U.S. patent application number 13/582899 was filed with the patent office on 2013-03-07 for modular building system utilizing composite, foam core panels.
This patent application is currently assigned to INNOVATIVE COMPOSITES INTERNATIONAL, INC.. The applicant listed for this patent is Terry Ball, Gregory Brower, Bryce Clark, Jerry Olszewski. Invention is credited to Terry Ball, Gregory Brower, Bryce Clark, Jerry Olszewski.
Application Number | 20130055669 13/582899 |
Document ID | / |
Family ID | 44541595 |
Filed Date | 2013-03-07 |
United States Patent
Application |
20130055669 |
Kind Code |
A1 |
Olszewski; Jerry ; et
al. |
March 7, 2013 |
MODULAR BUILDING SYSTEM UTILIZING COMPOSITE, FOAM CORE PANELS
Abstract
A system for constructing a structure comprises a plurality of
composite panels having a laminate structure comprising a foam core
to which are attached cover layers of the same or different
material. One or both of the cover layers may be comprised of
composite sub-layers. The system includes a number elongate and
preferably extruded components for connecting the panels to form
walls, roofs or floors for the structure. The system is modular,
thereby allowing for a time and cost efficient means of erecting a
structure.
Inventors: |
Olszewski; Jerry;
(Lambertville, MI) ; Brower; Gregory; (Fenton,
MI) ; Clark; Bryce; (Sault Sainte Marie, MI) ;
Ball; Terry; (Barbeau, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Olszewski; Jerry
Brower; Gregory
Clark; Bryce
Ball; Terry |
Lambertville
Fenton
Sault Sainte Marie
Barbeau |
MI
MI
MI
MI |
US
US
US
US |
|
|
Assignee: |
INNOVATIVE COMPOSITES
INTERNATIONAL, INC.
TORONTO
ON
|
Family ID: |
44541595 |
Appl. No.: |
13/582899 |
Filed: |
March 4, 2011 |
PCT Filed: |
March 4, 2011 |
PCT NO: |
PCT/CA2011/050131 |
371 Date: |
November 13, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61310991 |
Mar 5, 2010 |
|
|
|
Current U.S.
Class: |
52/283 ;
52/309.4; 52/582.2; 52/588.1; 52/794.1; 52/837 |
Current CPC
Class: |
B32B 2266/08 20130101;
B32B 15/046 20130101; E04B 1/14 20130101; E04B 5/026 20130101; B32B
5/18 20130101; E04C 2/296 20130101; B32B 3/06 20130101; B32B
2266/045 20130101; B32B 2419/06 20130101; B32B 2266/0228 20130101;
E04B 7/04 20130101; B32B 2471/00 20130101; E04C 3/29 20130101; E04B
7/22 20130101; B32B 2419/00 20130101; E04C 3/28 20130101; B32B
2607/00 20130101; B32B 2266/02 20130101; E04C 2/292 20130101 |
Class at
Publication: |
52/283 ;
52/794.1; 52/588.1; 52/309.4; 52/582.2; 52/837 |
International
Class: |
E04B 1/19 20060101
E04B001/19; E04C 3/28 20060101 E04C003/28; E04C 2/20 20060101
E04C002/20; E04B 1/38 20060101 E04B001/38; E04C 2/34 20060101
E04C002/34; E04C 2/38 20060101 E04C002/38 |
Claims
1. A system for constructing a structure comprising: a plurality of
generally planar wall panels, each of said wall panels having a
laminate structure comprising a rigid foam core slab sandwiched
between first and second cover layers, the wall panels defining at
least one of wall panels, roof panels or floor panels; and, a
plurality of panel connecting components for connecting the wall
panels to form at least one of walls, roofs, floors or combinations
thereof; the connecting members including means for receiving ends
of adjacent wall panels.
2. The system of claim 1, wherein the panel connecting components
include at least two slots for receiving and retaining ends of
adjacent wall panels.
3. The system of claim 1, wherein the connecting components
comprise elongate, extruded bodies.
4. The system of claim 1, wherein the connecting components include
corner connecting components, each of said corner connecting
components comprising a pair of angularly separated slots adapted
to receive ends of said wall panels forming a corner of the
structure.
5. The system of claim 1, wherein the connecting components include
first roof panel connecting components, each of said first roof
panel connecting components comprising a first engagement means for
engaging an upper end of a wall panel, and a second engagement
means adapted to engage ends of roof panels.
6. The system of claim 1, wherein the connecting components include
second roof panel connecting components, each of said second roof
panel connecting components comprising oppositely directed ledges
or slots for receiving ends of adjacent roof panels for forming a
ridge of a roof for the structure.
7. The system of claim 1, wherein the connecting components include
sill components, each of said sill components comprising a first
end for resting on a surface and a second end including a first
engagement means for engaging bottom ends of the wall panels.
8. The system of claim 7, wherein each of said sill components
includes a second engagement means for supporting ends of said
floor panels.
9. The system of claim 5, wherein the first engagement means of
each first roof panel connecting component comprises a bearing
surface for resting on the upper ends of the wall panels or ceiling
joints attached to the upper ends of the wall panels.
10. The system of claim 5, wherein the second engagement means of
each first roof panel connecting component is angled with respect
to the first engagement means for orienting the roof panel at a
desired pitch.
11. The system according to claim 1, wherein the first and second
cover layers of the wall panels are formed of the same or different
material.
12. The system of claim 11, wherein at least one of the first and
second cover layers comprises a composite layer comprising a sub
foam core covered by sub cover layers.
13. The system of claim 11, wherein the outer cover layer of the
roof panels comprises a metal sheet.
14. The system of claim 1, wherein the panel connecting components
comprise pins and corresponding keyholes provided on opposing ends
of wall panels, the pins being shaped to fit within the keyholes in
a locking arrangement to form a connection between adjacent wall
panels.
15. The system of claim 1, wherein the wall panels include
reinforcement members at opposed ends for providing at least one of
an attachment means or a strengthening means for the panels.
16. The system of claim 15, wherein the panel connecting components
are adapted to receive or engage the reinforcement members of
adjacent wall panels.
17. (canceled)
18. An I-beam comprising: a pair of support elements separated by a
web element, wherein the web element comprises a laminate structure
comprising a rigid foam core slab sandwiched between first and
second cover layers.
19. The I-beam of claim 18, wherein the support elements comprise
at least one of composite materials, extruded materials or
wood.
20. The I-beam of claim 19, wherein the support elements include
slots to receive opposing edges of the panel.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority from U.S.
