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Patent 3191460 Summary

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Claims and Abstract availability

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(12) Patent Application: (11) CA 3191460
(54) English Title: SYSTEMS AND METHODS FOR SEALING A PREFABRICATED PANEL
(54) French Title: SYSTEMES ET PROCEDES POUR SCELLER UN PANNEAU PREFABRIQUE
Status: Application Compliant
Bibliographic Data
(51) International Patent Classification (IPC):
  • B32B 3/08 (2006.01)
  • B32B 13/00 (2006.01)
  • B32B 37/00 (2006.01)
  • B32B 38/00 (2006.01)
  • E4C 2/06 (2006.01)
  • E4C 2/288 (2006.01)
(72) Inventors :
  • DOMBOWSKY, BENEDICT JOHN (Canada)
  • DOMBOWSKY, MICHAEL ANTHONY (Canada)
  • DOMBOWSKY, BRADEN LOUIS (Canada)
  • DOMBOWSKY, MARK BENEDICT (Canada)
(73) Owners :
  • NEXII BUILDING SOLUTIONS INC.
(71) Applicants :
  • NEXII BUILDING SOLUTIONS INC. (Canada)
(74) Agent: OYEN WIGGS GREEN & MUTALA LLP
(74) Associate agent:
(45) Issued:
(86) PCT Filing Date: 2021-08-12
(87) Open to Public Inspection: 2022-02-17
Availability of licence: N/A
Dedicated to the Public: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): Yes
(86) PCT Filing Number: 3191460/
(87) International Publication Number: CA2021051112
(85) National Entry: 2023-02-10

(30) Application Priority Data:
Application No. Country/Territory Date
63/065,366 (United States of America) 2020-08-13

Abstracts

English Abstract

Example embodiments of the described technology provide a prefabricated building panel. The prefabricated building panel may comprise an insulative core having first and second opposing faces. The prefabricated building panel may also comprise a cementitious layer covering one of the first and second opposing faces of the insulative core. The prefabricated building panel may also comprise a first interface between the insulative core and the cementitious layer. A sealing cap extending longitudinally along at least a portion of one edge surface of the panel may seal the interface.


French Abstract

Des exemples de modes de réalisation de la technologie décrite concernent un panneau de construction préfabriqué. Le panneau de construction préfabriqué peut comprendre un noyau isolant ayant des première et seconde faces opposées. Le panneau de construction préfabriqué peut également comprendre une couche cimentaire recouvrant l'une des première et seconde faces opposées du noyau isolant. Le panneau de construction préfabriqué peut également comprendre une première interface entre le noyau isolant et la couche cimentaire. Une coiffe d'étanchéité s'étendant longitudinalement le long d'au moins une partie d'une surface de bord du panneau peut sceller l'interface.

Claims

Note: Claims are shown in the official language in which they were submitted.


WHAT IS CLAIMED IS:
1. A prefabricated building panel, the panel comprising:
an insulative core having first and second opposing faces;
a first cementitious layer covering the first face of the insulative core;
a first interface formed between the first cementitious layer and the
insulative
core; and
a sealing cap extending longitudinally along at least a portion of an edge
surface of the panel, the sealing cap at least partially sealing the first
interface.
2. The panel of claim 1 wherein the sealing cap comprises a membrane.
3. The panel of claim 2 wherein the membrane comprises a waterproof
membrane.
4. The panel of claim 3 wherein the waterproof membrane is breathable.
5. The panel of any one of claims 2 to 4 wherein the membrane comprises an
upper
and a lower surface, the lower surface of the membrane in contact with the
edge
surface of the panel and wherein the lower surface of the membrane comprises
an adhesive.
6. The panel of any one of claims 2 to 5 wherein the membrane has a
thickness of
less than 5mm.
7. The panel of any one of claims 2 to 6 wherein the membrane wraps over at
least
one face of the insulative core.

