U.S. patent application number 13/210584 was filed with the patent office on 2013-02-21 for rapid deployment building system.
The applicant listed for this patent is Duane Armijo. Invention is credited to Duane Armijo.
Application Number | 20130042556 13/210584 |
Document ID | / |
Family ID | 47711616 |
Filed Date | 2013-02-21 |
United States Patent
Application |
20130042556 |
Kind Code |
A1 |
Armijo; Duane |
February 21, 2013 |
Rapid Deployment Building System
Abstract
A building system for rapid deployment. In one embodiment, the
building system comprises: a first panel having a front surface, a
back surface, an edge surface, and at least one structural element;
a second panel having a front surface, aback surface, an edge
surface, and at least one structural element; and at least one clip
for connecting the first panel to the second panel, wherein the
first panel and the second panel are formed of expanded
polystyrene.
Inventors: |
Armijo; Duane; (Scottsdale,
AZ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Armijo; Duane |
Scottsdale |
AZ |
US |
|
|
Family ID: |
47711616 |
Appl. No.: |
13/210584 |
Filed: |
August 16, 2011 |
Current U.S.
Class: |
52/309.4 ;
52/515; 52/582.1 |
Current CPC
Class: |
E04B 1/6183 20130101;
E04C 2/40 20130101; E04B 5/023 20130101; E04B 5/026 20130101; E04B
7/22 20130101; E04B 1/6125 20130101; E04B 2001/386 20130101; E04C
2/205 20130101; E04B 1/14 20130101; E04B 2001/6195 20130101 |
Class at
Publication: |
52/309.4 ;
52/582.1; 52/515 |
International
Class: |
E04B 1/38 20060101
E04B001/38; E04B 1/66 20060101 E04B001/66; E04C 2/20 20060101
E04C002/20 |
Claims
1. A building system for rapid deployment comprising: a first panel
having a front surface, a back surface, an edge surface, and at
least one structural element; a second panel having a front
surface, a back surface, an edge surface, and at least one
structural element; and at least one clip for connecting the first
panel to the second panel.
2. The building system of claim 1, wherein the first panel and the
second panel are formed of expanded polystyrene.
3. The building system of claim 2, wherein the first panel and the
second panel are molded or extruded.
4. The building system of claim 1, wherein the structural element
is integral with the first panel, the structural element running
substantially parallel with the edge surface.
5. The building system of claim 4, wherein the structural element
is made of light-gauge steel.
6. The building system of claim 4, wherein the first panel and the
second panel includes a plurality of structural elements set at
predetermined intervals in each of the first panel and second
panel, the plurality of structural elements running substantially
parallel to the edge surface.
7. The building system of claim 1, wherein the at least one clip is
formed of light-gauge steel.
8. The building system of claim 7, wherein the at least one clip
connecting the first panel to the second panel is fastened to each
panel via a fastener.
9. The building system of claim 8, wherein the fastener includes
one of a screw, a nail, a peg, or a latch.
10. The building system of claim 1, wherein one of the surfaces is
molded to appear like one of bricks, siding, wood, and stucco.
11. The building system of claim 1, further comprising: an exterior
coating covering each of the panels, wherein under the condition
that the panels are coupled together to form a building, the
exterior coating of the respective panels contacts one another to
substantially cover the complete exterior surface of the
building.
12. The building system of claim 11, wherein the exterior coating
comprises a non-cementitious coating.
13. A building system for rapid deployment comprising: a first
panel having a front surface, a back surface, an edge surface, and
at least one structural element; a second panel having a front
surface, a back surface, an edge surface, and at least one
structural element; at least one clip for connecting the first
panel to the second panel; and an exterior coating applied to each
of the first panel and second panel, wherein the exterior coating
comprises a non-cementitious coating, wherein the first panel and
the second panel are formed of expanded polystyrene, wherein the
first panel and the second panel are molded or extruded, wherein
the structural element is integral with the first panel, the
structural element running substantially parallel with the edge
surface, wherein the structural element is made of light-gauge
steel, wherein the first panel and the second panel includes a
plurality of structural elements set at predetermined intervals in
each of the first panel and second panel, the plurality of
structural elements running substantially parallel to the edge
surface, wherein the at least one clip is formed of light-gauge
steel, wherein the at least one clip connecting the first panel to
the second panel is fastened to each panel via a fastener.
Description
TECHNICAL FIELD
[0001] This invention relates generally to building components and
more particularly to panels used to create building walls, floors,
and ceilings.
BACKGROUND OF THE INVENTION
[0002] Building structures are typically constructed on-site from
wood, brick, stucco, and steel, as well as other materials. Wood
has always been a favorite because of its easy availability, its
hardiness and the ease with which it can be formed and connected to
make different shaped building structures. Wood is still the most
common element use as the basis for creating building walls and
building roofs in homes and smaller industrial buildings. Brick and
concrete blocks are also commonly used for walls in homes and
commercial buildings, and steel is used as the structural element
in some homes and in most commercial construction. In recent years
the construction industry has been working to develop building
construction techniques and material which are environmentally
friendly during both construction and usage of the building.
[0003] The use of wood is not always ideal because it uses the
natural resource of trees and there is much waste when the wood is
cut and much of it is discarded on the building site. For both
brick and steel, there is a push to reduce the energy consumption
of forming these basic building structures and in using recycled
material in the fabrication of the mortar and steel components.
There is a need for building components which use a minimum of
resources and energy to manufacture, which reduce die amount of
material waste at the building site, and which are energy efficient
once assembled into a building structure.
[0004] Typical building construction techniques include sending the
basic building blocks of wood, steel, bricks or blocks to the
building site, where they are cut, formed, and connected into a
building. This can require a high level of manpower and energy
consumption at the building site to construct the building, and can
result in wasted raw materials. There is a need for building
components which are formed to the correct size and shape during
manufacture and which can then be quickly and easily connected to
create a building at the site, resulting in a minimum of resource
usage and labor at the building site.
