Light weight post and beam construction system based on horizontally pre-slotted panels

Abstract

Modular building methods and systems using lightweight foam modular panels. Each panel includes one or more channels formed through the length of the foam body, where the channels are configured to receive splines therein. The channels may include pairs of top and pairs of bottom channels, each channel being offset from the center of the foam body, so that the channels are oriented towards the respective panel faces. Splines may also be positioned along the top and bottom of the panel (such splines forming a web center portion of an I-beam). In combination with the splines in the top and bottom channels, these web center portion splines form horizontally extending I-beams at the top and bottom of each panel, so that stacked panels include a horizontally extending I-beam there between. Side-by-side panels include vertical posts there between, such that the system forms a post and beam construction system.

Claims

1. A modular panel for use in constructing a wall of a building, the modular panel comprising: a body; a plurality of channels extending horizontally through a length of the panel, the plurality of channels including two top channels and two bottom channels, each channel being configured to receive an elongate spline therein, wherein each elongate spline once received in the channel is disposed horizontally within the body, without the elongate spline being exposed on an outside face of the body, so that the elongate spline is restrained once received within the channel, wherein the panel includes a cross-sectional geometry that is consistent across the length of the panel, with the top and bottom channels running length-wise through the panel, without any channels or splines running vertically through the panel, so that the panel can be formed by extrusion; and wherein top and bottom outer edges of the panel include a stair stepped or inclined configuration, so that when stacking one panel atop another panel, a horizontal seam therebetween is defined by an inclined or stair-stepped surface interior to the horizontal seam, so as to minimize or prevent water seepage between stacked panels.

2. A panel as recited in claim 1, wherein the two top channels are substantially parallel to one another, and the two bottom channels are substantially parallel to one another.

3. A panel as recited in claim 1, wherein the body comprises foam, the foam body further comprising: a first pre-cut slot in a first face of the panel; a second pre-cut slot in a second, opposite face of the panel; the first pre-cut slot being centered on a respective furring channel associated with the first face of the panel, the first pre-cut slot extending through the first face into the furring channel associated with the first face of the panel; and the second pre-cut slot being centered on a respective furring channel associated with the second face of the panel, the second pre-cut slot extending through the second face into the furring channel associated with the second face of the panel.

4. A panel as recited in claim 1, wherein the body is formed as an integral single piece of foam material, or as two initially separate halves, each half including one face, where the two separate halves are glued or otherwise attached together.

5. A panel as recited in claim 1, wherein substantially an entirety of the outside face of the body is planar, without any recessed channels formed therein, so that a wall surface defined by the outside face of the panel body is formed entirely by the body, rather than any splines positioned within channels formed in the outside face of the panel body.

6. A panel as recited in claim 1, wherein the panel is formed by extrusion.

7. A wall system built from a plurality of modular panels and a plurality of splines, the wall system comprising: a plurality of modular panels, each modular panel comprising: a body; and a plurality of channels extending horizontally through a length of the panel, each channel being configured to receive an elongate spline therein, wherein each elongate spline once received in the channel is disposed within the body, without the elongate spline being exposed on an outside face of the body, so that the elongate spline is restrained once received within the channel; and a plurality of elongate splines, wherein the splines are received within the channels of the bodies of the modular panels, the splines forming flanges of an I-beam that runs horizontally along a top or bottom of the modular panel; wherein the wall system is a post and beam type construction, and wherein the modular panels are oriented so that the channels and splines run horizontally and splines extend beyond panels to integrate with an adjacent post positioned between two adjacent side-by-side modular panels.

8. A wall system as recited in claim 7, wherein the splines disposed in the channels are not exposed on an outside face of the body, such that each spline has only 1 degree of freedom, along the length of the channel.

9. A wall system as recited in claim 7, wherein the splines are connected to the post by a lap joint.

10. A modular panel for use in constructing a building, the modular panel comprising: a foam body that is generally rectangular in shape; a first top channel extending horizontally through a length of the foam body, the first top channel being off-center relative to a thickness of the foam body, positioned towards a first face of the foam body; a second top channel extending horizontally through the length of the foam body, the second top channel being off center relative to the thickness of the foam body, positioned towards a second face of the foam body; a first bottom channel extending horizontally through the length of the foam body, the first bottom channel being aligned with and below the first top channel; a second bottom channel extending horizontally through the length of the foam body, the second bottom channel being aligned with and below the second top channel; wherein each of the top and bottom channels are exposed and open at top and bottom edges of the foam body, respectively, each of the top and bottom channels being rectangular in transverse cross-section, with a length of the transverse cross-section rectangle being oriented vertically, each top and bottom channel being configured to receive an elongate spline therein which is flexible in a direction that is normal to a width of the elongate spline; a web center portion of an I-beam member positioned on the top edge of the foam body, so as to be positioned between splines positioned in the top channels, forming an I-beam at the top edge of the foam body, where the splines in the top channels form the end flanges of the I-beam and the web center portion forms the web of the I-beam on the top edge of the foam body; and a web center portion of an I-beam member positioned on the bottom edge of the foam body, so as to be positioned between splines positioned in the bottom channels, forming an I-beam at the bottom edge of the foam body, where the splines in the bottom channels form the end flanges of the I-beam and the web center portion forms the web of the I-beam on the bottom edge of the foam body; wherein the panel includes a cross-sectional geometry that is consistent across the length of the panel, with the top and bottom channels running length-wise through the panel, without any recesses, channels or splines in the panel running cross-wise through the panel, so that the panel can be formed by extrusion.

