WO2017100772A1 - Système de construction à guidages et à panneaux - Google Patents

Système de construction à guidages et à panneaux Download PDF

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Publication number
WO2017100772A1
WO2017100772A1 PCT/US2016/066174 US2016066174W WO2017100772A1 WO 2017100772 A1 WO2017100772 A1 WO 2017100772A1 US 2016066174 W US2016066174 W US 2016066174W WO 2017100772 A1 WO2017100772 A1 WO 2017100772A1
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WO
WIPO (PCT)
Prior art keywords
panels
structural
building
panel
layer
Prior art date
Application number
PCT/US2016/066174
Other languages
English (en)
Inventor
III Alex H. EDWARDS
Donald BOUDREAUX
Mac ROBERT
Jonathan MARCANTEL
Gabriel COFILED
Mitch BROUSSARD
Original Assignee
Sustainable Holdings, 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
Application filed by Sustainable Holdings, Inc. filed Critical Sustainable Holdings, Inc.
Publication of WO2017100772A1 publication Critical patent/WO2017100772A1/fr

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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
    • E04C2/02—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
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D27/00—Foundations as substructures
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2/42—Walls having cavities between, as well as in, the elements; Walls of elements each consisting of two or more parts, kept in distance by means of spacers, at least one of the parts having cavities
    • E04B2/44—Walls having cavities between, as well as in, the elements; Walls of elements each consisting of two or more parts, kept in distance by means of spacers, at least one of the parts having cavities using elements having specially-designed means for stabilising the position; Spacers for cavity walls
    • E04B2/46—Walls having cavities between, as well as in, the elements; Walls of elements each consisting of two or more parts, kept in distance by means of spacers, at least one of the parts having cavities using elements having specially-designed means for stabilising the position; Spacers for cavity walls by interlocking of projections or inserts with indentations, e.g. of tongues, grooves, dovetails
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
    • E04B2/58—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal
    • E04B2/60—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal characterised by special cross-section of the elongated members
    • 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
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
    • E04C2/205—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
    • 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
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/46—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose specially adapted for making walls
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/50—Self-supporting slabs specially adapted for making floors ceilings, or roofs, e.g. able to be loaded
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2002/0202—Details of connections
    • E04B2002/0232—Undercut connections, e.g. using undercut tongues and grooves
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2002/0256—Special features of building elements
    • E04B2002/028—Spacers between building elements
    • E04B2002/0284—Spacers between building elements forming a unity with the building elements

Definitions

  • TITLE TRACK AND PANEL BUILDING SYSTEM
  • the present invention relates generally to systems and methods of constructing buildings. More particularly, the present disclosure relates to systems and methods of using modular building panels with framed insulating blocks.
  • Foam may be used for insulation purposes in residential buildings. Sometimes expanded foam is sprayed inside the walls or under the roofs of residential buildings to provide additional insulation. In recent years, insulating concrete forms (referred to as "ICF”) has been used in residential structures. Many different types of methods have evolved for building ICF residential buildings.
  • a problem with some foam systems is that much labor is required in the shaping, cutting or modifying the foam blocks for the particular structure.
  • a second problem is that after cutting, shaping or modifying the foam structure, the foam structure loses much of its insulating value.
  • the insulating foam may not have good structural integrity, so concrete must be used to give the strength necessary for the structure.
  • Custom passages, notches or other features may be added to a foam panel when it is to be installed, for example, to run electrical cables or plumbing.
  • making such features may require cutting into structural members associated with the panel. For example, to make passage for a conduit in an insulating panel, it may be necessary to cut a hole or notch in a metal rail supporting the panel. Such cutting adds time and complexity to the planning and construction of the building.
  • a building system includes a plurality of panels.
  • Each of the panels includes a plurality of studs configured to serve as structural members and a polymeric block including a structural layer defined by the width of the studs and an offset layer.
  • the offset layer extends in an interior direction from the structural layer.
  • Upper and lower lengthwise notches may be included in the offset layer of the polymeric block.
  • Non-structural elements may be installed in the upper and lower lengthwise notches for use in mounting interior elements (e.g., wall cladding) to the interior side of the panels.
  • the lateral edge of the structural layer may extend beyond the lateral edge of the offset layer.
  • the lateral edge of the offset layer may extend beyond the lateral edge of the structural layer.
  • One or more tracks couple with the studs of the panels such that the panels form a wall of a building. Adjacent panels may couple with one another at their lateral ends in a lap joint.
  • the building system includes one or more corner pieces that couple with adjacent panels to form a corner in a wall of the building.
  • Different corner pieces are provided for different types of corners (for example, exterior corner versus interior corner).
  • a method of building includes installing one or more lower tracks on a foundation; installing one or more corner pieces on at least one of the lower tracks; installing two or more panels on one or more of the tracks to form two or more walls, wherein at least one of the panels comprises an interior offset layer; coupling at least two of the panels with the at least one corner piece, wherein one of the wall panels installed in a different direction from the corner piece than at least one other of the wall panels; and installing one or more upper track pieces on the wall panels.
  • a roof system for a building includes two or more beams, one or more sets of opposing tracks mounted on at least two adjacent parallel beams to face one another across the span between the beams, and one or more panels that slide on the tracks.
  • the beams are in a parallel spaced relationship with one another.
  • the panels include insulation for the building.
  • a method of constructing a roof a building includes providing two or more beams in a parallel spaced relationship to one another; providing one or more sets of opposing tracks on at least one pair of beams; and sliding a plurality of the panels on the opposing tracks to form an insulating layer of the roof.
  • FIG. 1 illustrates one embodiment of one embodiment of a building panel.
  • FIG. 2 illustrates an exploded view of one embodiment of a building panel.
  • FIG. 3 illustrates an interior view of a building panel.
  • FIG. 4 illustrates one embodiment of a connection between building panels.
  • FIG. 5 illustrates one embodiment of a portion of a building including an interior offset layer and corner pieces.
  • FIG. 6a is a top view of a panel including an interior offset layer according to one embodiment.
  • FIG. 6b is a side view of the panel.
  • FIG. 7 shows a side view of a panel with an upper non- structural member in an upper lengthwise notch and a lower non- structural member in a lower lengthwise notch.
  • FIG. 7A is a front view of the upper portion of the panel shown in FIG. 7.
