CA2093237A1 - Panel building component - Google Patents
Panel building componentInfo
- Publication number
- CA2093237A1 CA2093237A1 CA002093237A CA2093237A CA2093237A1 CA 2093237 A1 CA2093237 A1 CA 2093237A1 CA 002093237 A CA002093237 A CA 002093237A CA 2093237 A CA2093237 A CA 2093237A CA 2093237 A1 CA2093237 A1 CA 2093237A1
- Authority
- CA
- Canada
- Prior art keywords
- building component
- panel building
- insulation core
- rigid insulation
- substantially rigid
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
Abstract
A panel building component is disclosed comprised of a substantially rigid insulation core (2), preferably of expanded polymer having thermal and sound insulation qualities, in combination with a perimeter of light gauge steel members (4, 6, 4, 8). Vertical members (4) of the perimeter are preferably fabricated with a ledge channel cross-section in which the ledges are disposed in engaged relationship with grooves embossed in the insulation core. The combination of the ledge channel cross-section vertical member (4) and lateral portions of the insulation core demarcated by the grooves form integral composite columns of substantial strength.
The panel is prefabricated and is available with interior fire resistant facing (12), exterior weather resistant facing (10), windows, doors, electrical wiring or other customization.
The panel is prefabricated and is available with interior fire resistant facing (12), exterior weather resistant facing (10), windows, doors, electrical wiring or other customization.
Description
2 ~ `' 7 PANEL BUILDING COMPONENT
Field of the Invention The present invention relates to the field of modular building components and, more particularly, to a panel which 5 achieves great insulation and strength with light weight by being formed from a composite of materials that produce a synergistic effect as a consequence of an interlocking relationship and makes use of the highly specific ~ualities of each material.
l0 Backqround of the Invention Much of the construction of buildings in the industrialized world, particularly in the United States, is of two types, wood frame and various kincls of material, including wood to cover the framework, or steel, usually 15 taken in combination with concrete in the form of prestressed concrete for framing and a variety of other materials to cover the same, frequently concrete block. On larger buildings, a prestressed concrete frame may be covered by glass, marble, stone, or the like. In all of the above 20 cases, insulation, which has become ever more important in an increasingly energy conscience ~orld, is frequently supplied as a separate layer interiorly of the outside structure above-described. When the covering material is concrete block, insulation in at least the exterior walls is 25 frequently omitted.
In order to achieve economies in the cost of construction, various efforts have been made to utilize pre-fabricated materials. Of course, the ultimate in pre-fabrication is with mobile homes which are simply transported 30 to the residence site, and usually then permanently fixed to a foundation. Other types of pre-fabricated or partially pre-fabricated construction methods are also well known such as A frame homes that are fre~uently used in rural areas as vacation retreats. There have also been very sophisticated 35 structures such as geodesic dome type structures of a type advocated by the well known American inventor Richard Buckminster Fuller. Examples of United States patents of this species either by Fuller or his associates are U.S.
WO92/21836 ~ PCT/~S92/04793 (~ 2 Patent No. 2,682,235 for a geodesic dome, U.S. Patent No.
2,881,717 for a paper board dome, U.S. Patent No. 2,905,113 for a plydome, U.S. Patent No. 2,914,074 for a catenary (geodesic tent), and other similar references such as U.S.
5 Patent No. 3,063,521, U.S. Patent No. 3,139,957, U.S. Patent No. 3,197,927, U.S. Patent No. 3,203,144, and U.S. Patent No.
Field of the Invention The present invention relates to the field of modular building components and, more particularly, to a panel which 5 achieves great insulation and strength with light weight by being formed from a composite of materials that produce a synergistic effect as a consequence of an interlocking relationship and makes use of the highly specific ~ualities of each material.
l0 Backqround of the Invention Much of the construction of buildings in the industrialized world, particularly in the United States, is of two types, wood frame and various kincls of material, including wood to cover the framework, or steel, usually 15 taken in combination with concrete in the form of prestressed concrete for framing and a variety of other materials to cover the same, frequently concrete block. On larger buildings, a prestressed concrete frame may be covered by glass, marble, stone, or the like. In all of the above 20 cases, insulation, which has become ever more important in an increasingly energy conscience ~orld, is frequently supplied as a separate layer interiorly of the outside structure above-described. When the covering material is concrete block, insulation in at least the exterior walls is 25 frequently omitted.