11. A panel as recited in claim 10, wherein the panel further comprises: a first interior channel extending horizontally through the length of the foam body, the first interior channel being positioned off-center relative to the thickness of the foam body, positioned towards a first face of the foam body, aligned with the top and bottom first channels; a second interior channel extending horizontally through the length of the foam body, the second interior channel being positioned off-center relative to the thickness of the foam body, positioned towards a second, opposite face of the foam body, aligned with the top and bottom second channels.

12. A panel as recited in claim 11, each interior channel being configured to receive an elongate spline therein which is flexible in a direction that is normal to a width of the elongate spline, wherein each elongate spline once received in the respective interior channel is disposed within the foam body, without the elongate spline being exposed on an outside face of the foam body associated with the respective channel, so that the elongate splines are restrained in all directions other than being able to slide within the channel within which the spline is received.

13. A panel as recited in claim 11, further comprising: a first pre-cut slot in the first face of the panel; a second pre-cut slot in the second, opposite face of the panel; the first pre-cut slot being centered on the first interior channel associated with the first face of the panel, the first pre-cut slot extending through the first face into the first interior channel; and the second pre-cut slot being centered on the second interior channel associated with the second face of the panel, the second pre-cut slot extending through the second face into the second interior channel.

14. A panel as recited in claim 10, wherein the foam body is formed as an integral single piece of material, or as two initially separate halves, each half including one face, where the two separate halves are glued or otherwise attached together.

15. A transition panel for use in transitioning from a wall to a roof in a building construction, the transition panel being positioned: between a stack of standard modular building panels forming a wall; and one or more standard modular roof panels forming a roof structure, wherein the standard modular building panels of the wall are substantially identical to the standard modular roof panels of the roof structure; wherein the transition panel comprises a roof leg and a wall leg, which are at an angle relative to one another, a vertical length of the wall leg accommodating an increased height to the wall by including a vertical length that adds to the wall height, the angle between the roof leg and the wall leg dictating a roof pitch associated with the roof; wherein the roof leg and the wall leg each include pairs of channels, into which flanges of an I-beam are selectively positioned.

16. A transition panel as recited in claim 15, wherein the transition panel connects to a panel according to claim 10 used in forming the wall, and another panel according to claim 10 used in forming the roof.

17. A transition panel as recited in claim 15, wherein the transition panel further includes one or more slots for insertion of eave stiffening members.

18. A transition panel as recited in claim 15, wherein the standard modular building panels and the standard modular roof panels are generally shaped as rectangular prisms.

19. A transition panel as recited in claim 15, wherein the channels of the transition panel have the same cross-sectional shape as channels formed in the standard modular building panels of the wall and the standard modular roof panels of the roof structure, such that all such channels can receive the flanges of the I-beam.

20. A transition panel as recited in claim 19, wherein the flanges and web of each I-beam are pre-assembled to form the I-beam.

21. A transition panel as recited in claim 19, wherein the flanges and web of each I-beam are assembled in-situ.

22. A transition panel for use in transitioning from a wall to a roof in a building construction, the transition panel being positioned: between a stack of standard modular building panels forming a wall; and one or more standard modular roof panels forming a roof structure; wherein the transition panel dictates a roof pitch associated with the roof; wherein the transition panel connects to a standard modular building panel used in forming the wall, and another standard modular building panel used in forming the roof, wherein each standard modular building panel comprises: a foam body that is generally rectangular in shape; a first top channel extending horizontally through the length of the foam body, the first top channel being off-center relative to the thickness of the foam body, positioned towards a first face of the foam body; a second top channel extending horizontally through the length of the foam body, the second top channel being off center relative to the thickness of the foam body, positioned towards a second face of the foam body; a first bottom channel extending horizontally through the length of the foam body, the first bottom channel being aligned with and below the first top channel; a second bottom channel extending horizontally through the length of the foam body, the second bottom channel being aligned with and below the second top channel; wherein each of the top and bottom channels are exposed and open at top and bottom edges of the foam body, respectively, each of the top and bottom channels being rectangular in transverse cross-section, with a length of the transverse cross-section rectangle being oriented vertically, each top and bottom channel being configured to receive an elongate spline therein; a web center portion of an I-beam member positioned on the top edge of the foam body, so as to be positioned between splines positioned in the top channels, forming an I-beam at the top edge of the foam body, where the splines in the top channels form the end flanges of the I-beam and the web center portion forms the web of the I-beam on the top edge of the foam body; and a web center portion of an I-beam member positioned on the bottom edge of the foam body, so as to be positioned between splines positioned in the bottom channels, forming an I-beam at the bottom edge of the foam body, where the splines in the bottom channels form the end flanges of the I-beam and the web center portion forms the web of the I-beam on the bottom edge of the foam body.

23. A wall system built from a plurality of modular panels and a plurality of splines, the wall system comprising: a plurality of modular panels, each modular panel comprising: a body; and a plurality of channels extending horizontally through a length of the panel, each channel being configured to receive an elongate spline therein, wherein each elongate spline once received in the channel is disposed within the body, without the elongate spline being exposed on an outside face of the body, so that the elongate spline is restrained once received within the channel; and a plurality of elongate splines, wherein the splines are received within the channels of the bodies of the modular panels, the splines forming flanges of a flange-web-flange member that runs horizontally along a top or bottom of the modular panel; wherein the wall system is a post and beam type construction, and wherein the modular panels are oriented so that the channels and splines run horizontally and splines extend beyond panels to integrate with an adjacent post.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) To further clarify the above and other advantages and features 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 drawings illustrate several embodiments of the invention, wherein identical reference numerals refer to identical or similar elements or features in different views or embodiments shown in the drawings.

(2) FIG. 1 is a top perspective view of an exemplary modular panel as described herein.

