Panelized Building System Utilizing Integrated Insulation

Abstract

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

Claims

1. (canceled)

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5. (canceled)

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16. (canceled)

17. (canceled)

18. (canceled)

19. (canceled)

20. A wall panel comprising: a. a structural framing mechanically adhered to a perforated reinforcing layer; b. a single monolithic layer of foam insulation having a cavity portion and a continuous portion, the cavity portion of the single monolithic layer of foam insulation is partially embedded in the structural framing thereby leaving an open cavity within the panel for the installation of utility elements and panel to panel attachments; c. the continuous portion of the single monolithic layer of foam insulation encapsulates the reinforcing layer; d. an exterior layer of building material is adhered to the continuous portion of the single monolithic layer of foam insulation; e. wherein the single monolithic layer of foam insulation that encapsulates the perforated reinforcing layer and the structural framing act together as a single structural unit to resist an applied load.

21. The wall panel of claim 1, wherein the perforated reinforcing layer is selected from the group consisting of expanded metal and wire mesh.

22. The wall panel of claim 1, wherein the exterior layer of building material is selected from the group consisting of membrane, felt, or plywood.

23. A panelized building system including the wall panel of claim 1, wherein: a. the structural framing has a plurality of C-studs positioned between a male vertical stud and a female vertical stud; b. the system includes a structural corner post, the structural corner post comprising: i. a corner tongue that attaches to the female vertical stud; ii. a corner groove that attaches to the male vertical stud;

24. The panelized building system of claim 23, wherein the corner tongue mechanically interlocks with the female vertical stud when interested into a groove on an exterior face of the female vertical stud and the corner groove mechanically interlocks with the male vertical stud when the male vertical stud is inserted into the corner groove to prevent the wall panel from shifting once connected to a corner post.

25. A panelized building system comprising a wall panel, at least one structural corner post, and at least one structural floor panel, wherein: a. the wall panel includes: i. a vertical male stud having a tongue that extends from a center portion of an exterior surface of the vertical male stud; ii. a vertical female stud having a groove cut into a center portion of an exterior surface of the vertical female stud; iii. a plurality of C-studs positioned between a male vertical stud and a female vertical stud, the C-studs embedded in a first insulation layer; and iv. two horizontal female tracks framing the vertical male and female studs and the C-studs with a top horizontal female track as a top surface of the structural framing and a bottom horizontal female track as a bottom surface of the structural framing, the top and bottom horizontal female tracks each having a groove cut into a center portion of the track; and b. the at least one structural corner post comprising: i. a corner exterior layer that forms the external corners of the panelized building system; ii. a corner tongue for inserting the groove cut into the vertical female stud; and iii. a corner groove for receiving the tongue extending from the vertical male stud, the corner groove and the corner tongue are joined to each other and the corner exterior layer by a pair of connectors; c. the at least one structural floor panel comprises: i. plurality of floor joists extending between two spandrels, the floor joints embedded in a floor insulation bonded to a floor exterior layer; ii. a first male floor track forming a top surface of a spandrel, the first male floor track having a tongue extending out from a center portion of the first floor track, the tongue on the first male floor track for inserting into a horizontal female track of a wall panel structural framing attached above the structural floor panel; and iii. a second male floor track forming a bottom surface of a spandrel, the second male floor track having a tongue extending out from a center portion of the second male floor track, the tongue on the second male floor track for inserting into a horizontal female track of a wall panel structural framing attached below the structural floor panel.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0027] 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.

[0028] 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:

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

[0030] FIG. 1B illustrates a cut away view of a roof panel in accordance with the preferred embodiment of the present invention;

[0031] 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;

[0032] 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;

[0033] FIG. 2C illustrates a sectional view of the spandrel shown in FIG. 2A in accordance with the preferred embodiment of the present invention;

[0034] FIG. 3A illustrates a sectional view of the wall panel shown in FIG. 1A in accordance with the preferred embodiment of the present invention;

[0035] FIG. 3B illustrates a sectional view of the floor panel shown in FIG. 2A in accordance with the preferred embodiment of the present invention;

[0036] FIG. 3C illustrates a sectional view of the roof panel shown in FIG. 1B in accordance with the preferred embodiment of the present invention;

[0037] 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;

[0038] FIG. 3F illustrates a sectional view of a corner post in accordance with the preferred embodiment of the present invention;

[0039] 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;

[0040] 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;

[0041] FIG. 6 illustrates another configuration of the floor assembly in accordance with the preferred embodiment of the present invention;

[0042] 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;

[0043] FIG. 8A illustrates the roof panel in a folded state in accordance with the preferred embodiment of the present invention; and

[0044] 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

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] FIG. 1A illustrates a wall panel 100 employed in the panelized building system. 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 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.