CA1220317A - Rigid foam panel construction - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE

A structural panel of rigid insulating of foam for use for example in walls or roofs of buildings. The panel has opposite planar surfaces with parallel first grooves on one surface to receive and carry strapping and parallel second grooves in the other surface, perpendicular to the first grooves, to receive the studs or rafters of the building. The structural panels according to the present invention receive cladding for the exterior walls and roof, thereby saving valuable construction time and effort by combining the insulation phase with the framing phase. A completely insulated, closed-in structure can be achieved using these panels, immediately after framing.

Description

3~7 The present invention relates to a structural foam panel and to a method of building which uses such panels.

BACKGROUND OF THY INVENTION

Particularly in North America where supplies of wood remain plentiful, buildings are often constructed with a framework of wooden studs and rafters. Insulation, for example in the form of fiberglass belts, is seated between the studs, the studs carrying the inside and outside wall&. Windows and doorways aye framed with the studs. For the roof, the rafters are covered for example with plywood, and then covered with a waterproof covering, on top of which the exterior roofing materials, such as shingles, are secured.
Such traditional construction of housing it labor intensive, and requires considerable time before a building is completely enclosed. This becomes a problem particularly in winter months where it becomes desirable to weatherproof and insulate a new building as quickly as possible. Many stages of construction, including initial framing, insulting and interior and exterior cladding, are required. Until a building is completely framed and insulated, during the winter months, it is defoliate to do much ox the interior work such as lazing in of plumbing and electrical wiring, and finishing the interior with drooling or the like.
Canadian Patent No. 1,116,371 of Lenin issued I.
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January 19, 1982, describes and illustrates a wall panel made of rigid foam insulation having opposed, parallel, rectilinear grooves on opposing outer surfaces for receiving the framing members of a building. The framing members, when in position in the grooves, are mechanically fastened together through the insulation. This type of insulated wall construction is advantageous, since it enables relatively speedy erection of a building by permitting the sheeting and insulating to be completed in one step. This type of wall panel however requires grooves at its edges within which splints are fitted, to secure adjacent panels together. These panels necessitate a lateral movement of one panel towards the other to place the first panel in final, juxtaposed position, beside the other, and this lateral movement may not always be convenient since it may be obstructed by the vertical studs, already in position in the building, which are to be fitted into the corresponding grooves on one side of the panel.
Other patents of general background interest, describing and illustrating rigid foam panels for use in construction, include Cenozoic Canadian Patent No. 1,049,217 issued February 27, 1979 {foam it secured to a rigid backing of for example bonded wood excelsior: Slavic Canadian Patent No.
1,169,222 issued June 19, 1984 (describing width adjustable expanded foam insulin panels to be inserted between studs in a building): Chamberlain Canadian Patent No. 699,949 issued December 15, lg64 (roofing panels made of insulation sandwiched I

between plywood or the like), and Gantner Canadian Patent No.
1,062,868 issued September 25, 1979 (insulation roof panels).
It is an object of the present invention to provide an easy, fast and efficient method of constructing insulated walls and roofs of buildings, and to provide panels winch will achieve this end.

