PANNEAU DE CONSTRUCTION LEGER ET SYSTEME DE CONSTRUCTION COMPRENANT DES COMPOSANTS LEGERS

LIGHTWEIGHT BUILDING PANEL AND BUILDING SYSTEM COMPRISING THE SAME

Abrégé français

Linvention concerne un système de panneau de construction modulaire. Le système de panneau de construction modulaire comprend des composants qui sont légers, polyvalents et rentables. Les panneaux de construction sont configurés et/ou traités pour retarder les flammes, résister au feu, à leau, aux rongeurs et/ou à la moisissure. Des trousses et des composants individuels du système sont également décrits.

Abrégé anglais

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

Revendications

THE EMBODIMENTS OF THE INVENTION FOR WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1 . A building panel comprising:
an expanded polystyrene (EPS) foam sheet; and
a plurality of metal studs; wherein each metal stud is generally a squared U-
shape and
comprises two arms and a base; wherein the arms of each metal stud are
inserted in the EPS
foam and wherein metal studs are inserted into both sides of the EPS foam
sheet.
2. The building panel of claim 1, wherein the metal studs are inserted into a
first side of the
EPS foam sheet are offset from the metal studs inserted into a second side of
the EPS foam
sheet.
3. The building panel of claim 1 or 2, wherein the EPS foam type 1 EPS foam.
4. The building panel of any one of claims 1 to 3, wherein the metal studs are
manufactured
from galvanized steel.
5. The building panel of any one of claims 1 to 4, wherein the studs extend
into the foam sheet
less than 20%, 30%, 40% or 50% of the total width of the EPS foam sheet.
6. The building panel of any one of claims 1 to 5, wherein the building panel
has a groove along
at least two edges to facilitate attachment to an adjacent panel.
7. The building panel of any one of claims 1 to 6, comprising a cut out for a
window or door.
8. The building panel of any one of claims 1 to 7, comprising a cut out or
recess.
9. The building panel of any one of claims 1 to 8, configured for a sill.
10. The building panel of any one of claims 1 to 6, configured as a roof
panel.
11. The building panel of any one of claims 1 to 6, configured as a floor
panel.
12. A kit comprising a plurality of building panels of any one of claims 1 to
11.
6
Date Recue/Date Received 2021-03-29