Application No. 61/310,991, filed Mar. 5, 2010, the entire contents
of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to composite, foam core panels
and to systems for constructing buildings using such panels.
BACKGROUND OF THE INVENTION
[0003] There is a demand for modular building systems that allow a
building to be erected in a simple and time efficient manner. To
address this need, various systems have been proposed that
incorporate prefabricated structural members that are transported
to a building site and assembled together to form a building. In
some cases, the structural members are completed wall units that
are generally large and difficult to transport and handle. It is
also known to use structural insulated panels in the construction
of walls, roofs etc. Such panels comprise a "sandwich" structure
made of an insulative foam core positioned between two layers of
plywood or oriented strand board (OSB) etc. Although such panels
provide the desired insulation function (due to the foam core), the
wood based "skins" are subject to deterioration due to elemental
exposure (i.e. water) or infestation by insects, microorganisms
(e.g. mold).
[0004] In one alternative, building panels have been proposed that
incorporate an insulative foam core, as with the panels described
above, but, instead of a wood based skin, these panels include
polymeric or metallic skins. In some cases, multiple layers of
skins are provided to address specific requirements such as
strength, water repellency etc. Some examples of such composite
building panels are provided in the following references: US
2008/0127607; US 2004/0067352; U.S. Pat. No. 7,527,865; U.S. Pat.
No. 6,481,172; U.S. Pat. No. 6,358,599; and U.S. Pat. No.
6,093,481.
[0005] In addition to various composite panels, various systems to
erect building using such panels are also known. In general, such
systems include connecting members that serve to join adjacent
panels together. One issue to address in such systems is to ensure
a complete seal around the enclosure to prevent water penetration
and/or heat loss. Some examples of known panel based building
systems are provided in the following references: U.S. Pat. No.
7,603,822; U.S. Pat. No. 6,418,681; U.S. Pat. No. 6,305,142; U.S.
Pat. No. 6,279,287; U.S. Pat. No. 5,921,046; and U.S. Pat. No.
5,373,678.
[0006] Although the above mentioned building systems have various
efficiencies, there still exists a need for an improved composite
panel and an improved building system incorporating same. For
example, a building system that can be assembled quickly and
efficiency would be desirable.
SUMMARY OF THE INVENTION
[0007] In one aspect, the present invention provides a system for
constructing a structure comprising: a plurality of generally
planar building panels, each of said wall panels having a laminate
structure comprising a rigid foam core slab sandwiched between
first and second cover layers, the panels comprising wall panels,
roof panels or floor panels; and, a plurality of panel connecting
components for connecting the panels to form walls, roofs, floors
or combinations thereof; the connecting members including means for
receiving ends of adjacent panels.
[0008] In one aspect, the present invention provides a system for
constructing a structure comprising: a plurality of generally
planar wall panels, each of the wall panels having a laminate
structure comprising a rigid foam core slab sandwiched between
first and second cover layers; and, a plurality of corner joint, or
connecting components including a pair of angularly separated slots
adapted to receive ends of the wall panels forming a corner of the
structure.
[0009] In another aspect, the invention provides a system further
comprising: a plurality of generally planar roof panels, each of
the roof panels having a laminate structure comprising a rigid foam
core slab sandwiched between first and second cover layers; and, a
plurality of roof joint, or connecting components including a first
engagement means adapted to engage upper ends of the wall panels,
when erected, and a second engagement means adapted to engage ends
of the roof panels.
[0010] In another aspect, the invention provides a system further
comprising a plurality of floor panels, the floor panels having a
laminate structure comprising a rigid foam core slab sandwiched
between first and second cover layers.
[0011] In other aspects, the invention provides sill components for
supporting wall panels and/or floor panels, ridge joint, or
connecting components, for forming roof panel into a ridge of a
roof, and seam connecting components for connecting adjacent wall
or roof panels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The features of the invention will become more apparent in
the following detailed description in which reference is made to
the appended drawings wherein:
[0013] FIG. 1 is cross sectional view of a panel according to one
aspect of the invention.
[0014] FIG. 1a is a cross sectional view of a panel according to
another aspect of the invention.
[0015] FIG. 2 is a schematic illustration of a panel manufacturing
method and apparatus according to an aspect of the invention.
[0016] FIG. 3 is a top cross sectional view of a linear wall joint
formed by two adjacent composite panels.
[0017] FIG. 4 is a top cross sectional view of a corner wall joint
formed by two adjacent composite panels.
[0018] FIG. 5 is a cross sectional elevation view of joint formed
between a wall panel and a roof panel according to one aspect of
the invention.
[0019] FIG. 6 is a cross sectional elevation view of a roof section
illustrating the joints between wall panels and roof panels and
between adjacent roof panels in a gabled roof format.
[0020] FIG. 7 is a cross sectional view taken along the line A-A of
FIG. 6.
[0021] FIG. 8 is a cross sectional elevation view of a base section
of a wall according to an aspect of the invention.
[0022] FIG. 9 is a cross sectional elevation view of a base section
of a wall according to another aspect of the invention.
[0023] FIGS. 10 to 12 are cross sectional elevation views of a base
section of a wall according to aspects of the invention showing
wall and floor panels in combination.
[0024] FIG. 13 is a cross sectional elevation view illustrating a
two composite floor panels according to one aspect of the
invention, supported on a joist.
[0025] FIG. 14 is a schematic illustration showing the various
components of the invention according to another embodiment.
[0026] FIG. 15 is a cross sectional elevation detail of a wall
construction according to an aspect of the invention showing the
base portion of the wall.
[0027] FIG. 16 is a cross sectional elevation detail of a wall
construction according to an aspect of the invention showing the
top portion of the wall.
[0028] FIG. 17 is top cross sectional view of a wall construction
detail according to an aspect of the invention showing a corner
formed by adjacent wall panels.
[0029] FIG. 18 is a cross sectional elevation detail of a roof
construction according to an aspect of the invention showing a
ridge formed by adjacent roof panels.
[0030] FIG. 19 is a cross sectional view of adjacent roof panels
illustrating an embodiment of a connection means there-between.
[0031] FIGS. 20 to 27 illustrate an example of a building
construction method according to an embodiment of the
invention.
[0032] FIG. 28 is a top cross sectional view of a panel assembly
showing a corner joint connection according to another aspect of
the invention.
[0033] FIG. 29 is a detail top cross sectional view of a panel
assembly showing one of the corner joint connections of FIG.