In order to achieve economies in the cost of construction, various efforts have been made to utilize pre-fabricated materials. Of course, the ultimate in pre-fabrication is with mobile homes which are simply transported 30 to the residence site, and usually then permanently fixed to a foundation. Other types of pre-fabricated or partially pre-fabricated construction methods are also well known such as A frame homes that are fre~uently used in rural areas as vacation retreats. There have also been very sophisticated 35 structures such as geodesic dome type structures of a type advocated by the well known American inventor Richard Buckminster Fuller. Examples of United States patents of this species either by Fuller or his associates are U.S.
WO92/21836 ~ PCT/~S92/04793 (~ 2 Patent No. 2,682,235 for a geodesic dome, U.S. Patent No.
2,881,717 for a paper board dome, U.S. Patent No. 2,905,113 for a plydome, U.S. Patent No. 2,914,074 for a catenary (geodesic tent), and other similar references such as U.S.
5 Patent No. 3,063,521, U.S. Patent No. 3,139,957, U.S. Patent No. 3,197,927, U.S. Patent No. 3,203,144, and U.S. Patent No.
3,810,33~.
Another reference which pursues l:he notion of a building component utilizing a panel is Zeihbrunner, U.S.
10 Patent No. 4,646,502 which teaches a panel construction element and building construction system employing such elements. That reference illustrates a profile frame and a filler material with cover panels that cover both the filler material and the profile frame. The frame includes a complex 15 cross-section of a type fabricated using an extrusion, which, in turn, leads to a substantially more expensive structure than that provided by the present invention without the interlocking advantages of the framing with the filler or polymeric material of the present invention.
Similarly, efforts have been made to provide modular building components which combine the coverage of area with insulation benefits. Several of these include two patents to Meyerson, U.S. Patent Nos. 4,769,963 and 5,086,599, both of which involve utilizing an expanded polymeric material taken in combination with aluminum sheet to produce a building panel with excellent insulation properties in a light weight construction component. To the extent that an expanded polvmeric material is utiliæed in these references, they bear some resemblance to the present invention. However, they 30 lack any significant structural strength because they are merely the combination of flat and folded aluminum or similar type material in combination with the expanded polymeric material.
The present invention relates to a unique composite 35-assembly that may be utilized for the construction of walls, roofs, and flooring,- for -a variety of structures and buildings. The preferred materials are light gauge steel or WO92/21836 ~ ~ 3 ' - ! PCT/US92/04793 structural strength in a ~ery specif ic interlocking relationship with an expanded polymeric material such as medium density polystyrene or polyurethane. The steel provides strength in both tension and compression, while the 5 expanded polymeric material provides thermal and sound insulation and substantial support in compression. The combination, therefore, provides a structural strength that is believed to be absent from the Meyerson references while at the same time providing the high insulation effects that lO these Meyerson references would be expected to provide, as well as having the advantage of low cost resulting in part from pre-fabrication and the ability to utilize the same in combination with external and internal facing materials that provide aesthetics, protection from the elements, 15 functionality, some additional insulation, and minimal construction labor. Indeed, the present invention provides an excellent substitute for concrete block when the same is used with a prestressed concrete frame, and with the optional exterior and/or interior surfaces, can also replace the 20 materials normally applied to the exterior and/or interior of concrete block.
Summary of the Invention Bearing in mind the foregoing, it is a principal object of the invention to provide a panel building component that 25 is light weight, low cost, has strong insulation properties, and excellent structural qualities.
Another object of the invention is to provide a panel building component that cooperates with a plurality of external and/or internal facing materials to produce an 30 attractive, functional, and fire resistant structure.
A further object of the invention is to provide a panel building component that is suitable for the replacement of concrete block construction.
A related object of the invention is to eliminate the 35 waste as caused by the use of concrete bïocks such as the additional ten percent builders normally order for breakage . ...... . .
WO92/21836 s~ PCT/US92/04793 ~1 J ~ 4 i~
as well as the added waste when window and door openings are not eliminated from estimates.
Another object of the invention is to provide a panel building component which eliminates the need for tie beams, 5 columns, furring, and studs.
A further object of the invention is to provide a panel building component which allows the finished materials to be laminated directly to the wall surface in a pre-fabricated format.
