WO1999014450A1

WO1999014450A1 - Building panels, building constructions, methods of forming building panels, and methods of forming building constructions

Info

Publication number: WO1999014450A1
Application number: PCT/US1998/017626
Authority: WO
Inventors: Larry M. Grossman; L. Myles Phipps; Jon R. Sayler
Original assignee: Sgp, Inc.
Priority date: 1997-09-18
Filing date: 1998-08-25
Publication date: 1999-03-25
Also published as: AU8919998A

Abstract

The invention includes pre-formed building panels and building constructed from pre-formed building panels. Additionally, the invention includes methods of forming pre-formed building panels and methods of forming buildings. In one aspect, the invention includes a method of forming a building panel comprising: a) forming a metal core, the metal core having first and second opposing ends; b) joining a first cap to the first opposing end; c) joining a second cap to the second opposing end; and d) forming a foam between the caps, the foam comprising a mass which encapsulates an entirety of the metal core between the ends. In another aspect, the invention includes a building comprising: a) a plurality of wall panels individually comprising a corrugated metal wire core completely encapsulated between end caps and within a low density material; b) the wall panels being abutted side-by-side to form a building wall; c) a cavity in the wall, the cavity not extending through the corrugated metal wire core; and d) electrical wiring witthin the cavity, the electrical wiring extending between at least two electrical components. In another aspect, the invention includes a building panel comprising a corrugated metal wire core substantially completely encapsulated in a low density material.

Description

DESCRIPTION Building Panels, Building Constructions, Methods Of Forming Building Panels, And Methods Of Forming Building Constructions Technical Field This invention pertains to methods of forming pre-formed building panels, and to methods of incorporating pre-formed building panels into a building construction. The invention also pertains to building constructions and pre-formed building panels. Background Art

There is a constant need for low-cost shelters that are easily and quickly erected, and that are formed from readily transportable materials. For instance, much of the world's population is relatively poor, and many live in areas where natural resources are scarce. Accordingly, it would be desirable to develop low-cost shelter constructions which could be transported and erected at population centers throughout the world.

Flexible materials, such as canvas, can be utilized to create low-cost and easily erected dwellings. Unfortunately, such materials typically do not provide adequate insulation for most climates. Also, many of the commonly utilized flexible materials, such as canvas and plastic sheets, rapidly degrade upon exposure to certain common environmental conditions, such as moisture and/or ultraviolet light.

Small, portable and relatively durable buildings have been designed and constructed in the past. Some of these buildings have been readily assembled from preformed panels. However, the building components for such constructions are frequently quite heavy and bulky, and thereby cause storage and handling problems. Additionally, it is generally desired to provide plumbing and electrical conduits within building structures. Frequently it is time-consuming and difficult to provide such plumbing and electrical conduits in conventionally constructed buildings.

For the above-discussed reasons, it is desirable to develop an alternative building construction. Ideally, such alternative building construction would comprise components that are readily transported and assembled in locations throughout the world, and that can be provided with suitable insulative properties to provide comfortable dwellings in a diversity of the world's climates. Further, such building construction would preferably be relatively resistant to weathering and degradation. Additionally, such building construction would preferably simplify provision of wiring and/or plumbing within the building construction. Brief Description of the Drawings

Preferred embodiments of the invention are described below with reference to the following accompanying drawings.

Fig. 1 is a perspective schematic view of a pre-formed building panel of the present invention.

Fig. 2 is a perspective schematic view of the Fig. 1 building panel at a preliminary processing step during construction of the Fig. 1 building panel, in accordance with a method of the present invention.

Fig. 3 is a cross-sectional end view of the Fig. 1 building panel, shown at a processing step subsequent to that of Fig. 2.

Fig. 4 is a cross-sectional, partially fragmented top view of the Fig. 3 building panel.

Fig. 5 is a front view of an alternative building panel formed according to a method of the present invention. Fig. 6 is a perspective view of a building constructed according to a method of the present invention.

Fig. 7 is a perspective schematic view of the Fig. 6 building at a preliminary processing step during construction of the Fig. 6 building, in accordance with a method of the present invention. Fig. 8 is a cross-sectional end view of the Fig. 6 building.

Fig. 9 is an expanded cross-sectional view of the zone illustrated as 9 in Fig. 8. Fig. 10 is a perspective view of an angled spacer of the present invention. Fig. 1 1 is an expanded cross-sectional view of the zone labeled 1 1 in Fig. 8. Fig. 12 is a fragmentary cross-sectional view along the line labeled 12-12 in Fig. 8.

Best Modes for Carrying Out the Invention and Disclosure of Invention

In one aspect, the invention encompasses a method of forming a building panel comprising: forming a metal core, the metal core having first and second opposing ends; joining a first cap to the first opposing end; joining a second cap to the second opposing end; and forming a foam between the caps, the foam comprising a mass which encapsulates an entirety of the metal core between the ends.

In another aspect, the invention encompasses a method of constructing a building comprising: providing a plurality of wall panels individually comprising a first corrugated metal wire core completely encapsulated between first end caps and within a first low density material; providing a plurality of roof panels individually comprising a second corrugated metal wire core completely encapsulated between second end caps and within a second low density material; abutting the wall panels side-by-side to form building walls; and abutting the roof panels side-by-side over the building walls to form a building roof. In yet another aspect, the invention encompasses a method of constructing a building comprising: providing a plurality of wall panels individually comprising a corrugated metal wire core encapsulated between end caps and within a low density material; abutting the wall panels side-by-side to form a building wall; forming a cavity in the wall, the cavity not extending through the corrugated metal wire core; and providing electrical wiring within the cavity, the electrical wiring extending between at least two electrical components.

In yet another aspect, the invention encompasses a building panel comprising: a corrugated metal wire core substantially completely encapsulated in a low density material.

In yet another aspect, the invention encompasses a building panel comprising: a corrugated metal core encapsulated in a low density material; the low density material having a first outer surface, the corrugated metal core being closer to the first outer surface at first locations and more distant from the first outer surface at second locations; and first markings on the first outer surface of the low density material to indicate the first locations.