28.
[0034] FIG. 30 is an elevational view along the line A-A of FIG.
29.
[0035] FIG. 31 is a top cross sectional view of a corner wall joint
formed by two adjacent composite panels according to another aspect
of the invention.
[0036] FIG. 32 is a cross sectional elevation detail of a wall
construction according to another aspect of the invention.
[0037] FIG. 33 is a cross sectional elevation detail of a roof
construction according to another aspect of the invention showing a
ridge formed by adjacent roof panels.
[0038] FIG. 34 is a cross sectional elevation detail of a roof
construction according to another aspect of the invention showing a
connection system for connecting a roof panel to a wall panel.
[0039] FIG. 35 is a cross sectional elevation detail of a roof
construction according to another aspect of the invention showing a
connection system for connecting adjacent roof panels.
[0040] FIG. 36 is a cross sectional elevation detail of a wall
construction according to another aspect of the invention showing a
connection system for connecting a wall panel to a base.
[0041] FIGS. 37 and 38 are cross sectional elevations of "I" beams
formed with panels according to another aspect of the
invention.
[0042] In the appended drawings, like numbers are used to identify
like elements. In some cases, where one element is similar to but a
variant of a previously shown element, the same reference numeral
is used but with suffix letters to distinguish the two.
DETAILED DESCRIPTION OF THE INVENTION
[0043] The invention is based on a system for constructing a
structure, or building, that incorporates a plurality of composite
panels that are joined together to form an enclosure. The system
also includes various joint, or connecting elements or components
for joining the panels. As discussed further below, the connecting
elements are designed according to the region of the joint. With
such a modular system, the structures formed with the invention are
capable of being quickly erected and, where necessary,
disassembled. The system of the invention may be provided in the
form of a kit and such aspect will be assumed to be encompassed by
the invention.
[0044] Various types of composite panels may be used with the
invention. However, in a preferred embodiment, the invention
comprises the use of a panel as shown in FIG. 1. As shown, the
panel 10 comprises a core 12 made of a rigid foam material. Various
types of foam materials can be used in the panels of the invention.
In general, the foam preferable has a closed cell structure and is
sufficiently rigid so as to prevent the panel from bending or
otherwise deforming. Some examples of foams that can be used in the
present invention include thermoplastic foams, thermoset foams,
metallic cellular sections, paper core sections etc. As will be
understood, the densities of the foams used in the panels of the
invention can be tailored depending upon the need. For example, in
situations where a higher degree of load bearing strength is
required, the foam used may be of a higher density. It will also be
understood that the depth of the foam core 12 may also be varied to
provide desired strength characteristics.
[0045] As also shown in FIG. 1, the panel 10 also includes two
cover layers 14 and 16, provided on opposed planar surfaces of the
foam core. As illustrated in FIG. 1, the cover layers 14 and 16 are
provided on the core 12 to form a laminate, or "sandwich"
structure. The cover layers 14 and 16 may, independently or
together, be formed of various materials. For examples, the layers
may comprise metal or wood sheathing or a plastic material. In the
latter case, the layers 14 and 16 may comprise the same or
different thermoplastic or thermoset polymers, including, but not
limited to, polyester, urethane, epoxy, polypropylene, poly
ethylene, polyvinylchloride etc. In one embodiment, where the
panels are used for housing, the layers 14 and 16 preferably
comprise polymer sheets. In situations where the cover layers
comprise a plastic material, such plastics may be reinforced with
various additive components such as fibres (e.g. glass fibres),
basalt, aramid etc.
[0046] In one embodiment, the panel 10 of the invention comprises a
polymer foam core with polymer cover layers 14 and 16. More
preferably, the cover layers are fibre reinforced. In a further
preferred aspect, the fibre reinforcement comprises a scrim
material such as fibreglass scrim. Other such reinforcement fibres
or materials will be known to persons skilled in the art.
[0047] The cover layers 14 and 16 are also preferably affixed to
the surfaces of the foam core 12. This can be achieved in a number
of ways such as by known heat lamination methods wherein an
adhesive applied to one of the foam core or cover layer surfaces is
heat activated. The adhesive can also be applied in a liquid form,
such as by coating or spraying an adhesive layer onto either the
foam core and/or cover layer surfaces. A preferred method of
forming the panels of the invention is illustrated in FIG. 2. As
shown, the panel 10 of the invention is formed by passing a sheet
of rigid foam material 12 through a press nip formed by two rollers
18. Supply rollers 20a and 20b provide the cover layers 14 and 16
on both sides of the foam core 12. The rollers 18a and 18b serve to
press the two layers 14 and 16, respectively, against the opposite
surfaces of the foam core 12. The formed panel 10 is then passed
through a laminating press 22 for forming a bonded surface between
the foam core 12 and the respective cover layer 14 and 16.
[0048] Although a description is provided above of a preferred
method of manufacturing the panels of the invention, it will be
understood that the panels for use in the building system discussed
herein may be manufactured using any other known method.
[0049] In a further embodiment of the invention the cover layers 14
and 16 described above may be replaced with separate composite
layers. Such an embodiment is shown in FIG. 1a, wherein the panel
10' is shown including a core 12, or "main core", essentially as
described above. That is, the main core 12 generally comprises a
rigid foam material. However, in FIG. 1a, the main core 12 is
covered with composite panels 11 and 13. Each of the cover panels
11a and 11b comprise a foam core, or "sub core". 13a and 13b,
respectively. The sub cores 13a and 13b are also formed of a foam
material as used for the main core 12. However, as illustrated in
FIG. 1a, the sub cores 13a and 13b are generally of a reduced
thickness as compared to the main core 12. The sub cores 13a and
13b are covered by external cover layers 15a and 15b, respectively.
The cores 13a and 13b are also covered by internal cover layers 17a
and 17b, respectively. The term "external" and "internal" as used
in connection with FIG. 1a refers to the positioning of the cover
layers 15a, 15b and 17a, 17b with respect to the main core 12.
Specifically, the "external" layers 15a and 15b are positioned
opposite to the main core 12 so as to form the external surfaces of
the panel 10'. Similarly, the "internal" layers 17a and 17b are
positioned between the main foam core 12 and the sub cores 13a and
13b, respectively. The composition of the sub cores 13a and 13b may
be the same or different depending on the specific need and each
may also, independently, comprise the same or different material as
is used to form the main core 12. Similarly, the external and
internal cover layers 15a, 15b and 17a, 17b, may also,
independently of each other, be formed of the same or different
materials, with such materials being chosen from those described
herein with respect to layers 14 and 16.