One more object of the invention is to reduce construction site clean-up costs as is caused by block, stucco, furring, tie beam and column work.
Another object of the invention is to reduce time consuming and expensive inspections on columns and tie beams.
Yet another object is to provide a panel building component which can be pre-~abricated using optimum matarials assembled under plant controlled conditions because of its pre-fabrication characteristics.
An additional object of the invention is to provide a 20 panel building component which can be mass produced in a high productivity and quality controlled environment at minimum cost.
A further object of the invention is to provide a panel building component which can be finished in a manufacturing 25 plant with pre-installation of doors and windows which can be pre-wired for electricity and other installations.
One more object of the invention is to provide a panel building component which will not shrink, swell, or warp out of its designed shape, and will be unaffected by climatic 30 changes, rot, or vermin.
Other objects and advantages of the present invention will become apparent to those skilled in the art upon r examination of the following detailed descriptions and the drawings.
In accordance with the principal aspect of the present invention, there is provided a panel building component comprised of a combination of a rigid insulation core in a I
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.
W09~/2l836 2 C ~ ~ 2 ~ r~
composite structure with a plurality of structural materials, preferably steel. The steel members form a perimeter about the rigid insulation core providing structural strength, particularly taken in combination with the compressive 5 strength of the core and the tensional and compressive strength of the structural members. These structural members include vertical members which provide support in compression, a cap member, a foot member, and optional external and interior facing. The cap and foot members are 10 preferably in the form of a standard channel having a web dimension that is substantially similar to the thickness of -~
the rigid insulation and can fit thereabout at the periphery thereof.
Vertical members are fabricated using a ledge channel 15 cross-section, also having a web dimension substan~ially similar to the thickness of the rigid insulation and flanges of sufficient dimension for the purpose presently described.
At the ends of the flanges are ledges which are disposed in engaging relationship and obedience to grooves in the rigid 20 insulation. The ledges are disposed in engaging relationship with said grooves to ~orm a structure that exceeds the strength of both the steel and the rigid insulation producing column of integral, but composite configuration referred to as integral co~posite columns. The structural members 25 forming the perimeter about the rigid insulation core are attached to each other using conventional fastening means such as by welding, or using screws or the like.
The invention will be better understood upon reference to the following detailed description and the drawings in 30 which:
Brief DescriPtion of the Drawinqs Figure 1 is a perspective partially broken away view of the panel building component.
Figure 2 is a perspective view of the rigid insulation 35 core illustrating: in- exploded relationship one -vertical--member and one foot member from which the panel building component is constructed.
. .
W092/2]836 PCT/US92/04793 ~ ~igure 3 show a partially ~roken away wall constructed of the panel building component and illustrating the disposition of window and door openings.
Detailed Description of Preferred Embodiment Figure 1 illustrates in perspective view the in~entive panel building component. A rigid insulation core 2 is preferably ~ormed of an expanded polystyrene or similar expanded polymeric material, sometimes referred to as foam, having a high insulative characteristic and substantial 10 strength in compression. The rigid insulation core 2 is surrounded about its periphery by a plurality of structural members including vertical members 4, a cap member 6, and a foot member 8. These structural members about the perimeter of rigid insulation core 2 may be attached at their 15 intersections by conventional fastening means such as by welding or by at least one screw 30~
Optionally disposed in laminated association with the panel is an external facing 10 such as siding, reflective glass, a simulated stucco material, or the like. Such 20 material can provide substantial aesthetics as well as add additional support and possible also insulative effects.
Also shown is an optional internal facing material, such as a gypson panel 12. Following installation of the panel in a construction site, ~allpaper, paint, or other decorative 25 materials may be readily applied to optional interior facing 12. Interior facing 12 is also preferably a fire resistant material, typically a five-eighths inch gypson drywall having a finish rating of not less than sixty minutes. In fact, because of the importance of this feature for previously 30 obtained approvals from code and other governmental agencies, the optional interior facing is shown disposed within the flanges of the cap and foot members, although the same may certainly be disposed in a laminated relationship exteriorly of these ~langes.
Of greatest significance concerning this invention is the efficiency of materials in creating a load bearing building component of great strength and light weight. The :'' . ' . ' '' . ~'' '. , .,: . "' .
