STRUCTURE WITH INTEGRATED INSULATION

Abstract

A structure with integrated insulation. The structure with integrated insulation includes a steel frame, the steel frame including a first vertical support beam and a second vertical support beam. The structure with integrated insulation also includes a building panel with integrated insulation. The building panel with integrated insulation including a first surface, a second surface, where the second surface is opposite the first surface, a first edge, where the first edge is disposed between the first surface and the second surface, and a second edge, where the second edge is disposed between the first surface and the second surface and is opposite the first edge. The building panel with integrated insulation being attached to the first vertical support beam on the first surface of the building panel with integrated insulation and attached to the second vertical support beam on the second surface of the building panel with integrated insulation.

Claims

1. A structure with integrated insulation, the structure with integrated insulation comprising: a steel frame, the steel frame including: a first vertical support beam; and a second vertical support beam; and a building panel with integrated insulation, the building panel with integrated insulation including: a first surface; a second surface, wherein the second surface is opposite the first surface; a first edge, wherein the first edge is disposed between the first surface and the second surface; and a second edge, wherein the second edge is disposed between the first surface and the second surface and is opposite the first edge; the building panel with integrated insulation being attached to the first vertical support beam on the first surface of the building panel with integrated insulation, wherein: the attachment between the first vertical support beam and the building panel with integrated insulation includes adhesive over an entirety of a web of the first vertical support beam in contact with the building panel with integrated insulation; and the building panel with integrated insulation being attached to the second vertical support beam on the second surface of the building panel with integrated insulation, wherein: the attachment between the second vertical support beam and the building panel with integrated insulation includes adhesive over an entirety of a web of the second vertical support beam in contact with the building panel with integrated insulation.

2. The structure with integrated insulation of claim 1, wherein the building panel with integrated insulation includes expanded polystyrene.

3. The structure with integrated insulation of claim 2, wherein the density of the expanded polystyrene is at least two pounds per cubic foot.

4. The structure with integrated insulation of claim 1, wherein the building panel with integrated insulation is approximately 48 inches wide.

5. The structure with integrated insulation of claim 1, wherein the building panel with integrated insulation is approximately 4 inches thick.

6. The structure with integrated insulation of claim 1, wherein the building panel with integrated insulation is approximately 6 inches thick.

7. The structure with integrated insulation of claim 1, wherein the first vertical support beam includes a T-beam.

8. The structure with integrated insulation of claim 1, wherein the first vertical support beam includes an I-beam.

9. A structure with integrated insulation, the structure with integrated insulation comprising: a steel frame, the steel frame including: a first vertical support beam; and a second vertical support beam; a building panel with integrated insulation, the building panel with integrated insulation including: a first surface; a second surface, wherein the second surface is opposite the first surface; a first edge, wherein the first edge is disposed between the first surface and the second surface; and a second edge, wherein the second edge is disposed between the first surface and the second surface and is opposite the first edge; and the building panel with integrated insulation being attached to the first vertical support beam on the first surface of the building panel with integrated insulation, wherein: the attachment between the first vertical support beam and the building panel with integrated insulation includes adhesive over an entirety of a web of the first vertical support beam in contact with the building panel with integrated insulation; and the building panel with integrated insulation being attached to the second vertical support beam on the second surface of the building panel with integrated insulation, wherein: the attachment between the second vertical support beam and the building panel with integrated insulation includes adhesive over an entirety of a web of the second vertical support beam in contact with the building panel with integrated insulation; and a covering, wherein the covering overlays an entirety of the first surface and the first vertical support beam.

10. The structure with integrated insulation of claim 9, wherein the building panel with integrated insulation includes a river configured to allow for placement of a utility line within the wall panel with integrated insulation.

11. The structure with integrated insulation of claim 9, wherein no portion of the first vertical support beam passes through the second surface of the building panel.

12. The structure with integrated insulation of claim 11, wherein no portion of the second vertical support beam passes through the first surface of the building panel.

13. The structure with integrated insulation of claim 9, wherein no portion of the second vertical support beam passes through the first surface of the building panel.

14. A structure with integrated insulation, the structure with integrated insulation comprising: a steel frame, the steel frame including: a first vertical support beam; and a second vertical support beam; a building panel with integrated insulation, the building panel with integrated insulation including: a first surface; a second surface, wherein the second surface is opposite the first surface; a first edge, wherein: the first edge is disposed between the first surface and the second surface; and a second edge, wherein: the second edge is disposed between the first surface and the second surface and is opposite the first edge; and the building panel with integrated insulation being attached to the first vertical support beam on the first surface of the building panel with integrated insulation, wherein the attachment between the first vertical support beam and the building panel with integrated insulation: includes adhesive over an entirety of a web of the first vertical support beam in contact with the building panel with integrated insulation; and creates a thermal break; the building panel with integrated insulation being attached to the second vertical support beam on the second surface of the building panel with integrated insulation, wherein the attachment between the second vertical support beam and the building panel with integrated insulation: includes adhesive over an entirety of a web of the second vertical support beam in contact with the building panel with integrated insulation; and creates a thermal break; and a backing secured within the building panel with integrated insulation, the backing configured to allow an external device to be attached to the building panel with integrated insulation.