[0050] It will be understood that a panel as shown in FIG. 1b would
offer several advantages. For example, such a panel would have
greater stiffness as compared to the panel of FIG. 1 and would also
be less susceptible to damage as the internal foam core 12 would be
protected by additional layers of material. In addition, the use of
three foam cores offers increased insulation value.
[0051] Although the following discussion will refer to panels
having the structure shown and described in reference to FIG. 1, it
will be understood that the panels shown and described in reference
to FIG. 1a may be used in the same manner wherever required.
[0052] Once the panels are formed, they may be used for forming
walls, floors, and roofs. Although such panels can be joined
together in various ways as known in the art, the invention
provides a unique assembly system incorporating connecting elements
or joint components. In a preferred embodiment, the attachment of
panels involves the use of molded, extruded or cast components that
are designed to attach to the ends of the panels. Further details
of the structure of these components are provided below. The joint,
or connecting components may be formed of various materials as will
be apparent to persons skilled in the art having regard to the
present disclosure. For example, the components may be formed from
metals, such as aluminum, or various polymers. In the latter
instance, the polymer materials may be reinforced with fibres etc.
to provided any desired physical properties (such as strength,
stiffness etc.). As also discussed below, the joint or connecting
components or elements may be solid or hollow structures.
[0053] FIG. 3 illustrates one aspect of the invention wherein two
panels 10a and 10b are provided in a linear, end to end manner to
form a wall section. Each of the panels includes respective cover
layers 14a, 16a and 14b, 16b. As shown in FIG. 3, the layers 14a
and 14b are directed internally and may therefore be referred to as
internal covers. Similarly, the layers 16a and 16b are face
outwardly of the building and may therefore be referred to as
external covers. As will be understood, the internal covers may
differ in composition from the external covers. The respective
internal and external cover layers may comprise any type of
suitable coating that is adapted to receive suitable paint,
colouring, or other surface that may be affixed thereto or provided
thereon. Similarly, where one of the covers, such as the external
cover, is exposed to the elements, the composition of same may be
adapted to withstand exposure to heat and cold, wind, or solar
radiation etc. Further, the internal cover layer may be adapted to
receive, if needed, typical wall coverings such as paint or drywall
etc. In one example, the outer layers 16a and 16b may comprise
plywood or a plywood sheathing overlying a polymer layer. It will
be understood that various combinations and types of materials may
be used for the respective internal and external coverings. Since
the panels 10a and 10b are used to form a section of a contiguous
wall, it will be understood that the core portions of each would
generally be of the same composition. In one example, the cores of
the panels may be chosen to provide a desired amount of thermal
insulation. For the purpose of the system of the invention, and as
discussed above, it will be understood that the core and cover
layers of the various panels described herein will have the
sufficient degree of strength and stiffness to allow the panels to
form a building. The parameters for designing the panels to meet
these requirements will be known to persons skilled in the art.
[0054] As shown in FIG. 3, in order to connect the ends of the
panels, a wall joint, or connecting component 24 is used. Wall
joint component 24 generally comprises a "T" shaped structure, in
end cross section, and includes a first flange 26 and a second
flange 28, extending generally perpendicularly from the first
flange. In the preferred embodiment, the second flange 28 has a
length, measure from the first flange, that is generally equal to
the thickness of the panels 10a and 10b. The first flange includes
an outer surface 30 and an inner surface 32. As shown in FIG. 3,
the inner surface 32 is divided into two sections by the second
flange 26. Each of such sections is adapted to receive a portion of
the panels 10a and 10b. As shown, the outer surfaces of the panels
10a and 10b are placed in contact with the inner surface 32 of the
first flange 26. Further, the opposed ends of the panels 10a and
10b are arranged to abut the second flange 26. In one embodiment,
an adhesive may be used to secure the outer surfaces of the panels
10a and 10b to the inner surface of the first flange 26. In one
example, as shown in FIG. 3, such adhesive may comprise a sealing
tape 34. It will be understood that forming a seal at the joint of
two panels is preferred in order to prevent ingress of moisture or
insects etc. and egress of heat through the joint. Similarly, if
needed, a further sealing tape or such may be used to secure the
ends of the panels to the respective surfaces of the second flange.
However, as will be understood, such ends of the panels would
primarily comprise the foam core component and, as such, a sealing
tape may not provide the same level of sealing.
[0055] The wall joint component 24 preferably includes an inner
plate 36 or cap, which is provided against the inner surface of the
panels 10a and 10b. As mentioned above, the second flange 28 is
generally of the same length as the thickness of the panels 10a and
10b. In such arrangement, as shown in FIG. 3, the end of the second
flange 28, opposite the first flange, 26, is generally flush with
the inner faces of the panels 10a and 10b. Thus, the plate 36 can
be arranged so as to abut portions of the inner faces of the panels
10a and 10b as well as the end of the second flange 28. This
arrangement is shown in FIG. 3. In this arrangement, fasteners 38
can be extended through the plate 36 and directly into the second
flange 28. Such fasteners may comprise, for example, nails or
screws. Similarly additional fasteners may connect the plate 26 to
the first flange 26 by passing such fasteners through the
respective panel sections, adjacent the second flange 28. If
needed, adhesives or sealing tape etc. (not shown) may be provided
at contact points between the plate 36 and the respective panels
10a and 10b to secure the plate 36 or to provide additional sealing
at the joint between the panels. As will be understood, the wall
joint component 24 will be vertically oriented when in use. The
component may be provided in specified lengths or may be cut to a
desired length at the site of the building being constructed.
Preferably, the wall joint component 24 comprises a single elongate
unit so as to form contiguous joint between adjacent wall panels.
In one embodiment, the wall joint component 24 may be formed as a
single body, wherein the plate 36 is formed as part of the second
flange 28. As can be understood from FIG. 3, in such an arrangement
the wall joint component will comprise oppositely directed slots
for receiving the ends of adjacent panels. In another embodiment,
the wall joint component 24 may comprise several sections that are
connected together. Such an arrangement may be used, for example,
where a single segment is too large for transportation or handling
etc.