.: : . . : . : . .: ,. . :.
interlocking aspects of the vertical members with lateral portions of rigid insulation produce integral composite columns having great strength.
Figure 2 shows the unadorned rigid insulation 2 after 5 the same has been embossed with rigid insulation grooves 28 which are shown in four locations. These rigid insulation grooves are dispos~d to receive in engaging relationship portions of the vertical member 4 as hereinafter described.
Turning first to the foot member 8, it will be seen 10 that in cross-section the foot member 8 has a standard channel 14 having a standard channel web 16 and standard channel flanges 18.
The vertical member 4 has a ledge channel cross-section 20 having a ledge channel web 22, ledge channel flanges 24 15 terminating in ledges 26. Ledges 26 are intended to be disposed in engaging relationship with rigid insulation grooves 28 when vertical member 4 i5 assembled with rigid insulation 2 to produce the integral composite columns having great strength. This great strength is achieved because the 20 integral composite column thereby created utilizes the advantage of the compressive strength of the rigid insulation material to maintain the positional integrity of the light gauge steel of the vertical member 4, thereby avoiding lateral deflection thereof. In a complimentary manner, the 25 light gauge steel prevents buckling of the lateral portions of the rigid insulation disposed within the ledge channel cross-section of the vertical members 4. Simultaneously, the lateral portions of the rigid insulation disposed within vertical members 4 remain integral with the remainder of the 30 rigid insulation core that forms the central portion of the panel. Similar strength advantages are achieved with the cap member 6 and foot member 8, but the strength of the integral composite column is not ordinarily needed in the horizontal direction. - - -In special applications, the ledge channel configuration may be employed for the cap member 6 and/or foot member 8 as required. In such event, the rigid - , : . i;, .i . ;
.
~, . . .
WO92/21836 ~j ~ PCT/US92/04793 C~ ';J i ._~
~ 8 insulation 2 would be furnished with corresponding grooves to achieve an engaging relationship with the ledges to be added to the cap member 6 and/or foot member 8.
Turning to figure 3, there is shown in partially broken 5 away view a wall constructed using the panel building component. Illustrated therein particularly is an door opening 32 and a window cut-out 34 which window cut-out is shown only in the external facing 10. The rigid insulation 2 is undercut to show the relationship thereof with vertical 10 members 4. Also undercut is internal facing 12 and cap member 6. Also seen is the edge of foot member 8. Although the door and window are not illustrated, it will be readily appreciated that said items can be installed into the inventive panel building component at the f actory 15 manufacturing site.
Of particular interest in this f igure is the utilization of three vertical members 4 in a single panel.
Such panels are frequently four feet wide by eight feet high, although other dimensions are within the contemplation of the 20 inventor. Depending upon the strength requirements for a particular edifice including those imposed by local building codes, it is appropriate to use more than two integral composite columns in a single panel. For example, in a location where a wall would ordinarily have studs on two foot 25 centers, the same spacing can be achieved by using one additional integral composite column two feet from either lateral edge of a four foot wide panel. Figure 3 illustrates how this is accomplished.
Careful examination of figure 3 also shows the 30 interrelationship of the rigid insulation 2 with the channel ledges 26 which are disposed within rigid insulation grooves 28. The width of the ledge channel web 22 and the standard channel web 16 is seen to be substantially equivalent to the thickness of rigid insulation 2. -;
Having described the presently preferred-embodiments of the invention, it should be~ understood that various , changes in construction and arrangement will be apparent to ., . ~ ,.. .. ..
,::
, . .
. .
2, ~ 3 ,.~
those ~killed in the art and fully contemplated herein without departing from the true spirit of invention.
Accordingly, there is covered all alternatives, modifications and equivalents as may be included within the spirit and 5 scope of the invention as defined in the appended claims.
, -' ~ .
Another reference which pursues l:he notion of a building component utilizing a panel is Zeihbrunner, U.S.
10 Patent No. 4,646,502 which teaches a panel construction element and building construction system employing such elements. That reference illustrates a profile frame and a filler material with cover panels that cover both the filler material and the profile frame. The frame includes a complex 15 cross-section of a type fabricated using an extrusion, which, in turn, leads to a substantially more expensive structure than that provided by the present invention without the interlocking advantages of the framing with the filler or polymeric material of the present invention.