8. The panel of claim 7 wherein the membrane wraps over the at least one
face of
the insulative core by an amount in the range between 0.25 inches and 2
inches.
9. The panel of claim 7 or claim 8 further comprising a sealant, the
sealant sealing
an interface formed between the membrane and the first cementitious layer.
10. The panel of claim 9 wherein the sealant comprises caulking.
11. The panel of claim 1 wherein the sealing cap comprises a liquid seal,
the liquid
seal covalently bonded to one or both of the insulative core and the first
cementitious layer.
12. The panel of claim 1 wherein the sealing cap comprises a fiberglass
cap.
13. The panel of any one of claims 1 to 12 further comprising:
a second cementitious layer covering the second face of the insulative core;
and
a second interface between the second cementitious layer and the insulative
core;
wherein the sealing cap at least partially seals the second interface.
14. The panel of any one of claims 1 to 12 further comprising:
a second cementitious layer covering the second face of the insulative core;
a second interface between the second cementitious layer and the insulative
core; and
16

a second sealing cap, the second sealing cap at least partially sealing the
second interface.
15. The panel of any one of claims 1 to 14 wherein the sealing cap extends
along at
least three edge surfaces of the panel.
16. The panel according to any one of claims 1 to 15 further comprising:
an opening for receiving at least one of a window and a door; and
an opening sealing cap, the opening sealing cap extending longitudinally
along at least a portion of one edge surface which defines the opening, the
opening sealing cap sealing the edge surface.
17. The panel according to claim 16 wherein the opening sealing cap extends
longitudinally along all of the edge surfaces which define the opening.
18. The panel according to any one of claims 1 to 17 wherein the sealing
cap
substantially prevents moisture from penetrating into the panel.
19. The panel according to any one of claims 1 to 18 wherein the sealing
cap
substantially prevents one or more pests from penetrating into the panel.
20. A method for fabricating a prefabricated panel, the method comprising
applying a
sealing cap at least partially along at least one edge surface of the panel,
the
sealing cap sealing at least one interface formed between an insulative core
of
the panel and a cementitious layer which covers a surface of the insulative
core.
21. The method of claim 20 wherein the sealing cap is wrapped along the
insulative
17

core prior to casting the cementitious layer.
22. Apparatus having any new and inventive feature, combination of
features, or sub-
combination of features as described herein.
23. Methods having any new and inventive steps, acts, combination of steps
and/or
acts or sub-combination of steps and/or acts as described herein.
18

Description

Note: Descriptions are shown in the official language in which they were submitted.


CA 03191460 2023-02-10
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SYSTEMS AND METHODS FOR SEALING A PREFABRICATED PANEL
Cross-Reference to Related Applications
[0001] This application claims priority from US Application No. 63/065366
filed 13 August
2020 and entitled SYSTEMS AND METHODS FOR SEALING A PREFABRICATED
PANEL which is hereby incorporated herein by reference for all purposes. For
purposes
of the United States of America, this application claims the benefit under 35
U.S.C. 119
of US application No. 63/065366 filed 13 August 2020 and entitled SYSTEMS AND
METHODS FOR SEALING A PREFABRICATED PANEL.
Field
[0002] This invention relates to building panels and in particular
cementitious
prefabricated building panels such as Concrete Structural Insulated Panels.
Example
embodiments provide systems and methods for achieving desired performance
characteristics.
Background
[0003] Constructing a building is typically an extensive project involving
significant
amounts of time and/or resources (labour, energy, materials, etc.). Moreover,
the carbon
footprint of a building built using existing systems and methods can be large.
[0004] Reducing the amount of time and/or resources required to construct a
building
can be desirable. Reducing the carbon footprint of a building can also be
desirable. With
more environmentally stringent building codes being passed regularly, reducing
the
amount of resources used to construct a building and the carbon footprint of
the building
is increasingly becoming a requirement to be in compliance with new building
codes.
[0005] One way the amount of time and/or resources required can be reduced is
by
constructing the building using prefabricated panels. Existing prefabricated
panels
however are heavy, cannot provide the required performance characteristics,
etc.
Additionally, existing prefabricated panels may be difficult to maneuver into
place and to
couple together.
[0006] There remains a need for practical and cost effective ways to construct
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prefabricated building panels using systems and methods that improve on
existing
technologies.
Summary
[0007] This invention has a number of aspects. These include, without
limitation:
= prefabricated panels comprising a sealing cap for achieving desired
performance
characteristics of a prefabricated panel;
= methods for constructing a prefabricated panel.
[0008] Further aspects and example embodiments are illustrated in the
accompanying
drawings and/or described in the following description.
Brief Description of the Drawings
[0009] The accompanying drawings illustrate non-limiting example embodiments
of the
invention.
[0010] Figure 1 is a schematic cutaway perspective view of a prefabricated
panel
according to an example embodiment of the invention.
[0011] Figure 2 is a partial cross-sectional view of a prefabricated panel
according to an
example embodiment of the invention.
[0012] Figure 3A is a partial cross-sectional view of a prefabricated panel
according to an
example embodiment of the invention.
[0013] Figure 3B is a partial cross-sectional view of a prefabricated panel
according to an
example embodiment of the invention.
[0014] Figure 4 is a partial cross-sectional view of a prefabricated panel
according to an
example embodiment of the invention.
[0015] Figure 5 is a block diagram illustrating a method according to an
example
embodiment of the invention.
Detailed Description
[0016] Throughout the following description, specific details are set forth in
order to
provide a more thorough understanding of the invention. However, the invention
may be
2