[0056] FIG. 4 illustrates a corner joint between two wall panels
10a and 10b. In this case, the panels are connected together by
means of a corner joint, or connecting component 40. As shown in
FIG. 4, the corner joint component comprises two slots 42 and 44,
adapted to receive panels 10a and 10b, respectively. The slots 42
and 44 are generally arranged at a 90.degree. orientation to each
other so as to form an orthogonal corner. However, it will be
understood that where any other angle is desired at a corner, a
respectively designed corner joint component can be used. However,
for typical construction, a 90.degree. orientation will be
understood to predominate. As shown in FIG. 4, the slots 42 and 44
are sized to enable a portion of the respective panels 10a and 10b
to be received therein. Once in place, fasteners 46 can be used to
secure the panels to the corner joint component 40. As with the
previous component, it will be understood that various types or
combinations of sealing and adhesive devices may be used to seal
the contact surfaces between the panels 10a and 10b and the corner
joint component 40. Although FIG. 4 shows the preferred corner
joint component 40 as comprising an elongate unitary body, it will
be understood that the inner, "L" shaped segment 49 of the
component may be formed as a separate body, in a manner similar to
the plate 36 discussed above.
[0057] FIGS. 5-7 illustrate the use of the panels of the invention
in forming roofs of the buildings. In particular, FIGS. 5-7
illustrate the joint formed at the upper end of a wall panel 10a
and a similar panel 10c used for forming a roof. As before, each of
the panels 10a and 10c include inner layers, 14a and 14c, and outer
layers 16a and 16c. The panels also include cores 12a and 12c. As
discussed above, the inner and outer layers 14 and 16 may be chosen
from appropriate materials that serve the desired purpose. The
layers 14a and 16a for the wall panel 10a were discussed
previously. The same materials may also be chosen for the layers
14c and 16c of the roof panel 10c. However, it will be understood
that due to the different role of the roof panels 10c, the layers
may be chosen from different materials. For example, the outer
layer 16c of the roof panel 10c may be designed with a material to
provide required water penetration resistance. In one example, the
outer layer 16c may comprise a metal sheet. The core sections 12a
and 12c may also be of the same or different materials. For
example, due to the fact that the roof panels 10c will need to
support loads applied against its planar surface, the stiffness of
such panels may need to be greater than that for the wall panels
10a. Thus, the core 12c and cover layers 14c and 16c may be formed
of the required materials to provide the required physical
characteristics.
[0058] As shown in FIG. 5, a roof joint, or connecting component 50
is provided for connecting a roof panel 10c to a generally
vertically oriented wall panel 10a. As shown in FIG. 5, the roof
joint component 50 is designed to provide an angular arrangement
between the generally vertical wall panel 10a and the roof panel
10c. As will be understood, such an arrangement provides the roof
with a pitch so as to facilitate water run off etc. It will also be
understood that the roof joint component 50 may be designed to
provide any degree of pitch for the roof of the building being
constructed. It will also be understood that roof joint component
50 comprises an elongate structure that preferably extends the
length of the wall. However, in cases of very long walls, it will
be understood that the roof joint component 50 may be provided in
sections that can be secured together so as to form a contiguous
structure.
[0059] The roof joint component 50 includes a first end 52 adapted
to connect with the upper edge of a wall panel 10a and a second end
54 adapted to connect with one edge of a roof panel 10c. The first
end 52 of the roof joint component 50 preferably includes a slot 56
for receiving the upper edge of the wall panel 10a. The slot 56
will be sized accordingly to receive the wall panel edge. The roof
joint component 50 and the wall panel 10a may be secured together
using fasteners 58. In one preferred embodiment, the fasteners
extend between opposite ends of the slot 56 and through a portion
of the wall panel 10a received within such slot. As described
previously, various adhesives or sealing members etc. may be used
to form a seal between one or more contact surfaces of the roof
joint component 50 and the wall panel 10a.
[0060] The second end 54 of the roof joint component 50 includes a
bearing surface comprising a ledge 60, adapted to receive one edge
of a roof panel 10c, and an edge 62 extending above the ledge 60,
adapted to brace against the end of the roof panel 10c received on
the ledge 60. It will be understood that adhesives or sealing
members may be provided between the contact surfaces of the roof
panel 10c and the roof joint component 50.
[0061] In a preferred aspect of the invention, the roof panel 10c
is provided with an external cover layer 16c that extends beyond
the core 12c and inner cover layer 14c. As shown in FIG. 5, the
external cover layer 16c extension 64 overlaps the upper edge 66 of
the second end 54 of the roof joint component 50 and, therefore,
the seam between the roof panel 10c and the component 50. As will
be understood, with such an arrangement, a continuous layer is
formed across the surface of the roof, thereby allowing for water
drainage over the roof while preventing seepage into the joint
between the roof panel 10c and the roof joint component 50.
[0062] The roof panel 10c may be connected to the roof joint
component 50 in various ways. However, in one aspect, as shown in
FIG. 5, such connection may be achieved with fasteners 68 that
extend through the extension 64 of the external layer 16c of the
roof panel 10c and into the upper edge 66 of the roof component
second end 54.
[0063] As indicated above, the embodiment illustrated in FIG. 5
shows a roof joint component 50 that is designed to provide an
angular arrangement between the generally vertical wall panel 10a
and the roof panel 10c. It will be appreciated that such angular
arrangement can comprise any desired pitch for the roof. Thus,
depending upon the design of the structure being erected, the roof
joint component can be adapted to provide the require angular
arrangement between the wall and roof panels (i.e. the pitch of the
roof). In one extreme, the roof may have no pitch. That is, the
roof would be flat and, for this purpose, the ledge 60 would be
orthogonal to the wall panel 10a. Thus, the roof panel 10c resting
on the ledge 60 would also be orthogonal to the wall panel 10a.
[0064] It will be appreciated that the span and pitch of the roof
panels described above will depend on the expected loads to be
supported. In some cases, where the size of the building is larger
than the panels, the roof may need to be composed of more than one
panel as measured from one wall to another. In such cases, a
connecting member similar to the wall joint component shown in FIG.
3 may be used to connect adjacent roof panels together. It should
be noted that a seam between roof panels may result in a zone of
weakness, particularly where the roof is flat, and, accordingly,
suitable reinforcement means may be provided to compensate. For
example, a beam or other such component may be provided to support
such seams. Typically, for small buildings, such as single room
structures, it may be possible for the walls and roof to be formed
from single panel sheets. In the case of a gabled roof, such as
shown in FIG. 5 and as discussed further below, two oppositely
directed panels would be required. Various orientations and
configurations of the panels are therefore possible according to
the invention.