(3) FIG. 2 is an end view of the modular panel of FIG. 1.

(4) FIG. 3 is a bottom perspective view of the modular panel of FIG. 1.

(5) FIG. 4 is a perspective view showing a vertical post against which the modular panel can be positioned and attached to, as well as a bottom plate and bottom flange splines, for reception into a first layer of placed modular panels.

(6) FIG. 5 is a perspective view showing the vertical post, bottom plate and bottom flange splines of FIG. 4, with a modular panel positioned over the bottom plate, with the splines inserted into the bottom channels of the modular panel.

(7) FIG. 6 is a progression from FIG. 5, showing placement of another panel on the opposite side of the post, showing how the various splines may span across both modular panels, sandwiching the post between the splines, and also showing splines positioned to form an I-beam formed from components placed into the top channels, and over the top of the modular panel.

(8) FIG. 7 is a progression from FIG. 6, showing placement of an additional stack of panels over the first layer of panels, with an in-situ formed I-beam constructed on site, therebetween.

(9) FIG. 8 is a progression from FIG. 7, showing a foam filler member installed over the vertical post, creating a flush surface across the panels on either side of the post.

(10) FIG. 9 shows a wall constructed similar to that of FIG. 8, further showing how the same panels may be use for a roof, positioned between truss members.

(11) FIG. 10 shows how an opening, e.g., for a door or window, may be provided for in the post and beam construction systems including the modular panels of the present invention.

(12) FIG. 11 shows how transition panels may be provided for connecting the panels used in a wall structure (e.g., such as that of FIG. 8) to the same standard panels used to form a roof structure.

(13) FIG. 12A shows a close up of the transition panel of FIG. 11, between the top most panel of the wall structure and the adjacent roof panel.

(14) FIG. 12B shows a close up of the floor panel of FIG. 11.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

I. Definitions

(15) Some ranges may be disclosed herein. Additional ranges may be defined between any values disclosed herein as being exemplary of a particular parameter. All such ranges are contemplated and within the scope of the present disclosure.

(16) Numbers, percentages, ratios, or other values stated herein may include that value, and also other values that are about or approximately the stated value, as would be appreciated by one of ordinary skill in the art. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result, and/or values that round to the stated value. The stated values for example thus include values that are within 10%, within 5%, within 1%, etc. of a stated value.

(17) All numbers used in the specification and claims are to be understood as being modified in all instances by the term about, unless otherwise indicated. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the subject matter presented herein are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

(18) It must be noted that, as used in this specification and the appended claims, the singular forms a, an and the include plural referents unless the content clearly dictates otherwise.

(19) Any directions or reference frames in the description are merely relative directions (or movements). For example, any references to top, bottom, up down, above, below or the like are merely descriptive of the relative position or movement of the related elements as shown, and it will be understood that these may change as the structure is rotated, moved, the perspective changes, etc.

(20) All publications, patents and patent applications cited herein, whether supra or infra, are hereby incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference.

II. Introduction

(21) In one embodiment, the present invention is directed to modular building methods and systems where the building is constructed using lightweight foam modular panels in which the panels include one or more horizontal channels formed through the length of the lightweight foam body of the panel. The channels are configured to receive flexible elongate splines, which may simply be flexible strips of OSB, plywood, or the like. It will be appreciated that such splines do not necessary need to be formed of wood, such that metal splines, or even other materials (e.g., plastic, or otherwise) could be used. The splines and associated channels into which they are received are configured so that the splines are not exposed on an outside face of the lightweight body, but so that the spline is restrained in the wall (e.g., it can only slide in and out of the channel once placedwith 1 degree of freedom).

(22) The channels may be configured to provide an interior horizontally positioned I-beam in a wall constructed with such panels, where each horizontal I-beam is positioned between vertically stacked panels. The flanges and web of each I-beam may be formed from the flexible elongate splines, such that the I-beam is not prefabricated, but is actually assembled in-situ, at the construction site, as the panels are positioned to build the wall structure. The horizontal I-beams may form part of a post and beam wall system, which the building system is particularly suited for. For example, the modular panels may be positioned between appropriately spaced apart vertical post members, while the horizontal I-beams run horizontally, between vertically stacked modular panels (i.e., along the wall's length).

(23) The panels may include channels for additional horizontal splines, beyond those that form the I-beams between vertically stacked panels. For example, the panels may include top and bottom channels which receive splines, which become the flanges of the I-beam. The panels may also include interior channels, e.g., positioned off-center relative to a thickness of the foam panel, towards the first and opposite second faces of the panel (which faces correspond to the inside and outside of a constructed wall structure). Such interior splines may serve as furring strips, for attachment points for nails, screws or the like, e.g., for sheathing or other material positioned over the wall, away from the panels top and bottom edges.

(24) The modular panels may have a thickness (e.g., foam thickness) that is typically greater than 4 inches, e.g., 5.5 inches, (the same width as a 26) or 7.25 inches (the same width as a 28). Because the panels include a cross-sectional geometry that is consistent across the length of the panel, they provide excellent flexibility in constructing any desired wall structure or building. For example, the foam panels may easily be cut off at whatever appropriate length, where the wall ends, or where a door, window or other opening is needed, in the horizontal direction of the wall. The vertical direction of the wall is easily formed by simply stacking a desired number of the panels on top of one another, forming the in-situ formed I-beams between each pair of stacked panels. Where desired, the top of a top-most panel could also be cut off, to accommodate an overall desired wall height, or the top-most standard wall panel may be topped with a transition panel that is configured to connect the wall panels to roof panels. Such a transition panel may include a wall portion that engages with the top-most wall panel, making up any desired additional wall height, allowing a user to accommodate any desired wall height.