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practiced without these particulars. In other instances, well known elements
have not
been shown or described in detail to avoid unnecessarily obscuring the
invention.
Accordingly, the specification and drawings are to be regarded in an
illustrative, rather
than a restrictive sense.
[0017] One aspect of the invention provides a prefabricated building panel.
The
prefabricated building panel comprises an insulative core. The insulative core
has
opposing faces. In currently preferred embodiments, cementitious material
covers at
least one of the opposing faces. A sealing cap may seal an interface (or
interfaces)
formed between the cementitious material and the insulative core.
Additionally, or
alternatively, the sealing cap may seal edges of the insulative core. The
sealing cap may
prevent (or reduce the likelihood of) moisture from penetrating into the core
of the panel
from outside, prevent (or reduce the likelihood of) pests such as insects
(e.g. ants,
termites, etc.), rodents (e.g. mice, rats, etc.), snakes, etc. from
penetrating into the core
of the panel and/or the like.
[0018] Figure 1 is a schematic cutaway perspective view of an example panel 10
according to an embodiment of the invention. Panel 10 has opposing faces 10A
and 10B.
A set of panels 10 may be used to construct a building, to insulate an
existing building
and/or the like. Preferably, panels 10 are plant finished (e.g. fully
manufactured at a
factory). Panels 10 may preferably be easily and quickly shipped to a
construction site
(e.g. on a flatbed truck, within shipping containers, on railway cars, etc.).
Panels 10 may,
for example, comprise wall panels, roof panels, floor panels, foundation
panels, etc.
Once panels 10 arrive at the construction site they may be easily and quickly
assembled
together.
[0019] Panel 10 comprises an insulative core 12. lnsulative core 12 provides
thermal
insulation for panel 10. lnsulative core 12 may also at least partially
structurally support
panel 10. lnsulative core 12 may also at least partially dampen sound
transmission
through panel 10. lnsulative core 12 preferably comprises a single piece of
insulation.
However, this is not necessary in all cases. In some embodiments insulative
core 12 is
made of two or more pieces of insulation.
[0020] Cementitious layers 13 and 14 cover surfaces of insulative core 12 of
example
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panel 10. Cementitious layer 13 corresponds to face 10A of panel 10.
Cementitious layer
14 corresponds to face 10B of panel 10. Cementitious layers 13 and 14 are
coupled to
insulative core 12. In some embodiments cementitious layers 13 and 14 are wet-
bonded
to the surfaces of insulative core 12 (e.g. the cementitious layers "self-
adhere" to the
faces of insulative core 12). The "wet-bonding" may provide an adhesive
chemical bond
directly between two surfaces that are to be coupled together (e.g. a face of
the
insulative core and a cementitious layer).
[0021] Optionally, panel 10 may comprise one or more structural elements 15.
The one
or more structural elements 15 may be configured to increase structural
strength of panel
10. For example, the one or more structural elements 15 may comprise (non-
limiting):
= a steel frame (e.g. a hollow structural section ("HSS") frame, one or
more !-
beams, etc.);
= a cementitious frame (e.g. a frame comprising at least one cementitious
material);
= a reinforced cementitious frame (e.g. a cementitious frame comprising
reinforcing
members such as re-bar, wire mesh, etc.);
= etc.
[0022] In some embodiments structural elements 15 extend around an entire
periphery
of panel 10. In some embodiments structural elements 15 extend only partially
around a
periphery of panel 10. For example, structural elements 15 may extend at least
partially
along one, two or three edges of panel 10. In some embodiments structural
elements 15
comprise at least one cementitious material that is identical to a
cementitious material of
one or both of cementitious layers 13 and 14.
[0023] An interface 16, such as an interface 16A or 16B, may be formed between
surfaces of a cementitious layer and insulative core 12 where the cementitious
layer
meets insulative core 12. Example panel 10 shown in Figure 1 comprises two
cementitious layers (e.g. cementitious layers 13 and 14). Interfaces 16A and
16B
(collectively interfaces 16) may be formed between cementitious layers 13 and
14 and
insulative core 12 respectively. Interface 16A may be formed between
cementitious layer
13 and insulative core 12 (e.g. where cementitious layer 13 meets insulative
core 12).
Interface 16B may be formed between cementitious layer 14 and insulative core
12 (e.g.
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where cementitious layer 14 meets insulative core 12).
[0024] A sealing cap 17 extends longitudinally along one or more edge surfaces
of panel
10. Sealing cap 17 may seal one or more interfaces 16 of panel 10. By sealing
the one or
more interfaces 16 of panel 10, sealing cap 17 may advantageously provide a
barrier
preventing (or reducing the likelihood of) moisture entering panel 10 via the
one or more
interfaces 16. Additionally, or alternatively, sealing cap 17 may direct
moisture away from
the one or more interfaces. Additionally, or alternatively, sealing cap 17 may
prevent (or
reduce the likelihood of) pests penetrating into insulative core 12 or other
components of
panel 10.
[0025] In some cases sealing cap 17 may prevent (or reduce the likelihood) of
edges of
panel 10 being damaged. For example, if panel 10 is to be used as a floor
panel, edges
of such panel 10 may be surrounded or covered by sealing cap 17. This may
advantageously prevent (or reduce the likelihood of) the edges of panel 10
being
damaged with, for example, chips, dents, etc.
[0026] In some embodiments sealing cap 17 provides an aesthetic feature. For
example,
covering edges of a panel with sealing cap 17 may give the panel a clean look
that is
visually pleasing.
[0027] Example panel 10 shown in Figure 1 comprises a sealing cap 17 extending
along
three surface edges of panel 10 (e.g. the top and two side edge surfaces of,
for example,
a vertical wall panel). However, sealing cap 17 may extend along any number of
edge
surfaces of a panel 10. What edge surfaces sealing cap 17 extends along may
depend
on an intended use of a panel 10. For example, sealing cap 17 may extend along
all
edge surfaces of a panel 10 intended to be used as a floor panel, a roof
panel, etc. In
some embodiments sealing cap 17 extends along edge surfaces which may be part
of a
vertical moisture flow path (e.g. paths along which moisture may flow from top
to
bottom).
[0028] Sealing cap 17 may be directly coupled to insulative core 12 and
cementitious
layers 13, 14.
[0029] In some embodiments sealing cap 17 is covalently bonded to insulative
core 12
and/or one or both of cementitious layers 13, 14. Sealing cap 17 may, for
example, be

