CA2363216A1 - Manufacture and assembly systems of structural insulated panels - Google Patents
Manufacture and assembly systems of structural insulated panels Download PDFInfo
- Publication number
- CA2363216A1 CA2363216A1 CA 2363216 CA2363216A CA2363216A1 CA 2363216 A1 CA2363216 A1 CA 2363216A1 CA 2363216 CA2363216 CA 2363216 CA 2363216 A CA2363216 A CA 2363216A CA 2363216 A1 CA2363216 A1 CA 2363216A1
- Authority
- CA
- Canada
- Prior art keywords
- frame members
- structural
- rigid board
- board insulation
- insulation
- 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
- 238000004519 manufacturing process Methods 0.000 title abstract description 10
- 238000009413 insulation Methods 0.000 claims abstract description 53
- 239000000853 adhesive Substances 0.000 claims abstract description 4
- 230000001070 adhesive effect Effects 0.000 claims abstract description 4
- 239000006260 foam Substances 0.000 claims abstract description 4
- 238000001228 spectrum Methods 0.000 claims description 3
- 238000013016 damping Methods 0.000 claims description 2
- 238000002347 injection Methods 0.000 claims description 2
- 239000007924 injection Substances 0.000 claims description 2
- 239000011152 fibreglass Substances 0.000 abstract description 10
- 239000000463 material Substances 0.000 abstract description 6
- 230000000704 physical effect Effects 0.000 abstract description 4
- 229910000831 Steel Inorganic materials 0.000 abstract description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 abstract description 3
- 229910052782 aluminium Inorganic materials 0.000 abstract description 3
- 238000009432 framing Methods 0.000 abstract description 3
- 239000002990 reinforced plastic Substances 0.000 abstract description 3
- 239000010959 steel Substances 0.000 abstract description 3
- 238000007493 shaping process Methods 0.000 abstract 2
- 239000002023 wood Substances 0.000 description 8
- 238000010276 construction Methods 0.000 description 5
- 206010061217 Infestation Diseases 0.000 description 2
- 230000004888 barrier function Effects 0.000 description 2
- 229910052602 gypsum Inorganic materials 0.000 description 2
- 239000010440 gypsum Substances 0.000 description 2
- 239000011120 plywood Substances 0.000 description 2
- 241000238631 Hexapoda Species 0.000 description 1
- 241000256602 Isoptera Species 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 230000002860 competitive effect Effects 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/78—Heat insulating elements
- E04B1/80—Heat insulating elements slab-shaped
-
- 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
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
- E04C2/22—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics reinforced
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- Electromagnetism (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Building Environments (AREA)
Abstract
Shaped rigid board insulation used in conjunction with structural frame members chosen for preferred qualities used in the system innovatively provides advantages in the manufacture ,assembly and performance of structural insulated panels for walls , roofs and floors of buildings. The structural panels maybe assembled in a factory or field assembled.
The physical properties of shaped rigid board insulation make it the more preferred material choice than fibreglass bat insulation in achieving the ultimate strength and thermal value in a structural frame panel system. Rigid board insulation physical properties make it ideal for cutting and shaping using simple hand tools or simple machines that are readily available. Cutting rigid board insulation into such shapes as triangles, rectangular, squares and shaping on one or both faces or one or both sides provides one of the components required in the panel assembly system and jigging system for the manufacture and assembly of structural framed insulated panels using shaped rigid board insulation.
The selection of some preferred materials used for structural frame members include steel, reinforced fibreglass, reinforced plastic and aluminum. In the manufacture of preferred structural frame members using steel, reinforced fibreglass, reinforced plastic or aluminum complex shapes are required to enhance the materials physical properties.
Preferred manufactured structural frame members can be made to exacting tolerance and cut to exacting tolerance. Sliding shaped rigid board insulation inside manufactured structural frame members stops the structural frame members from deforming which is preferred comparing to forcing rigid board insulation into structural frame members. Preferred manufactured structural frame members cut to exacting tolerance are preferred structural framing components used in the manufacture, assembly system and jigging system of shaped rigid board structural panels. Shaped rigid board insulation friction fitted into structural frame members allows the structural frame to be more ductile compared to foam injected panels or panels that require structural adhesive to bond the board insulation in place. In a shaped rigid board insulated structural panel building system with preferred structural frame members, with perimeter frame members and interior frame members or just perimeter frame members , the frames structural strength will be greatly enhanced by the rigidity of the shaped board insulation supporting the frame both vertically and horizontally and will have continuity of insulation and better overall performance.
