Note: Descriptions are shown in the official language in which they were submitted.
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The present invention relates to a structural foam
panel and to a method of building which uses such panels.
BACKGROUND OF THY INVENTION
Particularly in North America where supplies of wood
remain plentiful, buildings are often constructed with a
framework of wooden studs and rafters. Insulation, for example
in the form of fiberglass belts, is seated between the studs,
the studs carrying the inside and outside wall&. Windows and
doorways aye framed with the studs. For the roof, the rafters
are covered for example with plywood, and then covered with a
waterproof covering, on top of which the exterior roofing
materials, such as shingles, are secured.
Such traditional construction of housing it labor
intensive, and requires considerable time before a building is
completely enclosed. This becomes a problem particularly in
winter months where it becomes desirable to weatherproof and
insulate a new building as quickly as possible. Many stages of
construction, including initial framing, insulting and
interior and exterior cladding, are required. Until a building
is completely framed and insulated, during the winter months,
it is defoliate to do much ox the interior work such as lazing
in of plumbing and electrical wiring, and finishing the
interior with drooling or the like.
Canadian Patent No. 1,116,371 of Lenin issued
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January 19, 1982, describes and illustrates a wall panel made
of rigid foam insulation having opposed, parallel, rectilinear
grooves on opposing outer surfaces for receiving the framing
members of a building. The framing members, when in position
in the grooves, are mechanically fastened together through the
insulation. This type of insulated wall construction is
advantageous, since it enables relatively speedy erection of a
building by permitting the sheeting and insulating to be
completed in one step. This type of wall panel however
requires grooves at its edges within which splints are fitted,
to secure adjacent panels together. These panels necessitate a
lateral movement of one panel towards the other to place the
first panel in final, juxtaposed position, beside the other,
and this lateral movement may not always be convenient since it
may be obstructed by the vertical studs, already in position in
the building, which are to be fitted into the corresponding
grooves on one side of the panel.
Other patents of general background interest,
describing and illustrating rigid foam panels for use in
construction, include Cenozoic Canadian Patent No. 1,049,217
issued February 27, 1979 {foam it secured to a rigid backing of
for example bonded wood excelsior: Slavic Canadian Patent No.
1,169,222 issued June 19, 1984 (describing width adjustable
expanded foam insulin panels to be inserted between studs in
a building): Chamberlain Canadian Patent No. 699,949 issued
December 15, lg64 (roofing panels made of insulation sandwiched
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between plywood or the like), and Gantner Canadian Patent No.
1,062,868 issued September 25, 1979 (insulation roof panels).
It is an object of the present invention to provide an
easy, fast and efficient method of constructing insulated walls
and roofs of buildings, and to provide panels winch will
achieve this end.
SUMMARY OF THE INV~NTIOM
According to the present invention there it provided a
structural panel of rigid insulating foam, the panel having
opposite planar surfaces. The panel has parallel first grooves
in one surface which receive and carry strapping, and parallel
second grooves in the other surface, which are perpendicular to
the first grooves, to receive portions of spaced parallel
building elements such as studs or rafters. The grooves in one
surface are of a depth not to intersect the grooves in the
other surface. The panel is of a thickness to maintain
structural integrity and rigidity of the panel despite the
grooves therein.
In a preferred embodiment of the present invention,
the sides of the first grooves are contoured to retain mating
strapping inserted therein against normal release in a
direction away from the corresponding panel surface. These
first grooves may for example be contoured with outwardly
flared sides with increasing depth in the panel or
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alternatively may be formed of pairs of cooperating linear
slots, the slots of each pair being downwardly inclined into
the panel away from each other. In this latter instance the
strapping would be normally of sheet metal having cooperating
arms insertable into the slots.
It is preferred to form the panels with a pair of
opposite edges parallel to each other and perpendicular to the
first grooves, these edges having join means extending along
Their lengths. The joint means comprise, for one of these
edges all outward extension fish with one face and a
projection at the end thereof towards the other face, to form a
groove between the projection of the main panel body. The
joint means for the other of these edges is of a similar shape
and size but has its outward extension flush with the other
face and its projection oriented towards the first-mentioned
face. The extensions, projections and grooves of each joint
means are formed so that the projection from one edge of one
panel is fleshly received in the joint means groove of an edge
of a panel with familiarly formed joint means when positioned
adjacent thereto. This feature permits adjacent panels, with
overlapping edges, to be seated into position on vertical
studs, without the need to move each adjacent panel laterally
into position with respect to the last-po~itioned panel.