In yet another aspect, the invention encompasses a building comprising: a plurality of wall panels individually comprising a first corrugated metal wire core completely encapsulated between first end caps and within a first low density material, the wall panels being abutted side-by-side to form building walls; and a plurality of roof panels individually comprising a second corrugated metal wire core completely encapsulated between second end caps and within a second low density material, the roof panels being abutted side-by-side over the building walls and being at least partially supported by the building walls to form a building roof.

More specifically, the invention encompasses pre-formed building panels, and methods of constructing buildings from such pre-formed building panels. A pre-formed building panel 10 of the present invention is described with reference to Figs. 1-4.

Referring to Fig. 1, pre-formed building panel 10 comprises a rectangular shape. Panel 10 preferably comprises an overall dimension of about 4 feet by about 8 feet by about 4 inches, which enables building panel 10 to be readily substituted into conventional building constructions. Alternatively, panel 10 can comprises other dimensions of length, width and/or depth. End caps 12 and 14 are formed at ends of the rectangular shape, and a low-density material 16 is formed between end caps 12 and 14. In the context of this document, low-density material shall mean material having a density of less than about 20 lbs/ft³ and may comprise a number of materials known to persons of ordinary skill in the art. Such materials include low-density cement, which may be formed by aerating a cementitious mixture before curing the mixture. Other low-density materials include straw-based filler materials, textile-based filler materials, paper-based filler materials, and foams, such as, for example, polystyrene. A number of the above-listed materials are waste products in various regions throughout the world. Accordingly, the present invention advantageously encompasses utilization of waste products in pre-formed building panels.

End caps 12 and 14 are preferably metallic, and, as shown in Fig. 2, preferably comprise trough-like shapes. Such trough-like shapes are inverted over foam material 16. End caps 12 and 14 are preferably about 4 feet long by about 4 inches wide, and comprise a depth of about 1 inch. End caps 12 and 14 can be formed from conventional metallic building studs, which have an appropriate trough-like shape for utilization as caps 12 and 14. Accordingly, end caps 12 and 14 can advantageously readily be purchased in commercial markets throughout the world.

Fig. 2 illustrates panel 10 of Fig. 1 at preliminary processing step during formation of panel 10. A metal core 18 is formed between end caps 12 and 14. Metal core 18 provides strength to building panel 10, and provides most of the load-bearing capacity of panel 10. Metal core 18 comprises first and second opposing ends joined to end caps 12 and 14, respectively. Metal core 18 can be joined to end caps 12 and 14 by, for example, welding.

Metal core 18 comprises a plurality of first wire strands 20 arranged parallel to one another, and a plurality of second wire strands 22 arranged perpendicular to first strands 20 (only a few of the strands 20 and 22 are labeled in Fig. 2). Wires 20 and 22 are preferably ellipsoid or round in cross-sectional shape. Second wire strands 22 are adhered to first wire strands 20 by, for example, welding. First stands 20 are all substantially equidistantly spaced from adjacent first strands by a first space 24. Also, second strands 22 are substantially equidistantly spaced from adjacent second strands by a second space 26. Preferably, first space 24 is approximately equal to second space 26 such that first and second strands 20 form a wire mesh having substantially square openings.

Wire core 18 is preferably corrugated to increase a load-bearing capacity of the wire core. The load-bearing capacity of panel 10 can be adjusted by adjusting the number of wires 20 and 22 comprised within a panel construction, or by adjusting the thicknesses of wires 22 and 24 utilized within a panel construction. An example corrugated wire core 18 having a strength calculated to provide adequate load-bearing capacity for a dwelling constructed in an Inland Northwest portion of the United States comprises 4x4 W5xW5 (which means that the wire is 0.252 inches in diameter and spaced regularly on 4" centers, to provide a network of 4"x 4" squares). The shown embodiment of wire core 18 comprises fourteen strands 22 of 0.252 inch diameter wire and six corrugated bends.

Metal core 18 is substantially entirely encapsulated within low-density material 16 (shown in Fig. 1). Further, metal core 18 is completely encapsulated by low-density material 16 and metal caps 12 and 14. Such complete encapsulation of metal core 18 forms a panel 10 having substantially uniform properties throughout an entirety of its length, which can improve insulative properties of panel 10. Corrugated metal core 18 enables panels 10 of the present invention to be structurally rigid, while still being lightweight and relatively easy to transport. An entire panel constructed according to the present invention typically weighs less than about 60 pounds.

Panels 10 of the present invention may be transported as completely assembled panels, or in partially assembled form. Preferably, caps 12 and 14, as well as corrugated metal core 18, will be configured to nest during transport. Thus, panels 10 can be readily transported from a production facility in one location (such as in the United States) to a finishing facility in a distant location (such as in a country abroad) as unassembled metal cores 18, and caps 12 and 14. Individual cores 18 can then be assembled with caps 12 and 14 at the finishing facility and a low-density material 16 (shown in Fig. 1) can be provided to encapsulate cores 18 and complete formation of panels 10. Panels 10 can then be transported to building sites local to the finishing facility for utilization in building construction. Alternatively, panels 10 can be completely constructed at a production facility and shipped worldwide from the production facility. As another alternative, caps 12 and 14 can be joined to metal cores 18 at a production facility to form core-and-cap assemblies. The core-and-cap assemblies can then be transported worldwide to finishing facilities for subsequent incorporation of low-density materials 16 into the core-and-cap assemblies to produce panels 10.

As discussed above, low-density material 16 (shown in Fig. 1) can comprise a number of materials known to persons of ordinary skill in the art, including polymeric foam, paper, straw and low-density concrete. Preferably, however, low-density material 16 does not comprise concrete, as concrete disadvantageously complicates incorporating panels 10 into a building structure utilizing methods which are discussed below with reference to Figs. 6- 12. Most preferably, low-density material 16 (shown in Fig. 1 ) comprises polystyrene, as such tends to simplify incorporation of a panel 10 into the building structures discussed below with reference to Figs. 6-12.