CA 03191460 2023-02-10
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applied to one or more edge surfaces of panel 10 in liquid form (e.g. using a
roller, a
spray system, etc.). In such cases sealing cap 17 may be referred to as a
"liquid seal".
The liquid seal may, for example, comprise a two-part liquid applied membrane,
a single-
part liquid applied membrane and/or the like.
[0030] In some embodiments sealing cap 17 comprises a waterproof membrane that
may be adhered to the edges of panel 10. In some embodiments the membrane is
breathable. The membrane may, for example, comprise an adhesive (e.g. on one
side of
the membrane), may be bonded to panel 10 using a bonding agent and/or the
like. In
currently preferred embodiments the membrane cannot be penetrated by pests as
described elsewhere herein. In some embodiments the membrane has a thickness
less
than 5mm. In some embodiments the membrane has a thickness less than 3mm.
[0031] In some embodiments sealing cap 17 comprises a fiberglass cap. The
fiberglass
cap may be fabricated to mirror corresponding edge surfaces of panel 10. The
fiberglass
cap may advantageously increase structural strength of the panel.
[0032] In some embodiments sealing cap 17 comprises building wrap, a "Peel and
Stick"
membrane, stucco, stucco with embedded reinforcing members (such as mesh),
etc.
[0033] In some embodiments sealing cap 17 comprises reinforcing members. For
example, sealing cap 17 may comprise a reinforcing mesh or fibers embedded
within
sealing cap 17 (e.g. embedded within the liquid seal, embedded within the
membrane,
etc.).
[0034] Sealing cap 17 may extend laterally on either side of an interface 16.
In some
embodiments sealing cap 17 extends laterally at least 0.25 inches from an
interface 16
on either side of the interface. In some embodiments sealing cap 17 extends
laterally at
least 0.5 inches from an interface 16 on either side of the interface. Sealing
cap 17 may
laterally extend on each side of an interface by the same or a different
amount.
[0035] Sealing cap 17 is typically low-profile. "Low-profile" means that
sealing cap 17
minimally affects the dimensions of panel 10. In some embodiments sealing cap
17 has
a thickness of at most 1/16th of an inch. In some embodiments sealing cap 17
has a
thickness of at most 1/8th of an inch.
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[0036] In some embodiments sealing cap 17 conforms to a shape (or shapes) of
the
edge (or edges) of panel 10 which will be covered by sealing cap 17.
[0037] Sealing cap 17 is preferably made of a material having a low thermal
conductivity.
The low thermal conductivity may reduce the likelihood of sealing cap 17
creating a
thermal bridge.
[0038] In some embodiments sealing cap 17 is flush with faces 10A and 10B of
panel 10
(e.g. sealing cap 17 extends along an entire width of an edge).
[0039] Portions of sealing cap 17 which seal the same edge of panel 10 may be
the
same or different. For example, the portions of sealing cap 17 which seal the
same edge
may all comprise uniform dimensions and/or properties (e.g. material
composition,
performance characteristics, etc.). In some embodiments different portions of
sealing cap
17 which seal the same edge may comprise non-uniform dimensions and/or
properties
(e.g. material composition, performance characteristics, etc.).
[0040] Portions of sealing cap 17 which seal different edges of panel 10 may
have the
same or different dimensions. Additionally, or alternatively, portions of
sealing cap 17
which seal different edges of panel 10 may have the same or different
properties (e.g.
material composition, performance characteristics, etc.).
[0041] Figure 2 is a partial cross-sectional view of an example panel 10 which
does not
comprise a structural element 15. As shown in Figure 2, sealing cap 17 may
extend
laterally along an edge surface of panel 10 from cementitious layer 13 to
cementitious
layer 14. However this is not necessary. In some embodiments sealing cap 17
extends
laterally only partially along one or more surface edges of panel 10.
Additionally, or
alternatively, it is not necessary that insulative core 12 and cementitious
layers 13 and/or
14 are flush.
[0042] In some embodiments sealing cap 17 wraps over faces of insulative core
12 (see
e.g. Figures 3A and 3B). This may reduce complexity of manufacturing such
panel 10
(e.g. sealing cap 17 may be wrapped around insulative core 12 prior to one or
more
cementitious layers being formed). In such embodiments a first surface of
sealing cap 17
may be bonded to insulative core 12 and a second opposing surface of sealing
cap 17
may be bonded to the cementitious layer (e.g. cementitious layer 13, 14). A
sealant 18
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may seal one or more interfaces formed between sealing cap 17 and the
cementitious
layers (see e.g. Figure 3B).
[0043] Sealant 18 may, for example, comprise a caulking and/or the like.
Sealant 18 may
provide a further barrier preventing (or reducing the likelihood of) moisture,
pests, etc.
from penetrating into panel 10 via an interface formed at the point where
sealing cap 17
meets surfaces of the cementitious layers (e.g. cementitious layers 13 and
14). Different
interfaces formed between sealing cap 17 and cementitious layers may be
covered by
the same sealant 18 or with different sealants 18.
[0044] In some embodiments sealing cap 17 wraps over faces of insulative core
12 by at
least 0.5 inches. In some embodiments sealing cap 17 wraps over faces of
insulative
core 12 between 0.25 inches and 2 inches.
[0045] In some embodiments sealing cap 17 comprises a plurality of sealing
caps. For
example, as shown in Figure 4, sealing cap 17 may comprise a sealing cap 17A
sealing
interface 16A and a sealing cap 17B sealing interface 16B. Sealing caps 17A
and 17B
may be the same or different. Sealing caps 17A and 17B may be like any sealing
cap
described elsewhere herein.
[0046] In some embodiments the outer surface of sealing cap 17 is smooth. In
some
embodiments the outer surface of sealing cap 17 is coarse. A coarse outer
surface may
assist with coupling, adhering, bonding, etc. another panel or components of a
panel to
sealing cap 17.
[0047] lnsulative core 12 and cementitious layers 13, 14 may have different
thermal
expansion properties. In currently preferred embodiments sealing cap 17 is
flexible
enough to adapt to the different rates of thermal expansion of panel 10 while
maintaining
its barrier(s) (e.g. moisture barrier, pest barrier, etc.).
[0048] Various forces may be exerted on panel 10 and sealing cap 17. In
currently
preferred embodiments sealing cap 17 is durable enough to withstand any forces
exerted
on sealing cap 17. For example, sealing cap 17 is preferably durable enough to
withstand forces exerted on sealing cap 17 during construction of panel 10,
transport of
panel 10, assembly of a building using panel 10, wind forces on an assembled
panel 10,
seismic forces, etc.
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[0049] In some embodiments an interface 16 comprises a recess between
insulative
core 12 and a cementitious layer (e.g. cementitious layer 13, 14 described
elsewhere
herein). Optionally, sealing cap 17 may partially extend into the recess. This
may
strengthen the coupling of sealing cap 17 to insulative core 12 and the
cementitious
layer. Additionally, or alternatively, this may increase the strength and/or
durability of
sealing cap 17. Additionally, or alternatively, this may increase the
reliability of the barrier
provided by sealing cap 17. Additionally or alternatively, this may increase
the strength of
the barrier provided by sealing cap 17.
[0050] In some embodiments panel 10 comprises an opening for receiving a
window,
door, etc. In such embodiments a sealing cap as described elsewhere herein may
extend
longitudinally along one or more edge surfaces of panel 10 which define the
opening.
Preferably, such sealing cap extends along all of the edge surfaces which
define the
opening.
[0051] Panel 10 may comprise at least one connector. The connector may
facilitate
coupling of the panel to a building, coupling of the panel to other panels,
maneuvering of
the panel during construction (e.g. provides an attachment point for a hoist,
etc.), etc.
Additionally, or alternatively, panel 10 may comprise one or more structural
elements
(e.g. structural elements 15) as described elsewhere herein. Sealing cap 17
may, for
example (non-limiting):
= seal an interface formed between the connector and/or structural frame
and other
components of panel 10;
= seal interfaces 16 prior to installation of the connector and/or
structural frame;
= at least partially waterproof the at least one connector;
= at least partially waterproof structural elements 15;
= at least partially waterproof connections of building members such as, a
chimney,
a vent, a hose bib, an electrical plug, a lighting fixture, etc.;
= etc.
[0052] In some embodiments the connector comprises at least one aperture for
receiving
a connecting element (i.e. an element used to couple the connector to another
component of the structure under construction). In some embodiments the
connector
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comprises a cavity through which the connecting element may be accessed (e.g.
to
couple a nut to the end of the connecting element). In some embodiments the
connector
is a hollow steel element (e.g. a hollow rectangular steel section). In some
embodiments
the connector is like the connector(s) described in US Patent Application No.
63/003,401
filed 1 April 2020 and entitled SYSTEMS AND METHODS FOR COUPLING
PREFABRICATED PANELS TOGETHER, which is hereby incorporated by reference for
all purposes.
[0053] In some embodiments panel 10 comprises utility and/or service lines
running
through panel 10 such as electrical lines, plumbing, HVAC ducting, gas lines,
central
vacuum lines, etc. The utility and/or service lines may be interconnected
between panels
and thereby may extend beyond a sealing cap 17 of a panel 10. In some
embodiments
sealing cap 17 seals an interface formed between the utility and/or services
lines and
insulative core 12 and/or cementitious layers 13, 14.
[0054] In some embodiments sealing cap 17 comprises one or more apertures
through
which the utility and/or service lines may extend through. A seal provided
between two
adjacent panels once the panels are coupled together may provide a sufficient
barrier
such that moisture, pests, etc. cannot enter a panel 10 through any such
apertures in
sealing cap 17.
[0055] lnsulative core 12 may be made of rigid foam insulation. In some
embodiments
insulative core 12 is made of expanded polystyrene (EPS), polyisocyanurate
(polyiso),
extruded polystyrene (XPS) and/or the like. In some embodiments insulative
core 12 is
made of mineral fiber rigid insulation. In some embodiments insulative core 12
is at least
3 inches thick. In some embodiments insulative core 12 is between 3 and 24
inches
thick.
[0056] lnsulative core 12 typically has an insulative R-value of about R4 per
inch. In
some embodiments insulative core 12 has an insulative R-value of at least R12.
In some
embodiments insulative core 12 has an insulative R-value of at least R96. In
some
embodiments insulative core 12 has an insulative R-value between R12 and R96.
[0057] Cementitious layers 13 and 14 may be made of the same or different
cementitious
materials. In some embodiments at least one cementitious material has a
density in the

