U.S. patent application number 11/282351 was filed with the patent office on 2006-06-08 for apparatus, system and method of manufacture thereof for insulated structural panels comprising a combination of structural metal channels and rigid foam insulation.
This patent application is currently assigned to Shari Howard. Invention is credited to Ronnie Dale Onken, Yelena Onken.
Application Number | 20060117689 11/282351 |
Document ID | / |
Family ID | 36572619 |
Filed Date | 2006-06-08 |
United States Patent
Application |
20060117689 |
Kind Code |
A1 |
Onken; Ronnie Dale ; et
al. |
June 8, 2006 |
Apparatus, system and method of manufacture thereof for insulated
structural panels comprising a combination of structural metal
channels and rigid foam insulation
Abstract
A insulated structural panel is formed with a rigid foam core, a
plurality of vertical hat channels on either face of the rigid foam
core, and horizontal top and bottom L-channels on either face of
the rigid foam core. The plurality of vertical hat channels on
opposing faces of the rigid foam core are attached together so as
to compress the rigid foam core, thus adding structural strength to
the insulated structural panel.
Inventors: |
Onken; Ronnie Dale;
(Phoenix, AZ) ; Onken; Yelena; (Phoenix,
AZ) |
Correspondence
Address: |
BAKER BOTTS, LLP
910 LOUISIANA
HOUSTON
TX
77002-4995
US
|
Assignee: |
Shari Howard
|
Family ID: |
36572619 |
Appl. No.: |
11/282351 |
Filed: |
November 18, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60630506 |
Nov 23, 2004 |
|
|
|
Current U.S.
Class: |
52/309.7 |
Current CPC
Class: |
E04C 2/22 20130101; E04C
2/384 20130101 |
Class at
Publication: |
052/309.7 |
International
Class: |
E04C 1/00 20060101
E04C001/00 |
Claims
1. A insulated structural panel, comprising: a rigid foam core
having first and second faces; a plurality of hat channels on the
first and second faces of the rigid foam core; first L-channels on
the first and second faces of the rigid foam core toward a first
edge of the rigid foam core; second L-channels on the first and
second faces of the rigid foam core toward a second edge of the
rigid foam core wherein the second edge is opposite and parallel to
the first edge; the first and second L-channels are substantially
perpendicular to the plurality of hat channels and are attached
thereto; opposing ones of the plurality of hat channels are
attached together so as to be in compression with the first and
second faces of the rigid foam core; wherein each of the plurality
of hat channels are three dimensional structural members having at
least six bends along a long axis thereof.
2. The insulated structural panel according to claim 1, wherein
each of the plurality of hat channels comprises at least three
first faces and at least four second faces.
3. The insulated structural panel according to claim 2, wherein the
at least three first faces are substantially parallel with each
other, the at least four second faces are substantially parallel
with each other, and the at least three first faces are
substantially perpendicular with the at least four second
faces.
4. The insulated structural panel according to claim 1, wherein the
plurality of hat channels are embedded into surfaces of the first
and second faces of the rigid foam core.
5. The insulated structural panel according to claim 1, further
comprising at least one utility chase in the rigid foam core.
6. The insulated structural panel according to claim 1, wherein the
first and second L-channels, and the plurality of hat channels are
attached together with sheet metal screws.
7. The insulated structural panel according to claim 1, wherein the
first and second L-channels and the plurality of hat channels are
attached together with rivets.
8. The insulated structural panel according to claim 1, wherein the
opposing ones of the plurality of hat channels are attached
together with metal screws.
9. The insulated structural panel according to claim 1, wherein the
opposing ones of the plurality of hat channels are attached
together with non-thermally conductive means.
10. The insulated structural panel according to claim 1, further
comprising gluing the plurality of hat channels to the rigid foam
core.
11. The insulated structural panel according to claim 1, wherein
the plurality of hat channels are metal.
12. The insulated structural panel according to claim 1, wherein
the plurality of hat channels are steel.