A method for forming low-density material 16 from polystyrene is described with reference to Figs. 3 and 4. Metal wire core 18, with end caps 12 and 14 joined thereto (end caps 12 and 14 are shown in Fig. 2), is inserted within a mold 28. Mold 28 is configured to form a polystyrene foam into a shape of a flat panel extending between caps 12 and 14 (shown in Fig. 2). Mold 28 comprises side walls 30 and 32, as well as a bottom wall 34 and a top wall 36. Walls 30, 32, 34 and 36 are configured to contain a polystyrene foam as it expands within mold 28. End caps 12 and 14 are utilized as end walls within mold 28 to contain a polystyrene foam between the end caps as the foam expands within mold 28. Mold 28 further comprises orifices 38 configured to permit steam (not shown) to ingress and egress within mold 28. Expanded polystyrene beads 40 are provided within mold 28. Subsequently, steam is introduced through orifices 38 to heat and further expand polystyrene beads 40 to form a rectangular panel shape from the polystyrene. The polystyrene preferably extends at least VA" beyond metal core 18 on all sides so metal core 18 is completely encapsulated within a low-density foam 16 (shown in Fig. 1 ) formed from the polystyrene.

In alternative embodiments of the present invention which are not shown, low- density material 16 (shown in Fig. 1) can comprise a compound which is sprayed around a metal wire core within a mold and subsequently cured to form a rectangular shaped panel 10 (shown in Fig. 1 ). In such alternative embodiments, the sprayed material may be provided by, for example, spraying the material through a wand which is slowly pulled through a mold to fill the mold with a precursor of low-density material 16. The precursor can then be cured to form low-density material 16.

Another preferred embodiment panel of the present invention is described with reference to Fig. 5. In referring to Fig. 5, similar numbering to that utilized above in describing Figs. 1 -4 will be used, with differences indicated by the suffix "a", or by different numerals. Preferred panel 10a comprises an outer side surface 58 of low- density material 16a. Panel 10a further comprises markings 52, 54 and 56 on side surface 58 to indicate the locations of first and second strands 20 and 22 (shown in Fig. 2) of metal core 18 (shown in Fig. 2). Markings 52 and 54 both correspond to vertically extending strands 22, while markings 56 correspond to horizontally extending strands 20. Preferably, markings 52, 54 and 56 substantially overlay the locations of wires 20 and 22 (shown in Fig. 2) within panel 10a. Also preferably, each of markings 52, 54 and 56 will comprise a separate and distinct color or pattern. Markings 52, 54 and 56 can be formed by conventional methods, such as, for example, by painting and printing. In referring to Figs. 2 and 3, it will be evident that the corrugations of corrugated metal core 18 cause corrugated metal core 18 to comprise some vertically extending strands 22 which are relatively near to outer surface 58, and some which are relatively distant from outer surface 58. Markings 52 and 54 separately indicate vertically extending strands 22 which are relatively near outer surface 58 and vertically extending strands 54 which are relatively distant outer surface 58, respectively.

Panel 10a also comprises an back outer surface (not shown) which is on an opposing side of panel 10a from front outer surface 58. Wire strands 20 and 22

(shown in Fig. 2) will be in identical locations relative to the back surface as to the front surface. Accordingly, strands 20 and 22 can be labeled on the back surface with markings in identical locations as the markings 52, 54 and 56 on front surface 58. A difference between the relative locations of strands 22 (shown in Fig. 2) with respect to the back surface as opposed to front surface 58 is that the strands 22 which are most near front surface 58 are also the strands most distant from the back surface. Accordingly, the relative locations of makings 52 and 54 will preferably be reversed on the back surface in indicating which of vertically extending strands 22 (shown in Fig. 2) are nearest the back surface and which are furthest away from the back surface.

The above-discussed pre-formed panels 10 can be incorporated into building constructions. Preferred methods of forming such building constructions are described with reference to Figs. 6- 12. Referring to Fig. 6, a building 70 is illustrated. Building 70 comprises four walls consisting of a front wall 72, a side wall 74, a rear wall 71 (shown in Fig. 8 and shown partially constructed in Fig. 7) and a second side wall 73 (shown partially constructed in Fig. 7). Front wall 72 comprises pre-formed wall panels 80, 82 and 84, which are abutted side by side. Pre-formed wall panels 80 and 84 preferably comprise panels 10 (shown in Fig. 1 ). Panel 82 is described in more detail below and is designed to support a door 1 14. As well as being abutted against one another, adjacent wall panels can be adhesively adhered to one another with, for example, cement, two- faced adhesive tape, polymeric adhesives, and/or two-component adhesives. Additionally, the panels can have a groove formed along their edge for insertion of a foam member between adjacent panels to form a joint. Such groove can be formed as the panels are molded, or can be formed after molding the panels by, for example, a hot knife. The foam member comprises a piece of foam sized for insertion into the groove. Example dimensions for the groove are approximately one inch wide by one inch deep and having a length which extends from about cap 14 (shown in Fig. 1 ) to about cap 12 (shown in Fig. 1 ).

Side wall 74 comprises pre-formed panels 86, 88 and 90. Pre-formed wall panels 86 and 90 preferably comprise panels 10 (described above with reference to Figs. 1-5). Panel 88 is described in more detail below and is designed to support a window 1 16.