  • FIGS. 8A, 8B, and 8C are interior, side and top views of a panel.
  • FIG. 9 illustrates a section of building having alternate interior and exterior corners.
  • FIG. 10 is a top view of one embodiment of a panel having ends with staggered interior and exterior layers.
  • FIG. 11 is a top view illustrating one embodiment of an exterior corner piece.
  • FIG. 12 is a top view illustrating one embodiment of an interior corner piece.
  • FIGS. 13 A and 13B shown embodiment of an exterior corner pieces having upper and lower notches.
  • FIG. 14 illustrates one embodiment of an interior corner piece including junction- facing studs.
  • FIGS. 15A and 15B illustrate front and cross sectional top views of a portion of a track and panel system including a window.
  • FIG. 16 illustrates a top view of a portion of a track and panel system including a doorway, and window, and an exterior corner.
  • FIGS. 17A and 17B illustrate front and cross sectional top views of a track and panel system including a doorway.
  • FIG. 18 illustrates front, side, and top views of a door header panel.
  • FIG. 19 illustrates front, side, and top views of a window sill panel.
  • FIG. 20 illustrates front, side, and top views of a window header panel.
  • FIG. 21 illustrates a cross sectional view of a window header and sill installation in a panel system according to one embodiment.
  • FIG. 22 illustrates a cross sectional view of a window jamb installation in a panel system according to one embodiment.
  • FIG. 23 illustrates a cross sectional view of a door header panel installation in a panel system according to one embodiment.
  • FIG. 24 illustrates a cross sectional view of a door jamb installation in a panel system according to one embodiment.
  • FIG. 25 illustrates one embodiment of a window head and sill including panel notches.
  • FIG. 26 illustrates an alternate system for a corner of a building.
  • FIG. 27 and 28 illustrates one embodiment of a track and tack system for a building.
  • FIG. 29 illustrates a portion of a panel installed using a track and tack system in one embodiment.
  • FIG. 30 illustrates a side view of a roof system using insulated panels, installed on a beam-mounted track system.
  • FIG. 31 is schematic section view of the roof system shown in FIG. 30.
  • FIG. 32 is a detail view of a beam providing tracks for roof panels on both sides of the beam.
  • FIG. 33 illustrates installation of a panel in a track on a beam.
  • FIG. 34 is an exterior (top) view illustrating an insulating panel installed in a roof system between two parallel beams.
  • FIG. 35 is an interior (bottom) view illustrating an insulating panel installed in a roof system between two parallel beams.
  • FIG. 36 illustrates an alternate embodiment of a track and panel roof system.
  • an element is “structural” if it is intended to bear loads of a building (e.g., the weight of walls or a roof).
  • an element is “non-structural” if it is not intended to bear loads of a building.
  • elements such as channels or rails, that are designed to support or hold wall cladding, plumbing, electrical lines, or fixtures are non-structural.
  • stud or "framing stud”, means a primarily vertical member that can bear a downward load.
  • frame member means a member that can be coupled with one or more other members to form a frame.
  • a "polymeric material” means a material that is made at least primarily of one or more polymers.
  • a polymer means a naturally occurring or synthetic compound consisting of large molecules made up of a linked series of repeated simple monomers. Examples of polymers include polyolefins (such as polyethylene and polypropylene), polyurethanes, polyvinylchloride, polyesters, poly ethylene vinyl alcohol, polyvinyl alcohol, polycaprolactone, polylactic acid and foamed starch.
  • a polymeric material may be expanded foam, such as expanded polystyrene.
  • a polymeric material is fire retardant.
  • polymeric block means a block that is at least primarily made of a polymeric material.
  • a "lap joint” means a joint in which at least a portion of the elements overlap one another.
  • a "partial lap joint” means a joint in which only a portion of at least one of the members overlaps the other member. In a partial lap joint, the thickness of the overlapping members may be unequal.
  • One example of a partial lap joint is a half lap joint.
  • a "half lap joint” means a joint in which the joining members are notched or stepped such that portions of the members to overlap one another.
  • a "layer” refers to a layer or portion of the thickness of a panel or other member. In a typical installation of a panel, the layers would be in a vertical relationship, for example, an interior layer alongside of an exterior layer.
  • a panel may have layers that serve different functions, for example, one layer of a panel may be structural and insulating, while another layer of a panel is insulating but non-structural.
  • a framing stud is embedded in a polymeric block if the framing stud is inserted, pressed, or dropped into a pre-cut slot or channel in the block.
  • a framing stud may be embedded by expanding a loose foam material around the framing stud. In certain embodiments, there may be clearance between the surfaces (for example, a gap between the surfaces of a framing stud and the adjacent surfaces of a polymeric block).
  • a "c-shaped" cross section refers to a cross section that is generally in the form of a C.
  • a "u-shaped” cross section refers to a cross section that is generally in the form of a U.
  • a c-shaped member or a u-shaped member may include variations such as bumps, bulges, ridges, corrugations, lips, rounded corners, sharp corners, tapers.
  • FIG. 1 illustrates one embodiment of a building panel.
  • Building panels may be used, for example, as elements of a wall, floor, ceiling, or roof of a building.
  • Building panel 100 includes block 102 and frame 104.
  • Frame 104 includes main studs 106, top cross rail 108, and bottom cross rail 110.
  • Block 102 includes main body 112 and offset 114.
  • Building panel 100 is installed on slab 116.
  • Building panel 100 may be coupled to adjacent building panel 101.
  • Main studs 106 may extend in a vertical direction through block 102.
  • Offset 114 may extend from the framed portion of block 102 toward the interior portion of a building relative to frame 104. In FIG. 1, the thickness of the offset is shown as dimension 115. In one embodiment, frame members are about 3 and 5/8 inches up to about 7 and 5/8 inches in thickness, and the thickness of offset 114 is about 4 and 3/8 inches up to about 8 and 3/8 inches.
  • Interior surface studs 120 are mounted on the interior surface of offset 114. In the embodiment illustrated in FIG. 1, interior surface studs 120 are installed such that both interior surface studs 120 and main studs 106 run vertically and are parallel to each other. With respect to the cross section of the studs, however, interior surface studs 120 may be installed in a different orientation than main studs 106. In this case, interior surface studs 120 are installed such that the cross section of interior surface studs 120 is perpendicular to the cross section of main studs 106. In certain embodiments, different studs may run in different directions that one another.