Similarly, efforts have been made to provide modular building components which combine the coverage of area with insulation benefits. Several of these include two patents to Meyerson, U.S. Patent Nos. 4,769,963 and 5,086,599, both of which involve utilizing an expanded polymeric material taken in combination with aluminum sheet to produce a building panel with excellent insulation properties in a light weight construction component. To the extent that an expanded polvmeric material is utiliæed in these references, they bear some resemblance to the present invention. However, they 30 lack any significant structural strength because they are merely the combination of flat and folded aluminum or similar type material in combination with the expanded polymeric material.
The present invention relates to a unique composite 35-assembly that may be utilized for the construction of walls, roofs, and flooring,- for -a variety of structures and buildings. The preferred materials are light gauge steel or WO92/21836 ~ ~ 3 ' - ! PCT/US92/04793 structural strength in a ~ery specif ic interlocking relationship with an expanded polymeric material such as medium density polystyrene or polyurethane. The steel provides strength in both tension and compression, while the 5 expanded polymeric material provides thermal and sound insulation and substantial support in compression. The combination, therefore, provides a structural strength that is believed to be absent from the Meyerson references while at the same time providing the high insulation effects that lO these Meyerson references would be expected to provide, as well as having the advantage of low cost resulting in part from pre-fabrication and the ability to utilize the same in combination with external and internal facing materials that provide aesthetics, protection from the elements, 15 functionality, some additional insulation, and minimal construction labor. Indeed, the present invention provides an excellent substitute for concrete block when the same is used with a prestressed concrete frame, and with the optional exterior and/or interior surfaces, can also replace the 20 materials normally applied to the exterior and/or interior of concrete block.
Summary of the Invention Bearing in mind the foregoing, it is a principal object of the invention to provide a panel building component that 25 is light weight, low cost, has strong insulation properties, and excellent structural qualities.
Another object of the invention is to provide a panel building component that cooperates with a plurality of external and/or internal facing materials to produce an 30 attractive, functional, and fire resistant structure.
A further object of the invention is to provide a panel building component that is suitable for the replacement of concrete block construction.
A related object of the invention is to eliminate the 35 waste as caused by the use of concrete bïocks such as the additional ten percent builders normally order for breakage . ...... . .
WO92/21836 s~ PCT/US92/04793 ~1 J ~ 4 i~
as well as the added waste when window and door openings are not eliminated from estimates.
Another object of the invention is to provide a panel building component which eliminates the need for tie beams, 5 columns, furring, and studs.
A further object of the invention is to provide a panel building component which allows the finished materials to be laminated directly to the wall surface in a pre-fabricated format.
One more object of the invention is to reduce construction site clean-up costs as is caused by block, stucco, furring, tie beam and column work.
Another object of the invention is to reduce time consuming and expensive inspections on columns and tie beams.
Yet another object is to provide a panel building component which can be pre-~abricated using optimum matarials assembled under plant controlled conditions because of its pre-fabrication characteristics.
An additional object of the invention is to provide a 20 panel building component which can be mass produced in a high productivity and quality controlled environment at minimum cost.
A further object of the invention is to provide a panel building component which can be finished in a manufacturing 25 plant with pre-installation of doors and windows which can be pre-wired for electricity and other installations.
One more object of the invention is to provide a panel building component which will not shrink, swell, or warp out of its designed shape, and will be unaffected by climatic 30 changes, rot, or vermin.
Other objects and advantages of the present invention will become apparent to those skilled in the art upon r examination of the following detailed descriptions and the drawings.
In accordance with the principal aspect of the present invention, there is provided a panel building component comprised of a combination of a rigid insulation core in a I
' ... ... ..
., . . .: .. : , ~. : , . ~ . :
.
W09~/2l836 2 C ~ ~ 2 ~ r~
composite structure with a plurality of structural materials, preferably steel. The steel members form a perimeter about the rigid insulation core providing structural strength, particularly taken in combination with the compressive 5 strength of the core and the tensional and compressive strength of the structural members. These structural members include vertical members which provide support in compression, a cap member, a foot member, and optional external and interior facing. The cap and foot members are 10 preferably in the form of a standard channel having a web dimension that is substantially similar to the thickness of -~
the rigid insulation and can fit thereabout at the periphery thereof.