SUMMARY OF THE INV~NTIOM

According to the present invention there it provided a structural panel of rigid insulating foam, the panel having opposite planar surfaces. The panel has parallel first grooves in one surface which receive and carry strapping, and parallel second grooves in the other surface, which are perpendicular to the first grooves, to receive portions of spaced parallel building elements such as studs or rafters. The grooves in one surface are of a depth not to intersect the grooves in the other surface. The panel is of a thickness to maintain structural integrity and rigidity of the panel despite the grooves therein.
In a preferred embodiment of the present invention, the sides of the first grooves are contoured to retain mating strapping inserted therein against normal release in a direction away from the corresponding panel surface. These first grooves may for example be contoured with outwardly flared sides with increasing depth in the panel or Do alternatively may be formed of pairs of cooperating linear slots, the slots of each pair being downwardly inclined into the panel away from each other. In this latter instance the strapping would be normally of sheet metal having cooperating arms insertable into the slots.
It is preferred to form the panels with a pair of opposite edges parallel to each other and perpendicular to the first grooves, these edges having join means extending along Their lengths. The joint means comprise, for one of these edges all outward extension fish with one face and a projection at the end thereof towards the other face, to form a groove between the projection of the main panel body. The joint means for the other of these edges is of a similar shape and size but has its outward extension flush with the other face and its projection oriented towards the first-mentioned face. The extensions, projections and grooves of each joint means are formed so that the projection from one edge of one panel is fleshly received in the joint means groove of an edge of a panel with familiarly formed joint means when positioned adjacent thereto. This feature permits adjacent panels, with overlapping edges, to be seated into position on vertical studs, without the need to move each adjacent panel laterally into position with respect to the last-po~itioned panel.
Use of panels according to the present invention permits construction of a wall, totally insulated with foam, which is approximately three to seven times stronger than AL

conventionally sheeted and Eibreglassed insulated walls. The sheeting and insulating are completed in one step, the strapping, being horizontal in walls, producing a uniform rigidity to the wall as well as accommodating various kinds of siding. Once the wall is standing, it is weatherproofed and draft proofed to a large degree. The panels permit speedy erection of walls and roofs and are significantly labor saving in nature. During construction, the panels act as sway bracing, adding increased sheer strength over conventional methods of construction because the panels fit over existing studs and rafters. additionally they permit less heat transfer through the studs to the exterior of the building than most traditional forms of construction.

BRIEF DESCRIPTION OF THE DRYING

These and other objects and advantages of the invention will become apparent upon reading the following detailed description and upon referring to the drawings in which:
FIGURE 1 is a perspective side view, from the outside, of a wall built using panels according is the present invention;
FIGURE 2 is a bottom view of a series of wall panels being enlaced in position on studs;
FIGURE 3 is an enlarged, partial, section view of adjacent panels of FIGURE 2, illustrating the overlapping joint 3~7 between adjacent panels in accordance with the present invention:
FIGURE is a transverse section view of a wall of a building constructed using panels in accordance with the present invention:
FIGURE 5 is an enlarged, partial, section view of a portion of the wall of FIGURE 4 illustrating an example embodiment of strapping used in conjunction with the panels in accordance with the present invention:
FIGURE 6 is a perspective partial view of a panel according to the present invention illustrating alternative types of grooves for strapping FIGURE 7 is a perspective view of a potion of roof constructed using panels according to the present invention; and FIGURE R is a section view, from the side, of a wall and woof section constructed using panels in accordance with the present invention.
While the invention will be described in conjunction with example embodiments, it will be understood that it is not intended to limit the invention to such embodiments. On the contrary, it is intended Jo cover all alternatives, modifications and equivalents as may be included within the spirit and scope ox the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, similar features in the drawings have been given similar reference numerals.
Turning to the drawings, in FIGURE 1 -there is shown, from the exterior, a wall ox a building constructed using panels 2 in accordance with the present invention. These panels 2 are made of rigid insulating foam, such as foamed polystyrene, and haze opposite planar faces 4 and 6. The panels are preferably of rectangular shape.
In planar surface 4 ore formed a plurality of parallel grooves 8 to receive and carry strapping 10. Strapping 10 may be carried in grooves 8, as illustrated in FIGURES 4 and 5, so that it may be nailed as required to appropriate studs 12, or alternatively, as illustrated in FIGURE 6, the sides of grooves 8 may be contoured so that they hem elves retain strapping 10 with appropriately formed and contoured edges. As can be seen in FIGURE 6, one side 14 (or a required, both sides) of grooves 8 may be contoured so that it flares outwardly with increasing depth in the panel, in which case grooves 8 would receive from the side a correspondingly formed trapping member 10, for example of wood. Alternatively, grooves 8 may consist of cooperating pairs of linear slots 16, the slow 16 of each pair being downwardly inclined into the panel away from each other as illustrated in FIGURE 6. These pairs of slots retain the cooperating arms 18 of mating strapping 10 which are .
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CLUE