13. The insulated structural panel according to claim 12, wherein
the plurality of hat channels are light gauge steel.
14. The insulated structural panel according to claim 13, wherein
the light gauge steel is from about 20 gauge to about 14 gauge.
15. The insulated structural panel according to claim 13, wherein
the light gauge steel is galvanized.
16. The insulated structural panel according to claim 13, wherein
the light gauge steel is coated to inhibit rust.
17. The insulated structural panel according to claim 1, wherein
the first and second L-channels are steel.
18. The insulated structural panel according to claim 17, wherein
the first and second L-channels are light gauge steel.
19. The insulated structural panel according to claim 18, wherein
the light gauge steel is from about 20 gauge to about 14 gauge.
20. The insulated structural panel according to claim 18, wherein
the light gauge steel is galvanized.
21. The insulated structural panel according to claim 18, wherein
the light gauge steel is coated to inhibit rust.
22. The insulated structural panel according to claim 1, further
comprising a nailing strip attached to an outside face of each of
the plurality of hat channels.
23. The insulated structural panel according to claim 22, wherein
the nailing strip is wood.
24. The insulated structural panel according to claim 22, wherein
the nailing strip is treated wood.
25. The insulated structural panel according to claim 22, wherein
the nailing strip is wood.
26. The insulated structural panel according to claim 1, wherein
the rigid foam core comprises expanded polystyrene.
27. The insulated structural panel according to claim 1, wherein
the rigid foam core comprises polyurethane.
28. A insulated structural panel, comprising: a rigid foam core
having first and second faces; a plurality of hat channels on the
first and second faces of the rigid foam core; top L-channels on
the first and second faces of the rigid foam core toward a top edge
of the rigid foam core; bottom L-channels on the first and second
faces of the rigid foam core toward a bottom edge of the rigid foam
core wherein the bottom edge is opposite and parallel to the top
edge; the top and bottom L-channels are substantially perpendicular
to the plurality of hat channels and are attached thereto; opposing
ones of the plurality of hat channels are attached together so as
to be in compression with the first and second faces of the rigid
foam core; wherein each of the plurality of hat channels are three
dimensional structural members having six bends along a long axis
thereof, three first faces substantially parallel with each other,
four second faces substantially parallel with each other, wherein
the three first faces are substantially perpendicular to the four
second faces.
29. The insulated structural panel according to claim 28, wherein
the bottom L-channels are adapted for connection to a bottom
plate.
30. The insulated structural panel according to claim 29, wherein
the bottom plate is adapted for connection to a foundation.
31. The insulated structural panel according to claim 28, wherein
the top L-channels are adapted for connection to a top plate.
32. The insulated structural panel according to claim 31, wherein
the top plate is adapted for connection to a second floor.
33. The insulated structural panel according to claim 31, wherein
the top plate is adapted for connection to a roof support
means.
34. The insulated structural panel according to claim 1, further
comprising a header of hat channels forming an opening in the rigid
foam core for a window or door.
Description
RELATED PATENT APPLICATION
[0001] This application claims priority to commonly owned U.S.
Provisional Patent Application Ser. No. 60/630,506; filed Nov. 23,
2004; entitled "Apparatus, System and Method of Manufacture Thereof
for Insulated structural Panels Comprising a Combination of
Structural Metal Channels and Rigid Foam Insulation," by Ronnie
Onken; which is hereby incorporated by reference herein for all
purposes.
TECHNICAL FIELD
[0002] The present disclosure relates to insulated structural
panels used in building construction, more particularly, insulated
structural panels comprising a combination of structural metal
channels and rigid foam insulation.