15. The structure with integrated insulation of claim 14, wherein the backing includes a board.

16. The structure with integrated insulation of claim 14, wherein the backing is attached to the second vertical support beam.

17. The structure with integrated insulation of claim 14, wherein the backing is glued to the building panel with integrated insulation.

18. The structure with integrated insulation of claim 14, wherein the backing is flush with the first surface of the building panel with integrated insulation.

19. The structure with integrated insulation of claim 14, wherein the backing is recessed relative to the first surface of the building panel with integrated insulation.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] To further clarify various aspects of some example embodiments of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrated embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0019] FIG. 1A illustrates an example of a T-beam for use with an interior wall;

[0020] FIG. 1B illustrates an example of a T-beam for use with an exterior wall;

[0021] FIG. 2A illustrates an example of a connection between I-beams which are in line relative to one another;

[0022] FIG. 2B illustrates an example of a connection between I-beams which are not in line relative to one another;

[0023] FIG. 3 illustrates an example of a connection between a post and a wooden beam;

[0024] FIG. 4A illustrates a c-channel configured to receive an interior wall panel;

[0025] FIG. 4B illustrates a c-channel configured to receive an exterior wall panel;

[0026] FIG. 4C illustrates an angled c-channel configured to receive an interior wall panel;

[0027] FIG. 4D illustrates an angled c-channel configured to receive an exterior wall panel;

[0028] FIG. 4E illustrates an indentation in a roof panel configured to receive an c-channel;

[0029] FIG. 5A illustrates an example of a c-channel junction of interior walls forming a corner;

[0030] FIG. 5B illustrates an example of a c-channel junction of interior walls forming a T-junction;

[0031] FIG. 5C illustrates an example of a c-channel junction of an interior wall and an exterior wall forming a corner;

[0032] FIG. 5D illustrates an example of a c-channel junction of an interior wall and an exterior wall forming a T-junction;

[0033] FIG. 6A illustrates an example of an angled c-channel for an interior wall connected to an I-beam;

[0034] FIG. 6B illustrates an example of an angled c-channel for an exterior wall connected to an I-beam;

[0035] FIG. 6C illustrates an example of a c-channel for an interior wall connected to an I-beam;

[0036] FIG. 6D illustrates an example of a c-channel for an exterior wall connected to an I-beam;

[0037] FIG. 6E illustrates a side view of an example of a c-channel (for an interior wall or an exterior wall) connected to an I-beam;

[0038] FIG. 7 illustrates an example of a sill plate attached to an I-beam;

[0039] FIG. 8A illustrates an example of a backing for a hose bib;

[0040] FIG. 8B illustrates an example of a backing for a roof vent;

[0041] FIG. 8C illustrates an example of a backing for a wall vent;

[0042] FIG. 8D illustrates an example of a backing for a light fixture;

[0043] FIG. 8E illustrates an example of a backing for a turtle vent;

[0044] FIG. 8F illustrates an example of a backing for a cabinet;

[0045] FIG. 8G illustrates an example of a backing for a toilet;

[0046] FIG. 8H illustrates an example of a backing for a shower head;

[0047] FIG. 8I illustrates an example of a backing for a floor drain;

[0048] FIG. 8J illustrates an example of a backing for hardware;

[0049] FIG. 8K illustrates an example of a backing for a light;

[0050] FIG. 8L illustrates an example of a backing for a hand rail;

[0051] FIG. 8M illustrates an example of a backing for a heat register;

[0052] FIG. 8N illustrates an example of a backing for a return air vent;

[0053] FIG. 8O illustrates an example of a backing for a closet rod; and

[0054] FIG. 8P illustrates an example of a backing for a stair header.

DETAILED DESCRIPTION OF SOME EXAMPLE EMBODIMENTS

[0055] Reference will now be made to the figures wherein like structures will be provided with like reference designations. It is understood that the figures are diagrammatic and schematic representations of some embodiments of the invention, and are not limiting of the present invention, nor are they necessarily drawn to scale.

