U.S. patent application number 13/344179 was filed with the patent office on 2012-06-21 for wall panel and method of fabrication and use.
This patent application is currently assigned to STORMWALL SYSTEMS LLC. Invention is credited to Craig Buchanan, Scott Graham, Grady L. PAULEY.
Application Number | 20120151872 13/344179 |
Document ID | / |
Family ID | 46232562 |
Filed Date | 2012-06-21 |
United States Patent
Application |
20120151872 |
Kind Code |
A1 |
PAULEY; Grady L. ; et
al. |
June 21, 2012 |
WALL PANEL AND METHOD OF FABRICATION AND USE
Abstract
A building panel includes a sheet of wood material having
opposing surfaces and bounding edges. The sheet of wood material is
encased by a coating of a mixture of pigments and polymeric resins
electrostatically adhered to the opposing surfaces and edges, and
cured.
Inventors: |
PAULEY; Grady L.; (Phoenix,
AZ) ; Graham; Scott; (Dublin, IE) ; Buchanan;
Craig; (Wellington, NZ) |
Assignee: |
STORMWALL SYSTEMS LLC
Ruston
LA
|
Family ID: |
46232562 |
Appl. No.: |
13/344179 |
Filed: |
January 5, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11869429 |
Oct 9, 2007 |
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13344179 |
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Current U.S.
Class: |
52/745.09 |
Current CPC
Class: |
E04B 1/10 20130101; E04C
2/24 20130101 |
Class at
Publication: |
52/745.09 |
International
Class: |
E04B 2/56 20060101
E04B002/56 |
Claims
1-16. (canceled)
17. A method of erecting a building structure comprising the steps
of: providing a plurality of building panels, each including a
sheet of wood material having opposing surfaces and bounding edges,
and a coating of a mixture of pigments and polymeric resins
electrostatically adhered to the opposing surfaces and edges, and
cured; erecting exterior walls with the plurality of building
panels; erecting interior walls with the plurality of building
panels; laying ceiling panels on the exterior walls and interior
walls with the plurality of building panels; and fabricating boxed
openings in the interior walls with the plurality of building
panels; wherein: the plurality of structural building panels
provide a structural strength of the building structure without use
of a supporting framework other than the structural panels.
18. A method as claimed in claim 17 wherein the step of providing a
plurality of panels includes cutting the plurality of sheets of
wood material to pre-determined dimensions for the building
construction prior to the steps of electrostatically adhering and
curing.
19. A method as claimed in claim 18 wherein the step of cutting the
sheet of wood material to pre-determined dimensions includes
cutting openings therein.
20. The method of claim 17 wherein erecting comprises mechanically
coupling adjacent structural panels.
21. The method of claim 17 wherein erecting comprises mating joints
in proximate panels.
22. The method of claim 17 wherein erecting comprises coupling an
edge of a first structural panel to an edge of a second structural
panel without coupling the first structural panel and the second
structural panel to the supporting framework.
23. The method of claim 17 wherein erecting exterior walls
comprises coupling each structural panel to a foundation.
24. The method of claim 17 wherein erecting exterior walls
comprises coupling a batten to an exterior of the exterior wall for
attaching siding.
25. The method of claim 17 wherein each structural panel that forms
the exterior walls is one and one-half inches thick whereby the
exterior walls withstand winds of up to 250 miles per hour.
26. A method for erecting at least a portion of a building using a
plurality of structural panels, the method comprising: erecting at
least one exterior wall with one or more structural panels of the
plurality of structural panels; erecting at least one interior wall
with one or more structural panels of the plurality of structural
panels; wherein: the plurality of structural panels provide are of
sufficient strength to independently support each wall of the
building; each structural panel includes: a sheet of wood composite
material, the sheet having opposing surfaces and bounding edges;
and a coating on the opposing surfaces and the bounding edges; and
the coating comprises a powdery mixture of pigments and polymeric
resins that is electrostatically adhered to the opposing surfaces
and bounding edges of each structural panel and is cured to form
the coating.
27. The method of claim 26 further comprising forming a ceiling
with one or more structural panels of the plurality of structural
panels.
28. The method of claim 26 further comprising cutting one or more
panels of the plurality of structural panels before
electrostatically adhering the powdery mixture to the structural
panel such that all surfaces formed by cutting are covered by the
coating.
29. The method of claim 28 wherein cutting forms at least one of an
edge shape, a rebate joint, a miter joint, a window opening, and a
door opening.
30. The method of claim 26 wherein erecting at least one exterior
wall comprises mechanically coupling adjacent structural
panels.
31. The method of claim 26 wherein erecting at least one exterior
wall comprises mating joints in proximate panels.
32. The method of claim 26 wherein erecting at least one of an
exterior wall and an interior wall comprises coupling an edge of a
first structural panel to an edge of a second structural panel
without coupling the first structural panel and the second
structural panel to the supporting framework.