A roof 76 is formed over walls 71 , 72, 73 and 74. Roof 76 comprises preformed panels 92, 94, 96, 98, 100, 102, 104 and 106. Roof panels 92, 94, 96, 98, 100, 102, 104 and 106 are abutted side by side over the building walls and are supported, at least in part, by the building walls. Adjacent roof panels can be adhesively adhered to one another utilizing methods discussed above regarding the wall panels. The roofing panels of one side of roof 76 (panels 100, 102, 104 and 106) join the roofing panels from another side of roof 76 (panels 92, 94, 96 and 98) at a peak 108 of the roof. Over peak 108 is formed a roofing plate 1 10, which can comprise conventional materials. Roofing panels 92, 94, 96, 98, 100, 102, 104 and 106 preferably all comprise a substantially identical construction to one another. Also, wall panels 80, 84, 86 and 90 preferably comprise a substantially identical construction to one another. Additionally, the roof panels and wall panels can be identical to one another. However, as noted above, a load-bearing capacity of a pre-formed panel 10 (shown in Fig. 1) can be adjusted by varying the materials utilized in a corrugated metal wire core (shown as 18 in Fig. 3). Since the load-bearing requirements of the roof panels can be substantially different from the load-bearing requirements of the wall panels, it can be advantageous to utilize wall panels which are not identical to the roof panels. However, such advantage can be offset by a disadvantage of transporting and storing two different types of panels for a common project. Even if the internal construction of the wire core within the roof panels differs from the wire core of the wall panels, in preferred embodiments of the invention the roof panels and wall panels will be identical in overall size. Most preferably, the wall panels and roof panels will comprise dimensions of about 4 feet by about 8 feet by a depth appropriate for the insulation requirements of the building being constructed. A typical depth is about 4 inches.

The individual wall and roof panels are shown in Fig. 6 for clarity in explaining the methods and constructions of the present invention. In practice, such individual panels would likely not be visible in a finished building. For instance, the gaps between individual wall panels would preferably be covered with tape and then with a cementitious stucco-like material. Such stucco-like material would ideally have a composition which could be sprayed over a building to facilitate a quick and inexpensive application of the material to the building surface.

A suitable stucco-like material comprises from about 14% to about 35% (by weight) portland cement, from about 60% to about 80% aggregate, from 0% to about 10% calcium metasilicate, from 0% to about 5% water re-dispersible polymer, from 0% to about 2% polymeric fibers, from 0% to about 2% thixotropic material, and from 0% to about 5% colorant or pigment. A more preferred composition for the stucco-like material comprises from about 20% to about 24% portland cement, from about 68% to about 72% aggregate, from about 3% to about 7% calcium metasilicate, from about 0.5%) to about 4.5% water re-dispersible polymer, and from about 0.8% to about 1.2% polymeric fibers.

The portland cement can be type I/II grey or type I white. The aggregate is preferably ground marble or silica having particle sizes from about 0.5 to about 2 millimeters. The water re-dispersible polymer preferably comprises one or more polymers selected from the group consisting of vinyl acetate-ethylene copolymer, copolymers of vinyl acetate with vinyl ester of versatic acid, and acrylics.

The polymeric fibers preferably comprises one or more fibers selected from the group consisting of polypropylene single strands, polyamides, and polyacrylamides. The polyamides can comprise, for example, nylon (TM). The thixotropic material can comprise a number of compounds known to persons of ordinary skill in the art, including, for example, clay-based thixotropes, such as bentonite and its derivatives; cellulosics, such as methyl cellulose, and ethyl cellulose; and fiber-based thixotropes, such as the ceramic fiber material known as HSA and supplied by Unifrax Corporation.

The colorant can be either inorganic, organic or polymeric material. Among the suitable materials are iron-based earth tones, titanium dioxide and dolomite based whites, azo-based organic dyes for reds and pinks, chromium-based oxides for yellows and greens, and carbon blacks for black. In alternate embodiments of the invention, a fire barrier comprising, for example, a layer of fire resistant cloth, can be provided over interior and/or exterior surfaces of building 70 before provision of the above-discussed stucco-like compound. An example fire resistant cloth is Synteen (TM).

The gaps between individual roof panels would likely not be visible in a finished building because the roof panels would typically be covered with a weatherproofing material. Suitable weatherproofing materials are known to persons of ordinary skill in the art, and include, for example, shakes, shingles, fiberglass roofing and steel roofing. Preferably, the weatherproofing material would be applied over an entire surface of a roof, rather than just over gaps between roof panels. Roofing plate 1 10 would typically be provided over the weatherproofing material.

A rectangular-shaped spacer 1 12 is formed between panels 80, 82 and 84 of front wall 72 and peak 108 of roof 76. Rectangular-shaped spacer 1 12 can comprise, for example, a foam material cut to fit between panels 80, 82 and 84, and peak 108. Alternatively, spacer 112 can comprise other materials, such as, for example, wood. A spacer 1 13 (shown in Fig. 8), similar to spacer 1 12, comprises part of back wall 71 (shown in Fig. 8) of building 70. In alternative embodiments which are not shown, roof 76 can lie flat over wall panels 80, 82, 84, 86, 88 and 90. In such alternative embodiments, spacers 1 12 and 1 13 are, of course, not necessary.

Roof panels 100, 102, 104 and 106 are laterally offset by about one-half of a panel width relative to the wall panels 86, 88 and 90 that support them. Specifically, a front roof panel 100 and a rear roof panel 106 have about half their widths extending outwardly of the building walls and about half their widths supported by the building walls. Such offset of the roof panels enables the roof to extend beyond building walls and provides eaves for persons to stand under during ingress or egress from building 70. As noted above, building 70 comprises a door 1 14 in front wall 72. Door 1 14 preferably comprises a 3-foot width, such that an entirety of door 1 14 can be mounted within a single panel. Preferably, door 1 14 is pre-mounted within a panel 82 which has an overall dimension identical to wall panels 80 and 84, but which comprises a different composition than panels 80 and 84. For instance, panel 82 can, for example, comprise a sheet surrounding and supporting door 1 14. Such sheet can comprise, for example, plastic or wood. Further, panel 82 can comprise a window within the sheet that surrounds and supports door 1 14.

