BUILDING SYSTEM AND METHOD UTILIZING INTEGRATED INSULATION

Abstract

A panelized building system and method of construction utilizing a rigid framing combined with foam insulation is disclosed. The system may include a metal roof panel, at least one metal wall panel, a floor panel, at least one metal corner post and at least one foundational component. A single layer of foam insulation encapsulates partially fills a rigid framing and may be molded against a non-stick surface or bonded to an exterior building material. In either case, a single monolithic piece is formed. A utility cavity may be formed interior to the single layer of foam insulation. The exterior face may be textured, undulated, radiused, or shaped in myriad ways.

Claims

1. A wall panel comprising: a. a rigid framing; b. a single layer of foam insulation; c. the single layer of foam insulation extends beyond an exterior surface of the rigid framing; e. the single layer of foam insulation partially fills the rigid framing and encapsulates an exterior flange of the rigid framing; and f. a utility cavity is formed between an interior face of the single layer of foam insulation and an interior surface of the rigid framing.

2. The wall panel of claim 1, wherein an exterior face of the single layer of foam insulation is molded against a removable non-stick surface thereby allowing it to comprise any shape and any texture.

3. The wall panel of claim 1, wherein an exterior face of the single layer of foam insulation is bonded to a building product.

4. The wall panel of claim 3, wherein the building product is selected from the group consisting of plywood, glass, vinyl, sheet metal, stone, and felt paper.

5. The wall panel of claim 1, further comprising: a. an insulation reinforcement mesh adhered to the rigid framing using mechanical attachment; and b. the single application layer of foam insulation encapsulates the insulation reinforcement mesh; and c. wherein the insulation reinforcement mesh becomes an integral part of the continuous portion of the single application layer exterior to the rigid framing.

6. The wall panel of claim 1, wherein the rigid framing comprises: a. a vertical male stud; b. a vertical female stud; c. a plurality of C-studs positioned between the vertical male stud and the vertical female stud; d. a top horizontal female track; and e. a bottom horizontal female track.

7. The wall panel of claim 5, wherein the insulation reinforcement mesh is selected from a group consisting of: expanded metal, perforated metal, welded wire mesh, woven wire mesh, carbon fiber, and glass fiber.

8. The wall panel of claim 1, wherein the entire panel is radiused.

9. The wall panel of claim 2, wherein the exterior face of the single layer of foam insulation is corrugated.

10. The wall panel of claim 2, wherein the exterior face of the single layer of foam insulation is textured.

11. The wall panel of claim 2, wherein the exterior face of the single layer of foam insulation is undulated.

12. A method of constructing a wall panel comprising the steps of: a. providing a rigid framing; b. elevating the rigid framing above a non-stick surface such that a predetermined amount of space is formed between the rigid framing and the non-stick surface; c. applying a single layer of foam insulation, the single layer of foam insulation: i. fills the predetermined amount of space between the rigid framing and the non-stick surface; ii. fills an interior section rigid framing; iii. encapsulates an exterior flange of the rigid framing; d. leaving a utility cavity between an interior face of the single layer of foam insulation and an interior surface of the rigid framing; and e. allowing the single layer of foam insulation to dry wherein a solid monolithic piece is formed comprising the single layer of foam insulation fused to the rigid framing.

13. The method of claim 12, further comprising the step of removing the wall panel from the non-stick surface.

14. The method of claim 12, further comprising the steps of: a. adhering, using mechanical attachment, an insulation reinforcement mesh to the rigid framing; and b. encapsulating the insulation reinforcement mesh with the single layer of foam insulation wherein the solid monolithic piece includes the insulation reinforcement mesh.

15. The method of claim 12, further comprising the step of modifying the predetermined about of space between the rigid framing and the non-stick surface to achieve a desired level of insulation.

16. The method of claim 12, further comprising the step of undulating an exterior face of the single layer of foam insulation.

17. The method of claim 12, wherein the non-stick surface is corrugated.

18. The method of claim 12, wherein the non-stick surface is textured.

19. The method of claim 12, wherein the non-stick surface is radiused.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0026] Elements in the figures have not necessarily been shown to scale in order to enhance their clarity and improve understanding of these various elements and embodiments of the invention. Furthermore, elements that are known to be common and well understood to those in the industry are not depicted in order to provide a clear view of the various embodiments of the invention, thus the figures are generalized in form in the interest of clarity and conciseness.

