.
  • the track 400 has a C-shaped
  • the track 400 can be any anchors.
  • the track 400 can be any anchors.
  • the track 400 can be any anchors.
  • the track 400 can be constructed from one of
  • the track is formed of metal, aluminum, and the like.
  • the track is formed of metal, aluminum, and the like.
  • an anchor 402 including, but not limited to, one or a
  • the anchor is a combination of screws, bolts, welds, anchors, adhesive, and the like.
  • 402 can be constructed from one of metal, steel, and the like. In an embodiment of
  • the floor is pre-dried concrete and the base of the track 400
  • the type of structure includes, but are not limited to, a wall, roof, room, home, commercial building, strip mall, cold storage facility, and apartment
  • step 500 a set of tracks is
  • anchors are inserted through holes in the tracks and into the floor that the
  • the floor is concrete.
  • step 504 the walls of the structure are constructed.
  • the walls of the structure are constructed.
  • construction of a wall includes, inserting a set of building panels
  • the building panel can be lifted over the sidewalls of the track.
  • the track secures the interlocked building panels to one another in an upright
  • a ceiling constructed from the building panels can be secured to a wall
  • each sidewall being angled away from the
  • Fig. 6 of Fig. 1 is shown in Fig. 6. The method begins in step 600.
  • step 600 a first step of Fig. 1 is shown in Fig. 6.
  • the mold press includes an enclosure having a top panel
  • a mesh In an embodiment of the present invention, a mesh
  • a peripheral frame is coupled to the peripheral frame.
  • a peripheral frame is coupled to the peripheral frame.
  • dry fiber is laid on the bottom panel and/or provided on the top panel of
  • step 602 the top panel is placed on, and secured to the sidewalls.
  • the top panel is secured to the sidewalls
  • the studs and/or mesh can be surface treated for improved bonding.
  • a metal stud can be subjected to sand
  • a metal stud can be pretreated with a
  • An enclosed vacuum chamber can be used to excite the gas molecules
  • the plasma technology can be performed under atmospheric
  • oxygen functionalities created on the surfaces are chemically reactive and
  • step 604 a foam is injected and distributed consistently into the
  • the foam is injected within,
  • the peripheral frame and bonded to, the peripheral frame.
  • foam is injected within, over, and bonded to, the frame.
  • the foam has a thickness substantial equivalent to the thickness of
  • the foam has a thickness to substantially cover the stud members of the
  • the press can be any suitable material.
  • the density of the foam In an embodiment of the present invention, the density of the foam
  • foam can be based on the specific application that the building panel is going to be used. Any suitable temperature and pressure can be provided that allows the
  • the temperature may range from about 32 0 F to
  • reaction temperature is about 75 0 F to about
  • reaction occurs at a temperature of about 75 0 F
  • reaction occurs at a temperature of
  • the pressure may range from about 1 psi to about 15 psi.
  • the pressure is about 3 psi to about 10
  • reaction occurs under a
  • the foam can be any suitable foam material that is capable of being
  • foam material may be a thermoset material or a thermoplastic material.
  • polystyrene may include, but is not limited to, polystyrene, polyurethane, polyurea,
  • the material is a molded
  • the material is an extruded
  • polyurethane foam is used.
  • polyurethane foam may be a single-component polyurethane, where the main
  • reaction causes the blowing agent to convert into a gas and expand to form the
  • Curing is chemical, requires no air or moisture, and is independent of the
  • polyiscyanurate foam may be used for foam
  • the foam material includes polyurea
  • linkages and may be prepared by reacting an isocyanate with an amine-terminated
  • the foam includes urethane or urethane linkages, the foam
  • Suitable hydroxy-terminated components include, but are not limited
  • polyols including polyether polyols, polycaprolactone polyols, polyester polyols,
  • inventions include amine-terminated hydrocarbons, amine-terminated polyethers,
  • polycaprolactones and mixtures thereof.
  • the amine-terminated segments may be
  • NH 2 primary amine
  • NHR secondary amine
  • the curing agent may include hydroxy-terminated curing agents
  • the foam includes only aliphatic components to
  • This embodiment is especially useful when the
  • Foaming of the material of the invention may occur through the
  • blowing or foaming agents include, but are not limited to, organic blowing agents,
  • the material is foamed forcing a pressurized
  • Polymeric, ceramic, metal, and glass microspheres are useful in the invention, and may be solid or hollow and filled or
  • the foamed material may be closed-cell or open-cell, however, as
  • a closed-cell foam material forms a
  • a subsequent sealant is preferred to add hydrophobicity to the cured
  • step 606 the top panel of the mold press is removed.
  • step 708 the top panel of the mold press is removed.
  • the building panel is removed from the mold press.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Building Environments (AREA)

Abstract

A one layer building panel derives its structural integrity from a foam forming the layer that bonds to horizontal and vertical stud members with a mesh material disposed therein. The vertical members can be provided at the edges of the building panel. The horizontal members can be provided at the edges of the building panel and together with the vertical member form a peripheral frame for the building panel. The foam is bonded to the horizontal and vertical stud members using above ambient temperatures and pressures. A mesh can be provided within the foam. A fiber reinforced layer can be provided on the interior and/or exterior surfaces of the foam. Building panels can be connected to one another to construct a building wall and ceiling using stud members having an interlocking capabilities. The building panels can be inserted into tracks secured to a floor using anchors.

