CA2655466A1 - The hybrid sip wall system: structural steel & eps thermal-efficient wall panel pre-fabricated, pre-engineered, expandable polystyrene solid core and steel reinforced exoskeleton wall panel - Google Patents

Abstract

The Hybrid SIP Wall System Panel combines the strength and performance of cold-formed steel framing with the superior insulation properties of expanded polystyrene (EPS).
All steel used in the Hybrid SIP Wall System Panel is galvanized to industry standards to prevent rust.
Why this innovation?
Builders today are faced with more challenges than ever before:
*Energy efficient- Heating and cooling bills can be reduced drastically.
*Comfort- Structures are less "Drafty" and provide enhanced sound insulation.
*Lower Insurance premiums.
*Potential increased return on investment for property owners.
*Environmentally friendly, made from recycled materials.
*Peace of mind, knowing that they built their structure with a sustainable building solution.
This innovative technology virtually eliminates the transfer of temperature from one side to the other side. Creating a thermal gap throughout the entire wall or structure.
The result is a thermally efficient, high-performance building technology that is stronger than brick or conventional wood, lightweight, energy efficient and economical.
With the development of the Hybrid SIP wall system, Jeffrey Black has created a cost- effective, energy-efficient and structurally superior building alternative to conventional wood framing, insulation and sheathing.(we replace all three of these processes, inspections and waste in one simple step).Panels come in almost any size shape or design. They are shipped in 4'- 10' sections wideby however tall your walls are. Thickness of walls come in anywhere from a 2" up to 12"or greater if so desired. (a 4'x 8'x 6" thick panel only weights approximately 40 lbs.) A prefabricated, pre-engineered expandable polystyrene solid core and steel reinforced exoskeleton wall panel for building construction. Comprising a rectangular, tetragonal body of expandable polystyrene foam having two opposing primary structural studs securely bounded on its interior and exterior embodiment and on its end by two parallel end caps at least two light gauge metal studs in the exterior primary wall surface body, and two light gauge metal studs in the interior primary wall surface body, each stud having a c-shape body with a very specialized face, leg and hem design. The width of the wall panel between the two primary wall surfaces being three times greater than the leg of the studs, the expandable polystyrene foam extending into the central cavity of the stud to secure the stud to the body, The hem return inside the wall of each stud strengthens the entire embodiment of the structure and compliments the physical properties of both elements. Together forming a portion of the same primary wall surface of the interior body, also one stud is positioned at the opposing side on the exterior wall.
The distance between each of the studs, from the center to center of the studs is 24" O.C. being a standard building construction center-to-center distance for studs, the rectangular tetragonal body of Expandable Polystyrene foam having a tongue portion at each of its two parallel end walls, the tongue portion having a width equal to the width of the studs and adapted to be and receive each wall by and securing the opening of the building construction track to form a structural wall.

The present invention generally relates to building commercial or residential load bearing exterior wall systems. In particular, the present invention relates to a solid EPS core wall panel with a steel exoskeleton infused into the foam panels for residential or commercial walls.
Pre-manufactured and engineered in a factory. that exhibit improved strength, carbon footprint, and 100% recyclable with less weight, simplistic design and installation, and highest efficiency characteristics available. The present invention is directed to polystyrene solid core & metal exoskeleton (Structural) wall panels. In particular, lightweight, thermal efficient and sound insulating, sustainable unsurpassed energy saving wall system.. The panels, optionally, often and preferably, also constitute structural supporting members.
Design Standards:
*American Iron and Steel Institute (A.I.S.I.) "North AmericanSpecification for the Design of Cold-Formed Steel Structural Members," 2001 with 2004 amendments.
*American Welding Society (A.W.S.) D.1.3, 1998 "Structural Welding Code-Sheet Steel."
*American Society for Testing and Materials (A.S.T.M.)

Description

Description Specification Wall System of the Present Disclosure Referring to Fig. 1, the wall system can include one or more wall panels 1;
each wall panel 1 can include stiffeners or studs 2. The wall system can also include bottom track 3 and top track 4. Wall panels I can be assembled in adjacent fashion to create a wall structure. As shown in Fig. 2, bottom track 3 can be C-shaped, sheet metal having leg members 5, 6 extending upward from base member 7.
In one embodiment top track 4 is identical to bottom track 3. In the embodiment shown in Fig. 2, bottom track 3 can be constructed from 16 gauge galvanized steel sheet metal with the dimensions in inches shown therein although other structurally strong and relatively stiff materials and dimensions can be used depending on the desired structural specification of the completed wall. Base member 3 can be fastened to the concrete floor slab by any common means such as adhesive bonding or fasteners such as expansion bolts, concrete nails, etc. In the embodiment shown in Fig. 3, track 3 can be secured to a concrete floor using Redheads and nut washer combination. It is understood that the wall system of the present disclosure can be used to create other structures such as roofs.
As such fastening of bottom track to a floor would not be necessary.