inserted, from the side, into these slots. In this latter case, the strapping members 10 may be made, for example, of sheet metal, appropriately formed and shaped to fit into grooves 16. In both cases illustrated in FIGURE 6, grooves 8 and 16 retain the strapping 10 against normal release in a direction away from the corresponding panel surface 4.
In surface 6, on the interior of the wall section illustrated in FIGURE 1, are formed a plurality of grooves 20 (scurvy contour, in most instances), to receive, as illustrated in FIGURE 2, portions of studs 12. These grooves 20 are parallel to each other and run, through panels 2, in a direction perpendicular to that of grooves 8. A vapor barrier 21 may be placed along studs 12, between the studs and the panels 2, and held in position by the positioning of the panels with the studs 12 inserted in groove 20. In this way little or no stapling of the vapor barrier onto the studs, as is required in conventional wall constructions, is needed. A
continuous vapor barrier, with no breaks along the partition walls, may thus be provided very simply. As well, can be seen in FIGURE 2, moisture from the external (panel) side of the wall does not come into contact with the framing members (studs 12).
As can be seen in FIGURES 1 and 2, it is prey erred to have the framing members or studs 12 extend outwardly from the grooves 20 beyond the surface 6 of panels 2. This extension is preferably at least 2 inches, to permit easy electrical and plumbing installation, without danger of ripping vapor barrier 21. As well, this essentially creates a double wall system enabling additional biotype insulation to be installed if desired or a dead-air space, in which space the wiring and plumbing can run, unobstructed, on this inner side of the vapor barrier.
As can be appreciated, for example, in FIGURES 4 and 5, the thickness of panel 2 with respect to the depth of grooves 8 and 20 is such that the grooves on opposite surfaces of panels 2 do no intersect each other and the structural integrity and rigidity of the panels are maintained despite the presence of grooves 8 and 20 on opposite surfaces of the panels.
Turning to FIGURES 2 and 6, the sides of each panel lo which Lung parallel to grooves 20 are provided with joint means 22 which are intended to overlap with corresponding joint means on the corresponding sides of adjacent panels, interconnect therewith, and provide a seal to prevent or minimize passage of moisture, drafts or heat. As can be clearly seen in FIGURE 6, joint means 22 comprises an outward extension 24 flush with surface 6, and projection 26 at the end thereof oriented towards surface 4 of panel 2. This construction forms a groove 28 between the protection 24 and the main panel body extending along the entire length of this particular side ox panel 2. At the other side of panel 2 aye seen for example, in FIGURE 2), and similarly extending long the entire length of that wide of 3~L~7 the panel there is a corresponding joint means 2Z of a similar shape and size but having its outward extension 24 flush with surface 4 of panel 2 and its projection 26 oriented towards surface 6. These extensions 24, projections 26 and grooves 28 of each joint means 22 on the panels are formed so that the projections 26 from one side of one panel fleshly mate, as illustrated for example in FIGURE 2, in the joint means groove 28 of the confronting edge of the adjacent panel 2. This construction permits, as illustrated in FIGURE 2, the progressive placement of panels 2 in position on studs 12, in side-by-side arrangement, without the need for sideways or lateral movement of a panel being placed into position, with respect to the studs and panels already in position, as has been from time~to-time the case with prior art constructions using rigid foam panels.
A illustrated in FIGURE 3, the interior surfaces 30 of projections 26 may be provided with lips 32, near the upper end of each of the projections Z6, to physically lock the joint means 22 of adjacent panels in position. Otherwise, the panels are locked into position merely by frictional engagement of the projection 26 from one panel in the groove 28 of the adjacent panel.
In using panels 2 generally in construction of buildings, it will be appreciated that the grooves 8 and 20, and particularly groove 20, may be formed on site, being shaped and located as required for proper placement of studs 12 within The grooves may be formed with a common industrial router and an a~eropLiate router bit. This enables panels, where stud centers are inconsistent, to be quickly custom-made on site.
As will be understood from FIGURE l, holes for windows and doors may be cut in the panels on site, to conform to the required locations of doors and windows in the building as set out by the studding in place. windows and doors are framed oversexed in height and width and then boxed in with wood or any other appropriate material flush to the outside so that the windows and doors can be attached solidly.
Interior finishing of a building is carried out in a traditional fashion when using panels 2 according to the present invention, since the inner surface of studs lo are normally exposed. Thus drywall or other interior finishing may be secured directly to the studs or to s~rappillg fixed to the studs.
The horizontal strapping lo makes it possible to us, any vertical or angular siding. Horizontal siding for example is simply adhered with longer fineries into studs 12, through the strapping lo Panels Z applied to a wall system in a conventionally framed building are illustrated in the section view ox FIGURE
4. Appropriate header 40 and 42, trusses 44 and root rafter 46, floor joists 48 and filler panels 50 the latter glued and nailed to seal all joint) are illustrated mounted on a foundation 52 which has been appropriately combined with rigid insulation panels 54 extending up to the filler panels 50 as shown. Vapor barrier 21 can be installed under and around the floor joists I and up the wall as illustrated, as well as, if required, around the roof trusses I thereby creating a rip free continuous vapor barrier extending and enveloping the entire interior of the s~ructvre. (This feature is almost impossible to achieve with conventional building methods.) Washer Ed insulation nails may be used to secure header I and filler penal 50.
In actual construction of a wall section, remanufactured "starter panels" are used to begin the construction. These panels are specially cut for a corner stud or a corner with a flat member for backing. Once in place, the starter panel falls halfway into the first bay (between the studs). The joint means 22 between panels is positioned between stud, so that the next panel can slip in under the existing one without hitting a stud. When adjacent panels are engaged in position, a new panel it simply placed in position over the studs and its locking means 22 fitted into engaged position with the corresponding locking means 22 of the adjacent panel already in position. Thus, the joint between the panels is completed. Each panel it set into place one after the other (FIGURE 2) until the end of the wall is reached. The last panel is routed and cut to fit as required.
FIGURES 7 and 8 illustrate the application to roofing 3~7 of panels 2 in accordance with the present invention. As illustrated in FIGURES 7 and 8, panels 2 are supported on rafters 46 (FIGURE 8), portions of these rafters being inserted into appropriately positioned parallel grooves 20 on inner surfaces 6 (FIGURE 7). Weatherproof sheeting 56 may be appropriately fastened to strapping 10 on the exterior side of panels 4 and shingles 58 are then secured on top thereof as illustrated. Panels for the edges of the roof, at the ends of the rafters and a the gables, are appropriately modified as illustrated, in the former case to provide rafter tail extensions I secured to side panels 2 by means of support members 62 seated beneath strapping 10 in appropriate grooves in the panels, and in the latter case to provide gable overhang 64 secured to edge panels 2 by means of support members 66 and 68 (FIGURE 7). It will be appreciated by one skilled in the art that panels 2 significantly facilitate the construction of a building's roof, avoiding the need for plywood paneling or the like on top of the rafters before the application of weatherproof sheeting 56 and shingles 58. Panels 2 permit weatherproof sheeting 56 and shingles 58 to be secured directly thereto, without the need for plywood, while, it the tame time, providing insulation to the very top of the building. In other words, the top cord of rafters 46 is insulated, unlike most prior art building systems. Of course, the panels for the roofing system would normally be much thicker than those for the wall sections - for example a R-40 rating which might I