Description

POLY-BONDED FRAMED PANELS
BACKGROUND OF THE INVENTION
Field of the Invention:
[0001] The present invention relates to a building panel, method of
fabricating the building panel, and method of constructing a build employing the
building panel. More particularly, the present invention relates to a framed building
panel, method of fabricating the framed building panel, and method of constructing
a build employing the building panel, wherein the framed building panel has
increase structural integrity and is operable to construct a wall, roof, floor, ceiling,
room, and building.
Description of the Prior Art:
[0002] The construction industry is continuously attempting to find ways to
reduce the time, cost, and labor associated with the construction of a structure, such
as a building, wall, room, floor, ceiling and roof. Techniques used to reduce the
time, cost, and labor associated with the construction of a structure includes
prefabrication of various portions of a structure. Once the portion of the structure is
fabricated, it is then transported to the construction site for placement in its intended
location. One problem with such techniques is that the prefabricated portion of the
structure is constructed with conventional materials using the techniques that would be used on the construction site. Another problem with these techniques is that the
prefabricated portion is subject to damage during its transportation to the
construction site.
[0003] These techniques typically also require that the structural integrity of
the prefabricated portion of the building is derived solely from the frame of the
prefabricated portion. In some instances, the structural integrity of the prefabricated
portion of the building and the building itself is further derived from the specific
way a prefabricated portion needs to be assembled with another portion of the
building using connections, fasteners, and other coupling mechanisms specific to
using the prefabricated portion.
[0004] Accordingly, there is a need for a building panel having structural
integrity, a method of fabricating the building panel having structural integrity, and
method of constructing a building employing the building panel. There is a need
for the building panel having structural integrity and the method of fabricating the
building panel having structural integrity, where the structural integrity is derived
from the bonding of the foam to vertically and horizontally aligned stud members.
There is a need for the vertically and horizontally aligned studs to form a frame.
There is a need for the foam to define an interior side of the building panel and an
exterior side of the building panel. There is a need for the building panel having
structural integrity to couple to another building panel having structural integrity. There is a need for the building panel to interlock with an adjacent building panel
employing an interlocking stud. There is a need for the building panel to be held in
an upright position employing a track secured to a floor, such as with an anchor.
SUMMARY OF THE INVENTION
[0005] According to an embodiment of the present invention, a building
panel having structural integrity, a method of fabricating the building panel having
structural integrity, and method of constructing a building employing the building
panel are provided. The building panel is a one layer building panel that derives its
structural integrity from a foam forming the layer that bonds to horizontal and
vertical stud members. The vertical members can be provided at the edges of the
building panel. The horizontal members can be provided at the edges of the
building panel and together with the vertical member form a peripheral frame for
the building panel. The foam is bonded to the horizontal and vertical stud members
using above ambient temperatures and pressures. Building panels can be coupled to
one another to construct a structure, such as a room, floor, level and roof, using
vertical members at the edges having an interlocking capabilities. One or more
building panels can be inserted into one or more tracks secured to a floor to hold the
one or more building panels in an upright position. [0006] According to an embodiment of the present invention, a building
panel having structural integrity is provided. The building panel includes a
peripheral frame having a top horizontal stud member, a bottom horizontal stud
member, a left vertical stud member, and a right vertical stud member. A first end
portion of the top horizontal stud member joins to a first end portion of left vertical
stud member, a second end of the top horizontal stud member joins to a first end
portion of right vertical stud member, a first end portion of the bottom horizontal
stud member joins to a second end portion of left vertical stud member, and a
second end portion of the bottom horizontal stud member joins to a second end of
the right vertical stud member. A foam is formed at least within the peripheral
frame, wherein the foam is bonded to the peripheral frame. A first side of the foam
defines an exterior surface of the building panel, and a second side of the foam
defines an interior surface of the building panel. Mesh is provided within the foam.
[0007] In an embodiment of the present invention, the structural integrity of
the building panel is derived from the bonding of the foam to the peripheral frame.
[0008] In an embodiment of the present invention, the foam comprises a
thermoplastic material or a thermoset material.
[0009] In an embodiment of the present invention, the top horizontal stud
member, the bottom horizontal stud member, the right vertical stud member, and the left vertical stud member are constructed from one of: metal, aluminum, wood,
and plastic.
[00010] In an embodiment of the present invention, the top horizontal stud
member, the bottom horizontal stud member, the right vertical stud member, and
the left vertical stud member are configured as one of: a convention stud, a c-shaped
stud, and an interlocking stud.
[00011] In an embodiment of the present invention, a first side of the foam
defines an exterior surface of the building panel and a second side of the foam
defines an interior surface of the building panel.
[00012] In an embodiment of the present invention, a fiber reinforced surface
layer is applied to the exterior surface of the building panel.
[00013] In an embodiment of the present invention, a fiber reinforced surface
layer is applied to the interior of the building panel.
[00014] In an embodiment of the present invention, the foam and the mesh
extends to the outer boundary of the peripheral frame.
