CA3020236C - Lightweight building panel and building system comprising the same - Google Patents

Abstract

The invention provides a modular building panel system. The modular building panel system includes components that are lightweight, versatile, and cost effective. The building panels are configured and/or treated to be fire-resistant, flame retardant, water- resistant, rodent-resistant and/or mould-resistant. Also provided are kits and individual components of the system.

Description

MBM File No. 3726-103 LIGHTWEIGHT BUILDING PANEL AND BUILDING SYSTEM COMPRISING THE SAME
FIELD OF THE INVENTION
[001] This invention pertains generally to building panels and construction methods using building panels and in particular, rodent proof, mould proof, non-combustible, pre-designed light weight building panels.
BACKGROUND OF THE INVENTION

[002] Building panels are well known in the art as a way of making walls and/or partition spaces in a building. Building panels can be used to assembly walls quickly and can facilitate the construction of buildings, including portable buildings in remote locations.

[003] Remote communities may have unique challenges due to harsh climates and lack of or limited public infrastructure. These challenges include water damage that may result in mould growth, fire damage, structural deterioration from harsh climate conditions resulting in a need for regular significant repair or rebuild of buildings. Other challenges to remote communities include the challenges resulting from the remote, often hard to access locations. These challenges result in delays in both repairs to existing buildings and the construction of new buildings. These challenges are exasperated where building materials must be airlifted into the communities.

[004] This background information is provided for the purpose of making known information believed by the applicant to be of possible relevance to the present invention. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present invention.
SUMMARY OF THE INVENTION

[005] An object of the present invention is to provide a lightweight building panel and building system comprising the same. In accordance with an aspect of the present invention, there is provided a lightweight building panel and building system comprising the same.

MBM File No. 3726-103

[006] In accordance with another aspect of the invention there is provided a building panel comprising an expanded polystyrene (EPS) foam sheet and a plurality of metal studs.

[007] In accordance with another aspect of the invention, there is provided a kit comprising a plurality of building panels of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS

[008] These and other features of the invention will become more apparent in the following detailed description in which reference is made to the appended drawings.

[009] Figure 1 illustrates various views of a wall panel in accordance of with one embodiment of the invention detailing polystyrene foam panel with studs. Also detailed are optional elements for connecting multiple panels and optional cut outs for sills.

[010] Figure 2 illustrates various views of an alternative wall panel with window framing detail.

[011] Figure 3 illustrates various views of an alternative wall panel with opening for a door.

[012] Figure 4 illustrates various views of a corner wall panel detailing polystyrene foam corner piece with studs. Also detailed are optional elements for connecting the corner panel to two wall panels.

[013] Figure 5 illustrates various views of a roof panel detailing polystyrene foam roof piece with studs. Also detailed is optional element for sill.

[014] Figure 6 illustrates various views of an alternative roof panel detailing polystyrene foam roof piece with studs.

[015] Figure 7 illustrates various views of a floor panel detailing polystyrene foam floor piece with studs.

MBM File No. 3726-103 DETAILED DESCRIPTION OF THE INVENTION
Overview

[016] This invention provides a modular building panel system. The modular building panel system includes components that are lightweight, versatile, and cost effective. In some embodiments, the building panels are configured and/or treated to be fire-resistant, flame retardant, water-resistant, rodent-resistant and/or mould-resistant.

[017] The components can be used individually or components can be affixed together. In some embodiments, the modular building panel system is in the form of a kit which when assembled provides a specific building configuration. In othe embodiments, components may be used to build custom configurations. In some embodiments, the kits include accessories including doors, windows, and optionally other components necessary to provide a finished building.

[018] In some embodiments, the modular building panels are configured for shipment on pallets. Optionally, the modular building panel system components are configured to be stackable.

[019] In some embodiments, the modular building panel system is configured to provide housing or buildings for remote locations including remote communities, work camps, hunting camps, etc. In some' embodiments, the modular building system is configured to provide buildings for water treatment facilities, sewage treatment facilities, schools, training centres, corridors to affix one building to another, storage, hunting blinds, recreational vehicles, fishing huts, swimming pools, garages, military use, etc.

[020] In some embodiments, the modular building panel system are provided as kits that are optionally geared to the home improvement or do-it-yourself market, for example as Garage-In-A-Box or Greenhouse-In-A-Box.

[021] In some embodiments, structures built using the modular building panel system can be affixed to existing structures for extension or expansion of an existing structure.

[022] In some embodiments, the modular building panel system is used in conjunction with traditional building techniques.

MBM File No. 3726-103

[023] The modular building panel system in some embodiments is configured to facilitate repair of constructed building via component or panel replacement such that building constructed using this system have longer longevity of structure than a stick-build building.