require approximately 9 1/4 inches of thickness of panels 2 while the exterior walls (erg. FIGURE 4) on the other hand might be approximately 5 1/2 inches thick creating an R20 insulation value in the walls.
Insulating the top cord of the truss or rafter, and using that insulating as sheeting for the final roofing material also saves hours of work in truss bracing and preparation for sheeting. It also saves all the labor of insulating the ceiling. Once the panels have been clipped together and installed, the building is totally weather-proofed and ready for temporary heat if necessary. A normal home, for example could be heated or cooled after only two days of framing time. Thus, the system according to the present invention is ideal for construction in extreme weather conditions as, for example, found in the Arctic.
The strength of a wall totally insulated with foam panels according to the present invention is significantly stronger than conventionally sheeted and fibreglass-insulated walls. The use of horizontal strapping 10 in the manner stated herein produces a uniform rigidity to the wall. As previously indicated, panel Allah act as a sway brace, for both studs an rafters. The rectilinear (or square) form of the panels assists in ensuring the walls of the building are square.
The drawings depict only one kind of application of the panels according to the present invention, and one building system. It will be readily appreciated by one skilled in the art however that the strapping system of the present invention and the joint means of the panels can be used with any present building system which requires sheeting and insulation over its structural flaming. This therefore provides a wide variety of uses and applications of the present invention, from light residential to heavy commercial building, peaked or flat roof systems, insulated floors, etc..
Thus it is apparent that there has been provided in accordance with thy invention a panel construction system that fully satisfies the objects, aims and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and broad scope of the invention.

