APPARATUS, SYSTEM AND METHODS FOR STRUCTURAL EXERIOR WALL PANEL BUILDING SYSTEMS
20210115675 ยท 2021-04-22
Inventors
Cpc classification
E04C2/388
FIXED CONSTRUCTIONS
E04C2/428
FIXED CONSTRUCTIONS
E04C2/246
FIXED CONSTRUCTIONS
International classification
E04F13/24
FIXED CONSTRUCTIONS
E04B2/00
FIXED CONSTRUCTIONS
E04C2/24
FIXED CONSTRUCTIONS
Abstract
An exterior wall panel apparatus and system is disclosed which assists in the rapid construction of manufactured homes and commercial buildings, and which replaces traditional building materials with a full composite system and materials, to extend and increase the protective capabilities of traditional residential, industrial and commercial structures
Claims
1. An improved exterior wall panel apparatus, comprising: a sheathing, said sheathing comprising composite material, said sheathing configured in various shapes and sizes such that said sheathing has a height and width that are substantially greater than its depth, said sheathing having a front sheathing side and a back sheathing side; a plurality of vertical studs, said plurality of vertical studs comprising composite material, said plurality of vertical studs having a length that is substantially greater than its width and depth, said plurality of vertical studs having a front stud side and a back stud side; an epoxy, said epoxy located between the back sheathing side and the front stud side of the plurality of vertical studs, such that the combination of said sheathing, said plurality of vertical studs and said epoxy creates a sealed unit which can be used an exterior wall panel for a residential or commercial building.
2. The improved exterior wall panel apparatus of claim 1, wherein the sheathing material is a fiberglass.
3. The improved exterior wall panel apparatus of claim 2, wherein the sheathing material is a fiberglass ballistic armor plate.
4. The improved exterior wall panel apparatus of claim 1, wherein the material for the plurality of vertical studs is a fiberglass.
5. The improved exterior wall panel apparatus of claim 1, wherein the plurality of vertical studs are approximately the same as the length of said sheathing.
6. The improved exterior wall panel apparatus of claim 1, further comprising at least one c-channel connector
7. The improved exterior wall panel apparatus of claim 7, wherein the at least one c-channel connector is positioned at a head of said exterior wall panel apparatus.
8. The improved exterior wall panel apparatus of claim 7, wherein the at least one c-channel connector is positioned at a sill of said exterior wall panel apparatus.
9. The improved exterior wall panel apparatus of claim 6, wherein a continuous air gap is provided along the head of said exterior wall panel apparatus thereby providing a means for air to flow up through the ventilation air gap.
10. A method for manufacturing an improved exterior wall panel apparatus using a construction table, said construction table comprising scoring arms, said scoring arms capable of accepting and securing a sheathing, said sheathing comprising composite material, said sheathing configured such that said sheathing has a height and width that are substantially greater than its depth, and having a front sheathing side and a back sheathing side, comprising the steps of: Securing said sheathing with said scoring arms; Allowing for the attachment of at least one vertical stud to said sheathing, said at least one vertical stud comprising composite material, said at least one vertical stud having a length that is substantially greater than its width and depth, and having a front stud side and a back stud side, such that said front stud side of said at least one vertical stud will make contact with said back sheathing side of said sheathing; Applying an epoxy between said front stud side of said at least one vertical stud and said back sheathing side of said sheathing; Allowing said epoxy to cure.
11. The method for manufacturing an improved exterior wall panel of claim 10, wherein the sheathing material is a fiberglass.
12. The method for manufacturing an improved exterior wall panel of claim 11, wherein the sheathing material is a fiberglass ballistic armor plate.
13. The method for manufacturing an improved exterior wall panel of claim 10, wherein the material for the plurality of vertical studs is a fiberglass.
14. The method for manufacturing an improved exterior wall panel of claim 10, wherein the plurality of vertical studs are approximately the same as the length of said sheathing.
15. The method for manufacturing an improved exterior wall panel of claim 10, further comprising at least one c-channel connector.
16. The method for manufacturing an improved exterior wall panel of claim 15 wherein the at least one c-channel connector is positioned at a head of said exterior wall panel apparatus.
17. The method for manufacturing an improved exterior wall panel of claim 15, wherein the at least one c-channel connector is positioned at a sill of said exterior wall panel apparatus.