[0005] The construction and maintenance of temporary shelters also
pose several problems. When tents are used the tents are not energy
efficient and die wails are not sturdy. When wooden structures are
used as temporary shelters, the temporary building is difficult to
reuse due to nails and other connecting means which are hard to
efficiently separate from the building material once the structure
is taken down after the first use. Much of the building material is
wasted and often the structure can only be used once. Thus, there
is a need for building components which can be used to create
sturdy, energy efficient temporary structures that can be assembled
quickly and easily, and reused over and over.
[0006] Therefore, building components are proposed which are
manufactured to the needed size and shape at the factory, require
minimal energy resources to create and sustain a building, can be
reused in the case of temporary shelters, and require minimum labor
to assemble into a building.
SUMMARY OF THE INVENTION
[0007] The present invention relates to building components, and
more particularly to panels used to form walls, floors, and roofs
of buildings. The buildings constructed from these panels can be
homes, offices, storage facilities, or any other type of building
structure. The present invention discloses a building system
comprising a first panel formed of expanded polystyrene with a
front surface, a back surface, and an edge surface, and a second
panel formed of expanded polystyrene with a front surface, a back
surface, and an edge surface, wherein the first panel and the
second panel are used to form a portion of a building. In some
embodiments the first panel has a tongue, and the second panel has
a groove, and the tongue and the groove are used to couple the
first panel and the second panel together. In some embodiments the
tongue and groove are coupled together with a latch mounted in the
tongue of the first panel and a latch receiver mounted in the
groove of the second panel. The first panel and the second panel
can be formed by molding the expanded polystyrene, In some
embodiments the first and the second panel are formed by molding
other moldable materials. In some embodiments structural elements
are molded into the first or the second panel. The structural
element can be formed of light gauge steel.
[0008] In other embodiments of the present invention, the first and
second panel are joined together by a clip. The first and second
panels may be fastened to the clip via screws, and the clip may be
formed of light gauge steel.
[0009] A method of constructing a building is disclosed comprising
constructing a floor system for a building, and then assembling a
wail system from a plurality of expanded polystyrene panels,
wherein a first panel and a second panel are attached via a clip
system to join the two panels and to provide structural support.
The wall system is connected to the floor system, followed by
assembling a roof system and connecting the roof system to the wall
system. A door is attached to the wall system to form a building,
The method can include many other steps. In some embodiments
windows are added. In some embodiments additional doors are added.
In some embodiments the expanded polystyrene panels comprising the
wall system are formed by molding. In some embodiments the floor
system is comprised of expanded polystyrene panels. In some
embodiments the roof system is comprised of expanded polystyrene
panels.
[0010] The foregoing and other features and advantages of the
present invention will be apparent from the following more detailed
description of the particular embodiments of the invention, as
illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a top view, perspective view, and side view of a
panel 100 which is one embodiment of a component of building system
102 according to the invention.
[0012] FIG. 2 is a perspective view of panels 100 and 100a
according to the invention.
[0013] FIG. 3 is a perspective view of panels 100 and 100a of FIG.
2 connected using tongues 112 and grooves 114.
[0014] FIG. 4 is a top view, perspective view, and side view of
panel 100 of FIG. 1 with end caps 120 added.
[0015] FIG. 5a and 5b are a top view and side view, respectively,
of a panel 100 according to the invention with lock assemblies 129
added
[0016] FIG. 5c is a perspective view of lock assembly 129 used in
panel 100 according to the invention
[0017] FIG. 5d shows end and side views of rotating latch 136 and
latch receiver 138 of lock assembly 129.
[0018] FIG. 6a and 6b are additional perspective views of panels
100 and panels 100a according to the invention.
[0019] FIG. 7a and 7b are perspective views of panels 100b and 100c
according to the invention.
[0020] FIG. 8 is a top view, perspective view, and side view of a
panel 100d according to the invention.
[0021] FIG. 9a shows components of building system 102 as
embodiments of panels 100d connected together with hinge 160.
[0022] FIG. 9b and 9c shows embodiments of panels 100d of building
system 102 showing tongues 112, grooves, 114, and rotating latches
136 and latch receivers 138 of lock assembly 129.
[0023] FIG. 9d shows an embodiment of panel 100d with inner layer
154.
[0024] FIG. 10a and 10b shows components of building system 102 as
embodiments of panels 100e including exterior coating 150
[0025] FIG. 11a through FIG. 11e shows components of building
system 102 as embodiments of panels 100c connected as a
wall-to-roof connection.
[0026] FIG. 12a shows components of building system 102 as
embodiments of panels 100 connected together to form floor system
141.
[0027] FIG. 12b shows components of building system 102 as
embodiments of panels 100 connected together to form wall system
142, which is connected to floor system 141.
[0028] FIG. 12c shows components of building system 102 as
embodiments of panels 100 connected together to form roof system
143, which is connected to wall systems 142.
[0029] FIG. 12d shows components of building system 102 as
embodiments of panels 100 connected together to form building 140
with window 182 and door 183 attached.
[0030] FIG. 13 shows components of building system 102 as
embodiments of panels 100e connected as a wall-to-roof
connection
[0031] FIG. 14 shows components of building system 102 as
embodiments of panels 100d and how the various embodiments of
panels 100d can be connected in wail-to-floor connections,
wall-to-wall connections, wall-to-roof connections, and other
embodiments.
[0032] FIG. 15 shows a method 200 according to the invention where
method 200 is a method of constructing a building.
[0033] FIG. 16 shows components of building system 400 as
embodiments of panels 300 connected to horizontal panel 306.
[0034] FIG. 17 shows structural elements 316 and 318 in panels
300.
[0035] FIG. 18 shows embodiments of the deck floor and roof section
components of building system 400.
[0036] FIG. 19 shows an embodiment of panel 300 as used in building
system 400.
[0037] FIG. 20 shows an exemplary building system 400 according to
one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0038] As discussed above, embodiments of the present invention
relate to building components, and more particularly to panels used
to form walls, floors, and roofs of buildings.