Fig. 4 shows one embodiment panel of wall panel 1. Wall panel 1 can have a polymer foam insulating core A. In one embodiment, insulating core A can be a pre-formed foamed or expanded polystyrene (EPS) such as Styrofoam . The expanded polystyrene foam core A can include fiber reinforcement such as carbon fiber added in the polystyrene mix for added structural strength. Core A of wall panel 1 can be molded in a variety of shapes and sizes and cut to a desired size individually, by a saw or hot-wire cutting or pre-molded to the desired specifications. In one embodiment, core A can be pre-molded EPS and can have a height of 10 feet, a width of 4 feet and a thickness or depth of 6 inches. (See Fig.
16) The density of EPS care A can be 1.5 pounds per cubic foot.

As shown in figure 4, wall panel 1 can have two spaced apart parallel groove pairs 8, 9, 10, 11 of front side 12 along the entire height of wall panel 1 for receiving studs 2.
Similarly, rear side 13 can also include two grooves 14, 15, 16, 17 for receiving studs 2. Depending on the structural support desired, wall panel I can include more or less studs 2. Alternatively, a single channel spanning the length between the groove pairs and be used instead of the groove pairs to receive stud 2. Groove pairs 8, 9, 10, 11 can be positioned directly opposite of grooves 14, 15, 16, 17. Having studs received on opposites sides 12, 13 can provide all structural support. Material can be removed form core A between each groove pair 8, 9, 10, 11 and 14, 15, 16, 17 to create recessed areas 18 (also shown Fig. 7) so that when studs 2 are inserted in groove pairs, stud 2 can be flush with front and rear sides 12, 13 of core A. Figs.
7 and 17 also shows that core A can be marked with incidia 19 to assist in assembly of the wall structure and/or identify the maker and/or seller of the wall system.

In one embodiment groove pairs are positioned on wall panel 1 so that studs 2 are spaced about 24 inches on the center from each other. In prior wall construction insulating material is placed between studs span the width of the pre-covered or finished wall. This permits conduction from one side (interior or exterior) to the opposite side (interior or exterior) of the wall. Wall structures created with the wall system of the present disclosure do not allow conduction of heat, sound, vibration, etc. through the studs since the studs do not extend from one side to the opposite side. In other words, having studs 2 on both sides 12, 13 without contacting each other an only extend partial into core A prevents conduction from one side 12 to the other side 13 through studs 2. Wall panel I
does not have any conductive components passing through EPS core A from one side 12 to the other side 13 which results in superior insulative properties.

One of the front rear sides 12, 13 depending on which will face the interior of the structure to be constructed can have one or more horizontal channels 20, 22 and/or vertical channels 24 to receive utility runs such as electric and plumbing. In one embodiment shown in Fig. 4, wall panel 1 has one vertical channel 24 along the interior height of wall panel 1 and two horizontal channels 20, 22 along the entire width of wall panel 1. Channel 20 can be spaced eighteen inches from top end 26 and channel 22 can be spaced eighteen inches from bottom end 28. In one embodiment, channels 20, 22, 24 can have a square cross-sectional shape and specifically can be a 2.5 by 2.5 inch channel. Horizontal channels 20, 22 can be made to have a depth into wall panel 1 greater than the depth groove pairs 8, 9, 10, 11 extend into wall panel 1 in order to prevent studs 2 from impeding utility runs through horizontal channels 20, 22. Horizontal and vertical channels 20, 22, 24 and groove pairs 8, 9, 10, 11, 14, 15, 16, 17 can be pre-molded with the molding of core A or cut into core A after formation of core A.

Wall panel 1 can have left and right side ends 30, 32 having complementary mating members 34, 36 such that adjacent wall panels 1 can interlock or mate to create an interrupted or continuous wall surface as also shown in Fig. 5. This interlock creates a continuous insulated barrier. In the embodiment shown in Figs. 4 and 5, mating members 34, 36 are complementary L-shaped ends.
It is understood however that any interlocking or mating members can be used such as tongue and groove, jigsaw type mating and the like. End wall panels 1 such as those meeting other wall panels at a corner can either be molded to not include mating members 34, 36 or a portion of core A adjacent mating members 34, 36 can be removed by cutting with a saw or hot wire.

