Panel structure and building structure made therefrom

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This invention relates to improvements in panel structures, to improved building structures made therefrom, to methods for making and erecting such structures.

It is a principal object of the present invention to provide a building system which combines low cost on-site construction with high performance materials to create an energy-efficient building system usable under a wide variety of climatic conditions.

It is a further object of the invention to provide a building system which permits either on-site or prefabricated construction of buildings usable as residential houses, recreational units, mobile units, construction camp units, hospitals, schools, warehouses and the like.

It is a further object of the invention to provide a building system which makes possible the use of semi-skilled labor and requires no special lifting or construction equipment.

The present invention, among other things, provides a unique form of building panel structure, which panel structure is usable to form the side walls, roof, interior partitions and, optionally, the floor of a building structure.

It is a further important object of the invention to provide a unique building component comprising a composite of steel and plastic foam materials bonded together to impart to the resulting structure strength characteristics and other characteristics which are different from the characteristics of foam and steel considered separately.

A building panel structure in accordance with one aspect of the invention includes a plurality of elongated slabs of rigid structural foam insulating material to which steel reinforcing members are bonded to provide a composite structure of unique properties. In one form of the invention each slab includes a pair of major surfaces with a pair of recesses being disposed along each of the longitudinal side edges of the slab to define a tongue extending therealong, each such tongue projecting outwardly from a mid-thickness region of the slab. The slabs are disposed in side-by-side relation with the tongues of the respective slabs being in opposed abutting relationship and the adjacent recesses together defining opposed grooves located at the junctions between the slabs. A rigid framing member is disposed in each of these grooves with the opposing pairs of framing members serving to "sandwich" the abutting tongues of the adjacent slabs therebetween. The tongues of foam material serve to provide a thermal barrier between the framing members.

Preferably, each framing member comprises a tubular metal member although in some embodiments alternative structural materials such as wood or reinforced plastics could be used. Furthermore, in the preferred form of the invention, a suitable adhesive material serves to bond each framing member to the foam material next adjacent thereto.

In another form the building component comprises a slab of polystyrene or like foam material having recesses in its major surfaces in which opposed pairs of steel reinforcing members are received, the steel members being bonded to the foam material.

In this embodiment of the invention the foam slabs or panels are recessed along their edges to form a space for receiving a spline which holds two adjacent slabs or panels in assembled relation.

In a further embodiment of the invention slabs or panel of structural foam, which may take the form of the previously described embodiments, are utilized in conjunction with posts of structural foam of the same or higher density. The posts, which are rectangular or square in section, are recessed on two opposed surfaces to receive steel reinforcing members bonded in place and are recessed on two other opposed surfaces to receive splines for attachment to the main panels or slabs.

In a typical embodiment of the invention, the slabs of foam material comprise preshrunk and precut rigid polystyrene sheets. The framing members typically comprise galvanized tubular steel members. These tubes are interconnected by chemical welding to the polystyrene material. Pairs of perimeter framing members which typically comprise galvanized steel angles are fastened to the ends of the respective tubes and are chemically bonded to the foam along the perimeters of the panel structure. The system enables thermal bridging to be kept to an absolute minimum. The foam material serves to separate the pairs of framing members from one another and the steel angle members located at the perimeters of the panel are likewise spaced apart in the thickness direction of the panel thereby to avoid any substantial degree of heat flow from the interior to the exterior of the structure.

The building system of the present invention may be used with a wide variety of foundation systems as, for example, concrete slab on-grade, below grade foundations, pier supports, or granular base.

As noted above, the framework of the building system preferably comprises tubular steel. Tubular steel configurations combine high strength, stability and light weight and they may, of course, be galvanized to protect same against deterioration from corrosion. The tubular members may be of welded construction or may be roll formed. As used herein "tubular" applies to both forms. Tubular sections of the required strengths are determined depending upon the stresses and design criteria in any given location. Lateral bracing is provided to give the necessary stability against wind and earthquake loads. To achieve lateral stability against wind loads, a metal strap is installed in certain of the roof and wall panels, the gauge and width of the strap and the number of fasteners connecting same to the metal framing members of the walls and roof is determined by the anticipated wind loads on the wall and roof.

Building panels in accordance with the invention are designed to be used as floor, wall and roof systems. The panel thickness can be adjusted depending upon climatic conditions and building code requirements in the jurisdiction in which the building is being erected.

Panel structures in accordance with the invention incorporate rigid foam insulating material as a major part of the construction. The preferred material is expanded polystyrene which, as is well known, is produced from small beads that are thermally expanded and fused to form large blocks which are then cut into any desired size and thickness. Rigid foam insulation material has one of the lowest thermal conductivities of all common insulation materials thus making it a most versatile cost efficient insulation as well as providing a substantial degree of structural strength.