[0039] Conventional building construction materials and techniques
result in a high level of waste and energy-inefficiency. Using wood
to build structures reduces natural resources and much of the wood
is wasted on-site as wooden pieces are cut to fit. On-site
construction techniques require high labor costs and low re-use of
building materials after the life of the building. There is a need
in the construction industry for building components which use
resources more efficiently throughout the entire construction
chain, from manufacture of construction material and components,
through construction of a building, throughout the useful life of a
building, and by efficient recycling and reuse of materials after
the building life is ended. There is also a particular need for
building components for temporary structures and shelters which are
configurable, rapidly deployable, energy-efficient, and re-usable
many times. The current invention provides a solution to these
problems, disclosing panels used for constructing a building made
from energy conserving and recycled base materials. The panels
according to the invention are manufactured for modular, scalable,
and customizable construction, and the resultant structure composed
of these panels forms an energy efficient, user-friendly, long life
structure.
[0040] FIG. 1 shows an embodiment of the invention as panel 100, a
component of building system 102 according to the invention. FIG.
la shows a top view of panel 100 according to the invention. FIG.
lb shows a perspective view of panel 100, and FIG. 1c shows a side
view of panel 100.
[0041] FIG. 1 shows an embodiment of panel 100 having back surface
122, front surface 124, and four edge surfaces 125, 126, 127, and
128. Panel 100 has tongue 112 on edge 127 and groove 114 on edge
128. Panel 100 also includes four structural elements 116.
[0042] In this embodiment panel 100 is composed of expanded
polystyrene (EPS) material. Using expanded polystyrene allows
panels to be formed by molding. These panels can be formed in any
size and shape to create buildings of any size and shape, including
curved and multi-story structures. Using expanded polystyrene
results in panels with excellent thermal protection. The panels are
lightweight and can be used for walls, floors, or roof systems. The
EPS can be recycled after the useful life of the building is over.
Panel 100 is made of EPS material in this embodiment so that panel
100 has weight, strength and thermal characteristics suitable for
buildings. Indeed, panel 100 has insulative properties, including
at least R12 insulation in the panel 100 that is used in the walls
of the building and at least R15 insulation in the panel 100 that
is used in the floor or roof of the building. In this embodiment
panel 100 is formed from EPS but plastic, fiber, foam, or any other
suitable material can be used to form panel 100. In some
embodiments panel 100 is formed from material other than expanded
polystyrene. In some embodiments panel 100 can be made from an
anti-ballistic material.
[0043] Panel 100 can be made in any dimension suitable for the
building it will be forming. In a particular embodiment panel 100
is 5.5 inches thick, 48 inches wide, and 96 inches tall, or long.
In other embodiments panel 100 has other dimensions. The thickness
of panel 100 is chosen to provide the thermal and mechanical
requirements of the building to be formed. In some houses for
example, panel 100 will be thick enough to provide high thermal
insulation, high mechanical strength and a long lifetime. In other
embodiments, such as where panel 100 is used for temporary shelter
or temporary buildings, a thinner panel may be desired so that
panel 100 is lightweight and can be carried and assembled
easily.
[0044] Panel 100 in this embodiment is molded from EPS for ease of
manufacture, but in other embodiments panel 100 can be extruded or
formed into the correct dimensions using other means. In some
embodiments of the invention panel 100 has an air cavity within
panel 100. This will result in panels 100 that are lightweight.
[0045] Panel 100 as shown in FIG. 1 has tongue 112 on edge 127 and
groove 114 on edge 128. Tongue 112 of panel 100 is formed such that
it will couple with groove 114 of an adjacent panel 100, as shown
in FIG. 2 and FIG. 3. Tongue as used in this document is defined as
a protuberance from a structure which couples with a corresponding
groove in a mating structure to couple the two structures together,
And groove is defined as the corresponding mating channel for the
tongue, This is the common definition of tongue and groove as used
in the building industry. Tongue 112 and groove 114 are shown in
this embodiment as rectangular shaped structures, but any shape can
be used which will allow the two panels to repeatably, or
nonrepeatably, couple together. In some embodiments tongue 112 can
be circular or oval shaped. In some embodiments tongue 112 can be
shaped with ridges or curves. In some embodiments tongue 112 can
include multiple protuberances, and groove 114 can have multiple
channels. In the embodiment shown in FIG. 1 tongue 112 has a single
protuberance and groove 114 has a single channel.
[0046] Panel 100 includes structural elements 116 which provide the
function of structural studs within the panels. In this embodiment
structural element 116 is made of light gage steel to add
structural support to panel 100 and to provide a surface on the
front and back of panel 100 to attach or mount other structures to.
Structural elements 116 take the place of studs as used in a wood
frame building structure. Panel 100 has four square tubular
structural elements 116 as shown, two along front surface 124 and
two along back surface 122. Structural elements 116 can be formed
into panel 100 during molding, In this embodiment structural
elements 116 are formed of light gage steel, but in general
structural elements 116 can be formed of any suitable material such
as metal, plastic, wood, or any other material which will provide
the function of adding structural integrity and serving as a wall,
ceiling, or floor stud for mounting or attaching to. Structural
elements can take many different forms, as will be seen in later
figures, and be placed in any desired configuration relative to the
structure of panel 100. Creating panel 100 from molding allows the
shape and placement of elements within panel 100 to be flexible and
configurable during manufacture of panels 100. Panel 100 can have
other items molded into the structure of panel 100 as needed, Tubes
or channels can be molded into panel 100 to route wires or pipe
through. Wire mesh can be embedded into panel 100 to provide
electromagnetic interference (EMI) shielding, radio frequency (RF)
shielding, and/or infrared (IR) shielding as needed for the
building to be assembled using panel 100. Panel 100 can be molded
with openings or holes for windows, air vents, pipes, etc to be
installed or pass through. Since molds can be made in any shape,
size, and outline, the form of panel 100 is not limited by the
starting material as it is with wood or brick building
materials.
[0047] Panel 100 is shown in FIG. 1 as a flat square panel, with
tongue 112 on one edge and groove 114 on another edge. Panel 100
according to the invention, however, can be many different shapes
according to the intended use in the building. Panel 100 in some
embodiments is square, rectangular, triangular or any other shape
necessary in building a particular structure. Panel 100 can have
tongues 112 on multiple surfaces, including any of the edges or the
front surface 124 or back surface 122. Panel 100 can have grooves
114 on multiple surfaces, including any of the edges or the front
surface 124 or back surface 122.