As also was noted above, building 70 comprises a window 1 16 in side wall 74. Window 1 16 is preferably mounted over a partial-height panel 88, and is preferably sized such that window 1 16 and panel 88 together comprise dimensions substantially identical to the full height wall panels 86 and 90. Partial height panel 88 can be constructed identically to the above-discussed panel 10 (shown in Fig. 1), or can comprise other materials, such as, for example, plastic and/or wood. As window 1 16 rests on panel 88, there is no need to separately build a header to support window 1 16 as would be required in conventional building constructions. A method of mounting window 1 16 is to screw the window to an end cap at the top of panel 88 and to a rail (not shown) extending between the tops of panels 86 and 90. An alternative method of mounting window 1 16 is to adhesively adhere window 1 16 to one or more of panels 86, 88 and 90. Such adhesive adhering can be accomplished with glue or tape. Walls 72 and 74 are preferably supported within an upwardly open trough 120 that defines a periphery of building 70. Such is illustrated in Fig. 7, which shows building 70 at a preliminary step of construction.

Referring to Fig. 7, trough 120 is formed over a supporting surface 122. Surface 122 can comprise, for example, the ground, or a flooring material laid over the ground. In certain climates, it can be advantageous to elevate at least one of trough 120 and supporting surface 122 on a foundation. Wall panels 124, 126 and 128 are placed within trough 120 to form walls 71 and 73. Wall panels 124, 126 and 128 may be fastened to trough 120 by, for example, driving screws through the trough and into lower caps 12 of the panels.

Trough 120 preferably comprises a metal construction which is sized and shaped to have a cavity slightly wider than the 4-inch width of caps 12. Trough 120 then tightly receives and retains wall panels 124, 126 and 128. Trough 120 also preferably comprises a height of at least one inch so that trough 120 entirely covers a lower cap 12 of a wall panel inserted within the trough. Brackets 130 are utilized to attach the tops of adjacent panels to one another. Although brackets 130 are illustrated as short brackets configured to overlie a single joint between adjacent wall panels, such brackets can also be configured in the form of a single long bracket which extends over an entirety of a building wall. Further, although brackets 130 are illustrated as substantially plainer brackets which overlie only a top surface of adjacent panels, such brackets could also comprise a trough-type construction which is inverted and overlaid over adjacent panels. In more preferred embodiments of the invention, brackets 130 will comprise long troughs configured to overlie an entire wall of building 70 and retain the wall panels comprised by such wall. Such long trough will preferably be formed of metal and comprise a cavity having a depth of at least about one inch within which wall panels, such as panels 124, 126 and 128, are received. Such trough can be substantially identical to a single side of the illustrated trough 120. Wall panels 124, 126 and 128 can be retained within such trough-shaped bracket by screws extending through the side of the trough and into upper caps 14.

Fig. 8 illustrates a cross-sectional front view of the building 70 of Fig. 6. In the shown cross-sectional view, building 70 comprises roof panels 92 and 100, as well as wall panels 132 and 86. The illustrated panels 86, 92, 100, and 132 preferably comprise the constructions described above with reference to Figs. 1-5. Accordingly, the panels comprise a low-density material 16 surrounding wire strands 20 of a metal core 18 (shown in Fig. 2). Wire strands 20 can be utilized for mounting ordinary interior items within building 70. For instance, in the shown embodiment a light 134, a switch 136 and an outlet 138 are all mounted to wires 20. Items 134, 136 and 138 can be mounted to wires 20 by, for example, inserting an I-hook through low-density material 16 (shown in Fig. 1) and over wire 20, and then hanging the items from the I-hook. Additionally, although not shown, interior items can also be mounted on the wires 22 (shown in Fig. 2) by methods similar to those discussed above for hanging items from wires 20. It is noted that wires 20 can be utilized for mounting heavier items, other than the shown items, to a wall formed by method of the present invention. Such heavier items can include, for example, cabinets and mirrors. As wires 20 will frequently be utilized for mounting items within a building, it is particularly useful to mark the locations of the wires on outside surfaces of the panels in accordance with the methods discussed above regarding Fig. 5.

Fig. 8 further illustrates that peak 108 of roof 76 is supported by a beam 140. Beam 140 can comprise wood, or other materials known to persons of ordinary skill in the art, and preferably extends for substantially an entire length of roof 76. Beam 140 is supported by a support member 142 which can comprise, for example, a wooden post or other materials known to persons of ordinary skill in the art.

Also illustrated in Fig. 8 are coverings 121 that are provided over portions of trough 120 that extend interiorly into building 70. Coverings 121 can be formed from, for example, foam and are provided for insulative as well as aesthetic purposes.

Although not shown, coverings similar to coverings 121 could also be provided over portions of trough 120 that extend exteriorly of building 70.

Roof panels 92 and 100 are supported over wall panels 132 and 86 by angled spacers 144 which are shown and described with reference to Fig. 9.

Referring to Fig. 9, angled spacer 144 is between roof panel 92 and wall panel 132. Angled spacer 144 is shown in isolation in Fig. 10. Angled spacer 144 comprises a sloped portion 148 configured to underlay a surface of roof panel 92.

An extension 150 is between sloped portion 148 of angled spacer 144 and cap 14 of panel 132. Extension 150 is opposite an angle between sloped portion 148 and cap 14 of panel 132 and preferably has a notch 152 formed within it. Notch 152 distributes a force of roof 92 toward a center of wall panel 132, rather than along an edge of wall panel 132.

Angled spacer 144 further comprises a receiver portion 154 configured to receive cap 14 of wall panel 132. Receiver portion 154 preferably comprises a trough slightly wider than a width of cap 14 such that cap 14 is snugly retained within receiver portion 154. Receiver portion 154 can be fastened to cap 14 by, for example, driving a screw through receiver portion 154 and into cap 14. It is noted that angled spacer 144 can substitute for one or more of the brackets 130 shown in Fig. 7. Roof panel 92 is attached to angled spacer 144 through fastener 156, which can comprise, for example an I-bolt. In operation, fastener 156 is preferably attached to roof panel 92 before attaching roof panel 92 to angled spacer 144, and before attaching angled spacer 144 to wall panel 132. If fastener 156 is an I-bolt, I-bolt 156 can be attached to roof panel 92 by inserting I-bolt 156 through the relatively soft low-density material 16 and twisting until a wire 20 is hooked. A fastener spacer 158 is then inserted over I-bolt 156. Fastener spacer 158 comprises a pair of flanged ends 160 and 162, which are referred to herein as first and second flanged ends, respectively. First flanged end 160 is configured to support wire 20, and can be substantially flat, as shown, or can be upwardly curved to better retain wire 20. Second flanged end 162 is configured to butt against sloped portion 148 of angled spacer 144. Fastener spacer 1 58 thus forms a supporting extension between angled spacer 144 and wire 20 of the metal core 18 (shown in Fig. 2) of panel 92.