33. The method of claim 26 wherein erecting at least one exterior
wall comprises coupling each structural panel of the exterior wall
to a foundation.
34. The method of claim 26 wherein erecting at least one exterior
wall comprises coupling a batten to an exterior of the at least one
exterior wall for attaching siding.
35. The method of claim 26 wherein each structural panel that forms
the at least one exterior wall is one and one-half inches thick
whereby the portion of the building that uses the plurality of
structural panels withstands winds of up to 250 miles per hour.
36. A method for erecting at least a portion of a building using a
plurality of structural panels, the method comprising: erecting at
least one exterior wall with one or more structural panels of the
plurality of structural panels; erecting at least one interior wall
with one or more structural panels of the plurality of structural
panels; wherein: the plurality of structural panels independently
supports the at least a portion of a building; each structural
panel comprises: a sheet of wood composite material, the sheet
having opposing surfaces and bounding edges; and a coating on the
opposing surfaces and the bounding edges; and the coating includes
a powdery mixture of pigments and polymeric resins that is
electrostatically adhered to the opposing surfaces and bounding
edges of each structural panel and is cured to form the coating.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 11/869,429 filed Oct. 9, 2007 which is incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] This invention relates to wall panels.
[0003] More particularly, the present invention relates to wood
panels for use in buildings and a method by which they are
employed.
BACKGROUND OF THE INVENTION
[0004] In the field of building construction, a conventional
building is typically constructed as a masonry structure, framework
structure, or a combination of both. Masonry construction typically
includes the erection of masonry walls of brick, block, or
concrete. Frame construction includes the erection of a supporting
framework of wood or metal for stability and strength. The
structure defined by the framework is typically enclosed by
sheathing. Sheathing consists of sheet material hung from the
framework, typically on an outer surface thereof. Drywall or sheet
rock is employed to finish the interior of the structure, and is
typically hung from an inner surface of the framework. The
materials used for sheet material include wood, metal, glass and
plastic products. Upon assembly of the structure, additional
procedures or treatments are required to enhance the aesthetics of
the building and increase its durability and weathering ability.
The treatments, such as the application of paint, water barriers
and the like, can be costly and time consuming, but are necessary
to protect the sheet material from the elements.
[0005] While used extensively over the ages, these building types
each have drawbacks. Masonry buildings are labor intensive and
require a large amount of heavy materials. Frame buildings while
lighter, still require a large amount of time for construction.
Both of these building types require expensive materials and man
hours of labor for construction as well as various additional
steps, such as painting, for completion.
[0006] The sheathing materials used include composite sheet
material. For this specific application wood based sheets
(lignocellulosic composites) are addressed. Wood based composite
sheets include particle board, flake board, plywood and the like.
Sheet material formed of wood products such as these use various
binders to create a solid structure.
[0007] Binder compositions which are used in making such composite
wood sheets include phenol formaldehyde resins, urea formaldehyde
resins and isocyanates. Each of these types of binders has its
advantages and disadvantages. Phenolformaldehyde and
urea-formaldehyde binders are relatively inexpensive and have high
structural strength. Their disadvantages include emission of
formaldehyde which can pose health risks and absorption of
moisture. The emission of formaldehyde has been addressed to some
extent by reformulating the binders to include a lower percentage
of formaldehyde. While generally successful, the modification to
the phenolformaldehyde and urea-formaldehyde binders also adversely
impacts the structural strength of the final product. The other
disadvantage of composite sheets made with these binders, moisture
absorption, is more problematic. In humid and damp environments,
composite wood sheets of this type can swell and distort causing
many problems and reducing the life of the composite sheet.
[0008] Isocyanate binders provide sheets with good structural
strength and have no formaldehyde emissions. They tend to be more
expensive, and have some processing difficulties. A specific
problem in processing is that the isocyanate has a undesirably
rapid reaction with water present in the wood material and any
water present in the binder composition itself. This problem can be
reduced by utilizing wood materials that have very low moisture
content. To obtain wood materials having low moisture content, it
is often necessary to dry the materials. This can substantially
increase the cost of the final product, and more importantly, the
dried wood material tends to absorb moisture and swell when the
final product is used in humid environments.
[0009] It would be highly advantageous, therefore, to remedy the
foregoing and other deficiencies inherent in the prior art.
[0010] An object of the present invention is to provide a panel for
building construction.
[0011] Another object of the present invention is to provide a
panel system for building construction having moisture resistant
characteristics.
[0012] Yet another object of the present invention is to provide a
method of using the panel for constructing building with weather
withstanding ability.