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range of 5 to 35 MPA. In some embodiments at least one cementitious material
has a
density in the range of 35 to 90 MPA. In some embodiments at least one
cementitious
material has a density in the range of 90 to 200 MPA.
[0058] Although panel 10 has been shown as comprising two cementitious layers
(e.g.
cementitious layers 13 and 14) sealing cap 17 may be applied to other panels.
The other
panels may not necessarily comprise two cementitious layers. The other panels
may
comprise at least one interface (e.g. an interface 16 described elsewhere
herein)
between a cementitious layer made of a cementitious material and an insulative
core
(e.g. panels having a single cementitious layer, panels having at least one
cementitious
layer which partially extends over an edge surface of panel 10, etc.).
[0059] Another aspect of the invention provides a method for making a
prefabricated
panel as described herein.
[0060] Figure 5 is a block diagram showing an example method 30 for making a
panel
10.
[0061] In block 31 a form for casting a panel is prepared. The form may
comprise one or
more features to assist with extraction of a completed panel. Such features
may include
rounded interior corners, formwork that may be quickly uncoupled, etc.
[0062] In block 32 a panel is cast using the prepared form. Upon the panel at
least
partially being cured, the cast panel may then be extracted from the form.
[0063] In block 33 a sealing cap (e.g. sealing cap 17 described elsewhere
herein) is
coupled to the extracted panel. As described elsewhere herein, sealing cap 17
may be
applied to edge surfaces of the panel in liquid form using a roller, a spray
system or the
like. As another example sealing cap 17 may be bonded or adhered to edge
surfaces of
the panel (e.g. when sealing cap 17 comprises a membrane, fiberglass cap, etc.
as
described elsewhere herein).
[0064] In some embodiments sealing cap 17 is coupled to insulative core 12
prior to the
one or more cementitious layers of panel 10 being fabricated. For example, as
described
elsewhere herein a membrane may be adhered to one or more edges of insulative
core
12 prior to fabricating the cementitious layers. As another example, a
fiberglass cap may
11