[0065] FIG. 6 illustrates the connection of two roof panels 10c and
10d, forming a ridge 70 of a roof at a gable end thereof. As
discussed above, first ends 72c and 72d of respective roof panels
10c and 10d are connected to respective roof joint components 50c
and 50d. The roof panels 10c and 10d also include respective second
ends 73c and 73d, which are opposite to first ends 72c and 72d. The
seconds ends 73c, 73d are joined by a ridge beam component 80. The
ridge beam component 80 includes oppositely directed ledges 82c and
82d, which are adapted to receive the second ends 73c and 73d of
the respective roof panels 10c and 10d. As will be understood the
ledges 82c and 82d of the ridge beam component 80 are provided in
an angular format wherein each ledge is sloped downwardly and away
from the center of the component 80. Such an angular arrangement
corresponds to the pitch of the respective roof panels 10c and
10d.
[0066] The ridge beam component 80 will be understood to comprise
an elongate member that, in one aspect, extends the length of the
building being constructed. The beam component 80 can, if
necessary, be provided in sections. The ridge beam component 80
also preferably includes an elongate cap 84, which overlies an
upper end 86 of the ridge beam component 80 and also overlaps a
portion of the second ends 73c and 73d of the roof panels 10c and
10d. As will be understood, in such an arrangement, water drainage
is conducted over the cap 84 and across the seam formed between the
roof panels 10c and 10d and the ridge beam component 80. This
therefore serves to prevent water seepage into such seam.
[0067] The cap 84 may be secured to the roof assembly by various
means. For example, fasteners 88 may be provided through the cap 84
and into the upper end 86 of the ridge beam component 80. In
addition, sealing tape 90 or other such sealing or adhesive member
may be provided between the upper edge of the roof panels 10c and
10d and the contacted underside of the cap 84.
[0068] As mentioned above, the roof assembly shown in FIG. 6
comprises a gable end of the structure being erected. As such, the
roof assembly also preferably includes one or more pairs of gable
beam components, or gable beams, 92c and 92d, each extending from
the respective roof joint component 50c and 50d. As shown,
respective first ends, 94c and 94d, of the gable beams 92c and 92d,
are joined or connected to the opposed inner surfaces of respective
roof joint components 50c and 50d. The gable beams 92c,d have upper
edges 96c,d and lower edges 97c,d that are generally parallel with
each other. In the result the gable beams 92c and 92d generally
follow the same angle as the pitch of the roof panels 10c and 10d.
Thus, second ends 98c and 98d of the gable beams 92c and 92d meet
to form an apex 100 of the roof.
[0069] In a preferred embodiment, the upper edges 96c and 96d of
the gable beams 92c and 92d are provided with respective notches
that combine to form a trough 102 that is adapted to receive and
support the ridge beam component 80.
[0070] As will be understood, the roof structures illustrated in
FIGS. 5 and 6 serve to support and distribute the load of the roof
to the walls of the structures.
[0071] FIG. 7 illustrates a section of the gable plate 92c as taken
along the line A-A of FIG. 6 and shows the manner in which such
gable plate is attached to the gable end wall panel, shown at 10e.
As shown, the roof panel 10e is attached to the gable plate 92c in
the same manner as discussed previously with respect to FIG. 5. As
shown in FIG. 7, the gable plate 92c includes a slot 56e for
receiving the upper edge of the wall panel 10e in the same manner
as described above. It will be understood that wall panel 10e
includes a facing profile that matches the gable end of the
building being erected. The gable plate 92c includes a ledge 60e
that is adapted to receive the underside of the roof panel 10c. The
wall panel 10e is secured to the gable plate 92c by means of
fasteners such as shown at 58 in FIGS. 6 and 7.
[0072] FIGS. 8 and 9 illustrate aspects of the invention that serve
to support the base of the wall panels, shown as 10a. The wall
panels 10a are similar to the wall panels discussed above. As shown
in FIGS. 8 and 9, the wall panel 10a is supported by a sill
component 110. In particular, the sill component 110 includes a
lower base portion 112 and an upper panel supporting section 114.
The base portion 112 may rest on the ground 116 as shown in FIG. 8
or may rest upon a concrete slab 118 as shown in FIG. 9. Where the
sill component 110 rests on the ground, it would be preferred to
utilize cross ties 120 as shown in FIG. 8 so as to prevent relative
movement between opposite sill components 110. It will be
understood that the cross ties 120 may be provided only around the
perimeter of the building or at certain distances along the length
of the wall as may be needed to ensure the shape of the structure
is maintained. Where a concrete slab 118 is used, it would be
preferred to incorporate a ledge 122 along the outer edge of the
slab 118 in which to receive the base 112 of the sill component
110. Such an arrangement prevents the sill 110 from resting
directly on the ground. However, it will be understood that the
sill component 110 can equally rest on the ground and the concrete
slab can be provided along the inner surface thereof. In a further
alternative, the concrete slab 18 may be provided with various
forms of anchoring such as bolts, brackets and the like to receive
or engage the sill component 110.
[0073] In either case, where cross ties 120 or a concrete slab 118
is used, the sill component is preferably secured thereto by means
of fasteners 124. For example, as shown in FIG. 8, fasteners 124
are driven through the outer surface 111 of the sill component 110
and into the cross tie 120. In FIG. 9, the fasteners 124 are
similarly driven through the outer surface 111 of the sill
component and into the concrete slab 118. In the latter instance, a
masonry anchor 126, as known in the art, may be provided to receive
and engage the fastener 124.
[0074] The sill component 110 and the cross ties 120 may be formed
from the same materials as the other connection components of the
invention such as the wall joint component, the roof joint
component etc. As will be understood, the sill component comprises
an elongate structure that may run the length of the wall with
which it is associated. Where necessary, the sill component may be
formed of two or more sections that are connected together.
[0075] The upper end 114 of the sill component 110 includes an
upwardly opening slot 128 that is adapted to receive a portion of
the bottom end 130 of the wall panel 10a. The wall panel 10a may be
secured within the slot 128 using adhesives or sealing tape etc. as
discussed above. The wall panel 10a may be secured to the sill
component using fasteners 131. In a preferred embodiment, the
fasteners 131 extend from one side of the slot 128 to the other and
through the wall panel 10a. It will be understood that any length
of the wall panel 10a can be inserted into the slot 128. The length
of insertion would depend upon the size of the slot. It will also
be understood that the slot 128 aids in stabilizing the wall panels
10a and, therefore, the structure formed therewith.