Description

MBM File No. 3726-103
LIGHTWEIGHT BUILDING PANEL AND BUILDING SYSTEM COMPRISING THE SAME
FIELD OF THE INVENTION
[001] This invention pertains generally to building panels and construction
methods using
building panels and in particular, rodent proof, mould proof, non-combustible,
pre-designed light
weight building panels.
BACKGROUND OF THE INVENTION
[002] Building panels are well known in the art as a way of making walls
and/or partition
spaces in a building. Building panels can be used to assembly walls quickly
and can facilitate
the construction of buildings, including portable buildings in remote
locations.
[003] Remote communities may have unique challenges due to harsh climates and
lack of or
limited public infrastructure. These challenges include water damage that may
result in mould
growth, fire damage, structural deterioration from harsh climate conditions
resulting in a need for
regular significant repair or rebuild of buildings. Other challenges to remote
communities
include the challenges resulting from the remote, often hard to access
locations. These
challenges result in delays in both repairs to existing buildings and the
construction of new
buildings. These challenges are exasperated where building materials must be
airlifted into the
communities.
[004] This background information is provided for the purpose of making known
information
believed by the applicant to be of possible relevance to the present
invention. No admission is
necessarily intended, nor should be construed, that any of the preceding
information constitutes
prior art against the present invention.
SUMMARY OF THE INVENTION
[005] An object of the present invention is to provide a lightweight building
panel and building
system comprising the same. In accordance with an aspect of the present
invention, there is
provided a lightweight building panel and building system comprising the same.
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MBM File No. 3726-103
[006] In accordance with another aspect of the invention there is provided a
building panel
comprising an expanded polystyrene (EPS) foam sheet and a plurality of metal
studs.
[007] In accordance with another aspect of the invention, there is provided a
kit comprising a
plurality of building panels of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[008] These and other features of the invention will become more apparent in
the following
detailed description in which reference is made to the appended drawings.
[009] Figure 1 illustrates various views of a wall panel in accordance of with
one embodiment
of the invention detailing polystyrene foam panel with studs. Also detailed
are optional elements
for connecting multiple panels and optional cut outs for sills.
[010] Figure 2 illustrates various views of an alternative wall panel with
window framing detail.
[011] Figure 3 illustrates various views of an alternative wall panel with
opening for a door.
[012] Figure 4 illustrates various views of a corner wall panel detailing
polystyrene foam
corner piece with studs. Also detailed are optional elements for connecting
the corner panel to
two wall panels.
[013] Figure 5 illustrates various views of a roof panel detailing polystyrene
foam roof piece
with studs. Also detailed is optional element for sill.
[014] Figure 6 illustrates various views of an alternative roof panel
detailing polystyrene foam
roof piece with studs.
[015] Figure 7 illustrates various views of a floor panel detailing
polystyrene foam floor piece
with studs.
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MBM File No. 3726-103
DETAILED DESCRIPTION OF THE INVENTION
Overview
[016] This invention provides a modular building panel system. The modular
building panel
system includes components that are lightweight, versatile, and cost
effective. In some
embodiments, the building panels are configured and/or treated to be fire-
resistant, flame
retardant, water-resistant, rodent-resistant and/or mould-resistant.
[017] The components can be used individually or components can be affixed
together. In
some embodiments, the modular building panel system is in the form of a kit
which when
assembled provides a specific building configuration. In othe embodiments,
components may
be used to build custom configurations. In some embodiments, the kits include
accessories
including doors, windows, and optionally other components necessary to provide
a finished
building.
[018] In some embodiments, the modular building panels are configured for
shipment on
pallets. Optionally, the modular building panel system components are
configured to be
stackable.
[019] In some embodiments, the modular building panel system is configured to
provide
housing or buildings for remote locations including remote communities, work
camps, hunting
camps, etc. In some' embodiments, the modular building system is configured to
provide
buildings for water treatment facilities, sewage treatment facilities,
schools, training centres,
corridors to affix one building to another, storage, hunting blinds,
recreational vehicles, fishing
huts, swimming pools, garages, military use, etc.
[020] In some embodiments, the modular building panel system are provided as
kits that are
optionally geared to the home improvement or do-it-yourself market, for
example as Garage-In-
A-Box or Greenhouse-In-A-Box.
[021] In some embodiments, structures built using the modular building panel
system can be
affixed to existing structures for extension or expansion of an existing
structure.
[022] In some embodiments, the modular building panel system is used in
conjunction with
traditional building techniques.
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[023] The modular building panel system in some embodiments is configured to
facilitate
repair of constructed building via component or panel replacement such that
building
constructed using this system have longer longevity of structure than a stick-
build building.
[024] The building panel system can be configured such that buildings and
structures
constructed using the building panel system can achieve any R-value and for
thermal transfer.
[025] The modular building panel system is readily modifiable to include
additional angles,
components and fastening systems, if required. Other components that may be
part of the
building panel system include sill components, renewable energy components
including solar
panels, windows, doors, service panels, etc. In some embodiments, these
components are pre-
installed into panels. For example, panels incorporate materials so
installation is plug and play
and can incorporate renewable energy such as solar panels in the roof.
[026] The kits of the invention are generally designed to allow for structures
to be easily built
with lightweight materials, with little instruction. The kits themselves can
be modular and can be
modified by adding or subtracting panels.
[027] The buildings manufactured using the modular building system can be
optionally finished
on the exterior and/or interior with fire retardant material to meet and
exceed all building codes.
In some embodiments, the buildings can be finished with specific materials
such as color, guage
of siding, MgO board, exterior and/or interior MgO.
PANELS
[028] The panels are generally manufactured from expanded polystyrene (EPS)
foam and
have a plurality of metal studs configured and arranged to meet structural
requirements.
[029] In some embodiments, the EPS foam is type 1 EPS foam with a thermal
resistance of
3.75/inch, compressive resistance of 70 Kpa, flexural resistance of 17 Kpa,
water vapour
permanence of 5.2 perms, water absorption of 6%, mould and insect resistant,
non-toxic burn
and non-combustible. In alternative embodiments, type 2, 3, or 4 EPS foam is
used.
[030] The metal studs may be a variety of shapes and sizes, and gauges
depending on
application. In some embodiments, the metal studs are galvanized steel and are
configured as
vertical and/or horizontal supports.
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[031] In one embodiment, the metal studs has a generally squared U-shaped
cross section
comprising two arms and a base where the arms are inserted in the EPS foam
such that the
stud extends into the foam. Optionally, the studs are affixed to the EPS
panels using
appropriate fasteners. Optionally, the fasteners are manufactured from
stainless steel or are
galvanized.
[032] The panels may be provided with the studs pre-inserted or studs may be
inserted into
the EPS foam prior to use. In such embodiments, the EPS panels may include
cuts for the
studs.
[033] As shown in figure 1, the metal studs extend partially through the foam
and may be
provided on both sides of the EPS foam panel.
[034] In some embodiments, the panels are configured to facilitate joining of
adjacent panels.
Optionally, joining of adjacent panels may be via a tongue and groove joint.
Alternatively,
grooves are provided on opposite edges of a panel and a separate piece of EPS
foam sized to
fit within the grooves of adjacent panels is used to join adjacent panels.
[035] The panels may include cut outs for windows, doors or other accessories.
In some
embodiments, panels may be configured as service panels. Service panels will
be made thicker
and recessed complete with Electrical, communications and plumbing cut-outs.
Panels will be
thick enough to not require vapour barriers unless stipulated by Code.
[036] In some embodiments, the panels may be specifically configured as floor
or roof panels.
[037] Although the invention has been described with reference to certain
specific
embodiments, various modifications thereof will be apparent to those skilled
in the art without
departing from the spirit and scope of the invention. All such modifications
as would be apparent
to one skilled in the art are intended to be included within the scope of the
following claims.
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