CA 03191460 2023-02-10
WO 2022/032389 PCT/CA2021/051112
be coupled to one or more edges of insulative core 12 prior to fabricating the
cementitious layers.
[0065] In optional block 34, optional sealant (e.g. sealant 18 described
elsewhere herein)
may be applied to interfaces formed between sealing cap 17 and other
components of
panel 10.
[0066] In some embodiments the sealing cap is coupled to edge surfaces of
panel 10
using a "bottom-up" approach. In such embodiments the sealing cap may first be
coupled
to the lower most edge surfaces of the panel along which the sealing cap is to
extend. In
such embodiments the upper most edge surfaces of the panel along which the
sealing
cap is to extend may be coupled last. Portions of the sealing cap which extend
along
vertical (or generally vertical) edge surfaces of the panel may be coupled
from bottom to
top. Upper sections of the sealing cap may overlap lower sections of the
sealing cap.
Interpretation of Terms
[0067] Unless the context clearly requires otherwise, throughout the
description and the
claims:
= "comprise", "comprising", and the like are to be construed in an
inclusive sense,
as opposed to an exclusive or exhaustive sense; that is to say, in the sense
of
"including, but not limited to";
= "connected", "coupled", or any variant thereof, means any connection or
coupling,
either direct or indirect, between two or more elements; the coupling or
connection between the elements can be physical, logical, or a combination
thereof;
= "herein", "above", "below", and words of similar import, when used to
describe this
specification, shall refer to this specification as a whole, and not to any
particular
portions of this specification;
= "or", in reference to a list of two or more items, covers all of the
following
interpretations of the word: any of the items in the list, all of the items in
the list,
and any combination of the items in the list;
= the singular forms "a", "an", and "the" also include the meaning of any
appropriate
plural forms.
12