The physical properties of shaped rigid board insulation make it the more preferred material choice than fibreglass bat insulation in achieving the ultimate strength and thermal value in a structural frame panel system. Rigid board insulation physical properties make it ideal for cutting and shaping using simple hand tools or simple machines that are readily available. Cutting rigid board insulation into such shapes as triangles, rectangular, squares and shaping on one or both faces or one or both sides provides one of the components required in the panel assembly system and jigging system for the manufacture and assembly of structural framed insulated panels using shaped rigid board insulation.
The selection of some preferred materials used for structural frame members include steel, reinforced fibreglass, reinforced plastic and aluminum. In the manufacture of preferred structural frame members using steel, reinforced fibreglass, reinforced plastic or aluminum complex shapes are required to enhance the materials physical properties.
Preferred manufactured structural frame members can be made to exacting tolerance and cut to exacting tolerance. Sliding shaped rigid board insulation inside manufactured structural frame members stops the structural frame members from deforming which is preferred comparing to forcing rigid board insulation into structural frame members. Preferred manufactured structural frame members cut to exacting tolerance are preferred structural framing components used in the manufacture, assembly system and jigging system of shaped rigid board structural panels. Shaped rigid board insulation friction fitted into structural frame members allows the structural frame to be more ductile compared to foam injected panels or panels that require structural adhesive to bond the board insulation in place. In a shaped rigid board insulated structural panel building system with preferred structural frame members, with perimeter frame members and interior frame members or just perimeter frame members , the frames structural strength will be greatly enhanced by the rigidity of the shaped board insulation supporting the frame both vertically and horizontally and will have continuity of insulation and better overall performance.
Description
SPECIFICATION
1. The invention relates to a manufacture and an assembly system using shaped rigid board insulation in conjunction with preferred structural frame members to enhanced the performance of panels used for walls , roofs and floors of buildings.
1. The invention relates to a manufacture and an assembly system using shaped rigid board insulation in conjunction with preferred structural frame members to enhanced the performance of panels used for walls , roofs and floors of buildings.
2. The most common structural building panels in Canada , the United States of America and gaining increasing acceptance in other parts of the world are "
stick built " . These structural panels consist of horizontal sill plates nominally 2 inch by 3 inch or 2 inch by 4 inch or 2 inch by 6 inch manufactured out of wood. The vertical studs which are generally of one story high are nominally 2 inch by 3 inch or 2 inch by 4 inch or 2 inch by 6 inch manufactured out of wood and spaced at 12 inches on center or 16 inches on center or 24 inches on center. Spacing of vertical studs is governed by the load the panel must resist. The vertical studs are covered on the outside by oriented strand board or plywood or boards . Internal space is typically filled with fiberglass batt insulation covered with the vapor barrier and gypsum board.
Lateral bracing must be provided in the above system to stiffen the walls to prevent racking .
Lateral bracing in this system is usually achieved by lines of blocking placed between the studs or diagonal bracing or diagonal boarding or horizontal boarding with diagonal wood braces or plywood sheathing or combination of the above.
stick built " . These structural panels consist of horizontal sill plates nominally 2 inch by 3 inch or 2 inch by 4 inch or 2 inch by 6 inch manufactured out of wood. The vertical studs which are generally of one story high are nominally 2 inch by 3 inch or 2 inch by 4 inch or 2 inch by 6 inch manufactured out of wood and spaced at 12 inches on center or 16 inches on center or 24 inches on center. Spacing of vertical studs is governed by the load the panel must resist. The vertical studs are covered on the outside by oriented strand board or plywood or boards . Internal space is typically filled with fiberglass batt insulation covered with the vapor barrier and gypsum board.
Lateral bracing must be provided in the above system to stiffen the walls to prevent racking .
Lateral bracing in this system is usually achieved by lines of blocking placed between the studs or diagonal bracing or diagonal boarding or horizontal boarding with diagonal wood braces or plywood sheathing or combination of the above.
