Modular building methods and systems using lightweight foam modular panels which are based on fractal geometry. Each panel includes one or more channels formed through the foam body, where the channels are centered between adjacent fractal modules of the overall modular panel. The channels are configured to receive splines (e.g., dimensional lumber) therein. The entire system is based on dimensional lumber sizing. The rectangular panels include a pre-cut slot extending through one face, to the channel, while a score line is formed in the opposite face, aligned with the pre-cut slot of the opposite face. The panels may be easily and quickly cut with a box knife to reduce the number of fractal modules in a given panel, to provide a smaller panel still based on such fractal geometry. Such a cut is made along the score line, where the foam is no more than 2 inches thick.

A single leaf building component for use in separating walls in timber frame building construction. Two timber frame studs are held together at an edge by at least one acoustic connector. The connector holds the frames at a fixed distance, prevents sound transfer and provides a lifting point. Embodiments of the connector are described with the inclusion of a dampening material and having a timber body.

Modular building methods and systems using lightweight foam modular panels which are based on fractal geometry. Each panel includes one or more channels formed through the foam body, where the channels are centered between adjacent fractal modules of the overall modular panel. The channels are configured to receive splines (e.g., dimensional lumber) therein. The entire system is based on dimensional lumber sizing. The rectangular panels include a pre-cut slot extending through one face, to the channel, while a score line is formed in the opposite face, aligned with the pre-cut slot of the opposite face. The panels may be easily and quickly cut with a box knife to reduce the number of fractal modules in a given panel, to provide a smaller panel still based on such fractal geometry. Such a cut is made along the score line, where the foam is no more than 2 inches thick.

A building component utilizing a pourable polyurethane or structural foam that can be used for floors, walls, and roof assemblies with a frame with an interior, back or a front, multiple partition beams forming cells in said frame, pourable polyurethane or structural foam exterior backing attached to said frame back. The structural foam is poured into said cells to a desired level, and after said structural foam is poured into said cells, said interior backing is attached to said frame front. Cabling is used to improve movability of the invention, and improve on wind loading and seismic requirements of the present invention. Safety is also improved during the manufacturing process, loading, unloading, and in final assembly through the use of cabling.

A structural panel for building construction includes a series of truss members, and accompanying sinusoidal support elements in welded communication and enclosed in a planarly extended foam layer. Together, the structural panel allows for easy and efficient off-site assembly, which creates a lightweight panel with an increased weight-bearing capacity using inexpensive and versatile materials.

A structural panel for building construction includes a series of truss members, and accompanying sinusoidal support elements in welded communication and enclosed in a planarly extended foam layer. Together, the structural panel allows for easy and efficient off-site assembly, which creates a lightweight panel with an increased weight-bearing capacity using inexpensive and versatile materials.

A wood blocking blank for creating wood blocking for placement between metal studs includes a panel of a blocking material. The panel of blocking material has an original length and a standard width. The standard width is sized to a nominal stud width configured to fit between the metal studs. A groove is cut down the entire original length of the panel of blocking material approximate a first side of the panel of blocking material. The groove is configured for orienting the first side of the panel of blocking material in a soft side of a first metal stud and a second side of the panel of blocking material against the hard side of an adjacent metal stud. The groove is sized to receive the lip of the soft side of the metal stud.

According to one embodiment, an insulated structure includes a frame comprising a plurality of wall studs coupled together and a plurality of foam boards attached to the frame to form a continuous insulative wall. A plurality of fasteners attaches the foam boards to the frame. Each fastener includes an elongate shaft and a cap. The elongate shaft is configured to penetrate through a foam board and into a wall stud to couple the components together. The cap is configured to be positioned atop a foam board to distribute a load relatively evenly to the foam board. A sealing tape is applied across seams between adjacent foam boards and over the fasteners' caps to seal the wall. A sealing caulk is applied to secondary fasteners and penetrations to seal the wall. In some embodiments, the structure has a fastener density of about 1 fastener per 243 in.sup.2 of foam board.

A method of constructing a building using wall panel assemblies and roof panel assemblies that are made up of traditional framing materials, such as studs and interior walls, coated with insulating foam, except that the typical exterior sheathing is optional. Because the panel assembly is structurally sound and thermally insulated, the only reason to install an exterior sheath or additional roofing material is for aesthetic or practical purposes. A beneficial mode for readily applying insulating foam to provide for sealably joining roof panel assemblies to wall panel assemblies is disclosed.

A panelized building system utilizing structural framing combined with integrated insulation is disclosed. The system may include a roof system, at least one wall panel, a floor panel, at least one corner post and at least one foundational component. The roof system, the wall panel, the floor panel, the corner post and the foundational component are configured to mechanically lock to each to form a panelized building structure consisting of structural framing and composite foam insulation. The roof system, the floor panel, the corner post, and the foundational component of the panelized building system may be configured to mechanically lock to each other through a tongue-and-groove interlocking system.