CA 03191460 2023-02-10
WO 2022/032389 PCT/CA2021/051112
[0068] Words that indicate directions such as "vertical", "transverse",
"horizontal",
"upward", "downward", "forward", "backward", "inward", "outward", "left",
"right", "front",
"back", "top", "bottom", "below", "above", "under", and the like, used in this
description
and any accompanying claims (where present), depend on the specific
orientation of the
apparatus described and illustrated. The subject matter described herein may
assume
various alternative orientations. Accordingly, these directional terms are not
strictly
defined and should not be interpreted narrowly.
[0069] For example, while processes or blocks are presented in a given order,
alternative
examples may perform routines having steps, or employ systems having blocks,
in a
different order, and some processes or blocks may be deleted, moved, added,
subdivided, combined, and/or modified to provide alternative or
subcombinations. Each
of these processes or blocks may be implemented in a variety of different
ways. Also,
while processes or blocks are at times shown as being performed in series,
these
processes or blocks may instead be performed in parallel, or may be performed
at
different times.
[0070] In addition, while elements are at times shown as being performed
sequentially,
they may instead be performed simultaneously or in different sequences. It is
therefore
intended that the following claims are interpreted to include all such
variations as are
within their intended scope.
[0071] Specific examples of systems, methods and apparatus have been described
herein for purposes of illustration. These are only examples. The technology
provided
herein can be applied to systems other than the example systems described
above.
Many alterations, modifications, additions, omissions, and permutations are
possible
within the practice of this invention. This invention includes variations on
described
embodiments that would be apparent to the skilled addressee, including
variations
obtained by: replacing features, elements and/or acts with equivalent
features, elements
and/or acts; mixing and matching of features, elements and/or acts from
different
embodiments; combining features, elements and/or acts from embodiments as
described
herein with features, elements and/or acts of other technology; and/or
omitting combining
features, elements and/or acts from described embodiments.
13