The invention further comprises building constructions employing building panel structures as described above for at least one of the following: side walls, roof, interior partitions, and floor.

The system of the present invention is adaptable to both pre-fabrication or on-site construction. On-site construction preferably involves building each wall panel on the previously constructed base or sub-floor. As each wall panel is completed it is raised and secured in position to the base and abutting walls. Upon completion of exterior and interior load bearing walls, the roof panels are constructed and secured to the walls. Then windows and exterior doors are positioned and exterior siding or finish applied; facia and soffit are secured followed by the application of the roofing material.

Pre-fab erection entails similar procedures as above with some variations in fastening methods. Smaller panels can be factory assembled and transported to the building site.

Insofar as the exterior and interior finishes are concerned, various fire-rated finishes can be applied to the ceiling and walls as pre-formed sheets, stucco or paint spray applications, hand brushed or trowelled finishes. Roofing may be galvanized to pre-painted steel, asphalt shingles or other similar roofing materials. Any conventional type of flooring, windows and doors can be incorporated into the building system. Glass fiber reinforced acrylic resin coatings are particularly suitable for use on the exterior and interior surfaces of the polystyrene foam slabs; however, various other types of finishes, as noted above, are also suitable.

In all embodiments of the invention the basic building component is a unique composite of steel and polystyrene or other like plastic foam material which has the capacity to take structural loads and to provide superior thermal insulation. By utilization of different cross sections and densities the foam materials and different cross sections and gauge of steel members the composite basic components may be designed to acheive precise load handling capacities.

The present invention also provides for the unique design of combinations of steel and polystyrene or other like foam plastics so that the particular cross section developed including the density and thickness of the polystyrene and the cross section and gauge of the steel members all contribute to the structural capacities of the particular section to permit the determination of the load carrying capacity of a particular composite product. The bonding or chemical welding of the foam and steel members is effected in such a manner that the members work together as a single structural element with the strength characteristics of the foam and steel working together as a single entity.

This combination of materials gives a structural strength far exceeding all existing building code requirements.

It is a further important object of the present invention to provide a building system comprising a plurality of basic modular units which may be assembled in an essentially unlimited variety of patterns and configurations to provide increased strength when necessary and to accommodate window and door openings.

In all configurations certain of the studs or framing members are maintained on 16 inch or 24 inch centers to permit the installation of standard width interior finishing panels such as wall board and standard width exterior finishing panels such as wood or metal siding.

Typical embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings in which:

FIG. 1 is a perspective view of a building panel structure made in accordance with the principles of the present invention;

FIG. 2 is a section view taken along line 2--2 in FIG. 1 and looking in of the arrows;

FIG. 3 is a section view taken through a portion of a building constructed in accordance with the principles of the present invention;

FIG. 4 is an enlarged fragmentary cross-section illustrating details of the building structure illustrated in FIG. 3;

FIG. 4A illustrates, in section, the roof panel to gable end connection;

FIG. 4B illustrates, in section, a portion of the roof panel illustrating the metal framing members;

FIG. 4C illustrates, in section, outside wall panels at an outside corner of the building;

FIG. 4D illustrates a modified form of outside corner construction;

FIG. 4E illustrates, in section, a junction between an outside wall and an interior vertical partition;

FIG. 4F is similar to FIG. 4E and illustrates a somewhat modified form of outside wall to interior panel connection;

FIG. 5 is a perspective view of typical outside wall panel configuration secured to a suitable base;

FIGS. 6A and 6B are diagrammatic views illustrating the application of tension braces to certain of the structural panels of the building;

FIG. 6C illustrates a portion of a panel frame construcdton including a diagonal tension brace thereon;

FIG. 7 is partial cross-sectional view of a building panel structure illustrating the manner in which such panels may be partially pre-fabricated and shipped in a partially assembled manner;

FIG. 8 is a perspective view of a portion of the building structure which will assist in understanding the construction erection sequence;

FIGS. 9A through 9G are diagrams illustrating the sequence of construction of a building system in accordance with the present invention;

FIGS. 10A through 10D further illustrate steps in the construction of a building;

FIG. 11 is a horizontal section illustrating the basic building components constructed in accordance with a further embodiment of the invention;

FIG. 12 is a horizontal section illustrating a further embodiment of the invention comprising a unique combination of foam panels and composite posts;

FIGS. 13A through 13C are transverse section through three basic modular structural foam components;

FIGS. 14A through 14C are transverse sections of three basic modular structural foam components for use as end pieces on walls or roof sections.