  • one or more of studs in the frame of a building panel may be embedded in the building panel at a slant and others of studs in the frame of the building panel may run vertically.
  • the surface- mounted studs for a building panel may be installed at a slant, and the studs in the frame of the building panel may run vertically.
  • the surface- mounted studs are at an orientation that is perpendicular to that of the main studs.
  • a building panel may, nevertheless, in various embodiments include studs that are installed in other relative orientations to one another.
  • a stud in a building panel may be installed in an orientation that is 45 degrees relative to another stud in the building panel.
  • Block 102 may be made of a polymeric material.
  • block 102 is made of expanded polystyrene foam.
  • Block 102 may be of an insulating material.
  • the density of a block is between about 1.0 and about 2.0 pounds per cubic foot.
  • Some embodiments of a block include polymeric material having a density of 1 pound per cubic foot, 1.5 pounds per cubic foot, or 2.0 pounds per cubic foot.
  • a block of a building panel includes passages or openings.
  • block 102 includes cylindrical passages 1 18 and passages 121. Cylindrical passages 118 and passages 121 may be used for running conduit, electrical wires, plumbing, or other elements.
  • a block for a building panel may also include openings for doors or windows.
  • a block includes notches, channels, or other features for receiving, connecting, or meshing with other building elements.
  • passages are provided at spaced intervals along the length of a panel. For example, a vertical chase may be provided in the offset portion of building panel 100 at 8 inch intervals along the length of the panel.
  • Frame members such as main studs 106, top cross rail 108, bottom cross rail 110, may be made of a metal, such as steel or aluminum.
  • main studs 106, top cross rail 108, bottom cross rail 1 10 are made of 24 gauge galvanized steel.
  • Main studs 106, top cross rail 108, and bottom cross rail 110 may combine to form frame 104.
  • Top cross rail 108 may couple with main studs 106 at the top of block 102.
  • Bottom cross rail 108 may couple with main studs 106 at the top of block 102.
  • top cross rail 108 and bottom cross rail 110 are coupled to the main studs by way threaded fasteners, such as bolts or machine screws.
  • the cross rails for the panel may be connected to the main studs by way of rivets 117.
  • a building panel may be of any suitable dimensions.
  • a building panel may be, for example, between 8 feet and 18 feet tall. In one embodiment, a building panel is about 9 feet tall. In another embodiment, a building panel is about 50 inches tall.
  • Two or more panels may be stacked on one another. As shown in FIG. 1, the bottom portion of a building panel may have a notch corresponding to a step on the slab on which the panel is to be installed.
  • different building panels may be produced with different offset thicknesses.
  • different building panels may have different densities from one another.
  • an offset portion of a panel (for example, offset from a frame), has a different density than other portions of the panel.
  • the offset portion of block 110 is offset in an interior direction.
  • a panel block may, nevertheless, in various embodiments include an offset in other directions.
  • a panel block may include an offset in an exterior direction.
  • passages in a block for a panel are provided in a portion of the panel that is offset from frame members of the panel.
  • passages may be provided in offset 114 of building panel 100.
  • pipes, wiring, conduits or other elements may be routed in the passages without drilling or cutting in frame members for a panel.
  • FIG. 2 illustrates an exploded view of the building panel shown in FIG. 1.
  • Main studs 106 may reside in main slots 123.
  • Main studs 106 may be at least partially embedded in block 102.
  • main studs 106 are in place when block 102 is molded into a solid block.
  • main studs 106 may be held in position in loose polymeric material, such as beads or pellets, from which block 102 is made (for example, by way of a fixture).
  • Interior surface studs 120 may be installed in interior surface slots 126 in the offset portion of block 102.
  • each of studs 120 is inserted from the top (for example, through the top surface of offset 114).
  • cross members of frame such as top cross rail 108, bottom cross rail 110, or both, may be positioned in a block when the block is molded. In certain embodiments, all of the frame members of a panel are in place during molding of a block.
  • FIG. 3 illustrates an interior view of a building panel.
  • Interior surface studs 120 are installed on interior surface 130 of block 102 in slots 126 in the interior offset portion of block 102.
  • interior surface studs are press-fit into interior surface slots 126.
  • Interior surface studs 120 may be used for attaching additional building elements or decorative elements to building panels 100.
  • Interior surface studs 120 may run the full height of the offset portion. In some embodiments, two or more sections of studs are stacked within a particular slot. In this manner, relatively short lengths of studs (for example, scrap generated during construction of the building) can be used for the surface-mounted studs.
  • Block 102 includes junction box cavity 124.
  • Junction box cavity 124 may be adjacent to a pair of slots 126 for interior surface studs 120.
  • a junction box may be positioned injunction box cavity 124 and attached to interior surface studs 120.
  • FIG. 4 illustrates one embodiment of a connection between building panels.
  • Building panels 100a and 100b are connected with panel connector 140.
  • Panel connector 140 bridges the top of frames 104 of building panels 100a and 100b.
  • Panel connector 140 may connect building panels 100a and 100b at junction 144.
  • Pins 142 may pass through holes in panel connector 140 and engage in corresponding holes or sockets in frames 104, blocks 102, or both. In some embodiments, pins 142 temporarily hold building panels 100a and 100b together until a more permanent connection is established between the panels. For example, pins 142 may temporarily hold building panels 100a and 100b in place until building panels 100a and 100b are coupled to one another by way of an adhesive, or by way of threaded fasteners securing panel connector 140 to building panels 100a and 100b. Pins 142 may be made of any suitable material. In one embodiment, pins 142 are made of a polymer.
  • passages may be provided between internal passages in a panel and the surfaces of the panel.
  • passage 145 may be drilled to create access between passage 118 and the exterior face of panel 100a.
  • surface studs and studs of a frame are generally aligned with one another along the length of a panel, such that any obstruction of passages (such as passage 145) is minimized.
  • a building system includes insulated panels that can be coupled to form walls.
  • FIG. 5 illustrates one embodiment of a portion of a building.
  • Building 200 includes panels 202, corner piece 204, upper track 206, and lower track
  • Building 200 may also include window 210 and doorway 212.
  • Each of panels 202 includes block 214, studs 216, and interior studs 218.
  • Interior studs may be hat channels installed in slots in the interior face of panels 202.