One embodiment of stiffener or stud 2 is shown in Fig. 6. Stud 2 can be C-shaped and have legs 40, 42 extending from base 44. Each leg 40, 42 can have an inwardly extending tab or barb 46 to assist in securing stud 2 to wall panel 1. In one embodiment, the depth or thickness of core A can. be about three times greater than the distance legs 40, 42 extend from base 44. Stud 2 can be made from any number of strong relatively stiff structural materials such as metal, plastic or composite materials. In the embodiment shown Fig. 2, stud 2 is formed from about 18 to 20 gauge galvanized steel sheet metal having the dimensions in inches as shown.

To create a wall structure, one or more bottom tracks can be secured to a floor depending on the length to be spanned by the wall structure. After studs 2 have been inserted in groove pairs of core A, wall panel 1 can be mounted in bottom track 3 and fastened thereto using adhesives or fasteners. Bottom and top tracks 3, 4 can receive one or more wall panels 1 depending on the respective size of the wall panels 1 and tracks 3, 4. In the embodiment shown in Fig. 8 wall panel l is secured to bottom track 3 by screwing leg members 5, 6 of bottom track to each stud 2 on each of front and back sides 12, 13 with sheet metal screws. Another wall panel 1 having studs 2 inserted therein can be mounted in bottom track 3 and the two panels I can be brought together that mating member 36 of one wall panel 1 interlocks or mates with mating members 34 of another wall panel 1 and secured with screws as previously discussed. This process can continue until the desired length of wall structure is formed.

Top track 4 can be secured to wall panels 1 in the same fashion such as by screwing leg members 5, 6 of top track to each stud 2 on each of front and back sides 12, 13 with sheet metal screws. For added structural support, splice plate 48 connects one top track 4 to an adjacent top track 4 as shown in Fig. 8.

Splice plate 48 can be made of any strong and stiff material and secured to top tracks 4 by known methods such as adhesive bonding or fasteners. The dimensions of the splice plate depend on the dimensions of the top track 4. In the embodiment shown in Fig. 9, splice plate 48 is a 4 by 8 inch 16 gauge steel sheet metal and is secured to top track 4 with sheet metal screws.

Figs. 10 and I1 show assembly of bottom tracks 3 meeting at a corner and top tracks 4 meeting at a corner, respectively. To improve structural strength of the wall structure, bottom and top tracks 3, 4 can be overlapped by trimming a portion of an end of tracks 3, 4 as shown more clearly in Fig. 10. As also shown in Fig. 10, the overlapped bottom tracks 3 can be secured together and to the floor with bolt or screw passing through both tracks 3.

As shown in Fig. 12, a C-shaped end cap 50 can cover flat side 52 of corner wall panel 1A and secured to bottom track 3 and top track 4 (not shown). End cap 52 can be constructed of any strong stiff material. In the embodiment shown in Fig. 12, end cap 52 is made of 20 gauge galvanized steel sheet metal. Alternatively, side 13 of wall panel can be trimmed to size instead of utilizing a separate corner wall panel IA.

Fig. 13 shows jamb section 54 can be identical to wall panel 1 except for the dimensions of core A and studs 2. Also, the embodiment of jamb section 54 has flat sides 56, 58 but could be made to include mating members such as mating members 34, 36 to permit interlocking described above with respect to the interlocking of wall panels 1. One or more jamb sections 54 can be inserted between wall panels 1 to create window openings or entrance ways such as doorways. As shown in Fig.
14, jamb section 54 can be secured to the wall panels with L-shaped header 60 having perpendicular disposed members 62, 62. Headers 60 can be constructed of any strong and stiff material. In the embodiment shown in Fig. 14, headers are made of 16 gauge steel sheet metal and secured to wall panels and studs 2 with sheet metal screws or other known methods.

Trim track 66 shown in Fig. 15 can be used to trim window areas. Trim track 66 can have a base plate 68 sized to the window opening and strips 70, 72 extending perpendicularly from base plate 68. Strips 70, 72 can extend beyond the length of base plate 68 to permit securing of trim track 66 to wall panel 1 with screws or any other method. Trim track 66 is made of 20 gauge steel sheet metal and has the dimensions shown.

The wall system once assembled can be finished on the internal and external surfaces with suitable covering materials and paint or other finishing methods. In one embodiment, the inside surface of the wall system can be finished with dry wall attached thereto with any suitable means. Such means can include fasteners such as bolts or screws and/or adhesives. The outer surface likewise can be finished with dry wall, concrete sheets, stucco or other covering material.

Multiple wall systems can be combined to form structures such as a habitable building capable if bearing significant loads such as a roof and be structurally sounds for its intended purpose.

