Note: Descriptions are shown in the official language in which they were submitted.
WO92/21836 2 ~ `' 7
PANEL BUILDING COMPONENT
Field of the Invention
The present invention relates to the field of modular
building components and, more particularly, to a panel which
5 achieves great insulation and strength with light weight by
being formed from a composite of materials that produce a
synergistic effect as a consequence of an interlocking
relationship and makes use of the highly specific ~ualities
of each material.
l0 Backqround of the Invention
Much of the construction of buildings in the
industrialized world, particularly in the United States, is
of two types, wood frame and various kincls of material,
including wood to cover the framework, or steel, usually
15 taken in combination with concrete in the form of prestressed
concrete for framing and a variety of other materials to
cover the same, frequently concrete block. On larger
buildings, a prestressed concrete frame may be covered by
glass, marble, stone, or the like. In all of the above
20 cases, insulation, which has become ever more important in an
increasingly energy conscience ~orld, is frequently supplied
as a separate layer interiorly of the outside structure
above-described. When the covering material is concrete
block, insulation in at least the exterior walls is
25 frequently omitted.
In order to achieve economies in the cost of
construction, various efforts have been made to utilize pre-
fabricated materials. Of course, the ultimate in pre-
fabrication is with mobile homes which are simply transported
30 to the residence site, and usually then permanently fixed to
a foundation. Other types of pre-fabricated or partially
pre-fabricated construction methods are also well known such
as A frame homes that are fre~uently used in rural areas as
vacation retreats. There have also been very sophisticated
35 structures such as geodesic dome type structures of a type
advocated by the well known American inventor Richard
Buckminster Fuller. Examples of United States patents of
this species either by Fuller or his associates are U.S.
WO92/21836 ~ PCT/~S92/04793
(~ 2
Patent No. 2,682,235 for a geodesic dome, U.S. Patent No.
2,881,717 for a paper board dome, U.S. Patent No. 2,905,113
for a plydome, U.S. Patent No. 2,914,074 for a catenary
(geodesic tent), and other similar references such as U.S.
5 Patent No. 3,063,521, U.S. Patent No. 3,139,957, U.S. Patent
No. 3,197,927, U.S. Patent No. 3,203,144, and U.S. Patent No.
3,810,33~.
Another reference which pursues l:he notion of a
building component utilizing a panel is Zeihbrunner, U.S.
10 Patent No. 4,646,502 which teaches a panel construction
element and building construction system employing such
elements. That reference illustrates a profile frame and a
filler material with cover panels that cover both the filler
material and the profile frame. The frame includes a complex
15 cross-section of a type fabricated using an extrusion, which,
in turn, leads to a substantially more expensive structure
than that provided by the present invention without the
interlocking advantages of the framing with the filler or
polymeric material of the present invention.
Similarly, efforts have been made to provide modular
building components which combine the coverage of area with
insulation benefits. Several of these include two patents to
Meyerson, U.S. Patent Nos. 4,769,963 and 5,086,599, both of
which involve utilizing an expanded polymeric material taken
in combination with aluminum sheet to produce a building
panel with excellent insulation properties in a light weight
construction component. To the extent that an expanded
polvmeric material is utiliæed in these references, they bear
some resemblance to the present invention. However, they
30 lack any significant structural strength because they are
merely the combination of flat and folded aluminum or similar
type material in combination with the expanded polymeric
material.
The present invention relates to a unique composite
35-assembly that may be utilized for the construction of walls,
roofs, and flooring,- for -a variety of structures and
buildings. The preferred materials are light gauge steel or
WO92/21836 ~ ~ 3 ' - ! PCT/US92/04793
structural strength in a ~ery specif ic interlocking
relationship with an expanded polymeric material such as
medium density polystyrene or polyurethane. The steel
provides strength in both tension and compression, while the
5 expanded polymeric material provides thermal and sound
insulation and substantial support in compression. The
combination, therefore, provides a structural strength that
is believed to be absent from the Meyerson references while
at the same time providing the high insulation effects that
lO these Meyerson references would be expected to provide, as
well as having the advantage of low cost resulting in part
from pre-fabrication and the ability to utilize the same in
combination with external and internal facing materials that
provide aesthetics, protection from the elements,
15 functionality, some additional insulation, and minimal
construction labor. Indeed, the present invention provides
an excellent substitute for concrete block when the same is
used with a prestressed concrete frame, and with the optional
exterior and/or interior surfaces, can also replace the
20 materials normally applied to the exterior and/or interior of
concrete block.