Use of panels according to the present invention
permits construction of a wall, totally insulated with foam,
which is approximately three to seven times stronger than
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conventionally sheeted and Eibreglassed insulated walls. The
sheeting and insulating are completed in one step, the
strapping, being horizontal in walls, producing a uniform
rigidity to the wall as well as accommodating various kinds of
siding. Once the wall is standing, it is weatherproofed and
draft proofed to a large degree. The panels permit speedy
erection of walls and roofs and are significantly labor saving
in nature. During construction, the panels act as sway
bracing, adding increased sheer strength over conventional
methods of construction because the panels fit over existing
studs and rafters. additionally they permit less heat transfer
through the studs to the exterior of the building than most
traditional forms of construction.
BRIEF DESCRIPTION OF THE DRYING
These and other objects and advantages of the
invention will become apparent upon reading the following
detailed description and upon referring to the drawings in
which:
FIGURE 1 is a perspective side view, from the outside,
of a wall built using panels according is the present invention;
FIGURE 2 is a bottom view of a series of wall panels
being enlaced in position on studs;
FIGURE 3 is an enlarged, partial, section view of
adjacent panels of FIGURE 2, illustrating the overlapping joint
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between adjacent panels in accordance with the present
invention:
FIGURE is a transverse section view of a wall of a
building constructed using panels in accordance with the
present invention:
FIGURE 5 is an enlarged, partial, section view of a
portion of the wall of FIGURE 4 illustrating an example
embodiment of strapping used in conjunction with the panels in
accordance with the present invention:
FIGURE 6 is a perspective partial view of a panel
according to the present invention illustrating alternative
types of grooves for strapping
FIGURE 7 is a perspective view of a potion of roof
constructed using panels according to the present invention; and
FIGURE R is a section view, from the side, of a wall
and woof section constructed using panels in accordance with
the present invention.
While the invention will be described in conjunction
with example embodiments, it will be understood that it is not
intended to limit the invention to such embodiments. On the
contrary, it is intended Jo cover all alternatives,
modifications and equivalents as may be included within the
spirit and scope ox the invention as defined by the appended
claims.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, similar features in the
drawings have been given similar reference numerals.
Turning to the drawings, in FIGURE 1 -there is shown,
from the exterior, a wall ox a building constructed using
panels 2 in accordance with the present invention. These
panels 2 are made of rigid insulating foam, such as foamed
polystyrene, and haze opposite planar faces 4 and 6. The
panels are preferably of rectangular shape.
In planar surface 4 ore formed a plurality of parallel
grooves 8 to receive and carry strapping 10. Strapping 10 may
be carried in grooves 8, as illustrated in FIGURES 4 and 5, so
that it may be nailed as required to appropriate studs 12, or
alternatively, as illustrated in FIGURE 6, the sides of grooves
8 may be contoured so that they hem elves retain strapping 10
with appropriately formed and contoured edges. As can be seen
in FIGURE 6, one side 14 (or a required, both sides) of
grooves 8 may be contoured so that it flares outwardly with
increasing depth in the panel, in which case grooves 8 would
receive from the side a correspondingly formed trapping member
10, for example of wood. Alternatively, grooves 8 may consist
of cooperating pairs of linear slots 16, the slow 16 of each
pair being downwardly inclined into the panel away from each
other as illustrated in FIGURE 6. These pairs of slots retain
the cooperating arms 18 of mating strapping 10 which are
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inserted, from the side, into these slots. In this latter
case, the strapping members 10 may be made, for example, of
sheet metal, appropriately formed and shaped to fit into
grooves 16. In both cases illustrated in FIGURE 6, grooves 8
and 16 retain the strapping 10 against normal release in a
direction away from the corresponding panel surface 4.
In surface 6, on the interior of the wall section
illustrated in FIGURE 1, are formed a plurality of grooves 20
(scurvy contour, in most instances), to receive, as
illustrated in FIGURE 2, portions of studs 12. These grooves
20 are parallel to each other and run, through panels 2, in a
direction perpendicular to that of grooves 8. A vapor barrier
21 may be placed along studs 12, between the studs and the
panels 2, and held in position by the positioning of the panels
with the studs 12 inserted in groove 20. In this way little
or no stapling of the vapor barrier onto the studs, as is
required in conventional wall constructions, is needed. A
continuous vapor barrier, with no breaks along the partition
walls, may thus be provided very simply. As well, can be seen
in FIGURE 2, moisture from the external (panel) side of the
wall does not come into contact with the framing members (studs
12).