3. Although the above system is most commonly used , it still has problems. In the manufacture of wood structural frames there is always certain amount of waste because wood has a tendency to shrink, twist, warp and split because of its fibrous nature. In the manufacture of wood structural frames, skilled personnel called framers with a general knowledge of framing practices maybe required to build complex panels. Wood is a combustible material and subject to rot and termite infestation limiting its marketability. The National Building Code of Canada requires all outside walls in residential dwellings to have a thermal value minimum of R20. The most common insulation used to achieve this is fiberglass batt insulation . It requires frame members to be nominally 2 inch by 6 inch. Although structural frame members for single story residential dwellings could be smaller than nominally 2 inch by 6 inch they would not be able to accommodate the fiberglass insulation. This increases the framing cost of the single story residential dwelling and will decrease the interior floor space.
Building structural insulated panels using shaped rigid board insulation has many advantages over building panels using fibreglass insulation and wood structural frames..Some of these advantages include higher thermal value in a smaller frame, can be made with variety of frame members, lighter weight , material savings and ease of assembly.
Preferred rigid board insulation provides insulating R-value that is approximately double the insulation R-value of fibreglass batt insulation. In a shaped rigid board insulated building panel a insulation value of R20 can be achieved with a 2.5 inch core.Using fibreglass batt insulation this would be achieved using 5.5 inch cavity which would reduce the interior building size and increase material cost.
page 2 SPECIFICATION - item 3- continued Preferred shaped rigid board insulation has a compressive strength of 20 pounds per square inch. Used in conjuction with preferred structural frame members shaped rigid board insulation provides lateral bracing which increases the frame capacity to carry heavier loads, provides continuity of insulation and requires no fiuther diagonal support.
Lateral bracing prevents vertical frame members and walls from destorting horizontally.Lateral braced walls are considered and an essential design element used to resist high wind loads and seismic disturbances. Shaped rigid board insulation used in conjunction with preferred structural frame members requires no foam injection or structural adhesive to bond shaped rigid insulation in place. This economizes the complete assembly, more importantly though this allows the shaped rigid board insulation to act autonomous of the frame making the frame more ductile. In earthquakes , high wind loads and heavy snow loading where deflections and vibrations occur it is important that buildings absorb as much negative energy as possible created by these disturbances. Panels that are foam injected or the panels that require structural adhesive to bond rigid insulation in place are considered to be stiff panels. Stiff panels raise the natural frequency of buildings which increases the forces the buildings have to resist. It has been well documented that ductility, the ability of the structure to yield and deform without collapse is as important as the overall strength of the building. Ductile behavior helps absorb negative energy and also limits the forces that act upon structures.
In a manufacture of a structural building panel, which consist of a structural frame with perimeter frame members and interior frame members or just perimeter frame members mechanically attached, rigid board insulation is shaped on one or both faces or one or both sides to allow a broader spectrum of preferred structural frame members to be introduced into the panel assembly system. Preferred structural frame members maybe made of steel , reinforced plastic, reinforced fibreglass or aluminum and often have complex shapes to strengthen the physical properties comprised of webs, lips and flanges. Preferred frame members have properties that can resist fire, dryrot, rot cause by dampness and insect infestation adding to the performance of structural panels. Preferred frame members under normal service conditions in a factory or field environment will not shrink, split or wore. Properly shaped rigid board insulation will reduced distortion in frame members when placed inside. A wider spectrum of frame members should increase marketability of panels and provide a more competitive cost and supply helping to economize the panel system. Rigid board insulation when placed inside the structural frame members supports the frame both horizontally and vertically, making the frame more rigid which enhances overall strength of the frame. This minimizes the size of the structural frame members and amount required. This economizes the complete building assembly system. Rigid board insulation maybe placed on one or both faces of the frame and mechanically fastened This enhances the panels ability to handle heavier loads and deflection without increasing the frame size.Placing rigid board insulation over one or both faces of the frame also provides thermal resistance, noise damping, as well as excellent substrate for sheathing or membranes. Sheathing also maybe mechanically fastened to one or both faces of the panel frame increasing overall strength of the panel.
page 3 SPECIFICATION- item 3 -continued Gypsum board or other thermal barriers must be mechanically fastened to the interior face of the panel. When using precut and preshaped preferred rigid board insulation as a jig with preferred frame members cut to exacting size the assembly system requires no special skills or special equipment. This speeds up the assembly system and economizes the manufacture of structural framed panels. This structural framed panel system used for walls, roofs, and floors of buildings, using preferred shaped rigid board insulation and preferred structural frame members, increases the panels performance and can be used in conjunction with conventional building codes. Most building codes authorize two types of construction ;
engineered construction and construction by conventional rules. Engineered construction is carried out by design professionals , using the principles of limit states design to achieve desired performance.