FIGS. 15A and 15B are transverse sections through two basic infill modular foam units;

FIGS. 16 through 18 are transverse sections through typical wall sectwons constructed from various combinations of the basic modular units illustrated in FIGS. 13 through 15;

FIG. 19 is a perspective view of a top portion of a typical wall construction;

FIG. 20 is a perspective view illustrating the under surface of a roof panel;

FIG. 21 is a fragmentary vertical section illustrating the installation of a roof panel of FIG. 22 on the wall construction of FIG. 21;

FIG. 22 is a fragmentary perspective view of a portion of a wall incorporating a window equipped with solar blinds; and

FIG. 23 is a transverse section illustrating a modified wall construction incorporating a passive solar heat system.

With reference now to the drawings, FIGS. 1 and 2 illustrate a building panel structure 10 in accordance with the principles of the present invention, which basic form of panel construction, with minor variations, may serve as the side walls, roof, interior partitions and, if desired, the floor of a building structure.

As best seen in FIGS. 1 and 2, the panel structure 10 comprises a plurality of elongated slabs 12 of rigid structural grade polystyrene foam insulating material. Each slab 12 includes an opposing pair of major surfaces 14 with a pair of recesses 16 being disposed along each of the longitudinal side edges of each slab 12 to define a tongue portion 18 extending therealong. As best seen in FIG. 2, each such tongue portion 18 projects outwardly from a mid-thickness region of the slab. The slabs 12 are disposed in side-by-side co-planar relationship with the tongues 18 of the respective slabs being disposed in opposed abutting relationship. The adjacent recesses 16 together define opposed grooves located at the junctions between the slabs 12. A rigid framing member 20 is disposed in each of these grooves with the opposing pairs of framing members 20 serving to sandwich the abutting tongues 18 of adjacent slabs 12 there between. A layer 21 of suitable adhesive material serves to secure each framing member 20 of the opposed pair of members to the tongue 18 of insulating material which is sandwiched there between. The tongues 18 of polystyrene foam material serve to provide a thermal break or barrier between the framing members 20.

With further reference to FIG. 2 it will be noted that each framing member 20 comprises a hollow tubular member of rectangular cross-section. Each framing member 20 is of steel preferably galvanized thereby to resist corrosion. Where maximum strength is required the members 20 are preferably of welded construction. For reasons of economy, the members 20 may be roll formed. The roll formed members may be used where the strength requirements are less stringent or may be used throughout if made of increased gauge. It will be further noted from FIG. 2 that that surface of each framing member 20 which is directed outwardly of the panel is generally flush with the associated major surfaces 14 of the slabs of polystyrene associated therewith.

As best seen in FIG. 1, each of the opposing ends of the panel structure 10 has a pair of rigid perimeter framing strips extending there along. The respective pairs of perimeter framing strips are designated by reference numbers 22 and 24 in FIG. 1. In the embodiment of FIG. 1 these perimeter framing strips take the form of galvanized steel angle members. It will be noted that they are spaced apart in the direction of the thickness dimension of panel 10 thereby to provide a thermal break there between. These pairs of perimeter framing strips 22, 24 are also adhesively bonded to the polystyrene foam slabs. It will also be noted that the opposing ends of the framing members 20 are connected to associated ones of the pairs 22, 24 of perimeter framing strips so as to maintain the thermal break. The connection between the perimeter framing strips 22, 24 and the associated framing members 20 may be made by any suitable means such as by spot welding, riveting, or by self-threading screws etc.

The structural properties of rigid polystyrene insulation material are well known, The Dow Chemical Company for example, manufactures a wide variety of polystyrene foams suitable for use in building construction. Since the foam material will be subject to a certain degree of shear stress, especially at the interface between the foam and the framing members 20, particularly when the panel as a whole is subject to bending stresses as, for example, when such panels are used to form the roof sections of the building, the polystyrene foam should exhibit a substantial degree of shear strength depending of course on snow loadings, roof design, etc. Numerous foams are available commercially which have a shear strength of about 17-20 psi for one pound density and 24-30 psi for 1.5 density and which have a thermal resistance R of at least 3.85 and preferably 4.00 per one inch of thickness when measured in hours/square foot/degrees Fahrenheit/BTU. This material will usually have a compressive strength of about 9-13 psi for one pound density and 16-22 psi for 1.5 pound density and a tensile strength of about 20-30 psi for one pound density and 21-40 psi for 1.5 pound density. The average shear modulus will be in the order of 300-350 psi for one pound density and 430-535 psi for 1.5 pound density. (ASTM-C-273-53).