18. The method for manufacturing an improved exterior wall panel of claim 10, further comprising the steps of: Allowing for the attachment of at least one horizontal bracing to said sheathing, said at least one horizontal bracing comprising composite material, said at least one horizontal bracing having a length that is substantially greater than its width and depth, and having a front bracing side and a back bracing side, such that said front bracing side of said at least one horizontal bracing will make contact with said back sheathing side of said sheathing; Applying an epoxy between said front bracing side of said at least one horizontal bracing and said back sheathing side of said sheathing; Allowing said epoxy to cure.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] A complete understanding of the present embodiments and the advantages and features thereof will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
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DETAILED DESCRIPTION
[0053] As stated herein, the objective of the present disclosure is to provide an improved exterior wall panel apparatus and system for improving the process of the building of a residential, industrial and/or commercial structure, along with the improvements to the stability and protection of that structure once built. The objective of the present disclosure is to further provide the improved methods for building and transporting the novel exterior wall panel, and building the entire structure using the novel wall panels.
[0054] The specific details of the preferred embodiment or to alternative embodiments described herein are to the described system. Any specific details of these embodiments are used for demonstration purposes only, and no unnecessary limitations or inferences are to be understood therefrom.
[0055] Before describing in detail exemplary embodiments, it is noted that the embodiments reside primarily in combinations of components and procedures related to the system. Accordingly, the system components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
[0056] In general, the embodiments provided herein relate to structural building systems and in particular to exterior wall panel apparatus and systems, and the techniques that greatly reduce the amount of time to construct a structure. The system allows for constructing the exterior wall panels at the factory before transporting to the site, transporting the exterior wall panels to the site for constructing on-site, or a combination of both, while increasing the structural integrity of the structure.
[0057] Additionally, the embodiments provided herein disclose the methods for manufacturing, transporting and building structures utilizing novel exterior wall panel apparatus, in accordance with the present disclosure.
[0058] As used herein, the term structure relates to a building, which includes but is not limited to residential homes and industrial and commercial structures, which may include on-site or factory built homes and commercial buildings, premanufactured homes and buildings, mobile homes and buildings, modular homes and commercial buildings, and multi-unit homes or commercial buildings.
[0059] Referring to the drawings, wherein like reference numerals refer to the same or similar features in the various views,
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[0061] Each wall panel 12, 14, 16 is approximately 4 by 8, so the exterior wall panel system 20 made up of the first 12, second 14 and third 16 wall panels is 8 by 12. Accordingly, different size exterior wall panel systems 20 can be assembled from smaller exterior wall panels 10. The composite material front is located on the front side 22 of each exterior wall panel apparatus 10.
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[0071] An epoxy 56 can be applied to the space between the top 54 of the exterior wall panel 10 and the ceiling joist 50. The epoxy 56 will also be placed between the back side 28 of the vertical composite stud 24 and the back side 58 of the composite material front 18. In the preferred embodiment, the epoxy 56 is a 3M ScotchWeld Multi-Material Composite Urethane Epoxy.
[0072] An air gap 64 is located between the two composite heads 46 to allow air to circulate through and out of the vertical composite stud 24.
[0073] Similar to
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[0075] Similar to
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[0078] Likewise,
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[0085] In some embodiments, the exterior wall panel apparatus is constructed of a fiberglass composite 18. The fiberglass composite 18 is beneficial as it facilitates rapid assembly. Further, the wall panel system 20 includes a ventilation air gap 64 in which the composite head 46 provides a channel for air to flow up through the ventilation air gap 64, into an attic space (not shown) to be discharged through the attic's ventilation.
[0086] In some embodiments, the fiberglass composite 18 structure is highly resistant to wind damage and other common environmental damage such as earthquakes when compared to traditional systems known in the arts.
[0087] The present disclosure provides a process of determining uniform sizes for the exterior wall panels 10, as shown by example in
[0088] These sizes, along with other standard and custom sizes, facilitate the assembly of any size residential home or commercial building at a factory or on-site. These sizes also allow for easier transport to the job site, and require less effort when managing the exterior wall panels 10, whether at the job site or in the factory.