BACKGROUND
[0003] Building construction for houses and low rise commercial
building have been done with dimensional lumber, e.g., 2.times.
wood studs, bricks, mortar, plywood, stucco, etc. This is referred
to in the building industry as "sticks and bricks" construction and
is very labor intensive and time consuming for construction of a
building. More recently, prefabricated panels made of two sheets of
plywood or oriented strand board (OSB) with rigid foam insulation
therebetween have been used to construct wall, floors and/or roofs
of building. These prefabricated panels, called "structural
insulated panels" (SIP) may be fabricated at a manufacturing plant
and shipped to a jobsite for rapid erection of a building. The SIPs
are stronger and have better insulation properties then a framed
dimensional lumber building. Completion of the outer shell of a
building using SIPs is also much faster then framing with
dimensional lumber.
[0004] Typically, SIPs are made with 5/8 inch OSB and either
expanded polystyrene (EPS) foam or polyurethane (PU) foam. The EPS
foam is cut into dimensional sheets and the inside faces of the OSB
sheets are glued to the EPS sheet. This produces a structurally
strong and well insulated panel. PU SIPs are manufactured by
placing two OSB sheets in a jig and injecting the PU foam
therebetween. Once the PU foam has hardened the PU SIP is ready for
shipment to the construction site. Generally, SIPs are fabricated
at the factory with window and door opening precut. In addition
some PU SIPs also have preinstalled electrical conduit therein.
Most SIPs have channels precut in the foam for installation of
electrical wiring and/or plumbing.
[0005] Problems exist, however, in that SIPs are large and heavy,
and shipment to a job site and erection of the SIPs are expensive.
The average construction framing carpenter may not have the skill
set to install SIPs so that a factory crew usually will have to
erect the SIPs at the job site. OSB and plywood prices have greatly
increased due to greater demands created by extensive building and
have caused SIP prices to increase accordingly. Also OSB and
plywood are susceptible to termite and/or carpenter ant
infestation, wood decay from excessive trapped moisture, mold
and/or mildew.
SUMMARY
[0006] What is needed is a building panel that is both structural
and insulated, light weight, easy to erect, low cost, strong, able
to be fabricated and/or modified at the job site, resistant to
termite and/or carpenter ant infestation, and not affected by
excessive moisture, mold, mildew, and widely fluctuating building
lumber prices.
[0007] According to specific example embodiments of this
disclosure, a rigid foam core having a thickness from about 5.5
inches for expanded polystyrene (EPS) or from about 3.5 inches for
polyurethane (PU) to a maximum thickness (e.g., depending on
insulation value "R-factor" desired) as required may be sandwiched
between hat channels and angles. The hat channels may be attached
together at various points so that the rigid foam may be held in
tight compression between these hat channels. The hat channels may
be shaped into three dimensional structural members having at least
six bends along a long axis of the hat channel. For example, a hat
channel with six bends will have three first faces substantially
parallel with each other, four second faces substantially parallel
with each other, wherein the three first faces may be substantially
perpendicular to the four second faces and the three first faces
may be substantially parallel with a long face of the rigid foam
core. It is contemplated and within the scope of this disclosure
that the bends of the first and second faces of the hat channel may
be at any angle and relationship that may form the hat channel into
a structural member. A nailing strip may be attached to an outside
face of each of the hat channels. The nailing strip may comprise
wood, treated wood, composite wood/plastic, etc.
[0008] The rigid foam core may have a minimum density of about one
pound per cubic foot and a maximum density dependent upon
workability and insulation value "R-factor" desired. The hat
channels may be, for example but not limited to, galvanized steel
or coated metal from about 20 gauge to about 14 gauge, formed into
structural members and arranged in a standard centerline spacing.
The spacing and gauge may be determined by the structural load
requirements of the construction application. Channel or chases may
be formed in the rigid foam core for electrical wiring and/or
plumbing at the time of fabrication and/or during installation at
the construction site.