SUMMARY OF THE INVENTION
[0013] Briefly, to achieve the desired objects and advantages of
the instant invention, a building panel is provided. The building
panel includes a sheet of wood material having opposing surfaces
and bounding edges. The sheet of wood material is encased by a
coating of a mixture of pigments and polymeric resins
electrostatically adhered to the opposing surfaces and edges, and
cured.
[0014] Also provided is a method of fabricating a building panel.
The method includes forming a sheet of wood material,
electrostatically adhering a mixture of pigments and polymeric
resins to the sheet of wood material to completely encase the sheet
of wood material in a moisture resistant coating, and curing the
coating encasing the sheet of wood material.
[0015] Additionally, the step of curing includes heating the sheet
of wood material with the adhered mixture of pigments and polymeric
resins with ultra-violet light. In a specific aspect, the method
includes pre-heating the sheet of wood material with the adhered
mixture of pigments and polymeric resins prior to heating with
ultra-violet light.
[0016] The step of forming a sheet of wood material includes the
step of forming a sheet of composite wood material. A plurality of
wood piece is provided and mixed with a resin binder. The mixed
resin binder and wood pieces are formed in a sheet of wood material
with heat and pressure.
[0017] The step of forming the sheet of wood material can include
cutting the sheet of wood material to pre-determined dimensions for
a building construction prior to the steps of electrostatically
adhering and curing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Specific objects and advantages of the instant invention
will become readily apparent to those skilled in the art from the
following detailed description of a preferred embodiment thereof
taken in conjunction with the drawings, in which:
[0019] FIG. 1 is a cross sectional view of a panel according to the
present invention;
[0020] FIG. 2 is a plan view of a pre-cut panel according to the
present invention;
[0021] FIG. 3 is a is a simplified schematic illustration of an
exterior wall panel fastened to a foundation;
[0022] FIG. 4 is a perspective of panels used as exterior
walls;
[0023] FIG. 5 is a simplified top view of panels joined with a
rebate joint;
[0024] FIG. 6 is a simplified top view of panels joined with a
mitered joint;
[0025] FIG. 7 is a partial perspective view of panels joined as
interior walls;
[0026] FIG. 8 is a partial perspective view of panels joined as
interior walls;
[0027] FIG. 9 is a partial sectional side view of joined ceiling
panels;
[0028] FIG. 10 is a partial perspective view illustrating a truss
on the ceiling panels;
[0029] FIG. 11 is a top plan view of an interior wall box; and
[0030] FIG. 12 is a top plan view of another interior wall box.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] Turning now to the drawings in which like reference
characters indicate corresponding elements throughout the several
views, attention is first directed to FIG. 1 which illustrate a
sectional view of a panel according to the present invention,
generally designated 10. Panel 10 includes a wood composite sheet
material 12 fabricated of myriad pieces of wood. Conventional
composite wood sheet material includes particle board, flakeboard,
plywood and the like. These wood pieces can be of various shapes
and sizes and can be of newly acquired wood, recovered wood, or
recycled wood materials. The composite wood sheet material is
formed in a generally conventional manner. In this preferred
embodiment, flakeboard is the composite sheet material of choice
and will be described below.
[0032] The fabrication of flake board includes providing flakes or
pieces of wood material, generally of a substantially uniform size,
mixed with a binder resin, and bonded together with pressure and
heat. Most composite boards are produced by pressing a mat of resin
intermixed parts flat in a heated press. Extruded boards are
produced by forcing the resin imparted pieces between parallel
heated rollers. Wood composite sheet material 12 is then cut to the
desired dimensions, and can include shaped edges, such as bull
nose, rebated joints, miters and the like, and openings such as for
windows, doors, and the like.
[0033] To complete panel 10, wood composite sheet material 12 is
then sealed against moisture and provided with a durable and
esthetically pleasing surface. This is accomplished by providing a
mixture of fine particles of pigment and polymeric resin. The
powder is sprayed and adhered electrostatically to the surfaces of
wood composite sheet material 12 to form panel 10. Pre-heating
sheet material 12 is preferably part of this process. Panel 10 is
then heating in a curing oven utilizing UV radiation to fuse the
powder into a strong adhering coating 14. In this manner a
composite wood sheet material 12 is formed into panel 10 capable of
being subjected to the environment without adverse effects and
eliminating moisture absorption. Additionally, further steps during
construction are avoided, such as painting, weather proofing and
the like.
[0034] As can be seen with reference to FIG. 2, panel 10 can be
pre-cut prior to formation of coating 14. The desired edge shape,
rebate joints, miter joints, and the like, and openings such as
window and door openings are formed in composite wood sheet
material 12, so when coating 14 is formed, all surfaces, including
edges have the coating thereon.