(25) The modular panels can be formed on a CNC hot wire cutting device, where all necessary deep cuts are formed (as it can be difficult to accurately cut foam material thicker than about 2 inches without such a device). Because the panels are formed under such conditions, during manufacture, high precision and accuracy are possible (which is not practical to achieve on a job site). Furthermore, by cutting the panels on such a CNC device, the rectangular panels themselves can be formed to very high precision and accuracy dimensions. For example, a 2 foot by 4 foot panel, 5.5 or 7.25 inches thick will be perfectly square and plumb, allowing the panel itself to be used as a square, level, or jig. This characteristic greatly reduces the need for skilled labor, as the panel itself serves as a template (i.e., no tape measure or square is needed). This helps to ensure a robust composite structure having the proper geometry (e.g., right angled walls where such is desired, level floors, level ceilings, and the like).

(26) The present methods and systems of assembly allow for relatively open source construction, with a relatively high degree of customizability to the building being constructed, all achievable at lower cost and/or time as compared to existing methods of construction. Furthermore, even with such relative flexibility, little if any skilled labor is required. For example, a model or blueprint image of the building to be constructed could simply be provided, with the crew only being required to connect the modules as shown in the model or blueprint (e.g., akin to LEGO instructions)

(27) It is also advantageous that the foam material (e.g., expanded polystyrene, or other foamed insulative materials) from which the modular panels are constructed may be readily available nearly anywhere, such that the foam panels may be manufactured at a foam production facility near the construction site (minimizing shipping distance and expense). This provides savings and convenience in that the foam panels can be manufactured locally, avoiding the significant expense of shipping foam (which occupies a large volume, even though it weights little).

(28) For example, such foam may typically have a density from about 1 lb/ft.sup.3 to 2 lb/ft.sup.3, and provide an insulative value of about R4 per inch of foam thickness. A wall constructed using a 5.5 inch or 7.25 inch thick foam panel as described herein may provide an R value of about R25 or R30, respectively.

III. Exemplary Construction Methods and Systems

(29) FIGS. 1-3 show a modular panel 100 according to the present invention. Such panels can be used in building construction, and advantageously are typically fully compatible with existing building codes and standard construction practices, such that adoption of such a building system would not present the many regulatory and other hurdles associated with various other construction systems that have been proposed, some by the present Applicant.

(30) Modular panel 100 includes a lightweight body 102. Body 102 may comprise or otherwise be formed from a foam material, such as expanded polystyrene (EPS) foam. Such material may be rigid. Such panels may be precision cut from blocks of rigid, already cured EPS foam. For example, EPS foam is often available as 348 foot blocks. Such a block may be sufficient to produce several modular panels as shown in FIG. 1, which may each measure 24 feet, with a thickness of 7.25 inches (width of 28 dimensional lumber). While EPS foam may be particularly appropriate, other lightweight materials that can be molded (as the 348 foot EPS blocks are molded), easily cut using CNC hot wire cutting device, etc. may also be used.

(31) Each panel 100 includes one or more (e.g., a plurality of) channels 104 extending horizontally through the length of panel 100. In the illustrated configuration, panel 100 includes first and second interior channels 104a, 104b, each of which is positioned off-center relative to the thickness of foam body 102, with channel 104a positioned towards (i.e., closer to) panel face 106a and channel 104b positioned towards panel face 106b (i.e., closer to panel face 106b than the center of the thickness of foam body 102). Panel 100 also includes top and bottom channels, which will be discussed in further detail hereafter. In an embodiment, such a panel may actually not include the interior channels 104a, 104b, but only the top and bottom channels (i.e., the interior channels are optional). Each of channels 104a, 104b is sized and shaped to receive therein a flexible elongate spline, where the channels 104a, 104b are not open at faces 106a and 106b of panel 100, but are only open at left and right ends 108a, 108b of panel 100. In an embodiment, splines 116 are advantageously not dimensional lumber, which although readily available, is notorious for being warped, making it difficult to slide such a spline through channels 104a, 104b. Rather, splines may be formed from oriented strand board (OSB), plywood, or another material that is easily inserted into such a channel, and exhibits significant flexibility in the direction of the thickness of such sheet material. Such flexibility is readily apparent when holding such a strip of such sheet material at one end, as the other end will flex significantly downward under the weight of the sheet or strip alone. Such does not occur to the same degree with dimensional lumber, even in the same dimensions, as such dimensional lumber is significantly more rigid. Such OSB or similar spline materials are easily obtained, e.g., by ripping sheets of OSB or the like, which are as readily available as dimensional lumber, but with better flexibility in such direction, while exhibiting minimal if any warping. Although such OSB strips are a particularly suitable material, it will be apparent that a variety of other wood, plastic, or even metal materials could alternatively be used for splines.

(32) Channels 104a, 104b within panel 100 have dimensions just slightly larger than those of the elongate spline so as to not bind within the channel, but so as to be freely slidable therein (e.g., a clearance of 1/16 inch or so, as will be apparent to those of skill in the art, may be provided). FIG. 1 also illustrates the presence of reduced-size (e.g., half-size) top channels 104a and 104b at top end 110a of panel 100, and reduced-size (e.g., half-size) bottom channels 104a and 104a at bottom end 110b of panel 100. Such reduced-size (e.g., half-size) channels may be similar to interior channels 104, but are exposed at the top or bottom of the panel (although not exposed at the panel faces 106a, 106b), and may be intended to accommodate similarly sized splines that run through the reduced-size channel (e.g., half height), and another reduced-size (e.g., half-size) channel of an adjacent panel 100 stacked above or below the illustrated panel, when constructing a wall. Such splines in top and bottom channels 104a, 104b, 104a and 104b may form the flanges of an I-beam which is horizontally positioned, between adjacent stacked panels. Splines within interior channels 104 may not form part of an I-beam, but may serve as furring strips providing excellent attachment points within the panel, e.g., when securing drywall or other sheathing material over one or both panel faces 106a, 106b. Such splines in interior channels 104 may thus be optional, and may also increase the strength characteristics (e.g., shear) of the resulting wall, where included.