  • Corner piece 204 may be used to couple the panels 202 that meet at the corner.
  • Corner piece 204 may have a uniform cross section and extend the height of panels 202.
  • Corner piece 202 may include a polymeric block construction with one or more structural and non-structural studs held in the polymeric block.
  • the polymeric blocks of the panels and corner piece are constructed from 1 to 21b, 5 1 ⁇ 2" polystyrene panels in varying widths.
  • the track and panel system may include structural and non-structural steel.
  • Panels as described herein may couple with one another by way of a lap joint, one after another.
  • adjoining panels at a corner of a building may be j oined via a lap j oint.
  • the panels may be pre-cut to allow for cold form structural steel studs to be in- bedded on the exterior side of the panel and cold form non-structural steel studs or hat channels to be in-bedded on the interior of the panel.
  • the panel may also be cut with notches on top and bottom so that when placed in structural steel track, the panel can be attached in accordance with the 2012 International Residential Building Code on the bottom and a structural steel track can be attached on the top in accordance with the 2012 International Residential Building Code Section 603.
  • the panels may include interior offset layers.
  • the interior offset layers may include lengthwise notches at top and/or bottom.
  • the notches may accommodate non-structural members, such as channels.
  • Interior elements such as wall cladding may be secured to the wall by way of the non-structural members.
  • non-structural channels run in top and bottom notches over the length of a panel.
  • An interior offset layer may provide increased thermal insulation and accommodate fixtures, electrical lines, plumbing, ductwork, and other components and systems of the buildings.
  • Panels as described herein may specifically designed to allow for the above mentioned connecting methodology as well as the utilization of a non-structural angle component, which would be attached at the bottom to the foundation and on the interior side of the panel to the non- structural stud or hat channel and at the top to the structural track and on the interior of the panel to the non-structural stud or hat channel.
  • These non-structural components may serve as a way to secure interior wall coverings as well as interior hangings.
  • the panel may be cut with the structural components and non-structural components to be off-set such that access to all required Building Code connections can be made in accordance to code.
  • a system includes corner pieces that connect to wall panels at corner locations.
  • the corner pieces may be the same height as the wall panels.
  • Each corner piece may be either an exterior corner or an interior corner.
  • the builder may select the appropriate corner piece (for example, whether the exterior side of the corner piece is an inside corner or an outside corner) depending on location. Having corner pieces of multiple configurations may reduce a need for field-cutting of panels to build the corner portion of a building.
  • FIG. 6a is a top view of a panel including an interior offset layer according to one embodiment.
  • FIG. 6b is a side view of the panel.
  • Panel 230 includes polymeric block 232, structural studs 234, and surface hat channel members 236.
  • Polymeric block 232 includes upper lengthwise notch 238, lower lengthwise notch 240, vertical chase 242, and horizontal chases 244.
  • the width of structural studs 234 within block 232 defines a structural layer of polymeric block 232.
  • the portion of polymeric block 232 that is not within the width of structural studs 234 may be considered an offset layer. In this case, the offset layer is on the interior to the structural layer.
  • each of structural studs 234 is about 3 and 5/8 inches in width, 18 gauge steel.
  • FIG. 7 shows a side view of panel 230 with upper non-structural member 246 in upper lengthwise notch 238 and lower non-structural member 248 in lower lengthwise notch 240.
  • Either or both of front wall 250 of upper non-structural member 246 and front wall 252 of lower non-structural member 248 may lap over the interior face of panel 230.
  • Upper non-structural member 246 and lower non-structural member 248 may be attached to upper track 257 and lower track 259 and to surface hat channel members 236 where front walls 250 and 252 contact the interior face of panel 230.
  • Attachment may be way of glue, clips, screws, or other suitable fasteners.
  • Upper non-structural member 246 and lower non-structural member 248 may be used as attach points for items to be installed on the interior of panel 230, such as wall claddings.
  • FIG. 7A is a front view of the upper portion of the panel shown in FIG. 7.
  • non- structural interior elements are surface hat channel members 236, interior non-structural elements may in various embodiments have other forms and sizes. Examples of interior surface elements may hat channel, steel studs. Interior elements may vary in size and form depending on code and load requirements.
  • Non-structural members 246 and 248 may be, in one embodiment, steel channels 1 and 7/8 inches wide. Non-structural members 246 and 248 may be used for mounting of interior wall elements. For example, upper non- structural member 246 and lower nonstructural member 248 may be used as attach points for wall claddings.
  • FIGS. 8A, 8B, and 8C are interior, side and top views of a panel.
  • Panel 222 may be of similar form and construction to that described above relative to FIGS. 1 through 7A, including a polymeric block with framing studs and interior non-structural members.
  • Panel 222 includes upper notch 223 and lower notch 224.
  • notched end 225 includes a notch running from top to bottom and flat end 226.
  • the flat end of the panel may be suitable for use where door jambs or other framing of openings in a wall are located.
  • the notched end may couple with an adjacent panel in a lap joint, such as shown at the corner pieces in FIGS. 9-12.
  • the interior surface elements shown in FIGS. 8 A, 8B, and 8C are illustrated as hat channels.
  • the hat channels used as interior elements may be 1 1 ⁇ 2 inches by 2 1 ⁇ 2 inches, 25 gauge.
  • interior non-structural elements may nevertheless in various embodiments have other forms and sizes. Examples of interior surface elements may be 7/8 inch by 2 3/8 inch hat channel, (eighteen gauge or 25 gauge), 7/8 by 2 3/8 hat channel, or 1 5/8 steel stud.
  • a track and panel system includes different corner pieces depending on the type of corner.
  • FIG. 9 illustrates a section of building having alternate interior and exterior corners.
  • Building 257 includes wall 258 and interior floor 259.
  • Wall 259 includes panels 260, exterior corner piece 262, and interior corner piece 264.
  • Exterior corner piece 262 is used for exterior (outside-pointing) corners of the building.
  • Interior corner piece 264 is used for interior (inside-pointing) corners of the building.
  • the adjacent exterior surfaces span a 270 degree angle with respect to one another, and the adjacent interior surfaces span 90 degrees with respect to one another.
  • the adjacent interior surfaces span a 270 degree angle with respect to one another, and the adjacent exterior surfaces span 90 degrees with respect to one another.
  • corner pieces in FIG. 9 are shown as right angles, corner pieces may, in certain embodiments, have angles other than right angles.