[0048] Panel 100 does not have to be flat. FIG. 2 and FIG. 3 shows
how panel 100 and panel 100a are mated together to form a portion
of a building wall with corner 118. Panel 100a has corner 118 which
can form a corner in a wall. Corner 188 can also form a corner on a
roof, floor, or any other building surface, Panel 100a has
structural element 116a molded into the interior of corner 118 and
structural element 116 molded into the exterior of corner 118 to
add strength and structural integrity to corner 118. Panel 100 a
shows a 90-degree corner 118, but in some embodiments corners can
be molded into panel 100 which have different angles, typically
ranging from 0 to 180 degrees. Whatever angle is needed for the
building to be assembled can be molded into panel 100. It should be
understood that panel 100 can be constructed in any particular size
and shape needed to form any portion of a building as needed.
[0049] Tongue 112 of adjacent panels 100 mount into groove 114 of
panel 100 as shown in FIG. 2 and FIG. 3. In some embodiments tongue
112 and groove 114 can be formed so that this coupling is a
one-time coupling which can not be reversed. In some embodiments
tongue 112 and groove 114 are formed so that the coupling is
repeatable and reversible. In other embodiments tongue 112 and
groove 114 are coupled so that the attachment is not permanent but
may be difficult to reverse. The permanency of coupling is
determined by the building and its use. For temporary structures
which may be assembled and disassembled many times during the life
of the panels, couplings for tongue 112 and groove 114 which are
reversible may are used. For permanent structures it may be
desirable in some embodiments to couple tongue 112 and groove 114
in a permanent fashion. In other embodiments where the building is
long-term but changes might be desirable, the coupling can be
durable and reversible but not necessarily be quick to reverse.
[0050] FIG. 4 shows components of building system 102 according to
the invention including panel 100 with end caps 120. FIG. 4a shows
a cross-section of two end caps 120. End caps 120 in this
embodiment are formed of light gage steel and provide protection to
edges 127 and 128 of panel 100. FIG. 4b shows a top edge view of
panel 100 with end caps 120 mounted to respective ends 127 and 128.
FIG. 4c and FIG. 4d shows a perspective view and side view,
respectively, of panel 100 with end caps 120 mounted to edges 127
and 128. Tongue 112 and groove 114 of edges 127 and 128 can be the
weakest elements of panel 100 due to the small structural width and
the stresses they experience during shipping and assembling. End
caps 120 protect tongue 112 and groove 114 from chipping, breaking,
bending, mis-shaping, etc. and add structural strength after
assembling. End caps 120 can be formed into panel 100 during
manufacturing or added to panel 100 after forming panel 100. End
caps 120 can be any shape needed to match the contours of panel
100. End caps 120 in this embodiment are made of light gage steel,
but end caps 120 can be formed of any material capable of
protecting the edges of panel 100. End caps 120 can be made of
plastic, metal, or other durable material. The end caps 120 may am
the length of the panel 100 along the edges 127 and 128 or,
alternatively, the end caps 120 may cover only a portion of the
edges 127 and 128. Where the end caps 120 run the entire length of
the edges 127 and 128, the end caps 120 can have openings therein
to accommodate a latch 136 and latch receiver 138, to be discussed
in more detail below.
[0051] FIG. 5 shows components of building system 102 according to
the invention including panel 100 with lock assemblies 129. In this
embodiment lock assembly 129 is an R2-0267-02 lock from Allegis
Corporation. In other embodiments different lock assemblies 129 are
used. FIG. 5a shows a top view of two panels 100 coupled with lock
assemblies 129. FIG. 5b shows a side view of two panels 100 coupled
with lock assemblies 129. FIG. 5c shows a perspective view of lock
assembly 129, and FIG. 5d shows side cross-sections of lock
assembly 129. Lock assembly 129 is used to couple tongue 112 and
groove 114. In some embodiments lock assembly 129 can repeatably
couple tongue 112 and groove 114. In this embodiment lock assembly
129 includes latch 136, which includes rotating tumbler 131 and
latch actuator 135, and latch receiver 138. Panel 100 includes
latch hole 132, latch receiver hole 134, and lock access hole 130
(see FIG. 10). Latch 136 is positioned in panel 100 next to groove
114, in latch hole 132. Latch receiver 138 is positioned in panel
100 in latch receiver hole 134, in tongue 112 (see FIG. 10). Latch
136 and latch receiver 138 are positioned in panel 100 so that when
tongue 112 and groove 114 are mated for assembly, latch 136 can be
accessed through lock access hole 130 to activate latch 136, which
will couple latch 136 to latch receiver 138, which couples tongue
112 to groove 114, In this way latch 136 couples to latch receiver
138 of an adjacent panel 100, coupling adjacent panels 100
together. In this way tongue 112 is coupled to groove 114, coupling
adjacent panels 100 together, FIG. 5 shows panel 100 comprising six
latches 136 and six latch receivers 138, three on each of two
sides, but any number of latch 136 and latch receivers 138 can be
used along any appropriate edges to couple panels 100 together.
FIG. 5 shows latch 136 and latch receiver 138 being used to couple
together two panels 100 which are both flat, but latches 136 and
latch receivers 138 can be used with any type or shape of panel
100, such as corner panel 100a of FIG. 2 and FIG. 3, or any other
type or shape of panel 100.
[0052] FIG. 6a and FIG. 6b show additional illustrations of
components of building system 102 as panels 100 and 100a according
to the invention, including panel 100 and 100a formed of EPS,
tongue 112 and groove 114 molded into panel 100 and 100a, and
structural elements 116 molded into panel 100 and 100a.
[0053] FIG. 7a and FIG. 7b shows additional embodiments of panel
100 according to the invention, including corner panel 100b and
flat panel 100c. Panels 100b and 100c can be formed of molded EPS,
with tongue 112 and groove 114 on edges 127 and 128. Panels 100b
and 100d have structural elements 116 which consist of square
tubular structural element 116, corner structural elements 116a,
and v-shaped structural elements 116b. Panel 100b and 100c can have
a smaller thickness than panels 100 and 100a. It should be
understood that panel 100 can be made any suitable thickness
according to the strength, weight, and thermal and structural
characteristics needed for specific buildings. Panel 100b and 100c
can be used when lighter and thinner panels are desired. Any type
or placing of structural elements 116 can be used to provide the
desired structural or attachment requirements.