(33) The channels (particularly top and bottom channels 104a, 104b, 104a and 104b) which are associated with the internal horizontally extending I-beams that are formed in-situ, as the wall is assembled may be spaced apart from one another to accommodate any particular desired spacing of such I-beams, as dictated by the height of each modular panel. For example, in the illustrated configuration where the panel 100 is 2 feet high, such I-beams will be provided horizontally, 2 feet apart, between adjacent panels. Taller or shorter panels could be provided where it is desired to adjust such spacing. Similarly, the panel length (e.g., 4 feet) may dictate the spacing of adjacent vertical posts in the wall, which may be provided between adjacent panels placed side by side (while I-beams are provided between adjacent panels stacked one on top of another). Spacings other than 4 feet (e.g., 8 feet, 12 feet, etc.) for such posts, and for the panel length may be possible. Such spacing characteristics are well accepted within the building industry, and compatible with existing building codes, which allows the present panels and systems to be readily accepted and implemented, once made known by Applicant. Importantly, when a spline is received into any of the channels (104a, 104b, 104a, 104b, 104a or 104b), the spline is not exposed on either exterior face 106a or 106b of panel 100. Applicant has found that other systems that provide for structural members or other features that are exposed on the exterior of a panel exhibit a ghosting problem, in that even once such structures are finished over, because of the different material characteristics underlying drywall or other sheathing associated with such surface exposure at the face during framing, there is a noticeable ghost that shows up through paint or other interior or exterior wall finishes that plague such systems. It is thus important that no such spline surface exposure is provided with the present panels. The full interior and exterior faces 106a, 106b are provided entirely by the material from which the lightweight foam body is formed (e.g., EPS).

(34) In addition to ghosting issues, exposure of splines on the exterior surface also can result in thermal bridging problems, e.g., particularly where metal sheathing is present (e.g., on a roof or otherwise). By ensuring that the splines are positioned internally, rather than externally exposed, there is less of a problem of thermal bridging through the wall, which increases overall insulative efficiency of the wall, roof or other building structure constructed therefrom. Where thermal bridging occurs, undesired condensation can often occur in such spots due to a thermal gradient associated with such thermal bridging. The present systems ensure there is a thermal break between such structural spline members and any metal or other sheathing that may eventually be placed over roofs, walls, or the like.

(35) Furthermore, because the splines are positioned within the panel thickness, with approximately 1 to 2 inches of foam thickness between the spline and the nearest face, building codes do not require that electrical wiring (e.g., 120V) be run within conduit, as there is at least 1.5 inches between the exterior of any sheathing (e.g., inch or inch drywall or the like) applied over the panel and such electrical wiring. In addition, as shown in FIG. 1, the panel may actually include an internal raceway 136 for receipt of electrical wiring, etc.

(36) In FIG. 1, channels 104a, 104a and 104a are all vertically aligned with one another, spaced an equal distance from the face 106a of panel 100. Similarly, channels 104b, 104b and 104b are all also vertically aligned with one another, spaced an equal distance from face 106b. Because the channels are not centered in the panel's thickness, but are offset towards the respective faces, two such channels are provided at a given height, horizontally aligned with one another (e.g., channels 104a and 104b are at the same height, channels 104a and 104b are at the same height, and channels 104a and 104b are at the same height). While it may be possible to flip the panel 90, such that the I-beams would run vertically, the illustrated horizontal orientation of the panel (horizontal length greater than vertical height) is particularly advantageous in wall construction, as most variation in wall constructions occurs horizontally, rather than vertically (e.g., most walls are of a given height, with little variation beyond such standard heights). The channels are offset towards one of the two faces 106a, 106b of the foam body 102, with two channels at each given height (e.g., interior channels 104a, 104b are at a central portion (e.g., the middle) of the height, channels 104a and 104b are at the bottom of the panel, and channels 104a and 104b are at the top of the panel. Because 2 channels are present at any given height, equally spaced from their respective faces, the same length fasteners can be used to attach sheathing on one face of the panel versus the other face.

(37) In any case, when attaching such drywall or other sheathing, the present system avoids point loading onto screws, nails, or other fasteners employed, because of the foam thickness (e.g., 1 to 2 inches) between the sheathing and the spline encased within the foam panel. Such avoidance of point loading can be beneficial in an earthquake or the like, which may otherwise cause such fasteners to shear off.

(38) In addition to the various internal, top and bottom channels described, the illustrated panel 100 further includes a pre-cut slot 112 in face 106a of panel 100, centered relative to channel 104a. Pre-cut slot 112 extends from first face 106a into channel 104a. For example, such a pre-cut slot allows internal formation of channel 104a in body 102 with a CNC controlled hot wire cutter. The width of slot 112 is advantageously very narrow, e.g., rather than providing a wide opening from channel 104a to the area adjacent face 106a. For example, where the height of channel 104a may be just over 3 inches (e.g., to accommodate a 3 inch spline), the width of slot 112 (the width of which is parallel thereto) may be no more than 0.25 inch, or no more than 0.125 inch. Stated another way, the width of slot 112 may be no more than 20% of, 15% of, 10% of, or no more than 5% of the transverse cross-sectional height of channel 104a. On the face 106b, opposite face 106a, there is shown another pre-cut slot 112, identically configured, but with respect to channel 104b and face 106b. The alignment of slots 112 with interior channels 104 is further beneficial once a wall structure has been built, where the panels are stacked one over another, as the channels and splines may no longer be visible. The slots 112 are visible in such circumstances, allowing a user to quickly and easily see where the splines are located within a given wall structure. Such slots 112 make attachment of drywall or other sheathing over the foam panels very easy, as the slots 112 mark the location of the center of the splines, which are easily nailed or screwed into, through the thickness of the foam between channels 104 and each respective face 106a, 106b. As internal channels 104a, 104b are optional, if they are not included, the such pre-cut slots may also be omitted.