[00015] In an embodiment of the present invention, ate least one of the right
vertical stud member, the left vertical stud member, top horizontal stud member,
and bottom horizontal stud member is an interlocking stud operable to interlock
with an interlocking stud of an adjacent structural component. [00016] According to an embodiment of the present invention, an interlocking
stud to guide to edge of a first building panel into a receiving edge of another
building is provided.
[00017] In an embodiment of the present invention, a structural component
couples to the interlocking stud within the first side wall and second side wall.
[00018] In an embodiment of the present invention, the interlocking stud is
operable to interlock with another interlocking stud.
[00019] According to an embodiment of the present invention, an improved
modular building is provided. The building includes a first set of building panels
defining a perimeter of the modular building, wherein each of the building panels
include a peripheral frame having a top horizontal stud member, a bottom
horizontal stud member, a left vertical stud member, and a right vertical stud
member. A first end portion of the top horizontal stud member joins to a first end
portion of left vertical stud member. A second end of the top horizontal stud
member joins to a first end portion of right vertical stud member. A first end portion
of the bottom horizontal stud member joins to a second end portion of left vertical
stud member. A second end portion of the bottom horizontal stud member joins to
a second end of the right vertical stud member. A foam formed at least within the
peripheral frame is bonded to the peripheral frame. A first side of the foam defines
an exterior surface of the building panel, and a second side of the foam defines an interior surface of the building panel. Each of the building panels configured with
an interlocking stud as the left vertical stud member and the right vertical stud
member for interlocking with an adjacent building panel configured with an
interlocking stud as the left vertical stud member and the right vertical stud
member. A covering is supported by, and secured to, the set of building panels.
[00020] In an embodiment of the present invention, the covering is constructed
from a second set of building panels.
[00021] In an embodiment of the present invention, tracks includes a base
portion, a first track sidewall, and a second track sidewall and is anchored to a
foundation of the modular building with a set of anchors including, but not limited
to, anchor bolts or other similar methods.
[00022] In an embodiment of the present invention, an anchor is inserted
through a hole receptive in the base portion of a track into the foundation and a top
portion of the anchor engages the base portion of the track and the base portion of
the track engages the foundation.
[00023] According to an embodiment of the present invention, A system for
securing a wall of a building to a foundation is provided. The system includes a
track including a base portion, a first track sidewall, and a second track sidewall and
an anchor each having a J-shape configuration. BRIEF DESCRIPTION OF THE DRAWINGS
[00024] The above described features and advantages of the present invention
will be more fully appreciated with reference to the detailed description and
appended figures in which:
[00025] Figs. IA- IB depict exemplary diagrams of a building panel having
structural integrity according to an embodiment of the present invention;
[00026] Fig. 1C depicts an exemplary top view of a c-shaped stud with foam
and mesh according to an embodiment of the present invention;
[00027] Fig. 2 depicts an exemplary diagram of a building panel with a
diagonal stud member having structural integrity according to an embodiment of the
present invention;
[00028] Fig. 3 depicts an exemplary diagram of a building panel with an inner
vertical stud member having structural integrity according to an embodiment of the
present invention;
[00029] Fig. 4 depicts an exemplary diagram of an anchor and track according
to an embodiment of the present invention; [00030] Fig. 5 depicts an exemplary flow chart of a method for constructing a
structure using a set of building panels according to an embodiment of the present
invention; and
[00031] Fig. 6 depicts an exemplary flow chart of a method of fabricating the
building panel shown in Fig. 1.
DETAILED DESCRIPTION OF THE INVENTION
[00032] The present invention is now described more fully hereinafter with
reference to the accompanying drawings that show embodiments of the present
invention. The present invention, however, may be embodied in many different
forms and should not be construed as limited to embodiments set forth herein.
Appropriately, these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the present invention.
[00033] According to an embodiment of the present invention, a building
panel having structural integrity, a method of fabricating the building panel having
structural integrity and method of constructing a building employing the building
panel are provided. The building panel is a one layer building panel that derives its
structural integrity from a foam forming the layer that bonds to horizontal and
vertical stud members. The vertical stud members can be provided at the edges of the building panel. The horizontal stud members can be provided at the edges of
the building panel and together with the vertical stud member form a peripheral
frame for the building panel. The foam is bonded to the horizontal and vertical stud
members using temperatures and pressures above ambient. Building panels can be
coupled to one another to construct a structure, such as a room, floor, level and roof,
using vertical and horizontal stud members at the edges having an interlocking
capabilities. One or more building panels can be inserted into one or more tracks
secured to a floor to hold the one or more building panels in an upright position.