Vertical members are fabricated using a ledge channel 15 cross-section, also having a web dimension substan~ially similar to the thickness of the rigid insulation and flanges of sufficient dimension for the purpose presently described.
At the ends of the flanges are ledges which are disposed in engaging relationship and obedience to grooves in the rigid 20 insulation. The ledges are disposed in engaging relationship with said grooves to ~orm a structure that exceeds the strength of both the steel and the rigid insulation producing column of integral, but composite configuration referred to as integral co~posite columns. The structural members 25 forming the perimeter about the rigid insulation core are attached to each other using conventional fastening means such as by welding, or using screws or the like.
The invention will be better understood upon reference to the following detailed description and the drawings in 30 which:
Brief DescriPtion of the Drawinqs Figure 1 is a perspective partially broken away view of the panel building component.
Figure 2 is a perspective view of the rigid insulation 35 core illustrating: in- exploded relationship one -vertical--member and one foot member from which the panel building component is constructed.
. .
W092/2]836 PCT/US92/04793 ~ ~igure 3 show a partially ~roken away wall constructed of the panel building component and illustrating the disposition of window and door openings.
Detailed Description of Preferred Embodiment Figure 1 illustrates in perspective view the in~entive panel building component. A rigid insulation core 2 is preferably ~ormed of an expanded polystyrene or similar expanded polymeric material, sometimes referred to as foam, having a high insulative characteristic and substantial 10 strength in compression. The rigid insulation core 2 is surrounded about its periphery by a plurality of structural members including vertical members 4, a cap member 6, and a foot member 8. These structural members about the perimeter of rigid insulation core 2 may be attached at their 15 intersections by conventional fastening means such as by welding or by at least one screw 30~
Optionally disposed in laminated association with the panel is an external facing 10 such as siding, reflective glass, a simulated stucco material, or the like. Such 20 material can provide substantial aesthetics as well as add additional support and possible also insulative effects.
Also shown is an optional internal facing material, such as a gypson panel 12. Following installation of the panel in a construction site, ~allpaper, paint, or other decorative 25 materials may be readily applied to optional interior facing 12. Interior facing 12 is also preferably a fire resistant material, typically a five-eighths inch gypson drywall having a finish rating of not less than sixty minutes. In fact, because of the importance of this feature for previously 30 obtained approvals from code and other governmental agencies, the optional interior facing is shown disposed within the flanges of the cap and foot members, although the same may certainly be disposed in a laminated relationship exteriorly of these ~langes.
Of greatest significance concerning this invention is the efficiency of materials in creating a load bearing building component of great strength and light weight. The :'' . ' . ' '' . ~'' '. , .,: . "' .
.: : . . : . : . .: ,. . :.
interlocking aspects of the vertical members with lateral portions of rigid insulation produce integral composite columns having great strength.
Figure 2 shows the unadorned rigid insulation 2 after 5 the same has been embossed with rigid insulation grooves 28 which are shown in four locations. These rigid insulation grooves are dispos~d to receive in engaging relationship portions of the vertical member 4 as hereinafter described.
Turning first to the foot member 8, it will be seen 10 that in cross-section the foot member 8 has a standard channel 14 having a standard channel web 16 and standard channel flanges 18.
The vertical member 4 has a ledge channel cross-section 20 having a ledge channel web 22, ledge channel flanges 24 15 terminating in ledges 26. Ledges 26 are intended to be disposed in engaging relationship with rigid insulation grooves 28 when vertical member 4 i5 assembled with rigid insulation 2 to produce the integral composite columns having great strength. This great strength is achieved because the 20 integral composite column thereby created utilizes the advantage of the compressive strength of the rigid insulation material to maintain the positional integrity of the light gauge steel of the vertical member 4, thereby avoiding lateral deflection thereof. In a complimentary manner, the 25 light gauge steel prevents buckling of the lateral portions of the rigid insulation disposed within the ledge channel cross-section of the vertical members 4. Simultaneously, the lateral portions of the rigid insulation disposed within vertical members 4 remain integral with the remainder of the 30 rigid insulation core that forms the central portion of the panel. Similar strength advantages are achieved with the cap member 6 and foot member 8, but the strength of the integral composite column is not ordinarily needed in the horizontal direction. - - -In special applications, the ledge channel configuration may be employed for the cap member 6 and/or foot member 8 as required. In such event, the rigid - , : . i;, .i . ;
.