[0056] FIGS. 1A and 1B (collectively “FIG. 1”) show a T-beam 100. FIG. 1A illustrates an example of a T-beam 100 for use with an interior wall; and FIG. 1B illustrates an example of a T-beam 100 for use with an exterior wall. The T-beam 100 is a load-bearing structure with a “T” shaped cross section. The T-beam 100 can be used to support a wall panel (as described in first related application). The T-beam 100 can be made of any desired material including wood, steel, aluminum or any other desired material. Additionally or alternatively, the installation pattern of the T-beam 100 can create a thermal break (as described in third related application).

[0057] FIG. 1 shows that the T-beam 100 can include a flange 102. The flange 102 remains outside of the wall panel, acting as a frame. The flange 102 (the horizontal portion when viewed as a “T”) serves as a compression member in resisting compressive stresses. I.e., the flange 102 supplies a vertical “holding” force within the structure frame. The flange 102 can be approximately 2 inches wide. As used in the specification and the claims, the term approximately shall mean that the value is within 10% of the stated value, unless otherwise specified.

[0058] FIG. 1 also shows that the T-beam 100 can include a web 104. The web 104 (the vertical portion when viewed as a “T) serves to resist shear stress and to provide greater separation for the coupled forces of bending. The web 104 can be approximately 2 inches tall for use with an exterior wall panel and approximately 1.5 inches tall for use with an interior wall panel.

[0059] By way of example, a method of creating the T-beam 100 is described herein. The T-beam 100 starts out as a flat sheet of 20 gage steel (standard). Flange 102 is approximately two inches wide. To make flange 102 there will be two 180 degree bends, one on each end of the flange 102 and one (1) 180 degree bend on the bottom of the web 104. The first bend at the bottom of the top right side of the flange 102 is a one hundred and eighty (180) degree bend that is approximately seven eights (⅞″) of an inch that goes back to the center of the of flange 102. The second bend is at the left of the flange 102. This one hundred and eighty (180) degree bend is one (1″) inch in length and goes back to the center of the T-beam 100. At the end of this one (1″) inch bend will be a ninety (90) degree bend that is one and one half (1½″) inches (2 inches for an exterior wall) in length to create the web 104. At the end of the one and one half (1½″) inch web 104 on the T will be another one hundred and eighty (180) degree bend that will be one quarter (¼″) of an inch in length.

[0060] FIGS. 2A and 2B (collectively “FIG. 2”) illustrate an example of a connection 200 between I-beams. FIG. 2A illustrates an example of a connection 200 between I-beams which are in line relative to one another; and FIG. 2B illustrates an example of a connection 200 between I-beams which are not in line relative to one another. An I-beam, also known as H-beam, W-beam (for “wide flange”), Universal Beam (UB), Rolled Steel Joist (RSJ), or double-T (especially in Polish, Bulgarian, Spanish, Italian and German), is a beam with an I- or H-shaped cross-section. The horizontal elements of the “I” are flanges, while the vertical element is termed the web. The I-shaped section is a very efficient form for carrying both bending and shear loads in the plane of the web.

[0061] FIG. 2 shows that the connection 200 includes a plate 202. The plate 202 is a piece of structural steel or other material. The plate 202 is configured to be secured to each of the I-beams which secures the I-beams relative to one another. I.e., the plate 202 is of sufficient size and strength to ensure that the load placed on the intersection of the I-beams is sufficiently secured, as if the gap did not exist. I.e., ideally there is no loss of strength at the intersection secured by the plate 202. Each I-Beam will have four (4) pre drilled holes to attach to the plate 202. A total of eight (8) rivets will be used to secure the two I-Beams together at the ridge line, hips and valleys. As used in the specification and the claims, the phrase “configured to” denotes an actual state of configuration that fundamentally ties recited elements to the physical characteristics of the recited structure. As a result, the phrase “configured to” reaches well beyond merely describing functional language or intended use since the phrase actively recites an actual state of configuration.

[0062] FIG. 3 illustrates an example of a connection 300 between a post 302 and a wooden beam 304. The post (as described in second related application) is a structural element that can be attached to the end of a wall panel. The connection 300 allows the post to act as a support for the wooden beam 304. The wooden beam 304 acts to support the elements mounted above the wooden beam 304, such as another floor of the structure, a roof or any other element.

[0063] FIG. 3 shows that the connection 300 can include a plate 306. The plate 306 is a piece of structural steel or other material. The plate 306 is configured to be secured to both the post 302 and the wooden beam 304 securing the post 302 and the wooden beam 304 relative to one another. I.e., the plate 306 is of sufficient size and strength to ensure that the post 302 and the wooden beam 304 do not move relative to one another. The plate 306 is attached to the post 302 and the wooden beam 304 using rivets, screws, adhesive or any other desired attachment method.