[00034] Exemplary diagrams of a building panel having structural integrity
according to an embodiment of the present invention are shown in Figs. 1A-1B. In
the embodiment of Fig. IA, building panel 100 includes a top horizontal stud
member 102, a bottom horizontal stud member 104, a right vertical stud member
106, a left vertical stud member 108, and a foam member 110. The building panel
of Fig. IA includes an exterior panel side 112, an interior panel side 114, and a
mesh member 116 positioned within foam member 110 as shown in Fig. IB. In the
Fig. IA embodiment of the present invention, the top horizontal stud member 102,
bottom horizontal stud member 104, right vertical stud member 106, and left
vertical stud member 108 can be constructed from one of metal, aluminum, wood
and plastic. In an embodiment of the present invention, a stud member, such as top
horizontal stud member 102, bottom horizontal stud member 104, right vertical stud member 106, and/or left vertical stud member 108, can be configured as a
conventional stud, a c-shaped stud, an interlocking stud, or the like. In an
embodiment of the present invention, the foam member 110 forms around the c-
shaped stud members to provide increase structural integrity and mesh member 116
couples to c-shaped stud member as shown in Fig. 1C. In an embodiment of the
present invention, the mesh member 116 is provided within the foam member 110.
In an embodiment of the present invention, the mesh can span the extent of the
foam member 110 and couple to each of the top horizontal stud member 102,
bottom horizontal stud member 104, right vertical stud member 106, and left
vertical stud member 108. In an embodiment of the present invention, a set of mesh
members can be provided within the foam member 110 and extend from the top
horizontal stud member 102 to the bottom horizontal stud member 104. In an
embodiment of the present invention, a set of mesh members can be provided
within the foam member 110 and extend from the left vertical stud member 108 to
the right vertical stud member 106.
[00035] The mesh member 116 can be configured from materials including,
but not limited to, aluminum, steal, copper, and plastic. In an embodiment of the
present invention, the mesh size can be from 2 Mesh to 325 Mesh which means the
number of meshes per lineal inch of material. In an embodiment of the present
invention, the mesh size can be 5 Mesh to 300 Mesh. In an embodiment of the
present invention gauge of the mesh can be from 50 gauge to 10 gauge. In another embodiment, the mesh has a gauge ranging from 40 to 10. In an embodiment of the
present invention, the mesh has a gauge ranging from 30 to 15.
[00036] In an embodiment of the present invention, a surface of foam member
110 can be provided with a fiber reinforced surface layer as shown in Fig. 1C. The
fiber can be made from any material that strengthens the impact level of the panel
member 100. The material can be, but is not limited to, Fiberglass, Aramid, Carbon
and Natural fibers. In an embodiment of the present invention, the weight per
square yard of the fiber can range from 12 oz. to 300 oz. In an embodiment of the
present invention, the weight per square yard of the fibber can range from 12 oz. to
100 oz. In an embodiment of the present invention, the weight per square yard of
the fiber can range from 75 oz. to 200 oz. In an embodiment of the present
invention, the weight per square yard of the fibber can range from 125 oz. to 300
oz. The orientation of the fibers with respect to the longitudinal axis of the panel
surface can be 0, +/-5, +/-10, +/-15, +/-30, +/-45, +/-60 and +/-90 degrees or any
angle in between. The fiber layers can be either stitch bonded or woven together to
form multiple ply cloths which are utilized in the production of the panels.
[00037] In the Fig. IA embodiment of the present invention, top horizontal
stud member 102 and bottom horizontal stud member 104 are axially aligned and
positioned at the upper and lower periphery of building panel 100 to form the top
and bottom of building panel 100. In an embodiment of the present invention, top horizontal stud member 102 and bottom horizontal stud member 104 are axially
align and positioned at a predetermined distance from one another. In the Fig. IA
embodiment of the present invention, right vertical stud member 106 and left
vertical stud member 108 are axially aligned and positioned at the left and right
periphery of building panel 100 to form the left side and right side of building panel
100. In an embodiment of the present invention, left vertical stud member 108 and
right vertical stud member 106 are axially aligned and positioned at a predetermined
distance from one another. In an embodiment of the present invention, the vertical
stud members 106 and 108 extend the height of the building panel 100 and the
horizontal stud members 102 and 104 extend the length of the building panel 100.
In an embodiment of the present invention, the vertical stud members 106 and 108
of building panel 100 are configured to interlock with a vertical stud member of an
adjacent building panel 100 to form a wall or room. In an embodiment of the
present invention, the horizontal stud members 102 and 104 are configured to
interlock with the interlocking stud members of building panels used to form a
ceiling, roof, or floor of a structure. The building panel can be secured to a floor
member to hold the building panel in an upright position by methods including, but
not limited to, slots in the foundation or direct fixation with screws, welds or
adhesives.
[00038] In the Fig. IA embodiment of the present invention, the top horizontal
stud member 102, bottom horizontal stud member 104, right vertical stud member 106, and left vertical stud member 108 form a frame around panel member 110. In
the Fig. IA embodiment of the present invention, a first end portion of the top
horizontal stud member 102 squarely abuts a first end portion of left vertical stud
member 108. In the Fig. IA embodiment of the present invention, a second end of
the top horizontal stud member 102 squarely abuts a first end portion of right
vertical stud member 106. In the Fig. IA embodiment of the present invention, a
first end portion of the bottom horizontal stud member 104 squarely abuts a second
end portion of left vertical stud member 108. In the Fig. IA embodiment of the
present invention, a second end portion of the bottom horizontal stud member 104
squarely abuts a second end of right vertical stud member 106. In an embodiment
of the present invention, the members can be coupled, such as by screws, welding,
adhesive and bolts, at the points of abutment to further provide structural integrity.