[0027] The foregoing summary as well as the following detailed description of the preferred embodiment of the present invention will be best understood when considered in conjunction with the accompanying figures, wherein like designations denote like elements throughout the figures, and wherein:

[0028] FIG. 1A illustrates a cut away view of a wall panel in accordance with the preferred embodiment of the present invention;

[0029] FIG. 1B illustrates a cut away view of a roof panel in accordance with the preferred embodiment of the present invention;

[0030] FIG. 1C illustrates a rigid framing of a wall panel elevated from a surface with an insulation reinforcement mesh.

[0031] FIG. 1D illustrates a rigid framing of a radiused wall panel elevated from a surface with an insulation reinforcement mesh.

[0032] FIG. 1E illustrates a rigid framing of a wall panel elevated from a surface without an insulation reinforcement mesh.

[0033] FIG. 1F illustrates the application of a single layer of foam insulation to a corrugated non-stick surface.

[0034] FIG. 1G illustrates the application of a single layer of foam insulation to a textured non-stick surface.

[0035] FIG. 1H illustrates the application of a single layer of foam insulation to an undulated non-stick surface.

[0036] FIG. 2A shows a cut away view of a floor panel, illustrating a spandrel of the floor panel in accordance with the preferred embodiment of the present invention;

[0037] FIG. 2B illustrates a detailed cut away view of the spandrel of the floor panel shown in FIG. 2A in accordance with the preferred embodiment of the present invention;

[0038] FIG. 2C illustrates a sectional view of the spandrel shown in FIG. 2A in accordance with the preferred embodiment of the present invention;

[0039] FIG. 3A illustrates a sectional view of the wall panel shown in FIG. 1A in accordance with the preferred embodiment of the present invention;

[0040] FIG. 3B illustrates a sectional view of the floor panel shown in FIG. 2A in accordance with the preferred embodiment of the present invention;

[0041] FIG. 3C illustrates a sectional view of the roof panel shown in FIG. 1B in accordance with the preferred embodiment of the present invention;

[0042] FIGS. 3D and 3E illustrate a detailed view of a tongue and groove of the wall panel shown in FIG. 1A in accordance with the preferred embodiment of the present invention;

[0043] FIG. 3F illustrates a sectional view of a corner post in accordance with the preferred embodiment of the present invention;

[0044] FIG. 4 illustrates a wall assembly showing the wall panel being assembled with the corner post in accordance with the preferred embodiment of the present invention;

[0045] FIG. 5 illustrates a ground floor assembly showing the wall panel being assembled with the ground floor panel in accordance with the preferred embodiment of the present invention;

[0046] FIG. 6 illustrates another configuration of the floor assembly in accordance with the preferred embodiment of the present invention;

[0047] FIG. 7 illustrates a roof to floor assembly showing the roof panel being assembled with the floor panel in accordance with the preferred embodiment of the present invention;

[0048] FIG. 8A illustrates the roof panel in a folded state in accordance with the preferred embodiment of the present invention; and

[0049] FIG. 8B illustrates the roof panel in an unfolded state in accordance with the preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE FIGURES

[0050] In the following discussion that addresses a number of embodiments and applications of the present invention, reference is made to the accompanying figures that form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and changes may be made without departing from the scope of the present invention.

[0051] Various inventive features are described below that can each be used independently of one another or in combination with other features. However, any single inventive feature may not address any of the problems discussed above or only address one of the problems discussed above. Further, one or more of the problems discussed above may not be fully addressed by any of the features described below.

[0052] As used herein, the singular forms a, an and the include plural referents unless the context clearly dictates otherwise. And as used herein is interchangeably used with or unless expressly stated otherwise. As used herein, the term about means +/5% of the recited parameter. All embodiments of any aspect of the invention can be used in combination, unless the context clearly dictates otherwise.