(39) FIGS. 4-8 show progression of construction of a wall structure using a plurality of such panels 100, in a post and beam type construction. The horizontal beams are provided by in-situ formed I-beams, that are initially provided to the construction site prior to installation as lengths of separate OSB or similar elongate spline material, which splines are positioned in channels or on top and/or bottom of such panels to form the I-beams in place, as the wall is constructed. The vertical posts of the system are placed between adjacent panels oriented side by side, for the wall. In FIG. 4, there is shown a vertical post 138 (e.g., two 24s), positioned on a bottom plate 137 (e.g., a 24, other dimensional lumber, or the like) sandwiched between two splines 116 (which splines 116 will be inserted into bottom channels 104a and 104b) of panel 100. FIG. 5 shows one panel 100 in place relative to vertical post 138, bottom plate 137 and bottom splines 116.

(40) FIG. 6 shows two panels 100, positioned side by side, with vertical post 138 there between, separating the panels 100. FIG. 6 also shows the 3 components for the in-situ formed I-beam positioned on the top of panels 100. The vertical flanges of the horizontally extending I-beam are provided by splines 116 positioned in top channels 104a and 104b, while the web 116 of the I-beam 117 is provided by another spline (e.g., also an elongate strip of OSB or other suitable material), laid on the top planar edge 110a at the top of panel 100. The web spline 116 has a width equal to the spacing between top channels 104a and 104b, so as to span the distance between splines 116 placed therein, so that the two splines 116 (flanges of I-beam 117) and web 116 together form the I-beam. The 3 pieces of the I-beam 117 may be inserted one at a time, and glued together where such members 116, 116 contact one another (i.e., the sides of web 116). Glue may also be applied in channels 104a and 104b and on planar surface 110a, to secure the I-beam 117 within panel 100. A panel could be provided with web spline 116 already glued or otherwise secured to the top planar face 110a of panel 100, if desired. A pre-assembled I-beam could also be used.

(41) While web spline 116 may only have a length that is equal to that of the panel 100 (e.g., 4 feet), the splines that form the flanges of the I-beam 117 may have a length greater than the panel, so as to extend across the vertical post 138, as shown in FIG. 6. Splines 116 of I-beam 117 could be nailed, screwed, glued, or otherwise secured to vertical post 138 at this junction, between adjacent side-by-side panels 100. In an embodiment, shorter splines could also be used, e.g., but still span from one panel 100, across vertical post 138, to the adjacent panel 100 (e.g., length of 4 feet, or even less). It is not necessary that the flanges of the I-beam be formed from single continuous pieces of OSB or other suitable material. For example, short lengths of OSB waste material, which could be short pieces (e.g., 1 foot, 2 feet, 3 feet, 4 feet, etc.) could be fed into channels 104a, 104b to form each flange of the I-beam 117. Because such short lengths would be constrained within stacked top and bottom channels (e.g., 104a and 104a), and may be glued in place, they will provide a sufficiently strong I-beam for the post and beam wall construction systems described herein.

(42) FIG. 7 shows a further progression of the wall construction, now with 4 panels 100, two side-by-side, and two stacked one on top of another. There is no need to stagger seams between panels, although they could be staggered, if desired. While FIGS. 5-7 do not show splines 116 inserted into interior channels 104 of the panels 100 in order to better show other features, it will be appreciated that splines 116 can be inserted into any or all of such interior channels 104, as desired.

(43) FIG. 8 is similar to FIG. 7, but shows a filler piece 158 of foam positioned over the vertical post 138, to fill the gap between adjacent side by side positioned panels 100. For example, the illustrated wall may be 2 panels wide, and 2 panels high (e.g., about 8 feet long, 4 feet high). By stacking another 2 heights of panels, the wall may be 8 feet high. Any height may be achieved by simply stacking the needed number of panels, with an I-beam horizontally oriented between each set of stacked panels. Any length may be provided to such a wall, by simply placing additional vertical posts (e.g., at 4 foot intervals, or other interval), with one column of panels positioned between such posts. As is further evident from FIG. 8, where one panel 100 is stacked on top of another panel 100, there is an overlap profile between the adjoining panels at the seam 135, which prevents water from entering at what might otherwise be a simple horizontal seam between such stacked foam panels. In other words, the top and bottom outer edges of each panel include a stair stepped configuration at 133, as perhaps best shown in FIGS. 1-3, so that the horizontal seam 135 (FIG. 8) is followed by an inclined or stair-stepped surface, preventing water from seeping into channels 104a, 104b, 104a or 104b.

(44) Any of the splines may be more securely retained within any of the channels with any suitable adhesive. Without use of such an adhesive, the building system may actually be reversible, allowing dis-assembly of the components in a way that allows them to easily and quickly be re-assembled, e.g., at a different time, or in a different location. Such characteristics may be particularly beneficial for temporary structures (e.g., emergency housing, sets for plays or other drama productions, and the like). Where an adhesive is used, such adhesive may be injected into the channel through pre-cut slot 112 (for channels 104), injected directly into the open top or bottom channels (for channels 104a, 104b 104a or 104b), or placed on the splines 116, prior to channel insertion. Once drywall or other sheathing is placed over the foam panel faces 106a or 106b, nails or screws may further be used to secure such sheathing to the splines 116 within any of such channels.