[00039] In the Fig. IA embodiment of the present invention, panel member
110 extends and bonds to the inner side of each of the top horizontal stud member
102, bottom horizontal stud member 104, right vertical stud member 106, and left
vertical stud member 108. In the Fig. IA embodiment of the present invention, the
thickness of the panel member 110 is substantially the same as the width of the top
horizontal stud member 102, bottom horizontal stud member 104, right vertical stud
member 106, and left vertical stud member 108. The front side and back side of the
foam member 110 defines the exterior and interior of building panel 100. In an
embodiment of the present invention, building panel 100 conforms to chapter 26 of the International building code for requirements including, but not limited to, flame
spread and smoke spread.
[00040] In an embodiment of the present invention, panel member 110 extends
to the outer side of each of the top horizontal stud member 102, bottom horizontal
stud member 104, right vertical stud member 106, and left vertical stud member
108 and bonds to the back, front, and inner sides of each of the top horizontal stud
member 102, bottom horizontal stud member 104, right vertical stud member 106,
and left vertical stud member 108. In an embodiment of the present invention, the
panel member 110 thickness extends beyond the width of each of the top horizontal
stud member 102, bottom horizontal stud member 104, right vertical stud member
106, and left vertical stud member 108. In an embodiment of the present invention,
the front side and back side of the foam member 110 defines the exterior and
interior of building panel 100 as well as the exterior and interior of a wall, roof, or
ceiling for a structure constructed with building panel 100.
[00041] An exemplary embodiment of the building panel 100 of Figs. IA - IB
is shown in Fig. 2 with a diagonal stud member. In the Fig 2 embodiment of the
present invention, diagonal stud member 202 can be constructed from one of metal,
aluminum, wood and plastic. In the Fig. 2 embodiment of the present invention, a
first end portion of the diagonal stud member 202 abuts to a second end portion of
the top horizontal stud member 102 and a first end portion of right vertical stud member 106. In the Fig. 2 embodiment of the present invention, a second end
portion of the diagonal stud member 202 abuts a first end portion of the bottom
horizontal stud member 104 squarely and second end portion of left vertical stud
member 108. In the Fig. 2 embodiment of the present invention, panel member 110
extends and bonds to the inner side of each of the top horizontal stud member 102,
bottom horizontal stud member 104, right vertical stud member 106, and left
vertical stud member 108 as well as the right and left side of diagonal stud member
202. In an embodiment of the present invention, the members can be coupled at the
points of abutment to further provide structural integrity.
[00042] An exemplary embodiment of the building panel 100 of Figs. IA - IB
is shown in Fig. 3 with an inner vertical stud member. In the Fig. 3 embodiment of
the present invention, an inner vertical stud member 302 can be constructed from
one of metal, aluminum, wood and plastic. In the Fig. 3 embodiment of the present
invention, a fist end portion of an inner vertical stud member 302 squarely abuts the
top horizontal stud member 102 and a second end of the inner vertical stud member
302 squarely abut the bottom horizontal stud member 104. In the Fig. 3
embodiment of the present invention, panel member 110 extends and bonds to the
inner side of each of the top horizontal stud member 102, bottom horizontal stud
member 104, right vertical stud member 106, and left vertical stud member 108 as
well as the right and left side of inner vertical stud member 106. In an embodiment
of the present invention, the members can be coupled at the points of abutment to further provide structural integrity. In an embodiment of the present invention,
inner stud members can be configured to define openings for doors, windows, and
the like.
[00043] An exemplary side view of an anchor and track is shown in Fig. 4. In
the Fig. 4 embodiment of the present invention, the track 400 has a C-shaped
configuration having a base and two sidewalls projecting upward from the base,
which can be secured to a floor at the side of base opposite the sidewalls using one
or more anchors. In an embodiment of the present invention, the track 400 can be
used to hold one or more wall structures, such as a building panel 100, in an upright
position between the sidewalls. The track 400 can be constructed from one of
metal, aluminum, and the like. In an embodiment of the present invention, the track
can be secured to a floor using an anchor 402 including, but not limited to, one or a
combination of screws, bolts, welds, anchors, adhesive, and the like. The anchor
402 can be constructed from one of metal, steel, and the like. In an embodiment of
the present invention, the floor is pre-dried concrete and the base of the track 400
meets with a pre-dried concrete floor. Once the concrete dries, the track 400 and
anchor are securely fastened to the concrete floor.
[00044] An exemplary flow chart of a method of constructing a structure using
the building panels, anchor and track, and interlocking stud member is shown in
Fig. 5. The type of structure includes, but are not limited to, a wall, roof, room, home, commercial building, strip mall, cold storage facility, and apartment
building. The method begins with step 500. In step 500, a set of tracks is
positioned in a configuration to define the outer boundaries of a building. In step,
502, anchors are inserted through holes in the tracks and into the floor that the
tracks sit on. In an embodiment of the present invention, the floor is concrete. In
step 504, the walls of the structure are constructed. In the Fig. 5 embodiment of the
present invention, construction of a wall includes, inserting a set of building panels
within the sidewalls of the track and interlocking the interlocking stud members of
adjacent building panels. To inserting a building panel within the sidewalls of the
track, the building panel can be lifted over the sidewalls of the track. Interlocking
the interlocking stud of the building panel to the interlocking stud of an adjacent
building panel is performed prior to inserting the building panel into the track. The
interlocking of interlocking studs and insertion of interlocked building panels into
the track secures the interlocked building panels to one another in an upright
position. A ceiling constructed from the building panels can be secured to a wall
constructed of the ceiling panels employing an eave lock, wherein the eave lock has
a base portion and a pair of sidewall, each sidewall being angled away from the
base portion.