[0054] FIG. 8 shows additional components of building system 102
according to the invention including panel 100d having two tongues
112 on edge 127 and two grooves 114 on edge 128. Multiple tongues
112 and grooves 114 add strength and durability to the coupling of
adjacent panels 100d. FIG. 8a shows atop edge view of panel 100d,
FIG. 8b a perspective view of panel 100d, and FIG. 8c a side view
of panel 100d. Panel 100d as shown includes lock assembly 129. In
some embodiments panel 100d does not include lock assembly 129.
FIG. 9a shows multiple panels 100d coupled together using tongues
112, grooves 114, and lock assembly 129. In some embodiments panel
100d can include end caps 120 as shown in FIG. 9a. Panel 100d
includes structural elements 116c molded into panel 100d.
Structural elements 116c have a different shape than structural
elements 116, 116a, and 116b shown earlier. Structural elements
116c have a wing-shape as shown. Panel 100d can in some embodiments
include structural elements 116, 116a, or 116b shown in other
figures, or different shaped structural elements 116. It should be
understood that structural element 116 can take many different
shapes and forms as desired.
[0055] Panel 100 according to the invention can be formed in any
shape and connected in many ways to create a structure. Panels 100
can be used to form walls, floors or roofs of a building, or any
other structure. Panel 100 can be formed with a thickness that fits
the thermal and mechanical needs of the building to be formed.
Panel 100 can be formed with many different numbers and shapes of
structural elements 116 embedded therein, to provide the needed
attachment, support and strength.
[0056] FIG. 9a shows an additional embodiment of components of
building system 102 according to the invention, including panels
100d and coupled together with hinge 160. Hinge 160 allows panels
100d to rotate with respect to one another at a corner. Hinge 160
can be used to couple two panels 100 to form a wall-to-wall corner.
Hinge 160 can also be used to couple two panels 100 to form a
wall-to-floor corner. Hinge 160 can be used to couple two panels
100 together to form a door-to wall corner, Hinge 160 can be used
to couple two panels 100 together to form a wall-to-roof corner.
Hinge 160 is only one example of how multiple panels 100 can be
coupled together. Multiple panels 100 can be coupled together using
tongue 112 and groove 114, or multiple panels can be coupled
together using hinge 160. In some embodiments multiple panels can
be coupled together using different coupling means. These coupling
means can include screws, glue, bolts, nails, staples, locks,
hinges, etc.
[0057] FIG. 9b and FIG. 9c shows additional embodiments of panels
100d coupled together with tongues 112, grooves 114, and lock
assembly 129, which includes latch 136 and latch receiver 138.
[0058] Panels 100 according to the invention can be made with one
or more inner layers 154, as shown in FIG. 9d. FIG. 9d shows panel
100d with a single inner layer 154. Inner layer 154 can be made of
many different materials. In some embodiments inner layer 154 can
be air. In some embodiments inner layer 154 can be a Kevlar.RTM.
material as made by DuPont. In some embodiments inner layer 154 can
be plastic, EPS, rubber, or other material. In some embodiments
inner layer 154 can be an anti-ballistic material, FIG. 9d shows a
single inner layer 154, but some embodiments have multiple inner
layers 154.
[0059] FIG. 10 shows an embodiment of components of building system
102 as panel 100e, which has exterior coating 150 applied to the
outer surface. Exterior coating 150 can be added to protect the
outside of panel 100, protecting the surfaces from chipping,
wearing, denting, deteriorating, and damage from people, insects,
and animals during the lifetime of panel 100, Exterior coating 150
can be or can include a fire resistant coating to improve the fire
prevention capabilities of panels 100e. In some embodiments
exterior coating 150 can be an anti-ballistic material. Exterior
coating can be applied over top of panel 100 and in some
embodiments, over at least a portion of the end caps 120, as shown
in FIG. 10, Exterior coating 150 can be a hard coating, or it can
be a pliable coating. Exterior coating 150 can be applied over
panel 100 so that exterior coating 150 on a first panel 100 can
come into contact with the exterior coating 150 on a second panel
100 connected to the first panel 100. For example, the exterior
coating 150 can be formed on the horizontal panel 100e, shown in
FIG. 10a, except over the groove 114. The exterior coating 150 can
also be formed on the vertical panel 100e, shown in FIG. 10a,
except over the edge surface and tongue. When the tongue 112 of
vertical panel 100e is placed within the groove 114 of horizontal
panel 100e and the lock assembly 129 is actuated, the exterior
coating 150 of the vertical panel 100e can come into contact with
the exterior material 150 of the horizontal panel 100e, such that
the resulting building is completely covered with exterior coating
150. FIG. 10b shows a close-up cross section showing lock assembly
129 including latch 136, latch hole 132, latch receiver 138, latch
receiver hole 134, and lock access hole 130. Once tongue 112 is
inserted into groove 114, lock access hole 130 can be used with a
locking tool to activate latch 136 and couple it to latch receiver
138, maintaining the coupling of the two panels 100e. The coupling
shown in FIG. 10 can be a wall-to-wall coupling, a floor-to-wall
coupling, a wall-to-roof coupling, or a coupling between other
types of panels 100. FIG. 10 also illustrates how groove 114 does
not have to be on an end edge surface of panel 100. In FIG. 10
groove 114 is on surface 122 and tongue 112 is on edge 127. Tongue
112 and groove 114 can be on any surface of panel 100 to create a
coupling between any of the surfaces.