[0076] FIGS. 10 to 12 illustrate the use of the composite panels of
the invention as flooring panels. FIG. 10 illustrates an aspect of
the invention wherein a sill component 110 such as that shown in
FIG. 8 or 9 is used to support wall panel 10a. The invention
provides for the use of joists 134 that extend between opposite
sill components 110 (FIG. 10 shows only one sill component for
convenience; however, it will be understood that the opposite sill
would be of the same configuration but a mirror image of that shown
in the figure). Fasteners 136 are used to connect the sill
components 110 to the ends of the joists 134. As shown, the
fasteners are preferably secured by insertion through the external
surface of the sill component and into the ends of the joists 134.
It will be understood that all fasteners described herein may
comprise nails, screws, bolts or any other such known component or
device.
[0077] The joists 134 may be formed from any of the same material
as the various joint components and sill components mentioned
above. That is, the joists 134 may be formed as an extrusion and
may be provided to the job site as elongate units of a desired
size. Alternatively, the joists 134 may be cut to the size
requirements of the building.
[0078] The joists 134 shown in FIG. 10 are arranged in a known
manner as is commonly done in the field of construction. Once the
joists 134 have been installed, composite flooring panels 10f may
be laid there-over. The flooring panels 10f are constructed
generally in the same manner as the other panels described above.
That is, the flooring panels 10f comprise a foam core 12f having on
opposing surfaces thereof, facing or covering layers 14f and 16f.
In the view shown in FIG. 10, the lower surface 14f is placed over
the joists 134 while the upper surface 16f serves as the exposed,
floor surface. As before, the foam core 12f can be designed to have
any desired level of density. The cover layers 14f and 16f may
comprise the same or different materials. For example, the lower
surface, 14f may comprise a polymer sheet (as described above)
while the upper layer 16f may comprise plywood, OSB or other such
known flooring material. It will be understood that the material
used for the layers 14f and 16f may be chosen based on the specific
need. In one aspect, the upper layer 16f may be provided with a
finishing layer or film in order to accommodate traffic thereon or
to receive a further floor covering (e.g. tile, carpet, etc.)
[0079] The composite floor panels 10f may be secured to the joists
134 using various types or combinations of fasteners or adhesives
etc.
[0080] FIG. 11 illustrates a variation of the assembly shown in
FIG. 10. In FIG. 11, the sill component 110a is generally the same
as sill component 110 of FIG. 10 but is provided with a ledge 138,
which serves as a support for an edge portion of the composite
floor panel 10f. The floor panel 10f may then be secured to the
ledge 138 using fasteners 140 and/or adhesives etc. The joists 134a
are also similar to the joists described above with respect to FIG.
10; however, as shown in FIG. 11, these components may be designed
to accommodate the ledge 138. It will be understood that the size
of the ledge 138 may be varied depending on the amount of the floor
panel 10f that needs to be supported.
[0081] FIG. 12 illustrates the sill component 110a of FIG. 11 in a
section where no joist is used. As shown, the ledge 138 is adapted
to receive an edge portion of the floor panel 10f.
[0082] Typically, the composite floor panels will be provided in
specific sizes. Therefore, when a floor is being constructed, it is
expected that more than one panel will be needed. In such case, the
floor panels can be provided over the joists 134 or 134a as
described above. FIG. 13 illustrates the manner in which adjacent
composite floor panels, shown as 10f and 10g, may be supported on a
joist 134 to form the floor of a building. It will be understood
that the joist in FIG. 13 is identified with the reference numeral
134 for convenience only and that any other type of joist as
described herein (such as joist 134a) may be used. As shown, the
joists 134 are positioned as specific locations on the region of
the floor so as to lie under adjacent edges 142 and 144 of the
respective panels 10f and 10g. The edges 142 and 144 are thus
supported on the joist 134. Fasteners 146 may then be used to
secure the edges 142 and 144 to the joist 134. The fasteners 146
are extended through the panels 10f and 10g and into the joist 134.
It will be understood that adhesive or sealing tape etc. may also
be used to secure the panels to the joist. In a preferred aspect, a
joint cap 148 may be provided to cover the seam between the
adjacent panels 10f and 10g. As will be understood, the joint cap
148 serves to seal the seam between the panels. The joint cap 148
may be secured over the edges 142 and 144 of the panels 10f and 10g
using adhesives etc. In one aspect, fasteners 149 may be used to
secure the joint cap. The fasteners 149 would preferably extend
into the joist 134. In one aspect, the joint cap 148 may be
provided with a countersunk hold to receive a head of the fastener
149 so as to avoid protrusion above the level of the joint cap.
[0083] The building system of the invention as described above and
as shown in FIGS. 3 to 13 is particularly suited for erecting
temporary shelters such as sheds, hunting blinds, cabins and the
like. The system can, for example, be used to erect temporary
dwellings in emergency situations displacement of people in the
event of natural disasters etc. The modular nature of the panels
and related components allows the system of the invention to be
easily transported to a site where assembly of the building using
the various components can be conducted. It will be understood that
the sizes of the panels and components can be pre-determined so
that a building of a given size can be erected without any cutting
of panels or the related structural components. Further, since the
panels of the invention are mainly composed of a foam core, they
are generally lightweight in nature thereby facilitating the
construction process. Further, it will be appreciated the same
panels can be used for either walls, roof or floor of the building.
Therefore, the system of the invention can be designed with only a
single panel design, which will serve multiple purposes. It will be
understood that this feature greatly simplifies the assembly
process since the need for specific, single purpose panels is
obviated.
[0084] Where needed or desired, the panels of the invention can
also be designed to include doors, windows, access opening or vents
and the like. For example, in the case of doors, certain panels can
be designed to include a doorway opening and a door may comprise
any type of material joined to the doorway by a hinge (for example
a mechanical hinge or a "living" hinge). Various types of
insulation and/or weatherproofing can be incorporated to ensure the
doors or windows are adequately sealed. Similarly, window openings
may be provided by adding a clear glazing material in an opening,
with such glazing being fixed in position by any type of method
(e.g. mechanical, welding, adhesives etc.)
[0085] The external and internal surfaces of the layers of the
panels may be provided with coloring or various types of "skins" to
provide aesthetic or functional characteristics. For example, the
skin may serve to facilitate maintenance (i.e. cleaning) or to
provide camouflage. In the case of where the system of the
invention is used to erect hunting blinds, the external and
internal surfaces may have different patterned camouflage graphics.