  • a corner piece may have a 45 degree inside corner, a 45 degree outside corner, 60 degree inside corner, 60 degree outside corner, or any angle as may be needed for the layout of a particular building.
  • FIG. 10 is a top view of one embodiment of a panel having ends with staggered interior and exterior layers.
  • Panel 230 may have a two-layer construction (structural layer - offset layer) similar to that of building panel 100 described above relative to FIG. 1.
  • panel 230 includes structural layer 270, offset layer 272, and ends 274A and 274B.
  • offset layer 272 extends beyond the end face of structural layer 270, to form a stepped end.
  • structural layer 272 extends beyond the end face of offset layer 272, also forming a stepped end.
  • the step dimensions of ends 274A and 274B match one another such that any number of panels 230 can be place consecutively with the end 274A of one panel 230 aligns and overlaps end 274B of the next panel 230.
  • a wall is formed by placing panels 230 consecutively with their ends in a lap joint. Adjoining panels can be glued to another at the joints.
  • FIG. 11 is a top view illustrating one embodiment of an exterior corner piece. Exterior corner piece 262 may be used to join adjacent panels 230 at a corner of a building.
  • Exterior corner piece 262 may have a uniform cross section of the shape shown in FIG. 11. Exterior corner piece 262 may include a polymeric block with metal portions installed therein (for example, by sliding the metal members into vertical slots of the polymeric block).
  • Exterior corner piece 262 includes structural portion 280 and offset portion 282.
  • Structural portion 280 and offset portion 282 may correspond in width with structural portion 270 and offset portion 272 of panel 230 in both directions.
  • Offset portion 282 includes interior surface stud 290.
  • Structural portion 280 includes exterior corner stud 284 and end studs 286 and 288.
  • Faces of exterior corner piece 262 may couple two of panels 230 to form an exterior corner of a building.
  • Each of panels 230 may couple to exterior corner piece 262 in a lap joint, such as shown in FIG. 10.
  • Joints may be glued together, held by fasteners, or by a combination of glue and fasteners.
  • steel studs of the corner pieces are 3 5/8 steel channel, 18 gauge. Hat channels and corner channels in the corner pieces can be 24 gauge.
  • FIG. 12 is a top view illustrating one embodiment of an interior corner piece.
  • Interior corner piece 264 may be used to join adjacent panels 230 at a corner of a building.
  • Interior corner piece 264 may have a uniform cross section of the shape shown in FIG. 12. Interior corner piece 264 may include a polymeric block with metal portions installed therein (for example, by sliding the metal members into vertical slots in the polymeric block).
  • Interior corner piece 264 includes structural portion 300 and offset portion 282.
  • Structural portion 300 and offset portion 302 may correspond in width with structural portion 270 and offset portion 272 of panel 230 in both directions.
  • Offset portion 302 includes interior surface stud 304 and corner channel 306.
  • Structural portion 300 includes studs 308.
  • corner channel 306 is a furring channel.
  • Faces of interior corner piece 264 may couple two of panels 290 to form an interior corner of a building.
  • Each of panels 230 may couple to interior corner piece 264 in a lap joint, such as shown in FIG. 12.
  • Joints may be glued together, held by fasteners, or by a combination of glue and fasteners.
  • FIGS. 13A and 13B shown embodiment of an exterior corner pieces having upper and lower notches.
  • Exterior corner piece 320 includes block 322, exterior layer studs 324, and interior layer stud 326.
  • Upper notch 328 and lower notch 329 are provided at the top and bottom of the piece.
  • Electrical traces 327 are included in the interior layer of the corner piece.
  • both exterior corner pieces and interior corner pieces include upper and lower notches and electrical traces.
  • studs are provided at each surface of a corner piece that is used to join the corner piece to panels.
  • FIG. 14 illustrates one embodiment of an interior corner piece including junction-facing studs.
  • Corner piece 330 includes exterior layer studs 308, interior layer studs 332, and corner stud 334. Exterior layer studs 308 and interior layer studs 332 may face complementary surfaces of panels to form lap joints at an interior corner of a building.
  • building panels include, for example, wall panels, door panels, and window panels. Any or all of wall panels, door panels, and window panels may include a polymeric block with a frame. Any or all of the wall panels, door panels, and window panels may include block offsets from the frame of the panel.
  • one or more of the building panels for a building are cut to size and shape. Cutting of the panels may be performed on-site (for example, during construction of the building) or off-site.
  • FIGS. 15A and 15B illustrate front and cross sectional top views of a portion of a track and panel system including a window.
  • Track and panel system 340 includes panels 342, window sill panel 344, and window jamb panel 346.
  • Each of panels 342 includes a polymeric block with structural studs 350, hat channels 352, and chases 354.
  • Upper track 356 and lower track are provided at the top and bottom of the panel elements.
  • FIG. 16 is a top view illustrating a portion of a track and panel system including a doorway, and window, and an exterior corner.
  • Track and panel system 360 includes panels 342, corner piece 362, doorway 364, and window 366. Panels 342 may be as described above relative to FIGS. 15A and 15B.
  • FIGS. 17A and 17B illustrate front and cross sectional top views of a track and panel system including a doorway.
  • Track and panel system 380 includes doorway 382, door sill panel 384.
  • Each of panels 342 includes a polymeric block with structural studs 350, hat channels 352, and chases 354.
  • Upper track 356 and lower track are provided at the top and bottom of the panel elements.
  • FIG. 18 is front, side, and top views illustrating a door header panel.
  • Door header panel 400 includes polymeric block 402 including a structural layer and an offset layer, structural studs 404, rails 406, hat channels 408, and chases 410.
  • FIG. 19 is front, side, and top views illustrating a window sill panel.
  • Window sill panel 420 includes polymeric block 422 including a structural layer and an offset layer, structural studs 424, rails 426, hat channels 428, and chases 430.
  • FIG. 20 is front, side, and top views illustrating a window header panel.
  • Window header panel 440 includes polymeric block 442 including a structural layer and an offset layer, rails 444, and hat channels 444.
  • each of the panels includes both an upper and lower notch running the length of the panel.
  • notches may be provided at j only the upper location or the lower location, or at neither the upper or lower location.
  • panels may include one or more notches the span only a portion of the length of the panel.