Conventional construction is carried out by following prescriptive rules to achieve desired product and performance.
page 4 SPECIFICATION - item 3 - continued The drawings on the attached pages show typical arrangements of a complex frame members and shaped rigid board insulation .
The drawings are Drawing 2. Cross section of structural frame members and shaped rigid board insulation.
( see Page No. 8 ) Drawing 4 Components assembly using structural frame members and rigid board insulation.
( see Page No. 9 ) Drawing 6. Components assembly using structural frame members and cut and shaped rigid board insulation used as a jigging system.
see Page No. 10 ) page 5
Building structural insulated panels using shaped rigid board insulation has many advantages over building panels using fibreglass insulation and wood structural frames..Some of these advantages include higher thermal value in a smaller frame, can be made with variety of frame members, lighter weight , material savings and ease of assembly.
Preferred rigid board insulation provides insulating R-value that is approximately double the insulation R-value of fibreglass batt insulation. In a shaped rigid board insulated building panel a insulation value of R20 can be achieved with a 2.5 inch core.Using fibreglass batt insulation this would be achieved using 5.5 inch cavity which would reduce the interior building size and increase material cost.
page 2 SPECIFICATION - item 3- continued Preferred shaped rigid board insulation has a compressive strength of 20 pounds per square inch. Used in conjuction with preferred structural frame members shaped rigid board insulation provides lateral bracing which increases the frame capacity to carry heavier loads, provides continuity of insulation and requires no fiuther diagonal support.
Lateral bracing prevents vertical frame members and walls from destorting horizontally.Lateral braced walls are considered and an essential design element used to resist high wind loads and seismic disturbances. Shaped rigid board insulation used in conjunction with preferred structural frame members requires no foam injection or structural adhesive to bond shaped rigid insulation in place. This economizes the complete assembly, more importantly though this allows the shaped rigid board insulation to act autonomous of the frame making the frame more ductile. In earthquakes , high wind loads and heavy snow loading where deflections and vibrations occur it is important that buildings absorb as much negative energy as possible created by these disturbances. Panels that are foam injected or the panels that require structural adhesive to bond rigid insulation in place are considered to be stiff panels. Stiff panels raise the natural frequency of buildings which increases the forces the buildings have to resist. It has been well documented that ductility, the ability of the structure to yield and deform without collapse is as important as the overall strength of the building. Ductile behavior helps absorb negative energy and also limits the forces that act upon structures.
In a manufacture of a structural building panel, which consist of a structural frame with perimeter frame members and interior frame members or just perimeter frame members mechanically attached, rigid board insulation is shaped on one or both faces or one or both sides to allow a broader spectrum of preferred structural frame members to be introduced into the panel assembly system. Preferred structural frame members maybe made of steel , reinforced plastic, reinforced fibreglass or aluminum and often have complex shapes to strengthen the physical properties comprised of webs, lips and flanges. Preferred frame members have properties that can resist fire, dryrot, rot cause by dampness and insect infestation adding to the performance of structural panels. Preferred frame members under normal service conditions in a factory or field environment will not shrink, split or wore. Properly shaped rigid board insulation will reduced distortion in frame members when placed inside. A wider spectrum of frame members should increase marketability of panels and provide a more competitive cost and supply helping to economize the panel system. Rigid board insulation when placed inside the structural frame members supports the frame both horizontally and vertically, making the frame more rigid which enhances overall strength of the frame. This minimizes the size of the structural frame members and amount required. This economizes the complete building assembly system. Rigid board insulation maybe placed on one or both faces of the frame and mechanically fastened This enhances the panels ability to handle heavier loads and deflection without increasing the frame size.Placing rigid board insulation over one or both faces of the frame also provides thermal resistance, noise damping, as well as excellent substrate for sheathing or membranes. Sheathing also maybe mechanically fastened to one or both faces of the panel frame increasing overall strength of the panel.