[0009] A bottom track may be attached to a foundation and/or bottom
plate, e.g., treated dimensional wood, and a bottom edge of the
insulated structural panels attached thereto. The bottom track may
be, for example but not limited to, light gauge galvanized steel or
coated metal from about 20 gauge to about 14 gauge. A top plate may
be attached to the top edge of the insulated structural panels and
may be 2.times. (e.g., 2.times.4, 2.times.6, 2.times.10, etc.)
dimensional wood, treated or untreated, metal channel from about 20
gauge to about 14 gauge galvanized steel or coated metal, etc. The
top and bottom tracks (e.g., top and bottom plates) may be fastened
to the insulated structural panels with screws, rivets, metal nails
and/or spot welds depending upon structural load factors and job
site conditions. The ties between the hat channels and angles may
be metal, e.g., screws, rivets, spot welded tie rods, etc., or for
reduced thermal bridging they may be, nylon, carbon composite
filaments, rods, etc.
[0010] A method of manufacturing the insulated structural panels
comprising a combination of structural hat channels and rigid foam
insulation, according to specific example embodiments of this
disclosure, may comprise rigid foam cutting equipment, metal
forming equipment and panel fabrication and attachment equipment.
The panels may be manufactured in a factory using computer aided
design and computer aided manufacturing (CAD/CAM) and/or the panels
may be fabricated at the job site so as to utilized locally
obtainable raw materials, e.g., flat metal and rigid foam.
Fabrication at the job site may reduce shipping costs and increase
flexibility in panel design lead time. In addition, larger panels
may be readily fabricated at the job site because shipping of
oversized loads is no longer required. The manufacturing equipment
may be mounted on trucks and/or trailers or may be shippable and
easily set up at or near the job site. Thus, construction of a
large building or housing subdivision may have a insulated
structural panel manufacturing facility that is close to the job
site, resulting in lower delivery costs, shorter delivery times and
easy customization and/or modification of the insulated structural
panels. Also any panel shortages caused by field changes or
manufacturing errors may be easily remedied by supplying
replacement panels that may be easily fabricated as soon as they
are needed at the job site.
[0011] According to specific example embodiments of this
disclosure, the insulated structural panels may be easy adapted for
use as walls, roof and/or floors of a residential or commercial
building.
[0012] According to specific example embodiments of this
disclosure, the hat channels may make substantially 100 percent
contact with the rigid foam for increased lateral and axial load
capabilities.
[0013] According to specific example embodiments of this
disclosure, the insulated structural panels may be a very high
strength to weight ratio and improved cost effectiveness for
R-value obtained.
[0014] According to specific example embodiments of this
disclosure, the insulated structural panels may have widened
attachment points (e.g., three inches) at hat channel to top and
bottom angles that may greatly improve lateral load
capabilities.
[0015] According to specific example embodiments of this
disclosure, the insulated structural panels may be used for 100
percent "green" building at reasonable cost.
[0016] According to specific example embodiments of this
disclosure, the insulated structural panels may be configured as
flat/straight walls with a known and provable strength
capability.
[0017] According to specific example embodiments of this
disclosure, the insulated structural panels may be manufactured
with relatively inexpensive equipment.
[0018] According to specific example embodiments of this
disclosure, the insulated structural panels may facilitate lower
utility costs because of improved R-factor (insulation).
[0019] According to specific example embodiments of this
disclosure, the insulated structural panels may be easy to install
by basic unskilled labor. Two persons may install an 8 foot long by
8 foot high panel with relative ease.
[0020] According to specific example embodiments of this
disclosure, the insulated structural panels may be limited in size
only by shipping or jobsite limitations.