~, . . .
WO92/21836 ~j ~ PCT/US92/04793 C~ ';J i ._~
~ 8 insulation 2 would be furnished with corresponding grooves to achieve an engaging relationship with the ledges to be added to the cap member 6 and/or foot member 8.
Turning to figure 3, there is shown in partially broken 5 away view a wall constructed using the panel building component. Illustrated therein particularly is an door opening 32 and a window cut-out 34 which window cut-out is shown only in the external facing 10. The rigid insulation 2 is undercut to show the relationship thereof with vertical 10 members 4. Also undercut is internal facing 12 and cap member 6. Also seen is the edge of foot member 8. Although the door and window are not illustrated, it will be readily appreciated that said items can be installed into the inventive panel building component at the f actory 15 manufacturing site.
Of particular interest in this f igure is the utilization of three vertical members 4 in a single panel.
Such panels are frequently four feet wide by eight feet high, although other dimensions are within the contemplation of the 20 inventor. Depending upon the strength requirements for a particular edifice including those imposed by local building codes, it is appropriate to use more than two integral composite columns in a single panel. For example, in a location where a wall would ordinarily have studs on two foot 25 centers, the same spacing can be achieved by using one additional integral composite column two feet from either lateral edge of a four foot wide panel. Figure 3 illustrates how this is accomplished.
Careful examination of figure 3 also shows the 30 interrelationship of the rigid insulation 2 with the channel ledges 26 which are disposed within rigid insulation grooves 28. The width of the ledge channel web 22 and the standard channel web 16 is seen to be substantially equivalent to the thickness of rigid insulation 2. -;
Having described the presently preferred-embodiments of the invention, it should be~ understood that various , changes in construction and arrangement will be apparent to ., . ~ ,.. .. ..
,::
, . .
. .
2, ~ 3 ,.~
those ~killed in the art and fully contemplated herein without departing from the true spirit of invention.
Accordingly, there is covered all alternatives, modifications and equivalents as may be included within the spirit and 5 scope of the invention as defined in the appended claims.
, -' ~ .
Claims (18)
1. A panel building component comprising:
a substantially rigid insulation core of planar configuration having a plurality of vertical grooves embossed in proximity to lateral edges thereof to form lateral portions;
a plurality of vertical members having a ledge channel cross-section, each of said vertical members being disposed with a channel web in physical communication with the lateral edges of the substantially rigid insulation core, with channel flanges in physical communication with a planar face of the substantially rigid insulation core in proximity to the lateral edges thereof, and with channel ledges disposed in engaging relationship with the vertical grooves, which vertical members in combination with the lateral portions of the substantially rigid insulation core form a plurality of integral composite columns;
a cap member of channel cross-section disposed in physical communication about a top edge of the substantially rigid insulation core;
a foot member of channel cross-section disposed in physical communication about a bottom edge of the substantially rigid insulation core; and fastening means to connect vertical members to cap and foot members at corners of the substantially rigid insulation core.
a substantially rigid insulation core of planar configuration having a plurality of vertical grooves embossed in proximity to lateral edges thereof to form lateral portions;
a plurality of vertical members having a ledge channel cross-section, each of said vertical members being disposed with a channel web in physical communication with the lateral edges of the substantially rigid insulation core, with channel flanges in physical communication with a planar face of the substantially rigid insulation core in proximity to the lateral edges thereof, and with channel ledges disposed in engaging relationship with the vertical grooves, which vertical members in combination with the lateral portions of the substantially rigid insulation core form a plurality of integral composite columns;
a cap member of channel cross-section disposed in physical communication about a top edge of the substantially rigid insulation core;
a foot member of channel cross-section disposed in physical communication about a bottom edge of the substantially rigid insulation core; and fastening means to connect vertical members to cap and foot members at corners of the substantially rigid insulation core.
2. The panel building component of claim 1 which further comprises a internal facing material laminated to a first side of the substantially rigid insulation core.
3. The panel building component of claim 2 in which the interior facing material is comprised of a fire resistant substance.
4. The panel building component of claim 1 which further comprises an external facing material laminated to a second side of the substantially rigid insulation core.