Numerous adhesives are commercially available for bonding the polystyrene foam to the metal framing members. One highly suitable adhesive is known as "FLINTSTIK" (registered trademark) No. 230-21 made by the Flintkote Company of Canada Limited. This adhesive is a solvent type synthetic rubber based insulation adhesive. This material sets rapidly to give a strong resilient bond, the strength of which will exceed the shear strength of the polystyrene foam. The adhesive material should be applied to substantially the full length of each framing member thereby to provide an adequate bonding area between the metal and the foam.

The above basic panel construction, with minor modifications, may be used to form the walls, roof, internal partitions and, optionally the floor of a building structure.

Although not illustrated in FIGS. 1 and 2, the opposing major surfaces of the panel 10 may be coated with a skin of glass fiber reinforced synthetic resin thereby to protect the polystyrene foam from structural damage and to provide added strength to the structure. Preferably, the opposing surfaces of the panel are covered with a variety of skins, such as plywood, sheet rock or cementitious stucco-like material or glass reinforced acrylic resin coating having a thickness from about 3/16 inch to about 1/2 inches.

A typical building structure in accordance with the principles of the invention is illustrated in FIG. 3 with further details of such structure being shown in FIGS. 4A-4F, FIG. 5, and FIGS. 6A-6C.

With reference to FIG. 3, it will be seen that the building structure includes exterior load bearing wall panels 10a, roof panels 10b, and interior load bearing panels 10c. The end walls of the building are not shown in FIG. 3 nor are any additional interior partitions shown.

With further reference to FIG. 4 it will be seen that the exterior load bearing wall panel 10a includes polystyrene foam slabs 12a as described previously in relation to FIGS. 1 and 2 and is provided with vertically spaced pairs of tubular framing members 20a. The upper edge of exterior wall panel 10a is provided with a cap comprising spaced apart perimeter framing strips 22a while the lower edge of exterior wall panel 10a is provided with a sill comprising a similar pair of framing strips 24a. The outermost framing strip 24a is connected to the concrete slab floor 30 by means of a series of spaced apart pins or "RAMSET" (registered trademark) fasteners. These fasteners are illustrated by reference number 32. The upper peripheral framing strips 22a defining the cap are angled to match the slope of the roof panel 10b. The interior and exterior of wall panel 10a may be covered with a glass reinforced acrylic resin coating 3/16 inch to 1/2 inches thick. The exterior surface of wall panel 10a is also provided with any additional suitable decorative surface such as a decorative stucco manufactured by the Flintkote Company of Canada Limited. This stucco which is preferred is a polymer fortified cement based product which is mixed with water before use. Any other suitable form of decorative exterior finish may be used. The interior surface of wall panel 10a may likewise be covered with any suitable building material as, for example, fiberboard, wall panelling, plasterboard, etc.

In a typical embodiment of the invention, the wall panels 10a utilize 4" thick polystyrene foam insulation with the framing members comprising pairs of 1" by 2" by 18 gauge steel galvanized tubes located at 24" centers. The pre cut 4" thick polystyrene slabs were provided with tongues having a thickness of about 2" between the opposing tubular framing members 20a. The cap and sill peripheral framing strips 22a and 24a respectively consisted of pairs of 13/8".times.13/8".times.18 guage steel angles running continuously and screwed to the tubular steel framing members 20a. The exterior sill peripheral framing strip 24a was connected to the concrete foundation base using 1/8" steel drive pins located at 12" centers.

The roof panels 10b are of similar construction to the wall panels 10a except that they are usually made somewhat thicker thereby to provide additional bending strength. In a typical embodiment designed for a maximum deflection of L/240, the slabs of polystyrene foam had a thickness of 6". Both major surfaces of the roof panels were coated with a glass reinforced acrylic resin coating in the same fashion as for the wall panels. In addition, the exterior surface of the roof panels may be coated with a general purpose heavy duty protective coating such as "FLINTGUARD" 800-48 reinforced asphalt emulsion roof coating. This product is made by the Flintkote Company of Canada Limited.

With further reference to FIG. 4 it will be seen that the roof panels 10b are provided with a perimeter framing strips 22b and 24b which are similar to those described previously except that the included angles between the flanges of such members are adapted to suit the pitch of the roof. The lowermost set of roof panel framing members 20b are screwed to the cap members 22a by suitable sheet metal screws or the like. Suitable aluminum facing members may be applied to the exposed surfaces of the roof panels in a manner which need not be described further here.

With reference to FIGS. 4C and 4E, the interior load bearing panel 10c is constructed and functions in much the same manner as the previously described exterior load bearing wall panel 10a. The upper edge of the interior load bearing panel 10c has a cap defined by a pair of perimeter framing strips 22c shaped to match the oppositely directed slopes of the roof panels 10b while the lower edge of wall panel 10c is provided with a sill defined by perimeter framing strips 24c connected to the