[00045] An exemplary flow chart of a method of fabricating the building panel
of Fig. 1 is shown in Fig. 6. The method begins in step 600. In step 600, a
peripheral frame of stud members is placed in a mold press. In an embodiment of the present invention, the mold press includes an enclosure having a top panel,
sidewalls and a bottom panel. In an embodiment of the present invention, a mesh
is coupled to the peripheral frame. In an embodiment of the present invention, a
mesh is suspended within the peripheral frame. In an embodiment of the present
invention, dry fiber is laid on the bottom panel and/or provided on the top panel of
the mold press.
[00046] In step 602, the top panel is placed on, and secured to the sidewalls.
In an embodiment of the present invention, the top panel is secured to the sidewalls
with sufficient strength to sustain pressures achieved by the mold press. In one
embodiment, the studs and/or mesh can be surface treated for improved bonding.
Surface treatment can be effected by any of the several techniques known in the art,
such as corona discharge, plasma treatment, ozone treatment, sand blasting, brush
tumbling, and the like. Preferably, surface treatment is effected by grinding with an
abrasive wheel. As will be appreciated by those of ordinary skill in the art, the
effect of the surface treatment can vary based on the type of material used to
fabricate the stud and/or mesh. For example, a metal stud can be subjected to sand
blasting in order to increase the adhesion between the metal stud and the foam
material.
[00047] In an alternate embodiment, a metal stud can be pretreated with a
plasma thermal spray coating thus taking advantage of the ability of plasma technology to excite gas atoms and molecules into transient and nonequilibrium
conditions. An enclosed vacuum chamber can be used to excite the gas molecules
by subjecting the gas mixture to an electrified field of radio frequency (rf) energy.
In the alternative, the plasma technology can be performed under atmospheric
pressure and ambient temperature, without the use of vacuum equipment. The
oxygen functionalities created on the surfaces are chemically reactive and
permanent and allow the foam material to form a covalent bond to the modified
surface.
[00048] In step 604, a foam is injected and distributed consistently into the
mold press. In an embodiment of the present invention, the foam is injected within,
and bonded to, the peripheral frame. In an embodiment of the present invention, the
foam is injected within, over, and bonded to, the frame. In an embodiment of the
present invention, the foam has a thickness substantial equivalent to the thickness of
the stud members of the peripheral frame. In an embodiment of the present
invention, the foam has a thickness to substantially cover the stud members of the
peripheral frame.
[00049] In the Fig. 6 embodiment of the present invention, the press can be
maintained above-ambient pressure, where the pressure is directly related to the
density of the foam. In an embodiment of the present invention, the density of the
foam can be based on the specific application that the building panel is going to be used. Any suitable temperature and pressure can be provided that allows the
reaction to proceed. For example, the temperature may range from about 320F to
about 1800F. In one embodiment, the reaction temperature is about 750F to about
17O0F. In another embodiment, the reaction occurs at a temperature of about 750F
to about 15O0F. In yet another embodiment, the reaction occurs at a temperature of
about 800F to about 85°F. The pressure may range from about 1 psi to about 15 psi.
In one embodiment of the present invention, the pressure is about 3 psi to about 10
psi. In another embodiment of the present invention, the reaction occurs under a
pressure of about 5 psi to about 7 psi.
[00050] The foam can be any suitable foam material that is capable of being
injected and distributed consistently within the peripheral frame. For example, the
foam material may be a thermoset material or a thermoplastic material. The foam
may include, but is not limited to, polystyrene, polyurethane, polyurea,
polyisocyanurate, and the like. In one embodiment, the material is a molded
expanded polystyrene foam. In another embodiment, the material is an extruded
expanded polystyrene foam.
[00051] In still another embodiment, polyurethane foam is used. The
polyurethane foam may be a single-component polyurethane, where the main
components (isocyanate and a hydroxy-terminated component) are stored together
as a blended mix, accompanied by a blowing agent in liquid form, and catalyzed to cure when exposed to moisture in the air. On release from their pressurized
container, the two main components react chemically, and the heat from this
reaction causes the blowing agent to convert into a gas and expand to form the
cellular structure of the foam. When the reaction is complete, the gas is trapped
within the material. In two-component polyurethane, the same two main
ingredients and appropriate catalysts are kept apart until application. The chemical
reaction when they are combined is much faster than with one-component foam.
Curing is chemical, requires no air or moisture, and is independent of the
surrounding environment. As an alternative, polyiscyanurate foam may be used for
improved fire-resistance and higher R-values as compared to polyurethane foam.
[00052] In yet another embodiment, the foam material includes polyurea
linkages and may be prepared by reacting an isocyanate with an amine-terminated
component. Whether the foam includes urethane or urethane linkages, the foam
may be the result of a one-shot method or a prepolymer method. Those of ordinary
skill in the art will appreciate that the different methods have advantages and
disadvantages depending on the application.