(45) As described above, the splines 116 may have a length that is greater than the length of a given modular panel 100, such that a single spline 116 runs through aligned channels (similarly numbered) of more than one modular panel, positioned side by side. FIG. 8 further shows how once the splines 116 are inserted into any of the various channels, splines disposed therein are not exposed on the outside faces 106a, 106b of the foam bodies of panels 100. The splines are constrained within their channels, having only 1 degree of freedom therein (i.e., the ability to slide within the channel).

(46) Many of the following Figures described hereafter show various configurations and uses in which the panels, splines, and building systems may be employed, as well as methods of use therefore. FIG. 9 shows a wall formed from a plurality of panels 100, as well as how the panels may be used to form a roof structure, with panels positioned between adjacent truss members 130. In a similar manner as with the wall structures seen in FIGS. 5-8, I-beams 117 may be provided between adjacent stacked panels 100, while additional splines 116 may be provided, in interior central channels 104. The splines 116 in any such channels may extend beyond the length of each panel, for attachment to truss members 130, as shown. The truss members may simply be spaced apart at a distance equal to the length of the panels (e.g., 4 feet). The wall may include a cap plate 128, as shown (e.g., to which truss members 130 may be attached).

(47) Any desired roof pitch may be accommodated by such construction. Exemplary pitches include any desired pitch ratio, such as from 12/1 to 12/18 (e.g., 12/1; 12/2, 12/3; 12/4; 12/5; 12/6; 12/7; 12/8; 12/9; 12/10; 12/11; 12/12; 12/13; 12/14; 12/15; 12/16; 12/17; or 12/18). Another roof configuration using a transition panel is shown and described hereafter, in FIG. 11. A flat roof is of course also possible. As shown in FIG. 9, where roof panels 100 may not extend down the full height of trusses 130, any unfilled space below panels 100 can be used for electrical and/or plumbing runs.

(48) FIG. 10 illustrates how a door (or window) opening may be provided in any given wall, e.g., by placing vertical beams 138 at the ends of such an opening, which may be spanned by a conventional header 120. While the panels may be provided in lengths of 4 feet or any other desired length, they are easily cut, e.g., using a conventional circular saw (e.g., with a deep blade). They can easily be cut before insertion of any spline flanges and/or I-beams (in which case one is simply cutting through foam), or after such splines are inserted (in which case one is simply cutting through foam and typically OSB). Where desired, specialty header panels could be provided, e.g., including a header slot formed into panels 100, e.g., as disclosed in Applicant's U.S. Pat. No. 10,450,736, herein incorporated by reference in its entirety. Any of the concepts disclosed therein may be adapted for use with the present wall panels.

(49) While shown with straight planar walls, it will be appreciated that curved walls are also possible, e.g., by providing closely spaced (e.g., 6 inches or less, 4 inches or less, 3 inches or less, or 2 inches or less, such as 1 inch spacing) pre-cut slits into at least one face of the panel that is to be used in forming a curved wall. Such slits would allow the panel to be flexed, creating a curved face.

(50) A strap or any other desired typical connector may be used to attach any of the vertical posts 138 to a foundation, as will be appreciated by those of skill in the art, in light of the present disclosure.

(51) While electrical raceways 136 may provide a simple way to make electrical runs, other methods for wiring a structure using the present panel, post and beam constructions are also possible. For example, because the exterior of the wall prior to sheathing is formed from a material such as EPS foam that is easily worked, a portable hot wire cutting tool may be used to quickly cut traces or raceways through the foam face, in any configuration desired, for receipt of electrical wiring. Furthermore, current code allows such wiring to not need any conduit, where there is 1.5 inches or more between the exterior of any eventually applied sheathing, and the location of the wiring. The 1-2 inch foam thickness before reaching any of the channels (i.e., spline), coupled with a typical inch or inch drywall sheathing allows the wiring to simply be pressed into grooves cut into the foam face during wiring of the building, without the need for any conduit for housing such wiring.

(52) Where the wiring crosses over a spline, a spiked or other metal plate may simply be pressed over the wiring, over the spline, to prevent a fastener from penetrating the wiring, when attempting to fasten into the spline. Such forming of a raceway in the face of the panels can be quickly and easily accomplished after the panels have been raised into the desired wall structures, during wiring of the building. A portable hot wire groove cutting tool can be used for such raceway formation. Such a tool is very quick (e.g., an 8 foot groove length may be formed in a matter of seconds, and the grooves may be freely run over the face of the panels, without regard to spline location, and without passage through any splines (as would be typical in traditional framing). For example, such a groove may simply be drawn from a switch or other location to where the power is to be delivered (e.g., a light, outlet, etc.) in a straight line, across the panel(s) face(s).

(53) In an embodiment, either the interior, exterior, or both foam panel faces of walls of a building may be tiled over with cementitious panels, e.g., such as available from Applicant. Because of the presence of the splines within the channels of the wall system, screws or other fasteners may be used for such attachment. An adhesive may additionally or alternatively be used. Any suitable adhesive may be used to adhere such panels to the foam face. While epoxy or urethane adhesives may be suitable in theory, a polymer modified cement based adhesive may be preferred, as the urethane and epoxy adhesives have been found by the present inventor to be finicky, making it difficult if a user wishes to reposition a panel once it has initially been placed over the adhesive coated foam.