Fastener 156 preferably comprises a threaded extension and angled spacer 144 preferably comprises one or more orifices 147 (shown in Fig. 10) configured for receiving the threaded extension. The threaded extension (not labeled) of fastener 156 is passed through orifice 147 (shown in Fig. 10) of angled spacer 144 and a nut 171 is screwed onto the threaded extension to fasten roof panel 92 to angled spacer 144. Such attachment of roof panel 92 to angled spacer 144 forms a roof-panel-angled-spacer combination and preferably occurs before fastening angled spacer 144 to wall panel 132. The roof-panel-angled-spacer combination can be lifted onto panel 132 and fastened thereto. Coverings 160 can then be provided over angled spacer 144 and cap 14 to conceal spacer 144 and cap 14. Coverings 160 can be formed from foam or other commonly available materials, and are provided for aesthetic purposes as well as for insulative purposes. Referring next to Fig. 1 1 , an expanded view of peak 108 of roof 76 is illustrated. As discussed above regarding Fig. 8, peak 108 is supported by a beam 140. Between beam 140 and peak 108 is a U-shaped trough 163 and angled spacers 162 and 164 within the U-shaped trough. Such angled spacers are preferably identical to the angled spacer 144 described above with reference to Fig. 9. Spacers 162 and 164 are preferably held to roof panels 92 and 100, respectively, with fasteners and fastener spacers identical to the fastener 156 and fastener spacer 158 discussed above with reference to Fig. 9.

Coverings 166 and 168 are provided over spacers 162 and 164, respectively. Coverings 166 and 168 can comprise materials known to persons of ordinary skill in the art, including, for example, foam materials. Coverings 166 and 168 are provided for aesthetic purposes as well as for insulative purposes.

Roof panels 92 and 100 join at peak 108 and form a gap 170 overlaying beam 140 at their junction. Gap 170 is preferably substantially filled with a low- density material prior to placing roofing plate 1 10 over peak 108. Such low-density material can comprise, for example, a foam cut to substantially fill gap 170. In preferred aspects of the invention, such foam can be precut and provided to a building site to be placed within gaps 170.

The building construction of the present invention can advantageously substantially simplify providing wiring, plumbing, and other recessed components into the walls and ceiling of a building constructed according to the present invention. Such is described with reference to Fig. 12. Fig. 12 illustrates a pair of wall panels 132 and 124, and a ceiling panel 92 extending above them. Outlet 138, switch 136, and light 134 are electrically connected by a wire 172 which extends through panels 132, 124 and 92. In accordance with the present invention, wire 172 is recessed within a cavity formed in panels 132, 124 and 134. The cavity and the wire 172 preferably do not extend through a corrugated metal core 18 (shown in Fig. 2) of the panels.

In preferred embodiments, in which panels 132, 124 and 92 comprise polystyrene foam as a low-density material 16, wire 172 can be recessed by melting a chase into the panels. Such chase can be formed by, for example, utilizing a hot knife to melt foam 16 and simply dragging the hot knife through panels 132, 124 and 134 in a desired shape for a chase. Other methods of forming a chase within panels of the present invention will be recognized by persons of ordinary skill in the art. Such other methods could comprise, for example, routing. Once a chase is formed, wire 172 can be recessed within such chase.

Preferably, wire 172 will be held within the chase with a retaining fastener. Suitable retaining fasteners are, for example, conventional clips configured with barbed prongs. It has been found that the polystyrene foam of a preferred panel construction will satisfactorily hold a barbed prong of many conventional clips. Alternatively, wire 172 can be fastened within the chase with an adhesive.

In extending wire 172 from wall panel 124 to roof panel 134, wire 172 passes over angled spacer 144 (shown in Fig. 9). Preferably, cover 160 is provided over angled spacer 144 after passing wire 172 over angled spacer 144. Cover 160 then conceals both angled spacer 144 and wire 172. After wire 172 is retained within the chase, wire 172 may be covered with a mudding compound or with a foam material to fill the chase. Subsequently, a cementitious material can be applied to panels 132, 124 and 92 to cover the panels and to aesthetically conceal the chase. Preferably, such cementitious compound comprises the preferable composition described above for a stucco-like compound that is applied over the wall panels and roof panels. Also preferably, such cementitious material is applied over substantially all of an interior surface of building 70 after provision of wiring 172, and covers 121 (shown in Fig. 8), 160 (shown in Fig. 9), 166 (shown in Fig. 1 1 ) and 168 (shown in Fig. 1 1 ).

The above-described method for connecting electrical components can be utilized for a number of conventional electrical components, including, for example, outlet receptacles, fuse boxes, and other electrical devices such as switches and lights. Additionally, the method can be utilized for providing electrical wiring between adjacent wall panels, adjacent ceiling panels, or between both wall panels and ceiling panels. Further, the above-described method can be utilized for forming recesses in the walls and ceiling for retaining other building components besides electrical wiring. Such other building components can comprise, for example, water pipes and gas pipes.

It is noted that the methods of the present invention can be utilized for forming a variety of different building types, including, for example, dwellings, garages, office buildings and storage sheds.

Claims

1. A method of forming a building panel comprising: forming a metal core, the metal core having first and second opposing ends; joining a first cap to the first opposing end; joining a second cap to the second opposing end; and forming a foam between the caps, the foam comprising a mass which encapsulates an entirety of the metal core between the ends.

2. The method of claim 1 wherein the forming the metal core comprises forming a metal wire mesh and corrugating the metal wire mesh.