[0060] FIG. 11 shows additional components of building system 102
according to the invention including panels 100e and illustrating
how two panels 100e can be connected to make a wall-to-roof
connection, where the roof is slanted. FIG. 11a shows a
cross-section of two panels 100e connected via tongue 112, groove
114, and lock assembly 129. The edges of the two panels 100c are
angled so that one can be a slanted roof of a building. It should
be evident that panels 100 according to the invention can be any
shape, size, or angle to form whatever shape and size of building
structure is needed. FIG. 11b shows a close up of the corner
section with lock assembly 129. FIG. 11c shows a close up of `c`
channel 171 used on the interior of panel 100e used as a portion of
a roof. `C` channel 171 is adjustable and can add to the structural
integrity and strength of the building structure, specifically the
structural integrity of the roof and the adjoining walls. `C`
channel 171 includes wingnut 172 and slot 173, The length of the
`c` channel 171 running along the interior of the roof may be
adjusted using the wingnut 172 and slot 173. FIG. 11d shows a close
up of support piece 174 which is molded into panel 100e. Support
piece 174 has three studs 175 which couple support piece 174 to
panel 100e. Support piece 174 is connected by wingnut 172 and slot
173 to `c` channel 171. After coupling wall panel 100e to roof
panel 100e, wingnuts 172 can be adjusted and tightened in slots 173
to provide additional attachment and structural integrity between
wall panel 100e and roof panel 100e. For example, the pitch of the
`c` channel 171 referenced from the support piece 174 can be
adjusted using the wingnuts 172 in slots 173.
[0061] FIG. 12 illustrates components of building system 102 as
used to create building 140. FIG. 12a shows how panels 100
according to the invention are used to create floor system 141.
FIG. 12b shows panels 100 according to the invention being used to
create wall systems 142 connected to floor system 141. FIG. 12c
shows panels 100 according to the invention being used to create
roof system 143. FIG. 12d shows building 140 built from panels 100
after door 183 and window 182 have been added.
[0062] To create floor system 141 as shown in FIG. 12a, the ground
is prepared and leveled if required, and panels 100 laid out to the
proper size. Each panel 100 is connected to adjacent panels 100
using tongues 112 and grooves 114 and lock assemblies 129 if used.
It should be understood that panels 100 as shown can be any
embodiment of panel 100 including panels 100a, 100b, 100c, 100d, or
100c as shown and discussed earlier. Some panels 100 used in floor
141 may be different embodiments. Any combination and number of
panels 100 can be used to create floor 141 of the desired shape,
thickness, and size.
[0063] Wall systems 142 are created by coupling adjacent panels 100
as shown in FIG. 12b. Adjacent panels 100 can be coupled by
connecting tongues 112 to grooves 114 and actuating lock assemblies
129 if used. Not all panels in FIG. 12b are labeled panel 100, but
it should be understood that each panel can be a panel 100
according to the invention. Each panel can be an embodiment of
panel 100 as discussed and shown earlier, such as panel 100a, 100b,
100c, 100d, 100e, or any combination of these panels. Some panels
may be different embodiments of panel 100 according to the
invention. Wall systems 142 can be assembled and connected while
laying on the ground and then raised and connected to floor system
141 and adjacent wall systems 142. Or, wall systems 142 can be
assembled in place by starting with a panel 100 used as a corner
piece, connecting tongues 112 and groove 114 between panel 100 and
floor system 141, and continuing by attaching each successive panel
100 to create wall system 142.
[0064] Roof system 143 can be assembled separately from panels 100
and then raised and attached to wall systems 142. Or roof 143 can
be assembled in place on wall system 142. Not all panels in FIG.
12c are labeled panel 100, but it should be understood that each
panel can be a panel 100 according to the invention. Each panel can
be an embodiment of panel 100 as discussed and shown earlier, such
as panel 100a, 100b, 100c, 100d, 100e, or any combination of these
panels. Each tongue 112 is coupled to appropriate groove 114 and
lock systems 129 are activated if used.
[0065] Completed building 140 according to the invention as shown
in FIG. 12d is an embodiment of a rapidly deployable building 140
after a door 183 and a window 182 have been added. This particular
embodiment of building 140 constructed from a plurality of panels
100 can be constructed quickly and efficiently with a minimum of
labor costs. Panels 100 are made to the correct size and shape at
the factory and received ready to install. Moreover, each of the
panels 100 can be indentified as a floor panel, a wall panel, a
roof panel, a door panel, a window panel, or other applicable panel
within the building 140. Also, each of the panels 100 can be
labeled within the building system to assist the user in assembling
the panels into the building 140. Each panel 100 can have a set
position within the building 140, and this position can be marked
on the panel 100, for example, in color code or numerical code, to
ease assembly. This minimizes material waste at the site and speeds
construction. FIG. 12d shows a particular size and shape building
140, but it should be understood that the size and shape of
building 140 is configurable. In addition, internal wall systems
using panels 100 can be added to divide interior space into any
number of rooms and structures. Integrated power systems can be
added to provide power to building 140. Panels 100 can be used to
construct a building of any footprint that is durable, affordable,
and energy efficient. When the useful life of building 140 as shown
in FIG. 12d is over, it can be quickly and easily dismantled and
the panels 100 used again in another structure. After the useful
life of panel 100 is over it can be recycled. Ease of re-use and
recycling is designed into panels 100 by virtue of their modular
design, long life material, and integral coupling structure.
[0066] Panels 100 can be used to construct structures used as homes
and residences, commercial buildings, offices, storage facilities,
etc. The structures constructed from panels 100 can be temporary or
long-term structures. The examples provided here of components of
building system 102 and structures formed from building system 102
and panels 100 are not exhaustive of the possibilities. Many other
embodiments are possible. For instance, walls or other building
structures can be formed of multiple layers of panels 100. This
will add to the structural integrity and thermal characteristics of
the structure being created. In some embodiments layers of panels
100 can be coupled together with an air gap in between. In some
embodiments this air gap can be further filled with material such
as foam or additional EPS.
[0067] FIG. 13 shows additional embodiments of components of
building system 102 including using panel end cap mounting assembly
165 to provide the capability to mount additional structures to a
building constructed from panels 100. FIG. 13 shows a cross-section
of two panels 100e connected in a wall-to-roof configuration using
lock assembly 129 and tongue 112 and groove 114. In addition to
having end caps 120 over panel edges, panel end cap mounting
assembly 165 is inserted between the coupled edges of the two
panels 100e. Panel end cap mounting assembly 165 can be used to
mount many different structures to panels 100e. In this embodiments
panel end cap mounting assembly 165 provides a mount for truss 166
internal to the structure, and for roof structure 164 mounted
outside the structure. Roof structure 164 is mounted to panel end
cap mounting assembly 165 using roof structure mounting arm 163.