Summary of the Invention
Bearing in mind the foregoing, it is a principal object
of the invention to provide a panel building component that
25 is light weight, low cost, has strong insulation properties,
and excellent structural qualities.
Another object of the invention is to provide a panel
building component that cooperates with a plurality of
external and/or internal facing materials to produce an
30 attractive, functional, and fire resistant structure.
A further object of the invention is to provide a panel
building component that is suitable for the replacement of
concrete block construction.
A related object of the invention is to eliminate the
35 waste as caused by the use of concrete bïocks such as the
additional ten percent builders normally order for breakage
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WO92/21836 s~ PCT/US92/04793
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as well as the added waste when window and door openings are
not eliminated from estimates.
Another object of the invention is to provide a panel
building component which eliminates the need for tie beams,
5 columns, furring, and studs.
A further object of the invention is to provide a panel
building component which allows the finished materials to be
laminated directly to the wall surface in a pre-fabricated
format.
One more object of the invention is to reduce
construction site clean-up costs as is caused by block,
stucco, furring, tie beam and column work.
Another object of the invention is to reduce time
consuming and expensive inspections on columns and tie beams.
Yet another object is to provide a panel building
component which can be pre-~abricated using optimum matarials
assembled under plant controlled conditions because of its
pre-fabrication characteristics.
An additional object of the invention is to provide a
20 panel building component which can be mass produced in a high
productivity and quality controlled environment at minimum
cost.
A further object of the invention is to provide a panel
building component which can be finished in a manufacturing
25 plant with pre-installation of doors and windows which can be
pre-wired for electricity and other installations.
One more object of the invention is to provide a panel
building component which will not shrink, swell, or warp out
of its designed shape, and will be unaffected by climatic
30 changes, rot, or vermin.
Other objects and advantages of the present invention
will become apparent to those skilled in the art upon r
examination of the following detailed descriptions and the
drawings.
In accordance with the principal aspect of the present
invention, there is provided a panel building component
comprised of a combination of a rigid insulation core in a
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W09~/2l836 2 C ~ ~ 2 ~ r~
composite structure with a plurality of structural materials,
preferably steel. The steel members form a perimeter about
the rigid insulation core providing structural strength,
particularly taken in combination with the compressive
5 strength of the core and the tensional and compressive
strength of the structural members. These structural members
include vertical members which provide support in
compression, a cap member, a foot member, and optional
external and interior facing. The cap and foot members are
10 preferably in the form of a standard channel having a web
dimension that is substantially similar to the thickness of -~
the rigid insulation and can fit thereabout at the periphery
thereof.
Vertical members are fabricated using a ledge channel
15 cross-section, also having a web dimension substan~ially
similar to the thickness of the rigid insulation and flanges
of sufficient dimension for the purpose presently described.
At the ends of the flanges are ledges which are disposed in
engaging relationship and obedience to grooves in the rigid
20 insulation. The ledges are disposed in engaging relationship
with said grooves to ~orm a structure that exceeds the
strength of both the steel and the rigid insulation producing
column of integral, but composite configuration referred to
as integral co~posite columns. The structural members
25 forming the perimeter about the rigid insulation core are
attached to each other using conventional fastening means
such as by welding, or using screws or the like.
The invention will be better understood upon reference
to the following detailed description and the drawings in
30 which:
Brief DescriPtion of the Drawinqs
Figure 1 is a perspective partially broken away view
of the panel building component.
Figure 2 is a perspective view of the rigid insulation
35 core illustrating: in- exploded relationship one -vertical--
member and one foot member from which the panel building
component is constructed.
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W092/2]836 PCT/US92/04793
~ ~igure 3 show a partially ~roken away wall constructed
of the panel building component and illustrating the
disposition of window and door openings.
Detailed Description of Preferred Embodiment
Figure 1 illustrates in perspective view the in~entive
panel building component. A rigid insulation core 2 is
preferably ~ormed of an expanded polystyrene or similar
expanded polymeric material, sometimes referred to as foam,
having a high insulative characteristic and substantial
10 strength in compression. The rigid insulation core 2 is
surrounded about its periphery by a plurality of structural
members including vertical members 4, a cap member 6, and a
foot member 8. These structural members about the perimeter
of rigid insulation core 2 may be attached at their
15 intersections by conventional fastening means such as by
welding or by at least one screw 30~
Optionally disposed in laminated association with the
panel is an external facing 10 such as siding, reflective
glass, a simulated stucco material, or the like. Such
20 material can provide substantial aesthetics as well as add
additional support and possible also insulative effects.