[0053] Unless the context clearly requires otherwise, throughout the description and the claims, the words comprise, comprising, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of including, but not limited to. Words using the singular or plural number also include the plural and singular number, respectively. Additionally, the words herein, wherein, whereas, above, and below and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of the application.

[0054] The description of embodiments of the disclosure is not intended to be exhaustive or to limit the disclosure to the precise form disclosed. While the specific embodiments of, and examples for, the disclosure are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the disclosure, as those skilled in the relevant art will recognize.

[0055] FIG. 1A illustrates a wall panel 100 employed in the panelized building system. This embodiment comprises an integrated composite insulation and non-composite insulation. The integrated composite insulation building panel includes a structural framing attached to a layer of reinforcing element. The layer of reinforcing element can be selected from a group consisting of, but not limited to: expanded metal, perforated metal, welded wire mesh, woven wire mesh, carbon fiber, glass fiber and other suitable material, or any combination thereof. This layer of reinforcing element is described herein as an insulation reinforcement mesh. The insulation reinforcement mesh can be adhered to an exterior face of rigid framing using mechanical attachment. The term mechanically attached is well known in the field as a physical method of combining multiple components. Welding, machine fastening, and weaving wire mesh are considered examples of mechanical attachment. Welded or machined fastened to one face of the flange side is a wire mesh or expanded metal. The embodiment includes a fabricated galvanized C Channel, mechanically attached to form the wall panel 100. The invention achieves multiple purposes. First, it adds sheer value to the wall panel 100. Second, because it is encapsulated in urethane foam, it generates a complete integration of steel and urethane foam composite.

[0056] Once the wall panel 100 is constructed, the next process is the application of the foam insulation. The wall panel 100 is elevated off a surface. The surface can be flat or radiused to match a particular contour required based on specifications. For example, a 20-foot radius can be implemented to add architectural value. An exterior (outermost layer) of the wall panel 100 is set at a distance away from the interior to enable the formation of continuous insulation, as required by government code. Continuous insulation is defined in the relevant art as insulation that is continuous across all structural members without thermal bridges other than fasteners and service openings. The term continuous insulation is used interchangeably herein with the term single layer of foam insulation. Another term to describe the outermost layer of the wall panel 100 is a wall exterior layer 102. The urethane foam insulation can adhere to the surface of any wall exterior layer product that may be implemented, without the use of mechanical fasteners. The side of the wall panel 100 is closed in with a non-stick surface allowing for foam varying in thickness as required by specifications. The invention is a significant improvement in the field because it does not require pre-formed insulation that must be cut to fit into a panel shape. Further, for a design with a radiused or specific shape, flexible continuous insulation is an improvement over rigid foam material that will not bend. The urethane foam of the present invention is liquid and forms completely to any shape required. The foam expands through the wall panel 100 and encapsulates wire mesh or expanded metal. Further, the foam expands into the panel frame to the insulation thickness required, forming a steel and urethane composite.

[0057] Referring to FIG. 1A, the wall panel 100 adaptable for use in the panelized building system comprises a wall exterior layer 102, a first wall insulation 104, a wall insulation reinforcement 106, and a second wall insulation 108 impregnated in a rigid framing 110. The wall insulation reinforcement 106 can be an insulation reinforcement mesh. The outermost layer of the wall panel 100 is the wall exterior layer 102. Below the wall exterior layer 102, resides the first wall insulation 104. Beneath the first wall insulation 104 resides the wall insulation reinforcement 106 and the second wall insulation 108. The wall insulation reinforcement 106 is encapsulated with the first wall insulation 104 and the second wall insulation 108. The rigid framing 110 includes a vertical male stud 112, a vertical female stud 114, a plurality of C-studs 118 positioned between the vertical male stud 112 and the vertical female stud 114, a top horizontal female track 116 and a bottom horizontal female track 136.