[0064] FIGS. 4A, 4B, 4C, 4D, and 4E (collectively “FIG. 4”) illustrate an example of a c-channel 400. FIG. 4A illustrates a c-channel 400 configured to receive an interior wall panel; FIG. 4B illustrates a c-channel 400 configured to receive an exterior wall panel; FIG. 4C illustrates an angled c-channel 400 configured to receive an interior wall panel; FIG. 4D illustrates an angled c-channel 400 configured to receive an exterior wall panel; and FIG. 4E illustrates an indentation 402 in a roof panel configured to receive an c-channel 400. The c-channel 400 is a notch or groove that is shaped like a square “C”. I.e., it is a parallelogram with one side missing. If desired, the c-channel 400 can include a flange or other retaining mechanism near the open side. I.e., the “missing side” of the parallelogram may be partially missing only in order to better retain an external element within the c-channel 400. The c-channel 400 can receive a wall panel (as described in first related application) or some other structural element. E.g., a wall panel can be inserted into the c-channel 400 and then glued or otherwise permanently attached, creating a connection between the element containing the c-channel 400 and the element inserted into the c-channel 400. The c-channel 400 can include a metal or wood brace. The c-channel 400 can be glued into an indentation 402 cut out from a building panel with integrated insulation and/or attached to a desired element (such as an I-beam, wooden beam) or glued within the c-channel of a building panel with integrated insulation, configured to receive a wall panel.

[0065] The height of the c-channel 400 can be critical to create a thermal break (as described in third related application). For example, the c-channel 400 can be approximately 75% of the height of the indentation 402 cut in the building panel with integrated insulation into which the c-channel 400 will be inserted. E.g., if the indentation 402 cut in the building panel with integrated insulation is approximately 2 inches high then the c-channel 400 can be approximately 1.5 inches high. Making the c-channel 400 smaller that the indentation 402 cut in the building panel with integrated insulation can be critical to prevent a thermal bridge that passes through the entire panel.

[0066] One of skill in the art will appreciate that the that the “width” of the c-channel 404 will be the horizontal width and which is not necessarily the same as the size of the c-channel 400 as measured along the surface of the containing element, such as a roof panel. For example, the roof's pitch is its vertical rise divided by its horizontal span (or “run”), what is called “slope” in geometry and stair construction, or the tangent function in trigonometry. It is typically expressed with the rise first and run second, with the run denominated by the number 12, giving a ratio of how many inches of incline there is to each foot of run. For example, 3:12, 4:12, 5:12, and so on. To find the exact roof slope in degrees, one takes the arctangent. For example: arctan( 3/12)=14.0°. One of skill in the art will appreciate that the measured opening of the c-channel 400 in the roof panel with integrated insulation 110 may not be the exact width of the wall panel. I.e., because the roof panel with integrated insulation 110 may be installed at an angle the measured width along the surface of the roof panel with integrated insulation 110 will be longer than a horizontal measurement at the installed angled. For example, if the roof has a pitch of 6/12 (˜26.6 degrees) then the measured opening along the surface of the roof panel with integrated insulation 110 can be calculated by:

[00001]$\frac{w}{\cos \left({\tan }^{-1}\left(p\right)\right)}=\frac{w}{\frac{1}{\sqrt{1+p^2}}}=w\times \sqrt{1+p^2}$

where w is the horizontal width and p is the pitch expressed as a fraction or a decimal. For example, if the pitch is 6/12 then the opening across the surface is 6×√{square root over (1+(0.5).sup.2)}=6.708 inches for an exterior wall and 4.472 inches for an interior wall.

[0067] FIGS. 5A, 5B, 5C and 5D (collectively “FIG. 5”) illustrate examples of c-channel junctions 500. FIG. 5A illustrates an example of a c-channel junction 500 of interior walls forming a corner; FIG. 5B illustrates an example of a c-channel junction 500 of interior walls forming a T-junction; FIG. 5C illustrates an example of a c-channel junction 500 of an interior wall and an exterior wall forming a corner; and FIG. 5D illustrates an example of a c-channel junction 500 of an interior wall and an exterior wall forming a T-junction. Because the c-channels 400 are configured to receive an external element, such as a wall panel, there will be places where c-channels 400 meet one another forming a junction. The c-channel junction 500 can either be a corner (i.e., where both walls end) or a T-junction (i.e. one wall ends in the middle of another wall). The c-channel junction 500 is a bracket configured to receive the wall panels at the intersection.