Claims (17)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. panel of rigid insulating foam to be incorporated using conventional construction techniques with conventional framing means to create an integral structure system for a building, the panel having a main panel body with opposite planar surfaces and a pair of opposite edges parallel to each other, the panel having parallel first grooves in one surface running perpendicular to said edges to receive and carry strapping, and parallel second grooves in the other surface perpendicular to the first grooves, positioned to receive portions of conventional spaced parallel load-bearing framing means such as studs or rafters, the grooves in one surface being of a depth not to intersect the grooves in the other surface and the panel being of a thickness to maintain structural integrity and uniform rigidity of the panel despite the grooves therein, the edges having joint means extending along their lengths, the joint means comprising, for one of these edges, an outward extension flush with one surface, and a projection at the end thereof extending perpendicularly towards the other surface to form a joint means groove between the projection and the main panel body with the sides of the groove being perpendicular to its bottom, the joint means for the other of these edges being of a similar shape and size but having its outward extension flush with the other surface and its projection extending perpendicularly towards the first-mentioned surface, the extensions, projections and grooves of each joint means formed so that the projection from one edge of one panel flushly mates in the joint means groove of an edge of a panel with similarly formed joint means when positioned adjacent thereto.

2. A panel according to claim 1 wherein the sides of the first grooves are contoured to retain mating strapping inserted therein against normal release in a direction away from the corresponding panel surface.

3. A panel according to claim 2 wherein the first grooves are contoured with outwardly flared sides with increasing depth in the panel.

4. A panel according to claim 2 wherein the first grooves comprise pairs of cooperating linear slots, the slots of each pair being downwardly inclined into the panel away from each other, these pairs of slots each to retain the cooperating arms of mating strapping insertable therein against normal release in a direction away from the corresponding panel surface.

5. panel according to claim 1 in combination with strapping mateably received in the first grooves and retained therein against normal release in a direction away from the corresponding panel surface.

6. A panel according to claim 2 in combination with strapping contoured to mateably fit into the first grooves and held therein against normal release in a direction away from the corresponding panel surface.

7. A panel according to claim 3 in combination with strapping of rigid structural board contoured to mateably fit into the first grooves and held therein against normal release in a direction away from the corresponding panel surface.

8. A panel according to claim 4 in combination with sheet metal strapping having arms contoured to fit into the cooperating pairs of linear slots and held therein against normal release of the strapping in a direction away from the corresponding panel surface.