[0058] The method described in this paragraph and the aforementioned paragraphs is used for constructing a wall panel 100. The method and system can also be implemented in other panels, such as a roof panel 120 or floor panel 138. The foam insulation is implemented in a single application to form a single monolithic layer (single layer). Referring to FIG. 1A, the first wall insulation 104, second wall insulation 108, the reinforcement 106, and framing 110 are all one single monolithic piece. In order to show the individual components of the wall panel 100 in FIG. 1A, each component appears as a separate layer even though it is actually a single layer. A single layer is formed through a single application of foam insulation. This single layer system differs from systems which have multiple layers as a result of separate, non-continuous applications of foam. The single continuous application of foam creates a continuous portion formed exterior to the rigid framing 110 and interior to the wall exterior layer 102. The single layer of foam insulation adheres to the wall exterior layer 102. Further, the single layer encapsulates the insulation reinforcement mesh and partially fills the rigid framing, thereby forming a cavity insulation portion of the single application layer of foam insulation interior to the insulation reinforcement mesh. Non-limiting examples of wall exterior layers 102 are membrane, plywood, sheet metal, felt paper, glass, plastic, vinyl and the like. Cavity wall insulation is used to reduce heat loss through a cavity wall by filling the air space with material that inhibits heat transfer. This immobilizes the air within the cavity (air is still the actual insulator), preventing convection, and can substantially reduce space heating costs.

[0059] Referring to FIG. 1B, a roof panel 120 of the panelized building system is illustrated. The roof panel 120 includes a roof exterior layer 122, a first roof insulation 124, a roof insulation reinforcement 126 and a second roof insulation 128. The roof exterior layer 122 is the outermost layer of the roof panel 120. The first roof insulation 124 is beneath the roof exterior layer 122. Below the first roof insulation 124 is the roof insulation reinforcement 126 and the second roof insulation 128. The roof panel 120 further includes a plurality of purlins 130, a plurality of rafters 132 and a plurality of hinge plates 134.

[0060] Under the present invention, no outer layer of building material is necessary for any of the panel embodiments disclosed. Rather, the panels of the present invention may be assembled by positioning a metal frame (or other rigid framing element) as disclosed herein over a non-stick surface, such as polypropylene. The rigid framing of the panel is elevated from the non-stick surface and may be secured with a jig, leaving a required space between the outer face of the metal or rigid framing and the non-stick surface. The required spaced may be modified to achieve a desired insulation value (R-Value). Then, the single application of liquid foam insulation may be applied to fill the interior spaces of the rigid structural components and the space in between the rigid structural components and the non-stick surface. Then the panel formed by the rigid framing integrated with the single application of liquid foam insulation (after the liquid foam solidifies) is removed from the non-stick surface. This leaves a solid monolithic piece formed by the single application of liquid foam insulation fused to the other structural components of the panel. Other systems in the field require an outer layer of building material or rigid foam insulation to create a surface to add additional insulation thereon. Also, utilizing the present invention, the outer surface of the panel may be of any shape because the shape of the single application of liquid foam insulation would conform to any shape that it is molded against. For instance, the panel may be radiused as shown in FIG. 1D. It could be corrugated; it could be a sphere; it could be textured; it could include raised and lowered sections. As well, the rigid framing may be of any shape because the single application of liquid foam insulation would conform to the shape of the rigid framing. In other systems in the field, the foam must be custom cut to match up with the shape of the rigid framing. For example, a triangular frame would require the cutting of a triangular piece of outer building material or a triangular piece of exterior rigid insulation. Further, the single application of liquid foam insulation of the panel of the present invention may be of any thickness to provide any level of insulation capacity (R-Value) without any additional exterior insulation layer or exterior building material. No pre-formed or pre-cut material is necessary. Optionally, the panel may be molded up against felt or plywood. In other systems in the field, it is imperative that an outer layer of building material or rigid foam insulation to install the required interior foam insulation is included to achieve the required R-value. The foam insulation is also used to bond the rigid framings and the outer layer of building material together to form a building panel.

[0061] Referring to FIG. 1C, a rigid framing 202 of a wall panel 200 is elevated from the non-stick surface 202. The non-stick surface 203 is removable and can be replaced with different non-stick surfaces with various shapes and textures. The exterior face 210 of a single layer of foam insulation can have various shapes and textures as a result of being molded to different removable non-stick surfaces 203. The spacing 204 between the rigid framing 202 and the non-stick surface 203 can be set at any desirable thickness for application of the single layer of foam insulation 206. The foam insulation 206 has a preferred thickness thereby allowing compliance with applicable building codes. Two to six inches is a common thickness for the single layer of foam insulation 206. The single layer of foam insulation 206 can be installed on the interior, exterior, or is integral to any opaque surface of the building envelope. The rigid framing 202 can also have a plurality of C-studs 218. Alternatively, the rigid framing can include a vertical male stud, a vertical female stud, a top horizontal female track, and a bottom horizontal female track. The stud and track elements are shown in detail with reference to FIG. 1A.