[0021] According to specific example embodiments of this
disclosure, the insulated structural panels may be relatively easy
to install electrical wiring and electrical boxes, plumbing,
etc.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] A more complete understanding of the present disclosure
thereof may be acquired by referring to the following description
taken in conjunction with the accompanying drawings wherein:
[0023] FIG. 1 is a schematic drawing of an insulated structural
panel, according to a specific example embodiment of this
disclosure;
[0024] FIG. 2 is a schematic drawing of the insulated structural
panel of FIG. 1 showing a base channel and a 2.times. dimensional
lumber header, according to a specific example embodiment of this
disclosure;
[0025] FIG. 3 is a schematic drawing of a portion of the insulated
structural panel of FIG. 1 showing a more detailed view of the hat
channel, angle and top plate attachment, according to a specific
example embodiment of this disclosure;
[0026] FIG. 4 is a schematic drawing of a portion of the insulated
structural panel of FIG. 1 showing a more detailed view of a bottom
channel attached to the panel, according to a specific example
embodiment of this disclosure;
[0027] FIG. 5 is a schematic drawing of a portion of the insulated
structural panel of FIG. 1 showing a more detailed cutaway view of
an electrical chase, according to a specific example embodiment of
this disclosure;
[0028] FIG. 6 is a schematic drawing of a portion of the insulated
structural panel of FIG. 1 showing the attachment of parallel hat
channels in more detail, according to a specific example embodiment
of this disclosure;
[0029] FIG. 7 is a schematic view of a portion of the hat channels
without the rigid foam core, according to a specific example
embodiment of this disclosure;
[0030] FIG. 8 is a schematic view of a hat channel end, according
to a specific example embodiment of this disclosure;
[0031] FIG. 9 is a schematic cross sectional view of a hat channel,
according to a specific example embodiment of this disclosure;
[0032] FIG. 10 is a schematic drawing of a top view of the
insulated structural panel of FIG. 1, according to a specific
example embodiment of this disclosure;
[0033] FIG. 11 is a schematic drawing of a typical foundation
connection of the insulated structural panel of FIG. 1;
[0034] FIG. 12 is a schematic drawing of a roof truss connected to
the insulated structural panel of FIG. 1;
[0035] FIG. 13 is a schematic drawing of the insulated structural
panels of FIG. 1 connected together at a corner; and
[0036] FIG. 14 is a schematic drawing of door/window header and
jamb details for the insulated structural panel of FIG. 1.
[0037] While the present disclosure is susceptible to various
modifications and alternative forms, specific example embodiments
thereof have been shown in the drawings and are herein described in
detail. It should be understood, however, that the description
herein of specific example embodiments is not intended to limit the
disclosure to the particular forms disclosed herein, but on the
contrary, this disclosure is to cover all modifications and
equivalents as defined by the appended claims.
DETAILED DESCRIPTION
[0038] Referring now to the drawings, the details of specific
example embodiments are schematically illustrated. Like elements in
the drawings will be represented by like numbers, and similar
elements will be represented by like numbers with a different lower
case letter suffix.
[0039] Referring to FIG. 1, depicted is a schematic drawing of an
insulated structural panel, according to a specific example
embodiment of this disclosure. The insulated structural panel,
generally represented by the numeral 100, may comprise a rigid foam
core 102, a plurality of hat channels 104, top L-channels 106, and
bottom L-channels 108. The plurality of hat channels 104, top
L-channels 106, and bottom L-channels 108 may be on either long
side of the rigid foam core 102, e.g., the rigid foam core 102 is
"sandwiched" therebetween. The rigid foam core 102 may be, for
example but not limited to, expanded polystyrene (EPS),
polyurethane (PU) and the like. The L-channels 106 and 108 may be
fastened to the hat channels 104 by any appropriate means, e.g.,
sheet metal screws 110. At least one utility chase 112 may be
placed in the rigid foam core 102 and may be substantially vertical
and/or horizontal.
[0040] Referring to FIGS. 2, 3 and 4, depicted are schematic
drawings of the insulated structural panel of FIG. 1 showing a base
channel 220 and a 2.times. dimensional lumber header 222. The base
channel 220 may be attached to the bottom L-channels 108 and the
plurality of hat channels 104 by any appropriate means, e.g., sheet
metal screws 110. The base channel 220 may also be attached to a
building foundation 426 or floor (not shown). The base channel 220
may be securely attached to the foundation 426 or a floor (not
shown) in a level and straight manner so that the insulated
structural panel 100 may be even and straight when installed
thereon. A header 222 may be attached to the top L-channels 106 by
any appropriate means, e.g., sheet metal straps 224 and sheet metal
screws 110.