[00053] Any isocyanate available to one of ordinary skill in the art is suitable
for use according to the invention. Isocyanates for use with the present invention
include aliphatic, cycloaliphatic, araliphatic, aromatic, any derivatives thereof, and
combinations of these compounds having two or more isocyanate (NCO) groups per molecule. Suitable isocyanate-containing components include diisocyanates having the generic structure: O=C=N-R-N=C=O, where R is preferably a cyclic, aromatic,
or linear or branched hydrocarbon moiety containing from about 1 to about 20
carbon atoms.
[00054] Suitable hydroxy-terminated components include, but are not limited
to, polyols including polyether polyols, polycaprolactone polyols, polyester polyols,
polycarbonate polyols, hydrocarbon polyols, and mixtures thereof. Both saturated
and unsaturated polyols are suitable for use with the present invention. Non-
limiting examples of amine-terminated compounds for use with the present
invention include amine-terminated hydrocarbons, amine-terminated polyethers,
amine-terminated polyesters, amine-terminated polycarbonates, amine-terminated
polycaprolactones, and mixtures thereof. The amine-terminated segments may be
in the form of a primary amine (NH2) or a secondary amine (NHR).
[00055] If the prepolymer method is used to form a polyurethane or polyurea-
1 based material, the curing agent may include hydroxy-terminated curing agents,
amine-terminated curing agents, and mixtures thereof. For example, any of the
hydroxy-terminated compounds or amine-terminated compounds discussed above
are also suitable for use as a curative.
[00056] As known to those of ordinary skill in the art, aliphatic or saturated
components, i.e., components that do not include C=C or aromatic rings, produce foam materials that are less susceptible to ultraviolet light. As such, in one
embodiment (when applicable), the foam includes only aliphatic components to
result in a non-yellowing product. This embodiment is especially useful when the
panels are intended to be left unpainted once installed.
[00057] Foaming of the material of the invention may occur through the
addition of at least one physical or chemical blowing or foaming agent. Suitable
blowing or foaming agents include, but are not limited to, organic blowing agents,
such as azobisformamide; azobisisobutyronitrile; diazoaminobenzene;
N,N-dimethyl-N,N-dinitrosoterephthalamide;
N,N-dinitrosopentamethylene-tetramine; benzenesulfonyl-hydrazide; benzene- 1 ,3-
disulfonyl hydrazide; diphenylsulfon-3-3, disulfonyl hydrazide; 4,4'-oxybis benzene
sulfonyl hydrazide; p-toluene sulfonyl semicarbizide; barium azodicarboxylate;
butylamine nitrile; nitroureas; trihydrazino triazine; phenyl-methyl-uranthan;
p-sulfonhydrazide; peroxides; and inorganic blowing agents such as ammonium bicarbonate and sodium bicarbonate.
[00058] In another embodiment, the material is foamed forcing a pressurized
gas, such as nitrogen or carbon dioxide, into the polymerizing mixture. In another
embodiment, the material is foamed by blending microspheres with the composition
either during or before the molding process. Polymeric, ceramic, metal, and glass microspheres are useful in the invention, and may be solid or hollow and filled or
unfilled.
[00059] The foamed material may be closed-cell or open-cell, however, as
known to those of ordinary skill in the art, a closed-cell foam material forms a
hydrophobic top skin. As such, if the material of the invention is initially an open-
cell foam, a subsequent sealant is preferred to add hydrophobicity to the cured
material.
[00060] In step 606, the top panel of the mold press is removed. In step 708,
the building panel is removed from the mold press.
[00061] While specific embodiments of the present invention have been
illustrated and described, it will be understood by those having ordinary skill in the
art that changes can be made to those embodiments without departing from the
spirit and scope of the invention.

Claims

CLAIMS What I claim is:
1. A building panel having structural integrity, comprising:
a peripheral frame including a top horizontal stud member, a bottom
horizontal stud member, a left vertical stud member, and a right vertical stud
member, wherein a first end portion of the top horizontal stud member joins to a
first end portion of left vertical stud member, a second end of the top horizontal stud
member joins to a first end portion of right vertical stud member, a first end portion
of the bottom horizontal stud member joins to a second end portion of left vertical
stud member, and a second end portion of the bottom horizontal stud member joins
to a second end of the right vertical stud member;
a foam formed at least within the peripheral frame, wherein the foam is
bonded to the peripheral frame, a first side of the foam defines an exterior surface of
the building panel, and a second side of the foam defines an interior surface of the building panel; and
a fiber reinforce surface layer is provided on the building panel.
2. The building panel of claim 1, wherein the structural integrity of the building
panel is derived from the bonding of the foam to the peripheral frame.
3. The building panel of claim 1, wherein the foam comprises a thermoplastic
material or a thermoset material.
4. The building panel of claim 1, wherein the top horizontal stud member, the
bottom horizontal stud member, the right vertical stud member, and the left vertical
stud member are constructed from one of: metal, aluminum, wood, and plastic.