Roof structure 164 can be many different items, including but not
limited to antennae, solar panels, shade structures, water
collectors, etc. It should be understood that panels 100 can be
configured to include different forms of mounting structures to
connect and mount items needed for the operation, safety, and
comfort of the building constructed from panels 100.
[0068] FIG. 14 shows multiple embodiments of panels 100d and
accessories, including end caps 120 and lock assembly 129. Various
embodiments of panel 100d are shown which illustrate how coupling
between multiple panels 100d are made for wall-to-wall connections,
wall-to-floor connections, wall-to-roof connections, and
others.
[0069] FIG. 15 illustrates a method 200 of constructing a building
according to the invention, comprising steps 201 assembling a floor
system, and step 202 assembling a wall system from a plurality of
expanded polystyrene panels, wherein a first panel has a tongue on
a first surface, and a second panel has a groove on a second
surface, wherein the tongue and the groove couple the first panel
to the second panel. Method 200 also includes step 203 connecting
the wall system to the floor system, step 204 assembling a roof
system, step 205 connecting the roof system to the wall system, and
step 206 attaching a door to the wall system to form a building.
Method 200 according to the invention can include many other steps.
Step 201 can include using any embodiment of panels 100 as
components of the floor system, including panels 100a, 100b, 100c,
100d, 100c, or a different embodiment of panel 100 according to the
invention. Step 201 can in some embodiments include connecting
multiple panels 100 using tongue 112 and groove 114 or lock
assembly 129. Step 201 can include using multiple embodiments of
panel 100 to assemble a floor system.
[0070] Step 202 can include using any embodiment of panels 100 to
assemble a wall system, including panels 100a, 100b, 100c, 100d,
100e, or a different embodiment of panel 100 according to the
invention. Step 202 can in some embodiments include connecting
multiple panels 100 using lock assembly 129. Step 202 can include
using multiple embodiments of panel 100 as components of the wall
system. Step 202 can include using panels 100 according to the
invention that have an opening for windows, pipes, electronics or
other items which must pass through the wall system or reside
within the wall system.
[0071] Step 203 can include connecting the wall system to the floor
system using tongue 112 and groove 114. Step 203 can in some
embodiments include connecting the wall system to the floor system
using lock assembly 129. In some embodiments other means for
connecting the wall system to the floor system are used.
[0072] Step 204 can include assembling a roof system using panels
100 according to the invention. Step 204 can include using any
embodiment of panels 100 to assemble roof system, including panels
100a, 100b, 100c, 100d, 100e, or a different embodiment of panel
100 according to the invention. Step 204 can in some embodiments
include connecting multiple panels 100 using tongue 112 and groove
114. Step 204 can in some embodiments include connecting multiple
panels 100 using lock assembly 129. Step 204 can include using
multiple embodiments of panel 100 to assemble a roof system. Step
204 can include assembling the roof system separately from the wall
system and then raising the roof system over the wall system and
connecting them together as in step 205. In other embodiments step
205 connecting the roof system to the wall system can be
accomplished as the roof system is being assembled in step 204. In
this embodiment the roof system is assembled in place on top of the
wall system.
[0073] Step 205 can include connecting the roof system to the wall
system using tongue 112 and groove 114. Step 205 can including
connecting the roof system to the wail system using lock assembly
129. In some embodiments other coupling means are used to connect
the roof system to the wail system according to the invention.
[0074] Method 200 according to the invention can include many other
steps. Method 200 can include the steps of adding windows to the
building. Method 200 can include the steps of adding walls to the
interior of the building using embodiments of panels 100. Method
200 can include adding an integrated power system to the building.
Method 200 can include adding a plumbing system to the building.
Method 200 can include adding an air handling system to the
building.
Alternative Embodiment
[0075] In another embodiment of the invention, as shown in FIG. 16,
panels 300 may not include tongues and grooves, and may instead be
connected via clips 302. These clips 302 may offer many advantages
over the tongue and groove embodiment, including stronger
structural load capabilities, faster assembly, and cheaper
manufacturing.
[0076] In this embodiment panel 300 may be composed of expanded
polystyrene (EPS) material. Using expanded polystyrene allows
panels to be formed by molding. These panels can be formed in any
size and shape to create buildings of any size and shape, including
curved and multi-story structures. Using expanded polystyrene
results in panels with excellent thermal protection. The panels are
lightweight and can be used for walls, floors, or roof systems. The
EPS can be recycled after the useful life of the building is over.
Panel 300 may be made of EPS material in this embodiment so that
panel 300 has weight, strength and thermal characteristics suitable
for buildings, Indeed, panel 300 may have insulative properties,
including at least R12 insulation in the panel 300 that is used in
the walls of the building and at least R15 insulation in the panel
306 that is used in the floor or roof of the building, In this
embodiment panel 300 may be formed from EPS but plastic, fiber,
foam, or any other suitable material can be used to form panel 300,
In some embodiments panel 300 may be formed from material other
than expanded polystyrene. In some embodiments panel 300 may be
made from an anti-ballistic material.
[0077] Panel 300 may be made in any dimension suitable for the
building it will be forming. In a particular embodiment panel 300
is 6 inches thick, 48 inches wide, and 96 inches tall, or long, In
other embodiments panel 300 has other dimensions. The thickness of
panel 300 is chosen to provide the thermal and mechanical
requirements of the building to be formed. In some houses for
example, panel 300 will be thick enough to provide high thermal
insulation, high mechanical strength and a long lifetime. In other
embodiments, such as where panel 300 is used for temporary shelter
or temporary buildings, a thinner panel may be desired so that
panel 300 is lightweight and can be carried and assembled
easily.
[0078] Panel 300 in this embodiment may be molded from EPS for ease
of manufacture, but in other embodiments panel 300 may be extruded
or formed into the correct dimensions using other means. In some
embodiments of the invention panel 300 has an air cavity within
panel 300. This will result in panels 300 that are lightweight.