As can be seen in FIGURES 1 and 2, it is prey erred to
have the framing members or studs 12 extend outwardly from the
grooves 20 beyond the surface 6 of panels 2. This extension is
preferably at least 2 inches, to permit easy electrical and
plumbing installation, without danger of ripping vapor barrier
21. As well, this essentially creates a double wall system
enabling additional biotype insulation to be installed if
desired or a dead-air space, in which space the wiring and
plumbing can run, unobstructed, on this inner side of the vapor
barrier.
As can be appreciated, for example, in FIGURES 4 and
5, the thickness of panel 2 with respect to the depth of
grooves 8 and 20 is such that the grooves on opposite surfaces
of panels 2 do no intersect each other and the structural
integrity and rigidity of the panels are maintained despite the
presence of grooves 8 and 20 on opposite surfaces of the
panels.
Turning to FIGURES 2 and 6, the sides of each panel
lo which Lung parallel to grooves 20 are provided with joint means
22 which are intended to overlap with corresponding joint means
on the corresponding sides of adjacent panels, interconnect
therewith, and provide a seal to prevent or minimize passage of
moisture, drafts or heat. As can be clearly seen in FIGURE 6,
joint means 22 comprises an outward extension 24 flush with
surface 6, and projection 26 at the end thereof oriented
towards surface 4 of panel 2. This construction forms a groove
28 between the protection 24 and the main panel body extending
along the entire length of this particular side ox panel 2. At
the other side of panel 2 aye seen for example, in FIGURE 2),
and similarly extending long the entire length of that wide of
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the panel there is a corresponding joint means 2Z of a similar
shape and size but having its outward extension 24 flush with
surface 4 of panel 2 and its projection 26 oriented towards
surface 6. These extensions 24, projections 26 and grooves 28
of each joint means 22 on the panels are formed so that the
projections 26 from one side of one panel fleshly mate, as
illustrated for example in FIGURE 2, in the joint means groove
28 of the confronting edge of the adjacent panel 2. This
construction permits, as illustrated in FIGURE 2, the
progressive placement of panels 2 in position on studs 12, in
side-by-side arrangement, without the need for sideways or
lateral movement of a panel being placed into position, with
respect to the studs and panels already in position, as has
been from time~to-time the case with prior art constructions
using rigid foam panels.
A illustrated in FIGURE 3, the interior surfaces 30
of projections 26 may be provided with lips 32, near the upper
end of each of the projections Z6, to physically lock the joint
means 22 of adjacent panels in position. Otherwise, the panels
are locked into position merely by frictional engagement of the
projection 26 from one panel in the groove 28 of the adjacent
panel.
In using panels 2 generally in construction of
buildings, it will be appreciated that the grooves 8 and 20,
and particularly groove 20, may be formed on site, being
shaped and located as required for proper placement of studs 12
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within The grooves may be formed with a common industrial
router and an a~eropLiate router bit. This enables panels,
where stud centers are inconsistent, to be quickly custom-made
on site.
As will be understood from FIGURE l, holes for windows
and doors may be cut in the panels on site, to conform to the
required locations of doors and windows in the building as set
out by the studding in place. windows and doors are framed
oversexed in height and width and then boxed in with wood or
any other appropriate material flush to the outside so that the
windows and doors can be attached solidly.
Interior finishing of a building is carried out in a
traditional fashion when using panels 2 according to the
present invention, since the inner surface of studs lo are
normally exposed. Thus drywall or other interior finishing may
be secured directly to the studs or to s~rappillg fixed to the
studs.
The horizontal strapping lo makes it possible to us,
any vertical or angular siding. Horizontal siding for example
is simply adhered with longer fineries into studs 12, through
the strapping lo
Panels Z applied to a wall system in a conventionally
framed building are illustrated in the section view ox FIGURE
4. Appropriate header 40 and 42, trusses 44 and root rafter
46, floor joists 48 and filler panels 50 the latter glued and
nailed to seal all joint) are illustrated mounted on a
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foundation 52 which has been appropriately combined with rigid
insulation panels 54 extending up to the filler panels 50 as
shown. Vapor barrier 21 can be installed under and around the
floor joists I and up the wall as illustrated, as well as, if
required, around the roof trusses I thereby creating a
rip free continuous vapor barrier extending and enveloping the
entire interior of the s~ructvre. (This feature is almost
impossible to achieve with conventional building methods.)