page 3 SPECIFICATION- item 3 -continued Gypsum board or other thermal barriers must be mechanically fastened to the interior face of the panel. When using precut and preshaped preferred rigid board insulation as a jig with preferred frame members cut to exacting size the assembly system requires no special skills or special equipment. This speeds up the assembly system and economizes the manufacture of structural framed panels. This structural framed panel system used for walls, roofs, and floors of buildings, using preferred shaped rigid board insulation and preferred structural frame members, increases the panels performance and can be used in conjunction with conventional building codes. Most building codes authorize two types of construction ;
engineered construction and construction by conventional rules. Engineered construction is carried out by design professionals , using the principles of limit states design to achieve desired performance.
Conventional construction is carried out by following prescriptive rules to achieve desired product and performance.
page 4 SPECIFICATION - item 3 - continued The drawings on the attached pages show typical arrangements of a complex frame members and shaped rigid board insulation .
The drawings are Drawing 2. Cross section of structural frame members and shaped rigid board insulation.
( see Page No. 8 ) Drawing 4 Components assembly using structural frame members and rigid board insulation.
( see Page No. 9 ) Drawing 6. Components assembly using structural frame members and cut and shaped rigid board insulation used as a jigging system.
see Page No. 10 ) page 5
Claims (11)
1. A building system consisting of manufactured insulated structural framed panels for walls, roofs and floors of buildings. The panels are manufactured using preferred shaped rigid board insulation with preferred structural frame members to provide an assembly system and jigging system ,continuity of insulation, enhanced ultimate strength and a better overall performance.
2. A building system as defined in claim 1 That provides lateral bracing that prevents vertical frame members or walls from destorting horizontally using shaped rigid board insulation.
( drawing No.6 )
( drawing No.6 )
3. A building system as defined in claim 1 That minimizes the size of structural frame members ,using shaped rigid board insulation, to support the frame both horizontally and vertically, making the frame more rigid, allowing greater loads to be placed on the frame.
( drawing No.6 )
( drawing No.6 )
4. A building system as defined in claim 1 That by the very nature of the assembly becomes the moment resistance frame which requires no diagonal supports.
( drawing No.6 )
( drawing No.6 )
5. A building system as defined in claim 1 That requires no structural adhesive to bond the shaped rigid board insulation in place or foam injection.
( drawings No.2 , No.4 , No.6 )
( drawings No.2 , No.4 , No.6 )
6. A building system as defined in claim 1 That places rigid board insulation over one or both faces of the frame to increase the panels ability to handle greater loads in deflection without increasing the size of the frame members.
7. A building system as defined in claim 1 That places rigid board insulation over one or both faces of the frame to provide thermal resistance .
8. A building system as defined in claim 1 That places rigid board insulation over one or both faces of the frame to provide noise damping.
9. A building system as defined in claim 1 That if you cut and shape rigid board insulation it will provide a jigging system to assemble panels.
( drawings No.6 ) page 6 The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
( drawings No.6 ) page 6 The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
10. A building system as defined in claim 1 That if you shape rigid board insulation it will allow a broader spectrum of the frame members to be used .
( drawing No.2 )
( drawing No.2 )
11. A building system as defined in claim 1 That if you shape rigid board insulation in conjunction with preferred frame members it will provide an assembly system.
(drawings No.4 , No.6 ) page 7
(drawings No.4 , No.6 ) page 7
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA 2363216 CA2363216A1 (en) | 2001-11-20 | 2001-11-20 | Manufacture and assembly systems of structural insulated panels |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA 2363216 CA2363216A1 (en) | 2001-11-20 | 2001-11-20 | Manufacture and assembly systems of structural insulated panels |
Publications (1)
Publication Number | Publication Date |
---|---|
CA2363216A1 true CA2363216A1 (en) | 2003-05-20 |
Family
ID=4170557
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA 2363216 Abandoned CA2363216A1 (en) | 2001-11-20 | 2001-11-20 | Manufacture and assembly systems of structural insulated panels |
Country Status (1)
Country | Link |
---|---|
CA (1) | CA2363216A1 (en) |
-
2001
- 2001-11-20 CA CA 2363216 patent/CA2363216A1/en not_active Abandoned
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