(54) For example, the epoxy and urethane adhesives typically set very quickly, providing little time for the user to perform any needed repositioning or adjustment of a placed panel. Furthermore, because the bonding strength is so great, when attempting to reposition such a bonded panel, chunks of underlying foam may be pulled from the foam frame structure (floor, wall, ceiling, roof, or the like) when attempting debonding, which is of course problematic. A polymer modified cement based adhesive provides greater cure time, allowing some flexibility in positioning, and repositioning, before the bond between the panel and foam frame member becomes permanent and strong. That said, urethane and epoxy adhesives (e.g., foaming adhesives) may also be used, where desired. Methods and other characteristics for such tiling, information relative to adhesives, and the like is found within Applicant's Application Serial No. U.S. patent application Ser. No. 15/426,756 (18944.9), herein incorporated by reference in its entirety. Examples of Applicant's other building systems which may include various features that can be incorporated to some degree herein include U.S. patent application Ser. Nos. 13/866,569; 13/436,403; 62/722,591; 62/746,118; 16,549,901, and 16/653,579, each of which is incorporated herein by reference in its entirety. The last four patent applications describe exterior applied sealants that may be used, as such, in the present invention.

(55) All components and steps of the method and system can be handled without heavy equipment (e.g., cranes), with the possible exception of any very large, heavy reinforcing structural members that may be embedded in any of the foam modular panel members, positioned between such panels, or the like. In fact, the modular panels are so light as to be easily handled and positioned by a crew of women. For example, the panels (e.g., 2 feet4 feet) may weigh less than 40 lbs, less than 30 lbs, less than 20 lbs, or less than 15 lbs. The splines may also be handled and positioned by a crew of women. For example, because strips of such OSB material are very light (e.g., less than 10, 5 or even 3 lbs), and/or because there is typically no need to use splines that are of a single piece of continuous material, such crew members could push scrap material (e.g., scrap OSB strips) into the channels, which scrap material could serve as the splines. As a result, a construction site using such methods may generate very little, if any waste, e.g., far less such waste than is generated when using traditional framing techniques. In addition, it will be apparent that when constructing a given building, far fewer 24s will be needed, as there are no conventional single studs present in the construction, but rather use of OSB or similar elongate strips of material, as the splines are used, in conjunction with vertical post members (which may be formed from pairs of 24s), but which are only spaced typically every 4 feet, requiring far fewer 24s than a typical frame construction in which 24 studs are spaced at 24 or 16 inches on center.

(56) FIG. 11 shows an exemplary building construction that employs the panels 100 as described herein for construction of the walls, and which shows use of a transition panel 200 at the top of the wall structure, for providing a transition from such standard panels 100, to the same standard panels 100 used for the roof construction. Similar to panel 100, transition panel 200 is shown as including a pair of lower channels 104a and 104b, allowing formation of an I-beam the same as with any of the standard wall panels 100, between the top most wall panel 100 and transition panel 200. Panel 200 is also shown as including an additional pair of channels 105a and 105b, which are analogous to the top channels 104a and 104b of any of the standard wall panels, but which are oriented at an angle relative to bottom channels 104a, 104b, where the angle corresponds to the pitch of the roof being constructed. Channels 105a, 105b thus line up with the bottom channels 104a and 104b, respectively, of the standard panel 100 positioned as the first roof panel, adjacent transition panel 200, as shown. Transition panel 200 thus allows in-situ formation of an I-beam between the transition panel 200 and the top most wall panel 100, and another I-beam between the transition panel 200 and the adjacent roof panel 100. Transition panel 200 can include slots 203 for insertion of eave stiffening members FIG. 12A shows a close up of the eave area of FIG. 11, better showing how the transition panel 200 integrates with the adjacent roof panel 100 and the adjacent top most wall panel 100.

(57) FIG. 11 further shows a cap roof panel 202, configured to transition between standard roof panels 100, at the apex of such a pitched roof. Cap roof panel 202 also includes 2 pairs of edge channels, configured to be aligned with the top channels 104a w and 104b of the two adjacent roof panels 100. The pairs of edge channels of the cap roof panel are angled relative to one another, e.g., at double the angle defined between the pairs of channels in transition panel 200, as dictated by the pitch of the roof. Such transition panels 200 and cap roof panels 202 may be custom provided to the building site, along with a desired number of standard panels (for walls and roof), as determined from the plan or blueprint of the building being constructed.

(58) FIGS. 11 and 12B further shows how panels similar to standard panels 100 may be used to form the floor. Such floor panels 204 may be similar to the standard wall and roof panels 100, except that they may only include one top channel, and one bottom channel adjacent the face of the panel that becomes the interior floor. Because the panels are rotated (laid on the ground instead of oriented vertically, as in a wall construction), what would be top and bottom channels are now simply both adjacent to the upper floor face of the panel, one to the right, and one to the left (rather than top and bottom).

(59) The floor panel may not include channels adjacent the bottom face of the floor panels 204 (such panels may simply be positioned over a pea gravel base or the like). A notch 206 that is exposed on the bottom face of such floor panels 204 may be provided, e.g., to raise the floor panels up off such a gravel or other base, should such be desired. FIG. 12B shows a close up of such a floor panel, showing the notch 206.

(60) While the Figures illustrate construction of simple exemplary walls and buildings to illustrate concepts of the present construction methods and systems, it will be appreciated that the methods and systems may be used to construct a nearly endless variety of buildings.

(61) It will also be appreciated that the present claimed 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, not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. Additionally, as used in this specification and the appended claims, the singular forms a, an and the include plural referents unless the context clearly dictates otherwise.