[0035] Turning now to FIGS. 3 and 4, a method of constructing a
building using panel 10 of the present invention is illustrated. A
foundation 20 is first provided, and can be constructed in any
known manner, such as concrete slab, wood platform, and the like. A
sole plate 22 is laid on foundation 20, and the pre-sized panels 10
are then erected and braced as exterior walls 24. The foot edge of
panels 10 are held in position by an angle iron 23 extending
therealong and fastened to foundation 20. Panels 10 used for
exterior walls 24 of a building are preferably 11/2 inches thick,
and preferably measure 24 feet wide by 9 feet high. Battens 25 can
be attached using fasteners such as screws and glued to the
exterior surface of panels 10 used as exterior walls 24. Battens 25
extend vertically and provide additional strength and permit
attachment of siding if desired. The unique thickness and
dimensions of panels 10 allow the construction of buildings capable
of withstanding 200 mph winds. Additionally, since panels 10 have
been pre-cut to the desired dimensions and with the desired
openings such as for windows and doors prior to the completion of
the panel fabricating process with the addition of coating 14, all
surface are coated and protected against the elements.
[0036] Turning to FIGS. 5 and 6, panels 10 of exterior walls 24 are
joined employing rebate joints (FIG. 5) at perpendicular or end
joined panels 10, or mitered joints (FIG. 6) at perpendicular or
angled joined panels 10. The joints are glued with an adhesive 16
and coupled using fasteners such as screws 18.
[0037] Once panels 10 for exterior walls 24 are in place, interior
walls 27 are erected. Turning to FIG. 7, interior walls 27 are
attached to exterior walls 24 or other interior walls 27 (as shown)
using a rebate joint, fasteners such as screws, and an adhesive.
Panels 10 used for interior walls 27 are preferably 1 inch in
thickness. No headers are employed. Since all of the interior and
exterior panels are cut prior to installation very little
additional material removal is required. In this manner, the panels
are finished with coating 14 protecting the composite wood sheet
material 12 from adverse weather and in particular, moisture. Any
additional cuts or removal of material will be finished by adding a
pigment resin mixture, as in the coating, to the exposed edge.
Still referring to FIG. 7, the foot edge of panels 10 of interior
walls 27 are coupled to foundation 20 using any convenient means
such as anchors but preferably a tapcon fastening 19 is employed.
The edges of the interior walls can be shaped as desired, such as
being radiused or the like for esthetic purposes.
[0038] Referring to FIG. 8, angled interior walls are preferably
joined with panels 10 of interior walls 27 joined to panels 10 of
other interior walls 27 using rebate joints. Lesser angles can
employ miter joints instead.
[0039] Once interior walls 27 are positioned, ceiling panels 28 are
laid over the top edges of exterior walls 24 and interior walls 27
and attached by a fastener such as screws and an adhesive. As can
be seen in FIG. 9, panels 10 employed for ceiling panels 27 are
joined by an angled tongue and groove joint 30 supported by a plate
32 fastened to each panel 10 by fasteners 33. Plate 32 extends
along and across joint 30 between ceiling panels 28. With
additional reference to FIG. 10, trusses 35 are then positioned on
panels 10 used as ceiling panels 28 for the completion of a roof.
Once ceiling panels 28 are in place and attached to exterior walls
24 and interior walls 27, the bracing can be removed.
[0040] Interior walls 27 can appear unsubstantial at interior
openings such as doorways, archways and the like. This can be
esthetically improved by boxing the opening as illustrated in FIGS.
11 and 12. With reference to FIG. 11, the end of an interior wall
27 terminates in a box 40 formed of four pieces 42a, 42b, 42c, 42d
of a panel 10. The four pieces are joined using rebate joints as
illustrated, with channels formed in pieces 42a and 42c for
receiving the ends of pieces 42b and 42d. The pieces are fixed
using an adhesive within the joint, and a fastener such as screws.
Interior wall 27 terminates in a rebate joint with box 40. An end
of interior wall 40 is received in a channel formed in piece 42d. A
door frame 45, in this embodiment, is coupled to piece 42b. It will
be understood that an identical box is formed on the opposite side
of the door. It will also be understood that while interior wall 27
terminates centrally in piece 42d, interior wall 27 can terminate
at or closer to either pieces 42a or 42c. It is also noted that
corners of box 40 can be curved by providing curved edges to pieces
42a and 42c. A curved joint as illustrated can be employed on any
joint in the building.
[0041] Another embodiment of a box 40' is illustrated with
reference to FIG. 12. In this embodiment, only three pieces 42a',
42b' and 42c' are required. The fourth side of box 40' is provided
by the terminating interior wall 27'. A door frame 45' is attached
to piece 42c'. As will be understood, opening such as archways will
not employ doorframes and the like.
[0042] Various changes and modifications to the embodiments herein
chosen for purposes of illustration will readily occur to those
skilled in the art. To the extent that such modifications and
variations do not depart from the spirit of the invention, they are
intended to be included within the scope thereof, which is assessed
only by a fair interpretation of the following claims.
* * * * *