[0062] As shown, the foam insulation 206 extends beyond an exterior surface of the rigid framing 202. The single layer of foam insulation 206 partially fills the rigid framing 202 and encapsulates an exterior flange 208 of the rigid framing 202. A utility cavity 211 is formed between an interior face 209 of the single layer of foam insulation and an interior surface 212 of the rigid framing 202. The utility cavities 211 can be used for installing utility lines, as is well known in the field. Optionally, the non-stick surface may be replaced by a building product, said building product may comprise plywood, glass, vinyl, sheet metal, stone, felt paper, and/or similar materials.

[0063] The rigid framing 202 can optionally be attached to a layer of reinforcing element 205, also referred to as an insulation reinforcement mesh. The layer of reinforcing element 205 can be selected from a group consisting of, but not limited to: expanded metal, perforated metal, welded wire mesh, woven wire mesh, carbon fiber, glass fiber and other suitable material, or any combination thereof. The insulation reinforcement mesh 205 can be adhered to the rigid framing 202 using mechanical attachment or other suitable means. The term mechanically attached is well known in the field as a physical method of combining multiple components. Welding, machine fastening, and weaving wire mesh are considered some examples of mechanical attachment. Further, the single layer of foam insulation 206 can encapsulate the insulation reinforcement mesh 205. Once the insulation reinforcement mesh 205 is encapsulated, it becomes an integral part of the continuous portion of the single layer of foam insulation 206 exterior to the rigid framing 202.

[0064] The single application layer of foam insulation 206 may be applied to fill the interior spaces of the rigid structural components and the space in between the rigid structural components and the non-stick surface 203. The single layer of foam insulation 206 partially fills the rigid framing 202 and encapsulates an exterior flange 208 of the rigid framing 202. A utility cavity 211 is formed between an interior face 209 of the single layer of foam insulation and an interior surface 212 of the rigid framing 202. Next, the single layer of foam insulation 206 is allowed to dry so that a solid monolithic piece is formed. The solid monolithic piece formed is comprised of the single application layer of foam insulation 206 fused to the rigid framing 202. Then, the panel formed by the rigid framing 202 integrated with the single application of liquid foam 206 insulation (after the liquid foam solidifies) is removed from the non-stick surface 203. Alternatively, a building product as described earlier may replace the non-stick surface 203. If a building product is used, the building product would not be removed from the other components. Rather, it would adhere and become part of the panel. Further, an insulation reinforcement mesh may be adhered to the rigid framing using mechanical attachment or other means. The insulation reinforcement mesh can be encapsulated with the single layer of foam insulation so that the solid monolithic piece includes the insulation reinforcement mesh and the building product if a building product is substituted for a non-stick surface.

[0065] Referring to FIG. 1D, the rigid framing 302 of the wall panel 300 is elevated from the non-stick surface 303. The non-stick surface 303 is removable and can be replaced with different non-stick surfaces with various shapes and textures. The exterior face 310 of a single layer of foam insulation can have various shapes and textures as a result of being molded to different removable non-stick surfaces 303. In this embodiment, the wall panel 300 is radiused to a particular contour required based on specifications. The wall panel exterior 307 is bent (curved) in contrast to the straight wall panel exterior 207 shown in FIG. 1C. The spacing 304 between the rigid framing 302 and the non-stick surface 303 can be set at any desirable thickness for application of the single layer of foam insulation 306. The foam insulation 306 has a preferred thickness thereby allowing compliance with applicable building codes. Two to six inches is a common thickness for the single layer of foam insulation 306. The single layer of foam insulation 306 can be installed on the interior, exterior, or is integral to any opaque surface of the building envelope. As shown, the foam insulation 306 extends beyond an exterior surface of the rigid framing 302. The single layer of foam insulation 306 partially fills the rigid framing 302 and encapsulates an exterior flange 308 of the rigid framing 302. A utility cavity 311 is formed between an interior face 309 of the single layer of foam insulation and an interior surface 312 of the rigid framing 302. The rigid framing 302 can optionally be attached to an insulation reinforcement mesh 305. Further, the single layer of foam insulation 306 can encapsulate the insulation reinforcement mesh 305. Once the insulation reinforcement mesh 305 is encapsulated, it becomes an integral part of the continuous portion of the single layer of foam insulation 306 exterior to the rigid framing 302. The rigid framing 302 can also have a plurality of C-studs 318.