4223500 September, 1980 Clark et at. 523/94 Insulation molded, load bearing, prefabricated panels 4953334 September, 1990 Dickens 523/94 Economy building panel 5218803 June, 1993 Wright 524/811 Method of means for reinforcing a steel stud wall 5279089 January, 1994 Gulur 523/91.1 Insulate a wall system REFERENCES
A. American Institute of Steel Construction (A.I.S.C.) "Manual of Steel Construction," 13' edition.
B. American Iron and Steel Institute (A.I.S.I.) "North American Specification for the Design of Cold Formed Steel Structural Members," 2001 with 2004 amendments.
C. American National Standards Institute (A.N.S.1) A.N.S.I / AF & PA NDS -2005 "National Design Specification for Wood Construction."
D. American Society for Testing and Materials (ASTM):
1. ASTM A 370: Standard Test Methods and Definitions for Mechanical Testing of Steel Products.
2. ASTM C 518: Standard Test Method for Steady-State Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus.

3. ASTM C 1363: Standard Test Method for the Thermal Performance of Building Assemblies by Means of a Hot Box Apparatus.

4. ASTM D 3574: Standard Test Methods for Flexible Cellular Materials-Slab, Bonded, and Molded Urethane Foams.

5. ASTM E 72: Standard Test Methods of Conducting Strength Tests of Panels for Building Construction.

6. ASTM E 84: Standard Test Method for Surface Burning Characteristics of Building Materials.

7. ASTM E 90 Standard Test Method for Laboratory Measurement of Airborne Sound Transmission Loss of Building Partitions and Elements.07480-2 8. ASTM E 119: Standard Test Methods for Fire Tests of Building Construction and Materials.

9. ASTM E 283: Standard Test Method for Determining Rate of Air Leakage Through Exterior Windows, Curtain Walls, and Doors Under Specified Pressure Differences Across the Specimen.

10. ASTM E 330: Standard Test Method for Structural Performance of Exterior Windows, Doors, Skylights and Curtain Walls by Uniform Static Air Pressure Difference.

11. ASTM E 413: Classification for Rating Sound Insulation.

12. ASTM E 1332: Standard Classification for Determination of Outdoor-Indoor Transmission Class.
E. American Welding Society (A.W.S.) D.1.3, 1998 "Structural Welding Code-Sheet Steel."
F. Code Compliance Research Report (CCRR-0121) from Architectural Testing Inc.
G. ICC Reports: Dietrich Industries - ER-4784P (Steel Curtain Wall and Light Gage Structural Framing Products.
H. ICC Reports: Insulfoam & Nova Chemicals - ESR-1798 Expandable Polystyrene (EPS) Beads.

1. National Fire Protection Association (NFPA) - NFPA 259 Standard Test Method for Potential Heat of Building Materials.

Claims

We Claim:

1A panelized wall system with panels comprised of at least one polymeric insulated wall core having an exoskeleton (of steel) created from a horizontal bottom and top tracks and one or more vertical studs within the wall core and vertical studs secured between the top and bottom tracks.

1.A wall system comprising a top track and bottom track, at least one polymeric insulated wall core having one or more studs inserted in therein, the wall core and one or more studs secured between the top and bottom tracks.

1.A solid core polymeric insulated panelized wall system having a steel top track and bottom track with vertical structural steel studs on both sides of the panelized wall system (one being interior and the other being exterior) NOT TOUCHING IN THE MIDDLE. Thus Providing a THERMAL
BREAK or NO THERMAL BRIDGING of the STEEL in the wall whereas energy could flow from interior to exterior. They are connected inside the top and the bottom track on both sides (interior and exterior) to form structural integrity. The solid polymeric insulated core creates unsurpassed energy efficiency with no breaks leaks or gaps for energy loss or gain from interior to exterior.

Key Benefits of Steel Steel has long been the standard in the industry as a sound building material.
According to the Steel Framing Alliance, there are many reasons why steel framing has come to the forefront as one of the best and most attractive building materials for residential and commercial construction. Steel is a superior construction material.
-Highest strength- to- weight ratio of any other building material.
-100% recyclable.
-Non-combustible. Does not burn nor contribute fuel to the spread of fire.
-Inorganic. Will not warp, rot, split, crack or creep.
-Dimensionally stable. Does not expand or contract with moisture content.
(Because of its patent pending design the expansion and contraction from excessive has no damaging effects either).
Consistent material quality. Produced in strict accordance with national standards, no regional variations.

Key Benefits of EPS
As a material that has been used in the building and construction industry for more than 50 years, EPS
is a best-in-class building material:
-Superior insulation -Sound dampening, acoustical benefits.
-Engineered to reduce smoke and flame spread.
-Does not enable or support mold, mildew, and or moisture.
-Lightweight.
-Non biodegradable never looses its qualities or deteriorates.
-Long life span.
-100% recyclable.
-Insect and termite resistant.
-Pest and rodent resistant.