[0089] In order to manufacture the various size wall panels 10, specially designed construction tables 72 can be incorporated.
[0090] Further, a modified forklift truck with an extendable arm can be configured to pick up any size exterior wall panel 10, turn it over as needed to access both sides and all edges, stand the wall panel 10 up for easier access, and release it once it has been properly located and secured, greatly simplifies the manufacturing and construction process.
[0091] The present disclosure further includes a composite tongue system comprising fiberglass I beams in the preferred embodiment, with a secondary I beam inserted beneath the main beams for support. The tongue system was finished with a metal female hitch epoxied together. Additional L channels ran the length of the beams to help secure the beams to the trailer. Anti-twist brackets assisted in stabilizing the beams.
[0092] Additionally, the present disclosure provides for quick attach additions to decrease assembly time for the residential or commercial buildings. These quick attach additions include, but are not limited to, master closets and bathrooms, guest rooms, laundry rooms and/or offices, which could be delivered and attached to the building with little or no re-construction needed. The additions are configured to be connected or hooked into or on an existing building.
[0093] Likewise, a utility unit is disclosed that would hang on the end of the building. These utility units include, but are not limited to, heating and air conditioning units, hot water units, even electrical and pumps can be configured to be attached to the outside of the building, and configured to be all in one unit, to increase the interior space of the building. By placing these utility devices outside, any repair or replacement of the unit can be done from the outside, eliminated any mess or disruption by having those that repair the units outside the building. The same process could be used for solar panels, and multi-fuel generators, which may be used where those services may not be available. As such, these units can stand alone or be powered as necessary without reconfiguring the building utilities once it is built.
[0094] To the extent there is a need for concrete walls in a particular design, the present disclosure allows for a separate wall, for example 2 by 6, and using L brackets to allow for a 2-3 slurry coat of concrete to be poured into the wall during manufacturing or construction at the factory. This process provides the advantages of both the composite material and concrete, although it adds to the weight of the wall panels 10.
[0095] With this disclosure, modular units can be coupled together to build stand-alone hospitals quickly as needed for emergencies (or for permanent construction). For example, eight to twenty modular units can be assembled quickly anywhere in the world in emergency situations, where traditional brick and mortar or steel buildings would cost too much and take too much time to build.
[0096] Additionally, the present disclosure allows for break-down storage units to be shipped flat and constructed on site. These temporary storage units could offer temperature control, electricity, and protection from exterior elements and environments, and be bullet proof, if necessary.
[0097] Reference throughout the specification to various embodiments, some embodiments, one embodiment, or an embodiment, or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases in various embodiments, in some embodiments, in one embodiment, or in an embodiment, or the like, in places throughout the specification are not necessarily all referring to the same embodiment.
[0098] Further, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features structures, or characteristics of one or more other embodiments without limitation given that such combination is not illogical or non-functional. Although numerous embodiments of this disclosure have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this disclosure.
[0099] All directional references (e.g., plus, minus, upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the any aspect of the disclosure.
[0100] As used herein, the phrased configured to, configured for, and similar phrases indicate that the subject device, apparatus, or system is designed and/or constructed (e.g., through appropriate hardware, software, and/or components) to fulfill one or more specific object purposes, not that the subject device, apparatus, or system is merely capable of performing the object purpose. Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily infer that two elements are directly connected and in fixed relation to each other. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the present disclosure as defined herein in the appended claims.
[0101] Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated materials does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.
[0102] Many different embodiments have been disclosed herein, in connection with the above description and the drawings. It will be understood that it would be unduly repetitious and obfuscating to describe and illustrate every combination and sub combination of these embodiments. Accordingly, all embodiments can be combined in any way and/or combination, and the present specification, including the drawings, shall be construed to constitute a complete written description of all combinations and sub combinations of the embodiments described herein, and of the manner and process of making and using them, and shall support claims to any such combination or sub combination.
[0103] An equivalent substitution of two or more elements can be made for any one of the elements in the claims below or that a single element can be substituted for two or more elements in a claim. Although elements can be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination can be directed to a sub combination or variation of a sub combination.
[0104] It will be appreciated by persons skilled in the art that the present embodiment is not limited to what has been particularly shown and described hereinabove. A variety of modifications and variations are possible in light of the above teachings without departing from the following claims.