[0066] The single application layer of foam insulation 306 may be applied to fill the interior spaces of the rigid structural components and the space in between the rigid structural components and the non-stick surface 303. The single layer of foam insulation 306 partially fills the rigid framing 302 and encapsulates an exterior flange 308 of the rigid framing 302. A utility cavity 311 is formed between an interior face 309 of the single layer of foam insulation and an interior surface 312 of the rigid framing 302. Next, the single layer of foam insulation 306 is allowed to dry so that a solid monolithic piece is formed. The solid monolithic piece formed is comprised of the single application layer of foam insulation 306 fused to the rigid framing 302. Then, the panel formed by the rigid framing 302 integrated with the single application of liquid foam 306 insulation (after the liquid foam solidifies) is removed from the non-stick surface 303. Further, an insulation reinforcement mesh may be adhered to the rigid framing using mechanical attachment or other means. The insulation reinforcement mesh can be encapsulated with the single layer of foam insulation so that the solid monolithic piece includes the insulation reinforcement mesh.

[0067] Referring to FIG. 1E, a rigid framing 202 of a wall panel 250 is elevated from a non-stick surface 203 but this embodiment has no insulation reinforcement mesh. The wall panel 250 embodiment shown in FIG. 1E is similar to the wall panel 200 in FIG. 1C except for lacking an insulation reinforcement mesh. As aforementioned, the insulation reinforcement mesh 205 shown in FIG. 1C is optional. Further, the insulation reinforcement mesh 305 of the radiused wall panel 300 shown in FIG. 1D is also optional.

[0068] Referring to FIG. 1F, an example of a corrugated non-stick surface 403 is illustrated. After applying a single continuous layer of foam insulation 406, the exterior face 410 of the foam insulation is molded against the corrugated non-stick surface 403, thereby enabling the exterior face 410 to also become corrugated. A monolithic layer of foam insulation 406 is formed.

[0069] Referring to FIG. 1G, an overhead view of a textured non-stick surface 503 is illustrated. After applying a single continuous layer of foam insulation 506, the exterior face (not visible in overhead view) of the foam insulation is molded against the textured non-stick surface 503, thereby enabling the exterior face to also become textured. The textured non-stick surface 503 illustrated is one example of many possible textures that can be implemented. A monolithic layer of foam insulation 406 is formed.

[0070] Referring to FIG. 1H, an example of an undulated non-stick surface 603 is illustrated. After applying a single layer of foam insulation 606, the exterior face 610 of the foam insulation is molded against the undulated non-stick surface 603, thereby enabling the exterior face 610 to also become undulated. A monolithic layer of foam insulation 606 is formed.

[0071] Referring to FIG. 2A, a floor panel 138 of the panelized building system is illustrated. The floor panel includes a floor exterior layer 140, a floor insulation 142, a plurality of floor joists 144 and a spandrel 146. FIG. 2B shows a detailed cut away view of the spandrel 146. The spandrel 146 includes a first male floor track 150, a second male floor track 152 holding the plurality of floor joists 144 by means of a plurality of stiffeners 148. FIG. 2C illustrates a sectional view of the spandrel 146. The spandrel 146 further includes a first fill plate 156 connected to the first male floor track 150 and a second fill plate 158 connected to the second male floor track 152 to fix at least one of the plurality of floor joists 144 with the spandrel 146.