  • notches are shown a square, notches may, in various embodiments, be other shapes, such as rectangular, arcuate, or triangular.
  • FIG. 21 illustrates a cross sectional view of a window header and sill installation in a panel system according to one embodiment.
  • Header panel 460 includes panel block 462 and steel studs 464. Header panel 460 includes a structural layer and an offset layer, similar to that described above relative to FIGS. 1-8C.
  • siding 466 is coupled to panel block 462 and is supported on F-clip 468.
  • gypboard 470 is attached by way of vertical hat channel 472 and hat channel clip 473.
  • F- clip 474 supports lower clip 475.
  • Window 476 is secured to the panel by way of nail fin 477 and molding clip 478.
  • window 476 is a high efficiency window, Fibertec 300 series.
  • FIG. 22 illustrates a cross sectional view of a window jamb installation in a panel system according to one embodiment.
  • window jamb 500 the window, exterior siding 466, and gypboard 470 are installed in a manner similar to that described above relative to FIG. 18.
  • Rain screen blocking 502 spaces siding 470 from the panel.
  • the window jamb installation includes stud 467, which, in one embodiment, is a 1 and 5/8 steel stud. Stud 467 may provide structural rigidity to the installation.
  • FIG. 23 illustrates a cross sectional view of a door header panel installation in a panel system according to one embodiment.
  • door jamb 521 is installed on stud clip 522.
  • Exterior siding 466 is supported on angle 524. Flashing 526 is provided below angle 524.
  • Angle 469 may be provided for mounting of gypboard 470 or other interior elements. Rain screen blocking 502 spaces siding 470 from the panel.
  • FIG. 24 illustrates a cross sectional view of a door jamb installation in a panel system according to one embodiment.
  • door jamb installation 540 includes door jamb 542.
  • Door jamb 542 is installed on stud clip 544.
  • Exterior siding 466 and gypboard 470 are mounted in a manner similar to that described above relative to FIG. 18.
  • Rain screen blocking 502 spaces siding 470 from the panel.
  • the door jamb installation includes stud 467, which, in one embodiment, is a 1 and 5/8 steel stud.
  • FIG. 25 illustrates one embodiment of a window head and sill including panel notches.
  • Window header and sill include notches 552.
  • Angles 557 are mounted at upper one of the notches.
  • Hat channel 554 is provided in the notch above the window.
  • Angles 556 may be attached a pass below hat channel 554.
  • Hat channel 554 may be coupled to angles 556 and 557.
  • Gypboard 558 may be mounted to hat channel 554, angle 557, angle 556, or a combination thereof.
  • FIG. 26 illustrates an alternate system for a corner of a building.
  • Track and panel system 560 includes panel 562 and panel 564.
  • Panel 562 and panel 564 each include a structural layer and an offset layer. Panel 562 and panel 564 meet at corner 566. Panel 562 includes notch 568. Panel 562 and panel 564 may be coupled in an overlapping joint at corner 566 using glue, fasteners, or a combination of both.
  • a building is constructed using a track and panel system on a structural base.
  • the track and tack system for mounting panels to form the walls of the building.
  • FIG. 27 and 28 illustrates one embodiment of a track and tack system for a building.
  • System 580 includes channels 582 mounted on structural base 584 at the intended locations of the walls of the building. Each of channels 582 serves as a track for receiving one or more panels. In one embodiment, channel 582 is 3 5/8 inches wide, 18 gauge steel. Anchor bolts 587 may be placed at a suitable spacing along the length of each channel 582.
  • Non-structural angle brackets 586 may be provided on the interior side of channels 582.
  • the location of non- structural angle brackets 586 may be selected to correspond with the locations of interior studs or hat channels on the interior sides of the panels.
  • the bottom leg of each bracket may extend under the lower notch of a panel.
  • Each of brackets 586 may be aligned with, and coupled to, a stud, hat channel, or other vertical member on the interior face of one of the panels.
  • brackets 586 are adjustable (e.g., for height or horizontal position).
  • Brackets 586 may serve as non-structural members for mounting interior elements, such as cladding.
  • each of bracket 586 is a 1 1 ⁇ 2 inch by 2 5/8 inch angle bracket.
  • FIG. 29 illustrates a portion of a panel installed using a track and tack system in one embodiment.
  • Building 590 includes channel 582 and bracket 586 mounted on structural base 584.
  • Panel 592 is installed in channel 582.
  • Top channel 594 is installed on the top of panel 592 (top channel 594 may extend across multiple panels coupled to another in a row).
  • Hat channel 596 is provided on the interior of panel 592.
  • Bracket 597 may connect hat channel 596 to top channel 594.
  • Bracket 586 may connect hat channel 596.
  • other non-structural members such as studs, can be included on the interior side of a panel.
  • the bottom track and the non-structural tacks go down around the entire exterior of the structure. Then Corner #1 is put in place and fastened to the bottom track and the non-structural tacks. Then the panels go together and are fastened to the track and tacks as they are set in place.
  • the top track is placed on top in unto 12' sections with 2' overlap and fastened as it is placed into position. Then the tack angle non-structural fasteners are secured to the track and then to the non-structural components.
  • the track running 90 degrees from the one just described may be notched to accommodate the first track.
  • Top track may be attached in sections as described above and be a continual installation as the wall is going up. Successive panels may be slid together and glued on both side of the connecting cutouts. The panels may be independently attached to the top and base track. The corner pieces and the panels are glued together. Both top and bottom tracks may extend the length of the wall, including over the corner pieces.
  • corner pieces may allow for a more uniform panel design for a standard panel. Without the corner pieces, the construction team may, for example, be forced to make many different panels to make corners. Exterior and interior corner pieces may eliminate or reduce the need for making customer-specific and/or building- specific panels.
  • a roof system utilizes a track that is connected to a structural member. Panels may be slid into the track perpendicular to the structural member. The panels may be notched so that they are interlocking (similar to the wall system described above relative to FIGS. 7-12. Panels used in the roof system may utilize varying structural and non- structural steel components (depending on, for example, the roof design and load requirements.)
  • a track and panel system is used to construct an insulated roof of a building.
  • a series of insulated panels is installed on a pair of opposing track mounted on parallel beams.
  • FIG. 30 illustrates a side view of a roof system using insulated panels, installed on a beam-mounted track system.
  • FIG. 31 is schematic section view of the roof system shown in FIG. 30.