3. The method of claim 2 wherein the metal wire mesh comprises substantially square openings.

4. The method of claim 1 wherein the caps are configured in the shape of troughs inverted over the metal wire core.

5. The method of claim 1 wherein the panel is formed to dimensions of about 4 feet by about 8 feet by about 4 inches.

6. The method of claim 1 wherein the caps comprise metal.

7. The method of claim 1 wherein the metal wire core is placed in a mold before forming the foam, the mold being configured to contain the foam in a shape of a flat panel extending between the caps, the caps effectively forming ends of the mold.

8. The method of claim 1 wherein the forming of the foam comprises spraying the foam between the caps.

9. The method of claim 1 wherein the forming of the foam comprises expanding polystyrene beads between the caps.

10. A method of constructing a building comprising: providing a plurality of wall panels individually comprising a first corrugated metal wire core completely encapsulated between first end caps and within a first low density material; providing a plurality of roof panels individually comprising a second corrugated metal wire core completely encapsulated between second end caps and within a second low density material; abutting the wall panels side-by-side to form building walls; and abutting the roof panels side-by-side over the building walls to form a building roof.

1 1. The method of claim 10 wherein the first and second low density materials comprise foam.

12. The method of claim 10 wherein the first and second low density materials comprise polystyrene.

13. The method of claim 10 wherein the wall panels and roof panels are identical to one another.

14. The method of claim 10 wherein the wall panels and roof panels are not identical to one another.

15. The method of claim 10 wherein the first corrugated metal wire core is different than the second corrugated metal wire core.

16. The method of claim 10 wherein the first corrugated metal wire core comprises a different gauge metal wire than the second corrugated metal wire core.

17. The method of claim 10 further comprising adhesively adhering the wall panels to one another.

18. The method of claim 10 further comprising adhesively adhering the wall panels to one another with adhesive tape.

19. The method of claim 10 further comprising adhesively adhering the roof panels to one another.

20. The method of claim 10 further comprising: providing an angled spacer between at least one of the individual roof panels and at least one of the individual wall panels.

21. The method of claim 20 wherein the angled spacer is attached to the at least one roof panel before supporting the at least one roof panel on the at least one wall panel.

22. The method of claim 20 wherein the angled spacer comprises a sloped portion configured to underlay a surface of the at least one roof panel; and wherein the sloped portion is attached to a receiver portion configured to receive a top of the at least one wall panel therein.

23. The method of claim 22 wherein the angled spacer further comprises an extension between the sloped portion and the receiver portion, the extension having a notch cut into it to distribute a weight of the at least one roof panel.

24. The method of claim 22 further comprising: providing a fastener extending through the sloped portion to the second corrugated metal wire core of the at least one roof panel, the fastener comprising a bolt and a fastener spacer surrounding the bolt, the bolt comprising a hook configured to grasp the second corrugated metal wire core, the bolt comprising a threaded extension configured to extend beneath the sloped portion of the angled spacer, the fastener spacer comprising a pair of flanged ends, a first of the flanged ends being configured to support the second corrugated metal wire core of the at least one roof panel, a second of the flanged ends being configured to butt against the sloped portion of the angled spacer; and threading a nut on the threaded extension of the bolt to fasten the at least one roof panel to the angled spacer.

25. The method of claim 10 further comprising: before forming the building roof, providing a support beam across a center of the building, the support beam being configured to support a center of the roof; providing one or more first angled spacers between the roof panels and the wall panels; and providing one or more second angled spacers between the support beam and the roof panels.

26. The method of claim 25 wherein the building comprises opposing sides, wherein separate roof panels supported by walls at different opposing sides meet at the support beam, and wherein a gap is formed between the separate roof panels and overlaying the support beam, the method further comprising: substantially filling the gap with low density material and covering the gap with a roofing plate.

27. The method of claim 10 further comprising: providing a protective material over the roof, the protective material being selected from the group consisting of shakes, shingles, tiles, fiberglass roofing and metal roofing.

28. The method of claim 10 further comprising: before forming the building walls, providing a trough over a supporting surface, the trough being placed in a shape which defines a periphery of the building; and placing the wall panels within the trough to form the building walls.

29. The method of claim 10 further comprising: after forming the building walls, applying a cementitious material over a surface of the building walls.

30. A method of constructing a building comprising: providing a plurality of wall panels individually comprising a corrugated metal wire core encapsulated between end caps and within a low density material; abutting the wall panels side-by-side to form a building wall; forming a cavity in the wall, the cavity not extending through the corrugated metal wire core; and providing electrical wiring within the cavity, the electrical wiring extending between at least two electrical components.

31. The method of claim 30 wherein the low density material comprises a foam.

32. The method of claim 30 wherein the low density material comprises polystyrene.

33. The method of claim 30 wherein the at least two electrical components are both attached to the wall panels.

34. The method of claim 30 wherein the at least two electrical components comprise a switch and an electrical device controlled by the switch.

35. The method of claim 30 wherein the forming the cavity comprises removing low density material from the wall panels with a hot knife.

36. The method of claim 30 wherein the forming the cavity comprises removing low density material from the wall panels with a router.

37. The method of claim 30 further comprising: providing a fastener within the cavity to retain the electrical wiring.

38. The method of claim 30 further comprising: providing a covering over the electrical wiring within the cavity.

39. A building panel comprising: a corrugated metal wire core substantially completely encapsulated in a low density material.

40. The building panel of claim 39 comprising dimensions of about 4 feet by about 8 feet by about 4 inches.

41. The building panel of claim 39 wherein the low density material comprises foam, paper or straw.

42. The building panel of claim 39 wherein the low density material does not comprise concrete.

43. The building panel of claim 39 wherein the low density material comprises polystyrene.

44. The building panel of claim 39 wherein the corrugated metal wire core comprises a plurality of first strands arranged parallel to one another and a plurality of second strands arranged perpendicular to the first strands and welded to the first strands.