CA 03191460 2023-02-10
WO 2022/032389
PCT/CA2021/051112
[0072] Various features are described herein as being present in "some
embodiments".
Such features are not mandatory and may not be present in all embodiments.
Embodiments of the invention may include zero, any one or any combination of
two or
more of such features. This is limited only to the extent that certain ones of
such features
are incompatible with other ones of such features in the sense that it would
be
impossible for a person of ordinary skill in the art to construct a practical
embodiment
that combines such incompatible features. Consequently, the description that
"some
embodiments" possess feature A and "some embodiments" possess feature B should
be
interpreted as an express indication that the inventors also contemplate
embodiments
which combine features A and B (unless the description states otherwise or
features A
and B are fundamentally incompatible).
[0073] It is therefore intended that the following appended claims and claims
hereafter
introduced are interpreted to include all such modifications, permutations,
additions,
omissions, and sub-combinations as may reasonably be inferred. The scope of
the
claims should not be limited by the preferred embodiments set forth in the
examples, but
should be given the broadest interpretation consistent with the description as
a whole.
14

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

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Event History

Description Date
Letter Sent 2024-01-04
Inactive: Multiple transfers 2023-12-14
Letter sent 2023-03-03
Inactive: IPC assigned 2023-03-02
Inactive: IPC assigned 2023-03-02
Inactive: IPC assigned 2023-03-02
Inactive: IPC assigned 2023-03-02
Inactive: IPC assigned 2023-03-02
Request for Priority Received 2023-03-02
Priority Claim Requirements Determined Compliant 2023-03-02
Compliance Requirements Determined Met 2023-03-02
Inactive: IPC assigned 2023-03-02
Application Received - PCT 2023-03-02
Inactive: First IPC assigned 2023-03-02
Amendment Received - Voluntary Amendment 2023-02-10
National Entry Requirements Determined Compliant 2023-02-10
Application Published (Open to Public Inspection) 2022-02-17

Abandonment History

There is no abandonment history.

Maintenance Fee

The last payment was received on 2023-05-29

Note : If the full payment has not been received on or before the date indicated, a further fee may be required which may be one of the following

  • the reinstatement fee;
  • the late payment fee; or
  • additional fee to reverse deemed expiry.

Patent fees are adjusted on the 1st of January every year. The amounts above are the current amounts if received by December 31 of the current year.
Please refer to the CIPO Patent Fees web page to see all current fee amounts.

Fee History

Fee Type Anniversary Year Due Date Paid Date
Basic national fee - standard 2023-02-10 2023-02-10
MF (application, 2nd anniv.) - standard 02 2023-08-14 2023-05-29
Registration of a document 2023-12-14
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
NEXII BUILDING SOLUTIONS INC.
Past Owners on Record
BENEDICT JOHN DOMBOWSKY
BRADEN LOUIS DOMBOWSKY
MARK BENEDICT DOMBOWSKY
MICHAEL ANTHONY DOMBOWSKY
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
Documents

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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Cover Page 2023-07-17 1 46
Claims 2023-02-10 4 155
Claims 2023-02-09 4 91
Description 2023-02-09 14 641
Representative drawing 2023-02-09 1 33
Drawings 2023-02-09 4 90
Abstract 2023-02-09 2 71
Courtesy - Letter Acknowledging PCT National Phase Entry 2023-03-02 1 595
International search report 2023-02-09 4 180
Voluntary amendment 2023-02-09 6 217
National entry request 2023-02-09 6 191