[024] The building panel system can be configured such that buildings and structures constructed using the building panel system can achieve any R-value and for thermal transfer.

[025] The modular building panel system is readily modifiable to include additional angles, components and fastening systems, if required. Other components that may be part of the building panel system include sill components, renewable energy components including solar panels, windows, doors, service panels, etc. In some embodiments, these components are pre-installed into panels. For example, panels incorporate materials so installation is plug and play and can incorporate renewable energy such as solar panels in the roof.

[026] The kits of the invention are generally designed to allow for structures to be easily built with lightweight materials, with little instruction. The kits themselves can be modular and can be modified by adding or subtracting panels.

[027] The buildings manufactured using the modular building system can be optionally finished on the exterior and/or interior with fire retardant material to meet and exceed all building codes.
In some embodiments, the buildings can be finished with specific materials such as color, guage of siding, MgO board, exterior and/or interior MgO.
PANELS

[028] The panels are generally manufactured from expanded polystyrene (EPS) foam and have a plurality of metal studs configured and arranged to meet structural requirements.

[029] In some embodiments, the EPS foam is type 1 EPS foam with a thermal resistance of 3.75/inch, compressive resistance of 70 Kpa, flexural resistance of 17 Kpa, water vapour permanence of 5.2 perms, water absorption of 6%, mould and insect resistant, non-toxic burn and non-combustible. In alternative embodiments, type 2, 3, or 4 EPS foam is used.

[030] The metal studs may be a variety of shapes and sizes, and gauges depending on application. In some embodiments, the metal studs are galvanized steel and are configured as vertical and/or horizontal supports.

MBM File No. 3726-103

[031] In one embodiment, the metal studs has a generally squared U-shaped cross section comprising two arms and a base where the arms are inserted in the EPS foam such that the stud extends into the foam. Optionally, the studs are affixed to the EPS
panels using appropriate fasteners. Optionally, the fasteners are manufactured from stainless steel or are galvanized.

[032] The panels may be provided with the studs pre-inserted or studs may be inserted into the EPS foam prior to use. In such embodiments, the EPS panels may include cuts for the studs.

[033] As shown in figure 1, the metal studs extend partially through the foam and may be provided on both sides of the EPS foam panel.

[034] In some embodiments, the panels are configured to facilitate joining of adjacent panels.
Optionally, joining of adjacent panels may be via a tongue and groove joint.
Alternatively, grooves are provided on opposite edges of a panel and a separate piece of EPS
foam sized to fit within the grooves of adjacent panels is used to join adjacent panels.

[035] The panels may include cut outs for windows, doors or other accessories.
In some embodiments, panels may be configured as service panels. Service panels will be made thicker and recessed complete with Electrical, communications and plumbing cut-outs.
Panels will be thick enough to not require vapour barriers unless stipulated by Code.

[036] In some embodiments, the panels may be specifically configured as floor or roof panels.

[037] Although the invention has been described with reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art without departing from the spirit and scope of the invention. All such modifications as would be apparent to one skilled in the art are intended to be included within the scope of the following claims.

Claims (12)

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

1 . A building panel comprising:
an expanded polystyrene (EPS) foam sheet; and a plurality of metal studs; wherein each metal stud is generally a squared U-shape and comprises two arms and a base; wherein the arms of each metal stud are inserted in the EPS
foam and wherein metal studs are inserted into both sides of the EPS foam sheet.

2. The building panel of claim 1, wherein the metal studs are inserted into a first side of the EPS foam sheet are offset from the metal studs inserted into a second side of the EPS foam sheet.

3. The building panel of claim 1 or 2, wherein the EPS foam type 1 EPS foam.

4. The building panel of any one of claims 1 to 3, wherein the metal studs are manufactured from galvanized steel.

5. The building panel of any one of claims 1 to 4, wherein the studs extend into the foam sheet less than 20%, 30%, 40% or 50% of the total width of the EPS foam sheet.

6. The building panel of any one of claims 1 to 5, wherein the building panel has a groove along at least two edges to facilitate attachment to an adjacent panel.

7. The building panel of any one of claims 1 to 6, comprising a cut out for a window or door.

8. The building panel of any one of claims 1 to 7, comprising a cut out or recess.

9. The building panel of any one of claims 1 to 8, configured for a sill.

10. The building panel of any one of claims 1 to 6, configured as a roof panel.

11. The building panel of any one of claims 1 to 6, configured as a floor panel.

12. A kit comprising a plurality of building panels of any one of claims 1 to 11.

Date Recue/Date Received 2021-03-29