9. A panel according to claim 1 wherein the projections are provided with lock means extending along their interior surfaces to physically lock the joint means of adjacent panels in position.

10. A section of a building made from a series of similar panels according to claim 1. wherein the parallel first grooves of adjacent panels are aligned and wherein strapping is mateably received in the grooves and retained therein, the strapping for each first groove extending unbroken between a plurality of adjacent panels.

11. A panel according to claim 1 made of foamed polystyrene.

12. A method of construction of a wall or roof section of a building combining conventional framing means with a plurality of rigid insulating foam panels of a type having a main panel body with opposite planar surfaces and a pair of opposite edges parallel to each other, the panel having parallel first grooves in one surface running perpendicular to said edges to receive and carry strapping, and parallel second grooves in the other surface perpendicular to the first grooves, positioned to receive portions of conventional spaced parallel load-bearing framing means such as studs or rafters, the grooves in one surface being of a depth not to intersect the grooves in the other surface and the panel being of a thickness to maintain structural integrity and uniform rigidity of the panel despite the grooves therein, the edges of the panel being formed such that the edges of adjacent panels overlap when in position, the method comprising the steps of:
(a) arranging the panels progressively in position with the framing means, with the exterior side of the respective framing means seated within the corresponding second grooves, with the edges of adjacent panels positioned between adjacent framing means and overlapping to provide a seal to prevent or minimize passage of moisture, drafts or heat, and with the first grooves from one panel to the next being aligned from one panel to the next;
(b) inserting strapping s-trips in the first aligned grooves; and (c) securing the strapping strips to the framing members through the foam panels.

13. A method according to claim 12 further comprising the steps of cladding the section by securing cladding to the strapping.

14. A method according to claim 13 wherein the second grooves of the panels are formed of a depth such that the inner sides of the framing means, when the panels are in position, extend to the interior of the building beyond the corresponding surface of the panels, and wherein the interior finishing of the section of the building is secured to the inner sides of the framing means.

15. A method according to claim 14 wherein additional batt-type insulation is provided between the panels and interior finishing.

16. method according to claim 12, 13 or 14 further comprising the step of cutting in the panels holes for windows and doors as required.

17. A method of construction of a building combining conventional framing means with a plurality of rigid insulating foam panels of the type having a main panel body with opposite planar surfaces and a pair of opposite edges parallel to each other, the panel having parallel first grooves in one surface running perpendicular to said edges to receive and carry strapping, and parallel second grooves in the other surface perpendicular to the first grooves, positioned to receive portions of conventional spaced parallel load-bearing framing means such as studs or rafters, the grooves in one surface being of a depth not to intersect the grooves in the other surface and the panel being of a thickness to maintain structural integrity and uniform rigidity of the panel despite the grooves therein, the edges having joint means extending along their lengths, the joint means comprising, for one of these edges, an outward extension flush with one surface, and a projection at the end thereof extending perpendicularly towards the other surface to form a groove joint means between the projection and the main panel body with the sides of the groove being perpendicular to its bottom, the joint means for the other of these edges being of a similar shape and size but having its outward extension flush with the other surface and its projection extending perpendicularly towards the first-mentioned surface, the extensions, projections and grooves of each joint means formed so that the projection from one edge of one panel flushly mates in the joint means groove of an edge of a panel with similarly formed joint means when positioned adjacent thereto, the method comprising the steps of:
(a) arranging the panels progressively in position with the framing means, with the exterior sides of the respective framing means seated within the corresponding second grooves, and with the projections from the edges of the panels flushly mated in the joint means groove of the edge of adjacent panels to provide a seal to prevent or minimize passage of moisture, drafts or heat, with the first grooves being aligned from one panel to the next;
(b) inserting strapping strips in the first aligned grooves; and (c) securing the strapping strips to the framing members through the foam panels.