Washer Ed insulation nails may be used to secure header I and
filler penal 50.
In actual construction of a wall section,
remanufactured "starter panels" are used to begin the
construction. These panels are specially cut for a corner stud
or a corner with a flat member for backing. Once in place, the
starter panel falls halfway into the first bay (between the
studs). The joint means 22 between panels is positioned
between stud, so that the next panel can slip in under the
existing one without hitting a stud. When adjacent panels are
engaged in position, a new panel it simply placed in position
over the studs and its locking means 22 fitted into engaged
position with the corresponding locking means 22 of the
adjacent panel already in position. Thus, the joint between
the panels is completed. Each panel it set into place one
after the other (FIGURE 2) until the end of the wall is
reached. The last panel is routed and cut to fit as required.
FIGURES 7 and 8 illustrate the application to roofing
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of panels 2 in accordance with the present invention. As
illustrated in FIGURES 7 and 8, panels 2 are supported on
rafters 46 (FIGURE 8), portions of these rafters being inserted
into appropriately positioned parallel grooves 20 on inner
surfaces 6 (FIGURE 7). Weatherproof sheeting 56 may be
appropriately fastened to strapping 10 on the exterior side of
panels 4 and shingles 58 are then secured on top thereof as
illustrated. Panels for the edges of the roof, at the ends of
the rafters and a the gables, are appropriately modified as
illustrated, in the former case to provide rafter tail
extensions I secured to side panels 2 by means of support
members 62 seated beneath strapping 10 in appropriate grooves
in the panels, and in the latter case to provide gable overhang
64 secured to edge panels 2 by means of support members 66 and
68 (FIGURE 7). It will be appreciated by one skilled in the
art that panels 2 significantly facilitate the construction of
a building's roof, avoiding the need for plywood paneling or
the like on top of the rafters before the application of
weatherproof sheeting 56 and shingles 58. Panels 2 permit
weatherproof sheeting 56 and shingles 58 to be secured directly
thereto, without the need for plywood, while, it the tame time,
providing insulation to the very top of the building. In other
words, the top cord of rafters 46 is insulated, unlike most
prior art building systems. Of course, the panels for the
roofing system would normally be much thicker than those for
the wall sections - for example a R-40 rating which might
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require approximately 9 1/4 inches of thickness of panels 2
while the exterior walls (erg. FIGURE 4) on the other hand might
be approximately 5 1/2 inches thick creating an R20 insulation
value in the walls.
Insulating the top cord of the truss or rafter, and
using that insulating as sheeting for the final roofing
material also saves hours of work in truss bracing and
preparation for sheeting. It also saves all the labor of
insulating the ceiling. Once the panels have been clipped
together and installed, the building is totally weather-proofed
and ready for temporary heat if necessary. A normal home, for
example could be heated or cooled after only two days of
framing time. Thus, the system according to the present
invention is ideal for construction in extreme weather
conditions as, for example, found in the Arctic.
The strength of a wall totally insulated with foam
panels according to the present invention is significantly
stronger than conventionally sheeted and fibreglass-insulated
walls. The use of horizontal strapping 10 in the manner stated
herein produces a uniform rigidity to the wall. As previously
indicated, panel Allah act as a sway brace, for both studs an
rafters. The rectilinear (or square) form of the panels
assists in ensuring the walls of the building are square.
The drawings depict only one kind of application of
the panels according to the present invention, and one building
system. It will be readily appreciated by one skilled in the
art however that the strapping system of the present invention
and the joint means of the panels can be used with any present
building system which requires sheeting and insulation over its
structural flaming. This therefore provides a wide variety of
uses and applications of the present invention, from light
residential to heavy commercial building, peaked or flat roof
systems, insulated floors, etc..
Thus it is apparent that there has been provided in
accordance with thy invention a panel construction system that
fully satisfies the objects, aims and advantages set forth
above. While the invention has been described in conjunction
with specific embodiments thereof, it is evident that many
alternatives, modifications and variations will be apparent to
those skilled in the art in light of the foregoing
description. Accordingly, it is intended to embrace all such
alternatives, modifications and variations as fall within the
spirit and broad scope of the invention.