[0072] FIGS. 3A-3C show the sectional views of the wall panel 100, the floor panel 138 and the roof panel 120. FIGS. 3D and 3E illustrate a detailed view of a tongue 162 and a groove 160 of the wall panel 100 shown in FIG. 1A. There are several advantages of having a feature of an interlocking tongue 162 and groove 160. The interlocking feature enables the panels (e.g. wall panel 100, floor panel 138, roof panel 120) to interlock with the foundation of a building with a minimum number of required fasteners and a maximum sheer strength. Another advantage of the interlocking feature is an improvement in the efficiency of field installation. Once a base track is installed and leveled, there is no need for measuring or checking because the panels are precisely installed. The interlocking tongue 162 and groove 160 feature enables the automatic alignment of the panels. A totally panelized system, including wall panels 100, floor panels 138, roof panels 120, and base plates, eliminates the need to integrate with other installation methods that would require research into fit and fastening requirements. The panelized system enables simpler engineering and construction. Since all the components can be manufactured in a controlled environment, the components can be fit, and the entire structure can be assembled prior to field installation.

[0073] Another benefit of the present invention is that all the panels in the structure can be constructed of a single metal, such as steel. This is a significant improvement over hybrid building systems that integrate other construction methods such as floor systems, wood trusses, or roof trusses. Having a steel building structure can provide a shield to filter out various radio frequencies. For example, the steel structure can block out radio frequencies used by cell phones. A steel structure can be used as Faraday cage to eliminate or reduce radio frequencies and electromagnetic radiation. Required frequencies can be filtered into the steel structure through shielded cable while unwanted frequencies can be filtered out. Further, using an appropriate thickness for steel and wire mesh enables the structure to pass a missile test to withstand hurricanes and tornadoes. Having a metal structure without wood protects against insect damage and mold.

[0074] FIG. 3F illustrates a sectional view of a corner post 164 in accordance with the preferred embodiment of the present invention. The corner post 164 is adaptable for connecting wall panels 100 at the corners of the panelized building system. The corner post 164 includes a corner exterior layer 166, a corner insulation 168, a corner tongue 170 and a corner groove 172 attached to the corner insulation 168 by means of a pair of connectors 174, 176. The corner tongue 170 and the corner groove 172 enables to attach the wall panel 100 with the corner post 164. The corner tongue 170 attaches with the vertical female stud 114 of the wall panel 100 and the corner groove 172 attaches with the vertical male stud 112 of the wall panel 100. FIG. 4 illustrates a wall assembly showing the wall panel 100 to be assembled with the corner post 164 and to the spandrel 146 of the floor panel 138.

[0075] FIG. 5 illustrates a ground floor assembly showing the wall panel 100 being assembled with the ground floor panel 138. As shown in FIG. 16, the ground floor assembly is designed to firmly assemble the wall panel 100 with or without the window 178 with a base 180.

[0076] FIG. 6 illustrates another configuration of the floor assembly showing two wall panels 100, 182 being assembled with the floor panel 138. In this configuration, the bottom horizontal female track 136 of one wall panel 100 is positioned on the first male floor track 150 on the spandrel 146 of the floor panel 138 and the top horizontal female track 116 of another wall panel 182 is attached to the second male floor track 152 on the spandrel 146 of the floor panel 138.

[0077] FIG. 7 illustrates a roof to floor assembly showing roof panels attached to floor panels. In this configuration, for example, at least two roof panels 120, 184 are assembled with the floor panel 138. The at least two roof panels 120, 184 are attached together by means of the plurality of hinge plates 134 and held in position by means of a plurality of spreader beams 186 and a plurality of connector plates 190. The at least two roof panels 120, 184 are attached to the floor panel 138 by means of a plurality of support posts 188.

[0078] FIGS. 8A and 8B illustrate the roof panel assembly in a folded state and an unfolded state respectively. In the folded state, the plurality of connector plate 190 and the plurality of spreader beams 186 are coupled together. In the unfolded state, the plurality of connector plate 190 and the plurality of spreader beams 186 are detached from each other utilizing the plurality of hinge plates 134.

[0079] The foregoing description of the preferred embodiment of the present invention has been presented for the purpose of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teachings. It is intended that the scope of the present invention not be limited by this detailed description, but by the claims and the equivalents to the claims appended hereto.