5. The building panel of claim 1, wherein the top horizontal stud member, the
bottom horizontal stud member, the right vertical stud member, and the left vertical
stud member are configured as one of: a convention stud, a c-shaped stud, and an
interlocking stud.
6. The building panel of claim 1, wherein a first side of the foam defines an
exterior surface of the building panel.
7. The building panel of claim 6, further comprising a mesh provided within the
foam.
8. The building panel of claim 6, wherein a second side of the foam defines an
interior surface of the building panel.
9. The building panel of claim 6, wherein the fiber reinforce surface layer is
provided on the exterior surface of the building panel.
10. The building panel of claim 7, wherein the foam and the mesh extends to the
outer boundary of the peripheral frame.
11. The building panel of claim 1, wherein at least one of the right vertical stud
member, the left vertical stud member, top horizontal stud member, and bottom
horizontal stud member is an interlocking stud operable to interlock with an
interlocking stud of an adjacent structural component.
12. An improved modular building, said building comprising:
a first set of building panels defining a perimeter of the modular building,
wherein each of the building panels include a peripheral frame having a top
horizontal stud member, a bottom horizontal stud member, a left vertical stud
member, and a right vertical stud member, wherein a first end portion of the top
horizontal stud member joins to a first end portion of left vertical stud member, a
second end of the top horizontal stud member joins to a first end portion of right
vertical stud member, a first end portion of the bottom horizontal stud member joins
to a second end portion of left vertical stud member, and a second end portion of the
bottom horizontal stud member joins to a second end of the right vertical stud
member, and a foam formed at least within the peripheral frame, wherein the foam is bonded to the peripheral frame, a fiber reinforced layer provided on at least some
of the foam, a first side of the foam defines an exterior surface of the building panel,
and a second side of the foam defines an interior surface of the building panel, each
of the building panels configured with an interlocking stud as the left vertical stud
member and the right vertical stud member for interlocking with an adjacent
building panel configured with an interlocking stud as the left vertical stud member
and the right vertical stud member; and a covering supported by, and secured to, the set of building panels.
13. The improved modular building of claim 12, wherein the covering is
constructed from a second set of building panels.
14. The improved modular building of claim 12, further comprising a set of tracks,
wherein each track in the set of tracks includes a base portion, a first track sidewall,
and a second track sidewall and is anchored to a foundation of the modular building
with a set of anchors eliminate J-shape! comprising a round metal disc affixed to the
end of a bent steel rod.
15. The improved modular building of claim 14, wherein an anchor in the set of
anchors is inserted through a hole receptive in the base portion of a track in the set of tracks into the foundation and a top portion of the anchor engages the base
portion of the track and the base portion of the track engages the foundation.
16. The improved modular building of claim 14, wherein the set of building panels
are inserted within the first track sidewalls and the second track sidewalls of the set
of tracks.
17. The improved modular building of claim 12, wherein the fiber reinforced
surface layer is provided on the exterior surface of at least one building panel.
18. The improved modular building of claim 12, further comprising a mesh
provided within the foam.
PCT/US2006/031258 2005-08-11 2006-08-09 Poly-bonded framed panels WO2007021867A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA002660456A CA2660456A1 (en) 2005-08-11 2006-08-09 Poly-bonded framed panels

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US11/201,156 2005-08-11
US11/201,156 US7621101B2 (en) 2005-08-11 2005-08-11 Poly-bonded framed panels
US11/350,741 US7836663B2 (en) 2005-08-11 2006-02-10 Poly-bonded framed panels
US11/350,741 2006-02-10

Publications (1)

Publication Number Publication Date
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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ITMO20090274A1 (en) * 2009-11-17 2011-05-18 Lombrico S R L PANEL FOR BUILDING
US9732525B1 (en) 2016-09-01 2017-08-15 Bryan Scott Mello Method and apparatus for manufacturing building panels
US10875218B2 (en) 2016-09-01 2020-12-29 Bryan Scott Mello Method and apparatus for manufacturing building panels

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4633634A (en) * 1985-08-30 1987-01-06 Nemmer Albert E Building side wall construction and panel therefor
US5722198A (en) * 1993-02-03 1998-03-03 Bader; Harold Building wall assembly method
US6564521B1 (en) * 2000-05-12 2003-05-20 Brown Paul A Structural sandwich panels and method of manufacture of structural sandwich panels

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4633634A (en) * 1985-08-30 1987-01-06 Nemmer Albert E Building side wall construction and panel therefor
US5722198A (en) * 1993-02-03 1998-03-03 Bader; Harold Building wall assembly method
US6564521B1 (en) * 2000-05-12 2003-05-20 Brown Paul A Structural sandwich panels and method of manufacture of structural sandwich panels

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ITMO20090274A1 (en) * 2009-11-17 2011-05-18 Lombrico S R L PANEL FOR BUILDING
US9732525B1 (en) 2016-09-01 2017-08-15 Bryan Scott Mello Method and apparatus for manufacturing building panels
US10500772B2 (en) 2016-09-01 2019-12-10 Bryan Scott Mello Expanded foam-filled building panel
US10875218B2 (en) 2016-09-01 2020-12-29 Bryan Scott Mello Method and apparatus for manufacturing building panels

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