[0041] Referring to FIG. 5, depicted s a schematic drawing of a
portion of the insulated structural panel of FIG. 1 showing a more
detailed cutaway view of the electrical chase 112, according to a
specific example embodiment of this disclosure. Since the
electrical chase 112 is exposed during construction, wiring and
device electrical boxes may be easily installed in the rigid foam
core 102.
[0042] Referring to FIG. 6, depicted is a schematic drawing of a
portion of the insulated structural panel of FIG. 1 showing the
attachment of parallel hat channels 104 in more detail, according
to a specific example embodiment of this disclosure. The hat
channels 104 may be attached together with ties 602, e.g., screws,
tie rods, etc., or for reduced thermal bridging they may be, nylon,
carbon composite filaments, rods, etc. so as to maintain
compression of the rigid foam core 102. The rigid foam core 102 may
additionally be glued or otherwise attached to the inside faces of
the hat channels 104. Referring also to FIG. 10, depicted is a
schematic drawing of a top view of the insulated structural panel
of FIG. 1. There may be a plurality of ties 602 biasing together
opposing hat channels 104, e.g., on opposite faces of the rigid
foam core 102. The ties 602 in combination with the hat channels
104 and rigid foam core 102 may provide an I-beam type of
structure.
[0043] Referring now to FIGS. 7, 8 and 9, depicted are schematic
views of portions of the hat channels, according to a specific
example embodiment of this disclosure. The hat channels 104 may be
shaped into three dimensional structural members having at least
six bends, generally represented by the numeral 704, along a long
axis of the hat channel 104. For example, a hat channel 104 with
six bends 704 will have three first faces 706 substantially
parallel with each other, four second faces 708 substantially
parallel with each other, wherein the three first faces 706 may be
substantially perpendicular to the four second faces 708 and the
three first faces 706 may be substantially parallel with a long
face of the rigid foam core 102. It is contemplated and within the
scope of this disclosure that the bends of the first and second
faces 706 and 708 may be at any angle and relationship that may
form the hat channel 104 into a structural member.
[0044] Referring to FIG. 11, depicted is the insulated structural
panel 100 attached to a concrete foundation footer 426a with a
foundation tie strap 1120.
[0045] Referring to FIG. 12, depicted is a schematic drawing of a
roof truss connected to the insulated structural panel of FIG. 1.
The roof truss 1202 may be attached to the top plate 222 by any
appropriate means, e.g., sheet metal straps and/or nails, etc.
[0046] Referring to FIG. 13, depicted is a schematic drawing of
insulated structural panels 100a and 100b connected together at a
corner by any appropriate means, e.g., sheet metal straps, sheet
metal screws, etc. (not shown).
[0047] Referring to FIG. 14, depicted is a schematic drawing of
door/window header and jamb details that may be incorporated into
the insulated structural panels 100. A king hat channel 104 may be
attached to upper and lower L-channels 106a and 106b, respectively.
A short hat channel 104a may be connected to the upper and lower
L-channels 106a and 106b, respectively. For greater head loads,
e.g., wider header spans, at least one additional horizontal hat
channel 104b may be included in the header on each side (face) of
the foam core 102.
[0048] While embodiments of this disclosure have been depicted,
described, and are defined by reference to example embodiments of
the disclosure, such references do not imply a limitation on the
disclosure, and no such limitation is to be inferred. The subject
matter disclosed is capable of considerable modification,
alteration, and equivalents in form and function, as will occur to
those ordinarily skilled in the pertinent art and having the
benefit of this disclosure. The depicted and described embodiments
of this disclosure are examples only, and are not exhaustive of the
scope of the disclosure.
* * * * *