45. The building panel of claim 44 further comprising markings on an outer surface of the building panel to indicate the locations of the first and second strands within the building panel.

46. The building panel of claim 44 wherein the first strands are all substantially equidistantly spaced from adjacent first strands by a first space and wherein the second strands are all substantially equidistantly spaced from adjacent second strands by a second space.

47. The building panel of claim 46 wherein the first space is approximately equal to the second space.

48. The building panel of claim 39 wherein the metal wire core comprises opposing ends, the building panel further comprising metal caps joined to the opposing ends of the metal wire core, the metal wire core being completely encapsulated by the metal caps and low density material.

49. The building panel of claim 48 wherein the metal caps are configured in the shape of troughs inverted over the metal wire core.

50. A building panel comprising: a corrugated metal core encapsulated in a low density material; the low density material having a first outer surface, the corrugated metal core being closer to the first outer surface at first locations and more distant from the first outer surface at second locations; and first markings on the first outer surface of the low density material to indicate the first locations.

51. The building panel of claim 50 wherein the first markings substantially overlay the first locations.

52. The building panel of claim 50 further comprising second markings on the first outer surface to indicate the second locations.

53. The building panel of claim 52 wherein the second markings substantially overlay the second locations.

54. The building panel of claim 52 wherein the first markings comprise a first colored material substantially overlaying the first locations and the second markings comprise a second colored material substantially overlaying the second locations, the first colored material being of a different color than the second colored material.

55. The building panel of claim 50 further comprising: a second outer surface of the low density material, the second outer surface being on an opposing side of the panel from the first outer surface, the corrugated metal core being closer to the second outer surface at third locations and more distant from the second outer surface at fourth locations; and third markings on the second outer surface of the low density material to indicate the third locations.

56. The building panel of claim 55 wherein the third markings substantially overlay the third locations.

57. The building panel of claim 55 further comprising fourth markings on the second outer surface to indicate the fourth locations.

58. The building panel of claim 57 wherein the fourth markings substantially overlay the fourth locations.

59. A building comprising: a plurality of wall panels individually comprising a first corrugated metal wire core completely encapsulated between first end caps and within a first low density material, the wall panels being abutted side-by-side to form building walls; and a plurality of roof panels individually comprising a second corrugated metal wire core completely encapsulated between second end caps and within a second low density material, the roof panels being abutted side-by-side over the building walls and being at least partially supported by the building walls to form a building roof.

60. The building of claim 59 wherein the wall panels and roof panels are identical to one another.

61. The building of claim 59 wherein the wall panels and roof panels are not identical to one another.

62. The building of claim 59 wherein the first corrugated metal wire core is different than the second corrugated metal wire core.

63. The building of claim 59 wherein the first corrugated metal wire core comprises a different gauge metal wire than the second corrugated metal wire core.

64. The building of claim 59 wherein the wall panels comprise edges and grooves in the edges, and wherein the wall panels are joined to one another with adhesive and with a foam member extending between grooves in adjacent wall panels.

65. The building of claim 59 wherein the roof panels comprise edges and grooves in the edges, and wherein the roof panels are joined to one another with adhesive and with a foam member extending between grooves in adjacent roof panels.

66. The building of claim 59 further comprising: an angled spacer between at least one of the individual roof panels and at least one of the individual wall panels.

67. The building of claim 66 wherein the angled spacer comprises a sloped portion configured to underlay a surface of the at least one of the individual roof panels; wherein the sloped portion is attached to a receiver portion configured to receive a top of the at least one wall panel therein; and wherein the top of the wall panel is received within said receiver portion.

68. The building of claim 67 wherein the angled spacer further comprises an extension between the receiver portion and the sloped portion, the extension having a notch cut into it to distribute a weight of the roof portion.

69. The building of claim 67 further comprising: a fastener extending through the sloped portion to the second corrugated metal wire core of the at least one roof panel, the fastener comprising a bolt and a fastener spacer surrounding the bolt, the bolt comprising a hook configured to grasp the second corrugated metal wire core, the bolt comprising a threaded extension configured to extend beneath the sloped portion of the angled spacer, the fastener spacer comprising a pair of flanged ends, a first of the flanged ends being configured to support the second corrugated metal wire core of the at least one roof panel, a second of the flanged ends being configured to butt against the sloped portion of the angled spacer; and a nut threaded on the threaded extension of the bolt to fasten the roof panel to the angled spacer.

70. The building of claim 59 further comprising: a support beam across a center of the building, the support beam being configured to support a center of the roof, the roof panels being supported by the support beam and the wall panels; at least one first angled spacer between the roof panels and the wall panels; and at least one second angled spacer between the support beam and the roof panels.

71. The building of claim 70 wherein the building comprises opposing sides, wherein separate roof panels supported by walls at different opposing sides meet at the support beam, and wherein a gap is formed between the separate roof panels and overlaying the support beam, the building further comprising: a low density material substantially filling the gap; and a roofing plate covering the low density material and the substantially filled gap.

72. The building of claim 59 further comprising: a trough over a supporting surface and in a shape which defines a periphery of the building; and wherein the wall panels are supported on edge within the trough to form the building walls.

73. The building of claim 59 further comprising: a cementitious material over the building walls.

74. A building comprising: a plurality of wall panels individually comprising a corrugated metal wire core completely encapsulated between end caps and within a low density material; the wall panels being abutted side-by-side to form a building wall; a cavity in the wall, the cavity not extending through the corrugated metal wire core; and electrical wiring within the cavity, the electrical wiring extending between at least two electrical components.

75. The building of claim 74 wherein the at least two electrical components are both attached to the wall panels.

76. The building of claim 74 further comprising: a plurality of roof panels forming a roof above the wall panels, the plurality of roof panels comprising individual roof panels, the individual roof panels comprising a second corrugated metal wire core completely encapsulated between second end caps and within a second low density material; a second cavity in at least one of the roof panels, the second cavity not extending through the second corrugated metal wire core; and electrical wiring within the second cavity, the electrical wiring extending between at least two electrical components.