Also shown is an optional internal facing material, such as
a gypson panel 12. Following installation of the panel in a
construction site, ~allpaper, paint, or other decorative
25 materials may be readily applied to optional interior facing
12. Interior facing 12 is also preferably a fire resistant
material, typically a five-eighths inch gypson drywall having
a finish rating of not less than sixty minutes. In fact,
because of the importance of this feature for previously
30 obtained approvals from code and other governmental agencies,
the optional interior facing is shown disposed within the
flanges of the cap and foot members, although the same may
certainly be disposed in a laminated relationship exteriorly
of these ~langes.
Of greatest significance concerning this invention is
the efficiency of materials in creating a load bearing
building component of great strength and light weight. The
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W092/21836 PCT/US92/04793
interlocking aspects of the vertical members with lateral
portions of rigid insulation produce integral composite
columns having great strength.
Figure 2 shows the unadorned rigid insulation 2 after
5 the same has been embossed with rigid insulation grooves 28
which are shown in four locations. These rigid insulation
grooves are dispos~d to receive in engaging relationship
portions of the vertical member 4 as hereinafter described.
Turning first to the foot member 8, it will be seen
10 that in cross-section the foot member 8 has a standard
channel 14 having a standard channel web 16 and standard
channel flanges 18.
The vertical member 4 has a ledge channel cross-section
20 having a ledge channel web 22, ledge channel flanges 24
15 terminating in ledges 26. Ledges 26 are intended to be
disposed in engaging relationship with rigid insulation
grooves 28 when vertical member 4 i5 assembled with rigid
insulation 2 to produce the integral composite columns having
great strength. This great strength is achieved because the
20 integral composite column thereby created utilizes the
advantage of the compressive strength of the rigid insulation
material to maintain the positional integrity of the light
gauge steel of the vertical member 4, thereby avoiding
lateral deflection thereof. In a complimentary manner, the
25 light gauge steel prevents buckling of the lateral portions
of the rigid insulation disposed within the ledge channel
cross-section of the vertical members 4. Simultaneously, the
lateral portions of the rigid insulation disposed within
vertical members 4 remain integral with the remainder of the
30 rigid insulation core that forms the central portion of the
panel. Similar strength advantages are achieved with the cap
member 6 and foot member 8, but the strength of the integral
composite column is not ordinarily needed in the horizontal
direction. - - -
In special applications, the ledge channel
configuration may be employed for the cap member 6 and/or
foot member 8 as required. In such event, the rigid
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WO92/21836 ~j ~ PCT/US92/04793
C~ ';J i ._~
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insulation 2 would be furnished with corresponding grooves to
achieve an engaging relationship with the ledges to be added
to the cap member 6 and/or foot member 8.
Turning to figure 3, there is shown in partially broken
5 away view a wall constructed using the panel building
component. Illustrated therein particularly is an door
opening 32 and a window cut-out 34 which window cut-out is
shown only in the external facing 10. The rigid insulation
2 is undercut to show the relationship thereof with vertical
10 members 4. Also undercut is internal facing 12 and cap
member 6. Also seen is the edge of foot member 8. Although
the door and window are not illustrated, it will be readily
appreciated that said items can be installed into the
inventive panel building component at the f actory
15 manufacturing site.
Of particular interest in this f igure is the
utilization of three vertical members 4 in a single panel.
Such panels are frequently four feet wide by eight feet high,
although other dimensions are within the contemplation of the
20 inventor. Depending upon the strength requirements for a
particular edifice including those imposed by local building
codes, it is appropriate to use more than two integral
composite columns in a single panel. For example, in a
location where a wall would ordinarily have studs on two foot
25 centers, the same spacing can be achieved by using one
additional integral composite column two feet from either
lateral edge of a four foot wide panel. Figure 3 illustrates
how this is accomplished.
Careful examination of figure 3 also shows the
30 interrelationship of the rigid insulation 2 with the channel
ledges 26 which are disposed within rigid insulation grooves
28. The width of the ledge channel web 22 and the standard
channel web 16 is seen to be substantially equivalent to the
thickness of rigid insulation 2. -;
Having described the presently preferred-embodiments
of the invention, it should be~ understood that various
,
changes in construction and arrangement will be apparent to
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those ~killed in the art and fully contemplated herein
without departing from the true spirit of invention.
Accordingly, there is covered all alternatives, modifications
and equivalents as may be included within the spirit and
5 scope of the invention as defined in the appended claims.
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