  • the panels used in a track and panel system are the same as those used to form the walls of a building. For example, the panels described in FIGS. 1 through 8C above may be employed in a roof system.
  • various panels used in a roof system include a structural layer includes a set of embedded structural studs and an offset layer that does not include a structural studs (though it may include non-structural members such as surface studs or hat channel for mounting interior elements such as gypboard panel for ceilings).
  • building 600 includes roof system 602.
  • Roof system 602 includes beams 604, panels 606, roof 608, and channels 610.
  • beams 604 are 14 inch by 5 inch LVL beams. Beams 604 may be in parallel spaced relationship to one another. Channels 610 are attached to the sides of beams 604 near the top such that the openings of the channels face each other across the span between adjacent beams. In one embodiment, channels 610 are 3 5/8 inch steel channels, 18 gauge.
  • Non-structural angle brackets 614 are attached to beams 604 below channels 606. Non-structural angle brackets by tie into non- structural elements on the bottom side of panels 606, such interior surface studs 616.
  • Panels 606 may include a polymeric block having multiple layers and embedded metal members, such as described above relative to FIGS. 1-8C.
  • Panels 606 include structural layer 617 and offset layer 619.
  • Structural layer 617 includes structural studs 620.
  • Offset layer 619 includes interior surface studs 616.
  • roof system 602 panels 606 may be successively installed into channel 606 on opposing channels between a pair of adjacent beams at the higher end of the roof system, then slid down along the channel. (For illustrative purposes, the right- most of panels 606 is shown as not fully slid into place.) As each panel reaches its position, a lap joint is formed between the panel and the panel immediately preceding it in the installation. In some embodiments, an adhesive is used at the joint between the panels. Once each panel is in place, structural studs 620 of the panel may be fastened to the opposing channels 610 to secure the panel in place. Roof 608 may be installed after all of panels 606 have been installed and secured.
  • a roof slopes downwardly in both directions from an apex.
  • panels may be installed at the apex and slid down toward the walls until the channels are filled up to the apex on each side of the building.
  • Roof system may have any suitable slope.
  • roof has a slope of 1 inch per foot.
  • a roof has a slope of 1 ⁇ 2 inch per foot.
  • the beams in FIG. 31 are shown at 8 foot spacing.
  • the spacing between beams may, however, vary from embodiment to embodiment, depending factors such structural requirements for the building and the layout of the building.
  • a building may include any number of track and panel sections, in any arrangement.
  • FIG. 32 is a detail view of a beam providing tracks for roof panels on both sides of the beam.
  • Channels 610 may be mounted on beams 604. The channels may be secured using conventional fasteners. Structural studs 620 in insulating panels 606 are fastened to panel. Attachment plate 621 is secured on top of beam 614. Attachment plates may be provided at each of one or more beams to secure roof 608 to the beams.
  • Non- structural angle brackets 614 are fastened to beams and interior surface studs 616.
  • Ceiling 623 may be installed on non-structural angle brackets 614, interior surface studs 616, or a combination of the both.
  • FIG. 33 illustrates installation of a panel in a track on a beam.
  • Fasteners 625 are provided to couple structural studs 620 of panel 606 to channel 610.
  • Fasteners 627 are provided to couple interior surface studs 616 to non-structural angle brackets 614.
  • Fasteners 627 are provided to couple non- structural angle brackets 614 to beam 604.
  • FIG. 34 is an exterior (top) view illustrating an insulating panel installed in a roof system between two parallel beams.
  • Panel 606 includes structural studs 620 (near side) and interior surface studs 616 (far side).
  • FIG. 35 is an interior (bottom) view illustrating an insulating panel installed in a roof system between two parallel beams.
  • Panel 606 includes interior surface studs 616
  • the wider layer of the panel is installed "face-up" on the tracks, such that the wider layer of the panels are on top in the installed condition.
  • the roof system described in FIGS. 30 through 35 was shown installed the layer including structural studs (e.g., 3 5/8 wide) in the channel. Panels may nevertheless, in other embodiments, be installed include ridges, grooves, or studs that allow it be installed in any suitable channel.
  • FIG. 36 illustrates an alternate embodiment of a track and panel roof system.
  • Roof system 640 is generally similar to roof system 602 described above relative to FIGS 30-35, except that the top layer of the insulating beam is narrower.
  • the insulating panel may include a 1 5/8 inch by 1 1 ⁇ 4 steel structural stud, and slide into a 1 5/8 inch steel channel.
  • a narrow track such as shown in FIG. 36 may be suitable for relatively shorter spans between beams (for example, a four-foot span).
  • the track and panel system includes a stud on an extended rim of the panel that engages in a groove (in this case, the inside of the channel) mounted on the beams, which serves a track for the rim.
  • a groove in this case, the inside of the channel
  • the groove/rim arrangement of the system may be reversed.
  • each of the beams may be outfitted with one or more rails that serve as tracks and engage in corresponding grooves on the panels.
  • finishing elements or materials such as drywall
  • the non- structural channel runs vertically 16" OC.
  • the non-structural channels may be used to attach interior wall coverings such as drywall, as well as any of various decorative items.
  • Various types of siding or other exterior elements may be attached to, or placed in front of, the exterior surfaces of building panels.
  • a building is assembled by placing two or more building panels on a surface to form a row. Building panels may be connected by any of the various approaches described above. In some embodiments, each panel is free standing when placed on the slab or other supporting element or structure. As such, in some embodiments, a building is constructed without bracing elements to hold the building panels in place during construction.
  • one or more building panels are installed on a footing.
  • the footing may account for geometric variances or features of a slab or foundation. For example, a footing may compensate for curvature or a slope in a slab on which the building panel is to be mounted.
  • electrical lines or plumbing lines are pre-installed in building panels.
  • windows, doors, or other apertures may be created in a building panel prior to delivery to a building site. Creating openings or apertures may reduce the time to a construct the building.
  • a building panel includes a polymeric block, a frame coupled to the polymeric block, and a base member coupled to the polymeric block, the frame, or both.
  • the base member couples with a slab.
  • a method of constructing a building includes placing two or more building panels including polymeric blocks on a slab.
  • the base of the building panels may be fastened to the slab.
  • a building in an embodiment, includes a slab and two or more building panels.
  • Each of the building panels may include a polymeric block and a base. The bases of the building panels are fastened to the slab.