5. The panel building component of claim 1 wherein the fastening means is welding.
6. The panel building component of claim 1 wherein the fastening means are screws.
7. The panel building component of claim 1 wherein the vertical members are fabricated from light gauge steel.
8. The panel building component of claim 1 wherein the cap member is fabricated from light gauge steel.
9. The panel building component of claim 1 wherein the foot member is fabricated from light gauge steel.
10. The panel building component of claim 1 wherein the substantially rigid insulation core is medium density expanded polystyrene.
11. A panel building component comprising:
a substantially rigid insulation core of planar configuration having a plurality of vertical grooves embossed in proximity to lateral edges thereof to form lateral portions;
a perimeter of structural members in physical communication about lateral and top and bottom edges of the substantially rigid insulation core said members being attached to each other; and integral composite columns being formed of structural members having a vertical configuration and a ledge channel cross-section, the ledges of which are disposed in engaging relationship with vertical grooves embossed in proximity to lateral edges of the substantially rigid insulation core.
a substantially rigid insulation core of planar configuration having a plurality of vertical grooves embossed in proximity to lateral edges thereof to form lateral portions;
a perimeter of structural members in physical communication about lateral and top and bottom edges of the substantially rigid insulation core said members being attached to each other; and integral composite columns being formed of structural members having a vertical configuration and a ledge channel cross-section, the ledges of which are disposed in engaging relationship with vertical grooves embossed in proximity to lateral edges of the substantially rigid insulation core.
12. The panel building component of claim 9 which further comprises a internal facing material laminated to a first side of the substantially rigid insulation core.
13. The panel building component of claim 10 in which the interior facing material is comprised of a fire resistant substance.
14. The panel building component of claim 9 which further comprises an external facing material laminated to a second side of the substantially rigid insulation core.
15. The panel building component of claim 9 wherein the structural members are attached to each other by welding.
16. The panel building component of claim 9 wherein the structural members are attached to each other using screws.
17. The panel building component of claim 9 wherein the structural members are fabricated from light gauge steel.
18. The panel building component of claim 9 wherein the substantially rigid insulation core is medium density expanded polystyrene.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US70934591A | 1991-06-03 | 1991-06-03 | |
| US709,345 | 1991-06-03 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2093237A1 true CA2093237A1 (en) | 1992-12-04 |
Family
ID=24849475
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002093237A Abandoned CA2093237A1 (en) | 1991-06-03 | 1992-06-02 | Panel building component |
Country Status (3)
| Country | Link |
|---|---|
| AU (1) | AU2163092A (en) |
| CA (1) | CA2093237A1 (en) |
| WO (1) | WO1992021836A1 (en) |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0691441A1 (en) * | 1994-02-21 | 1996-01-10 | Peter W. P. Graulich | Structual bearing panel and panel core for building |
| US5644872A (en) * | 1995-03-06 | 1997-07-08 | Perdue; Jay | Sound absorbing panel |
| CN103015623B (en) * | 2013-01-07 | 2015-09-02 | 张建忠 | A kind of fixed installation structure of precast plate |
| JP7116571B2 (en) * | 2018-03-29 | 2022-08-10 | 大和ハウス工業株式会社 | wall panel |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3445974A (en) * | 1967-02-13 | 1969-05-27 | Clifford I Bragman | Thermal barrier of insulating material and metal frame members |
| CH652786A5 (en) * | 1984-07-24 | 1985-11-29 | Kinson Dev Et Const Sa | PANEL-SHAPED BUILDING ELEMENT AND CONSTRUCTION WITH THIS BUILDING ELEMENTS. |
| DE3445895A1 (en) * | 1984-12-15 | 1986-06-19 | Carry-Space Leichtbauelemente GmbH, 4000 Düsseldorf | PANEL-SHAPED COMPOSITE ELEMENT FOR CONSTRUCTION |
-
1992
- 1992-06-02 CA CA002093237A patent/CA2093237A1/en not_active Abandoned
- 1992-06-02 AU AU21630/92A patent/AU2163092A/en not_active Abandoned
- 1992-06-02 WO PCT/US1992/004793 patent/WO1992021836A1/en active Application Filing
Also Published As
| Publication number | Publication date |
|---|---|
| AU2163092A (en) | 1993-01-08 |
| WO1992021836A1 (en) | 1992-12-10 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Dead |