[0068] FIGS. 6A, 6B, 6C, 6D and 6E (collectively “FIG. 6”) illustrate an example of a c-channel 400 connected to an I-beam 602. FIG. 6A illustrates an example of an angled c-channel 400 for an interior wall connected to an I-beam 602; FIG. 6B illustrates an example of an angled c-channel 400 for an exterior wall connected to an I-beam 602; FIG. 6C illustrates an example of a c-channel 400 for an interior wall connected to an I-beam 602; FIG. 6D illustrates an example of a c-channel 400 for an exterior wall connected to an I-beam 602; and FIG. 6E illustrates a side view of an example of a c-channel 400 (for an interior wall or an exterior wall) connected to an I-beam 602. A c-channel 400 connected to an I-beam 602 allows an I-beam 602 supporting an floor, roof or other structure to receive a wall panel with integrated insulation. I.e., the wall is created and the c-channel 400 can be placed over the wall panels making up the wall, forming an intersection between the wall and floor or roof.

[0069] FIG. 6 shows that the c-channel 400 is attached to the flange of the I-beam 602 using a screw, nut and bolt, rivet, weld or other attachment. Rivets are a permanent mechanical fastener. Before being installed a rivet consists of a smooth cylindrical shaft with a head on one end. The end opposite the head is called the buck-tail. On installation the rivet is placed in a punched or drilled hole, and the tail is upset, or bucked (i.e., deformed), so that it expands to about 1.5 times the original shaft diameter, holding the rivet in place. To distinguish between the two ends of the rivet, the original head is called the factory head and the deformed end is called the shop head or buck-tail. Because there is effectively a head on each end of an installed rivet, it can support tension loads (loads parallel to the axis of the shaft); however, it is much more capable of supporting shear loads (loads perpendicular to the axis of the shaft).

[0070] FIG. 7 illustrates an example of a sill plate 702 attached to an I-beam 602. A sill plate 702 or sole plate in construction and architecture is the bottom horizontal member of a wall or building to which vertical members are attached. The word plate is typically omitted in America and carpenters speak simply of the “sill”. Other names are ground plate, ground sill, groundsel, and mud sill. The sill plate 702 is usually composed of lumber but can be any material. The sill plate 702 typically carries the wall framing (posts and studs) and floor joists.

[0071] FIG. 7 shows that the sill plate 702 is attached to the I-beam 602 using screws 704. The screws 704 are threaded cylinders that secure the I-beam 602 relative to the sill plate 702. I.e., the screw prevents separation and lateral motion of the I-beam 602 relative to the sill plate 702. One of skill in the art will appreciate that the I-beam 602 can be attached to the sill plate 702 using any desired fastener, including bolts, rivets, adhesive, or any other desired fastener.

[0072] FIGS. 8A, 8B, 8C, 8D, 8E, 8F, 8G, 8H, 8I, 8J, 8K, 8L, 8M, 8N, 8O and 8P (collectively “FIG. 8”) illustrate an example of a backing 800 attached to a structure with integrated insulation. FIG. 8A illustrates an example of a backing 800 for a hose bib; FIG. 8B illustrates an example of a backing 800 for a roof vent; FIG. 8C illustrates an example of a backing 800 for a wall vent; FIG. 8D illustrates an example of a backing 800 for a light fixture; FIG. 8E illustrates an example of a backing 800 for a turtle vent; FIG. 8F illustrates an example of a backing 800 for a cabinet; FIG. 8G illustrates an example of a backing 800 for a toilet; FIG. 8H illustrates an example of a backing 800 for a shower head; FIG. 8I illustrates an example of a backing 800 for a floor drain; FIG. 8J illustrates an example of a backing 800 for hardware; FIG. 8K illustrates an example of a backing 800 for a light; FIG. 8L illustrates an example of a backing 800 for a hand rail; FIG. 8M illustrates an example of a backing 800 for a heat register; FIG. 8N illustrates an example of a backing 800 for a return air vent; FIG. 8O illustrates an example of a backing 800 for a closet rod; and FIG. 8P illustrates an example of a backing 800 for a stair header. The backing 800 can include a sheet of wood or other material. The backing 800 acts as a brace or support for an external element to be mounted. The backing 800 can be secured to a building panel with integrated insulation, an I-beam, a T-beam or some combination thereof using adhesive, mechanical fasteners or any other desired attachment mechanism.

[0073] The backing 800 is secured to the structure with integrated insulation using adhesive. In particular, the adhesive is applied to the entirety of the surface of the backing 800 that is in contact with the structure with integrated insulation. This ensures that air gaps are removed, minimizing thermal bridging. Additionally or alternatively, it ensures that the backing 800 remains in place regardless of any force that would be applied by the external element.

[0074] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.