  • a base for a building panel may be made of any suitable material.
  • a base is a strip or angle of sheet metal.
  • a base of a panel may be a strip of wood (for example, a 2 by 4).
  • a building panel includes a solid polymeric block having an aperture, and a frame coupled in the aperture. Reinforcing elements are coupled to the frame along at least one side of the aperture. The reinforcing elements may inhibit deformation of the frame in the aperture.
  • a method of making a building panel includes providing a frame for an aperture. At least one side of the frame is reinforced with reinforcing elements. Loose polymeric material is provided adjacent to the frame. A solid polymeric block is formed from the loose polymer material such that the frame the frame defines an aperture in the solid block. The reinforcing elements may inhibit deformation of the frame in the aperture.
  • a panel includes slots for carrying conduit, cables, plumbing, or other elements.
  • the horizontal slots may intersect vertical slots in the panel.
  • slots for running conduits, plumbing, wires, or other elements have a dovetail cross section.
  • vertical studs on opposing sides of a panel are offset from one another. In one embodiment, vertical studs on opposing sides of a panel are staggered with respect to one another.
  • air cavities are provided in a panel. Air cavities may be sized and shaped to provide thermal isolation, acoustic isolation, or both, between the interior and the exterior of the panel.
  • one or both sides of a panel includes cross bracing.
  • the ends of each of the cross bracing members by couple to junctions at the 4 corners of the panel.
  • the crossing members may be attached to one or more additional vertical studs (for example, at the intersection of the cross members with one another.
  • a building panel is a shear panel.
  • a panel includes 2 5/8 inch studs. In one embodiment, a panel is about 5 1 ⁇ 2 inches. Examples of other thicknesses for a panel include about 2 3/8 inches, or 3 1 ⁇ 2 inches.
  • the cross section of a stud or other structural member is in the form of a hat section.
  • a stud or other structural member of a panel may nevertheless have any other suitable cross section.
  • a stud may have a c-shaped cross-section, a u-shaped cross-section, an arcuate cross section, a corrugated cross section, or vee-shaped cross section.
  • multiple building panels are produced from a solid block made in one molding process.
  • Each of the building panels may be produced by slicing the building panel from a solid larger solid block.
  • the frames include studs and cross rails.
  • Fixture elements may maintain frames in the desired spacing from one another during a molding process.
  • Loose polymeric material such as polymeric beads or pellets, may be introduced into the mold around and within frames.
  • the loose polymeric material includes pre-foamed polystyrene beads.
  • the polymeric material may be heated to fuse the media.
  • the block may be allowed to cool to form stock block. At this point, the frame elements are fixed in place in the stock block.
  • the fixture elements may be removed.
  • the cutting station may include a hot wire cutting system with one or more hot wires.
  • the hot wire system may be used to slice stock blocks at planes to create multiple block segments. Each of the segments may form a building panel. Each building panel may include one of frames and a block.
  • the hot wire system may be used to perform additional shaping and cutting, such as adding notches, cavities, passages, or windows to the panel.
  • a building panel includes a frame section 3 and 5/8 inches thick, with an offset in one direction of 3 and 5/8 inches and an offset in the other direction of 5 and 3/8 inches.
  • a building panel includes a frame section 3 and 5/8 inches thick, with an offset in one direction of 4 and 3/8 inches and no offset (offset of zero) in the other direction.
  • a building panel includes a frame section 3 and 5/8 inches thick, with an offset in one direction of 8 and 3/8 inches and no offset (offset of zero) in the other direction.
  • a block for producing building panels includes a solid polymeric block and two or more building panel frames coupled to the solid polymeric block.
  • the solid polymeric block may be sliced into portions (for example, segmented) to produce two or more building panels.
  • Each of the building panels so produced may include one of the building panel frames.
  • the frames are included in the block in an array such that the block can be sliced in two more different directions to slice off rows or columns of building panels from the block.
  • panels are aligned to promote flow of the polymeric material during formation of the solid block.
  • a cradle is used to align elements during formation. Holes may be provide in steel to improve flow, for example, to allow the polymeric material to reach spaces in or around doors and windows.
  • Steam may be used to heat the loose polymeric material.
  • the oven is heated to a temperature of about 212 degrees F to about 220 degrees F. In one embodiment, the oven is heated to a temperature of about 200 degrees F to about 250 degrees F.
  • the polymeric material is heat molded. For example, the polymeric material is molded to expand against metal elements, such as frame elements. In certain embodiments, a vacuum is pulled such that the polymeric material is vacuum packed.
  • a polymer material is selected to reduce moisture retention.
  • a block is formed from a closed cell polystyrene. The block may be allowed to cure. In one process, the block is allowed to cure for about 3 days.
  • buildings, panels, or other components and features thereof, and methods of producing or constructing buildings and their components are as described in U.S. Patent Application No. 13/926,426 entitled “MODULAR BUILDING PANEL WITH FRAME” filed June 25, 2013 (the "'426 application”), which is incorporated by reference as if fully set forth herein.
  • aspects and components of the inventions described in this application may be combined with aspects and components of the '426 application.
  • a solar power generation system is installed on a track and panel system built residence.
  • FIGS. 1 through 28 dimensions, spacing, and standard components are indicated. The dimensions, spacing, and components may nevertheless differ from those shown on the drawings and will vary from embodiment to embodiment, depending on the structural requirements, layout, and various other factors.

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Abstract

La présente invention concerne un système de construction qui comprend une pluralité de panneaux. Chacun des panneaux comprend une pluralité de goujons conçus pour servir d'éléments structuraux et un bloc polymère qui comprend une couche structurale définie par la largeur des goujons et une couche décalée. La couche décalée s'étend dans une direction intérieure de la couche structurale. Des encoches longitudinales supérieures et inférieures peuvent être incluses dans la couche décalée du bloc polymère. Des éléments non structuraux sont installés dans les encoches longitudinales supérieures et inférieures pour servir au montage d'éléments intérieurs (par exemple un revêtement mural) sur le côté intérieur des panneaux.
PCT/US2016/066174 2015-12-11 2016-12-12 Système de construction à guidages et à panneaux WO2017100772A1 (fr)

Applications Claiming Priority (2)

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US201562266430P 2015-12-11 2015-12-11
US62/266,430 2015-12-11

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