[0079] In this embodiment, panels 300 fit into channels 304.
Channels 304 may be fastened to a horizontal panel 306, which may
be a floor panel, a roof panel, or a combination of a floor panel
and a roof panel. In one embodiment, as shown in FIG. 1, horizontal
panel 306 is a six inch steel deck topped with one inch of EPS 308.
Once panels 300 are fitted into a corresponding channel 304, panel
300 may be fastened at a stud to the channel 304. Panels 300 and
horizontal panel 306 may also be coated with a proprietary coating,
which may include a non-cementitious coating.
[0080] Clips 302, which connect panels 300 to other panels 300 or
to horizontal panel 306 may be a structural component manufactured
out of light-gauge steel. Clips 302 may be secured to panels 304
and horizontal panel 306 via fasteners 310. Fasteners 310 may
include nails, screws, pegs, or any other of structural fastener
used in the building industry.
[0081] As shown in FIG. 17, panels 300 include structural elements
316, 318 which provide the function of structural studs within the
panels 300. In this embodiment, structural elements 316, 318 are
made of light gage steel to add structural support to panel 300, to
provide a surface on the front, back and sides of panel 300 on
which to fasten clips 302 or other structures. Structural elements
316, 318 take the place of studs as used in a wood frame building
structure. Panel 300 may include a number of end structural
elements 316 located along the edges, and may also include a number
of center structural elements 318 located within panel 300 and
between end structural elements 316. Structural elements 316, 318
may be formed into panel 300 during molding. Structural elements
316, 318 may be formed of light gage steel, but in general may be
formed of any suitable material such as metal, plastic, wood, or
any other material which will provide the function of adding
structural integrity and serving as a wall, ceiling, or floor stud
for mounting or attaching to. Structural elements 316, 318 can take
many different forms and be placed in any desired configuration
relative to the structure of panel 300. Creating panel 300 from
molding allows the shape and placement of elements within panel 300
to be flexible and configurable during manufacture of panels 300.
Panel 300 may have other items molded into the structure of panel
300 as needed. Tubes or channels may be molded into panel 300 to
route wires or pipe through, Wire mesh may be embedded into panel
300 to provide electromagnetic interference (EMI) shielding, radio
frequency (RF) shielding, and/or infrared (IR) shielding as needed
for the building to be assembled using panel 300. Panel 300 can be
molded with openings or holes for windows, air vents, pipes, etc to
be installed or pass through. Since molds can be made in any shape,
size, and outline, the form of panel 300 is not limited by the
starting material as it is with wood or brick building
materials.
[0082] As shown in FIG. 18, some embodiments may include a roof
section 340 and/or a deck floor 350, Roof section 340 may include a
plate with a flat top portion 342 and a ridged bottom portion 344.
Deck floor 350 may include a flat top portion 352 and a ridged
bottom portion 354, and may include a coating 356 on top of the
flat top portion 352. Other embodiments may include an alternative
roof section 360 and/or an alternative deck floor 370. Alternative
roof section 360 may include a first plate with a flat top portion
361 and a ridged bottom portion 362, and a second plate with a flat
bottom portion 363 and a ridged top portion 364, where the ridged
bottom portion 362 of the first plate connects with the ridged top
portion 364 of the second plate. Alternative deck floor 370 may
include a first plate with a flat top portion 371 and a ridged
bottom portion 372, and a second plate with a flat bottom portion
373 and a ridged top portion 374, where the ridged bottom portion
372 of the first plate connects with the ridged top portion 374 of
the second plate. Alternative deck floor 370 may include a coating
376 on top of the flat top portions 371. Roof section 340, deck
floor 350, alternative roof section 360 and alternative deck floor
370 may be used in conjunction with the panels 300 shown in FIG.
16, and may be connected via clips 302.
[0083] One embodiment of a panel 300 is shown in FIG. 19, As
discussed previously, panel 300 may include end structural elements
316 and center structural elements 318. Clips 302 may secure each
panel 300 to an adjoining panel 300. Though only two panels 300 are
shown in FIG. 19 and both panels 300 lie in the same plane, any
number of panels 300 may be utilized in any configuration and in
any number of different shapes according to the intended use in the
building. Panel 300 in some embodiments may be square, rectangular,
triangular or any other shape necessary in building a particular
structure. Panels 300 can also be joined at angles ranging from 0
to 180 degrees to create a corner portion of a building. Whatever
angle is desired for the building to be assembled can be created by
panels 300 and an appropriately angled clip 302. It should be
understood that panel 300 can be constructed in any particular size
and shape needed to form any portion of a building as needed.
[0084] FIG. 20 shows components of a building system 400 according
to the invention including panels 300 and horizontal panels 306.
Horizontal panels 306 may comprise a roof section 340, deck floor
350, alternative roof section 360, or alternative deck floor 370,
or any combination of those components. Panels 300 are connected to
each other via clips 302. Panels 300 are also connected to
horizontal panels 306 via clips 302. Clips 302 may be fastened to
panels 300 and horizontal panels via screws (not shown), or any
other type of suitable fastener. FIG. 20 depicts one embodiment of
a building system 400 of the present invention, a two-story
structure. The first floor 410 comprises a number of panels 300
connected via clips 302 which create a wall structure. The wall
structure of first floor 410 is enclosed by horizontal panels 306
at the top and bottom of the first floor 410. The second floor 420
comprises a number of panels 300 connected via clips 302 which
create a wall structure. The wall structure of second floor 420 may
be enclosed by horizontal panels 306 at the top and bottom of the
second floor 420.
[0085] The embodiments and examples set forth herein were presented
in order to best explain the present invention and its practical
application and to thereby enable those of ordinary skill in the
art, to make and use the invention. However, those of ordinary
skill in the art will recognize that the foregoing description and
examples have been presented for the purposes of illustration and
example only. The description as set forth is not intended to be
exhaustive or to limit the invention to the precise form disclosed.
Many modifications and variations are possible in light of the
teachings above without departing from the spirit and scope of the
forthcoming claims.
* * * * *