In this way, the panels can be configured in two alternate
configurations such as a forest camouflage for forest hunting or a
wetlands camouflage for waterfowl hunting. Thus, the system of the
invention can be designed to serve multiple purposes thereby
providing greater flexibility of use.
[0086] In the above discussion, emphasis was placed on using the
system of the invention to erect temporary or emergency structures.
However, as discussed further below, the invention can equally be
used to erect more permanent, low cost modular housing or other
such structures.
[0087] FIG. 14 illustrates schematically some of the elements of a
system in accordance with another aspect of the invention. As
shown, a generalized structure 200 includes a number of wall panels
202 and a number of roof panels 204. The wall panels 202 rest on
base plate or sill components 206. At the corners of the structure
200, corner joint components 207 connect the adjacent wall panels
202 forming the corner. Roof joint components 208 serve to connect
wall panels 202 to roof panels 204. Ridge components 210 serve to
connect roof panels 204 at a location of the ridge forming the roof
of the structure. As discussed above, in some cases, the ridge
component may be omitted, such as where a flat roof is desired.
[0088] The structure of the wall and roof panels, 202 and 204, is
generally the same as that described above. Similarly, the various
joint components are also made of the same general materials as
described above.
[0089] The base plate or sill component 206 according to the aspect
of the invention comprises a generally "U" shaped member defining a
slot 212 into which bottom portions of the wall panels 202 are
received. The roof joint, or connecting component 208 is generally
of the same configuration as described above (such as with regard
to FIGS. 8 to 12) and includes a slot 214 for receiving top
portions of the wall panels 202 and a ledge 216 for receiving edge
portions of roof panels 204. The ridge joint component 210
according to this aspect of the invention comprises a generally "C"
shaped structure defining a slot 218 that is adapted to receive
edge portions of roof panels 204. As shown, the slot 218 of the
ridge component 210 is angularly provided in a manner corresponding
to the pitch of the roof as will be understood by persons skilled
in the art.
[0090] FIG. 15 illustrates the use of a wall panel 202 of the
invention with typical concrete foundation walls 220. As shown, in
constructing a wall, one or more sill components 206 are first
secured to typical wood joists 222 in a manner known in the art.
The joists 222 are secured to the foundation wall 220 as is
typically done. Following this, wall panels 202 are placed into the
slot 212 of the sill components 206. It will be understood that the
sill components 206 will generally be provided around the perimeter
of the foundation wall.
[0091] As mentioned above, the composite wall panel 202 shown in
FIG. 15 is of the same general construction as described above. The
panel 202 includes a rigid foam core 224 composed, for example, of
a foamed polymer. Further, as with all composite panels of the
present invention, the foam may be designed to provide desired heat
and/or sound insulation properties by adjusting the density of the
foam and/or the thickness of the core itself. For example, when
used for forming walls, the composite panel may comprise a foam
core made of expanded polystyrene foam and may comprise a thickness
of 6 inches. The overall dimensions of the panel itself may vary
depending on the desired size. Although large panels would be
preferable so as to limit the number of seams in the wall, such
panels may be difficult to transport and manipulate. Further,
providing panels of "standard" sizes, such as 4 feet.times.8 feet,
construction of the building would be easier.
[0092] The foam core 224 is provided with cover layers or skins,
comprising a first layer 226, which faces the inside of the
building being erected, and a second layer 228, which faces the
externally facing side of the panel. As discussed above, the layers
226 and 228 may be the same or different in composition as needed.
For example, each of the cover layers may comprise a polymer sheet
adhered to the foam core material. Typically, when the building is
erected, both of the layers 226 and 228 may be provided with other
covering or sheathing as may be needed or desired. For example, as
shown in FIG. 15, the inwardly facing layer, 226, may be covered by
drywall 230 or other known covering. Similarly, the externally
facing layer 228 may be covered by siding 232 or other commonly
known external sheathing.
[0093] FIG. 16 illustrates a detail showing the construction of a
building and, in particular, illustrating the connection between a
composite panel wall and a composite panel roof according to an
aspect of the invention. The detail shown in FIG. 16 may, for
example, comprise the upper portion of the wall shown in FIG. 15.
For this reason, the same numbering of like elements will be used
for convenience. In the embodiment shown in FIG. 16, the building
is constructed using commonly known joists, such as wood joists
233. For this reason, the composite wall panel 202 is preferably
provided with a wall cap 234, which may be similar in structure to
the sill component 206 shown in FIG. 15. The wall cap 234 may be
connected to the upper end of the panel 202 using fasteners,
adhesives or any combination thereof. It will also be understood
that sealing material such as tape or caulking may also be used.
The joists 233 are then provided to rest on the wall cap 234. In a
preferred embodiment, the joists 233 may be provided with a slot or
cut-out 236 to fit over and engage the wall cap 234.
[0094] FIG. 16 illustrates the composite roof panels 240 used for
constructing the roof of the building. As with the wall panels 202,
the composite roof panels 240 are also of the same construction as
described above. Namely, the roof panels 240 comprise a rigid foam
core 242 and inner facing and outer facing cover layers, 244 and
246, respectively. As with the wall panels, the foam core 242 of
the roof panels 240 may be designed in terms density and
dimensions, for various heat or sound insulation properties. In one
example, the core may comprise expanded polystyrene foam of 8
inches in thickness. As described above, the cover layers 244 and
246 may be of the same or different composition. For example, each
of the cover layers 244 and 246 may comprise a polymer sheet
adhered to the foam core material. On the inner layer, standard
sheathing material such as drywall 248 may be provided over the
inner facing cover layer 244. The outer facing layer 246 may
comprise a metal sheet or such metal sheet may be provided as an
external sheathing over a polymer outer facing layer. This
discussion has focussed on metal clad roofing. However, it will be
understood that various types of roofing may be provided on the
building such as wood or asphalt shingles etc. The invention will
be understood to not be limited to any particular type of internal
or external sheathing.
[0095] In FIGS. 5 to 7, the roof joint component was described as
being a unitary structure having one end for engaging the top of a
wall panel and another end for engaging an end of a roof panel.
However, in the embodiment shown in FIG. 16, another embodiment of
a roof joint, or connecting component is shown at 250. This
embodiment of the roof joint component 250 includes a base 252
comprising a generally flat portion that is adapted to be
positioned atop the upper ends of the joists 233 described above.
The roof joint component 250 may be secured to the joists 233 in
various known ways such as with fasteners (e.g. nails), adhesives
etc. The roof joint component 250 further includes a ledge 254
adapted to receive the ends 255 of the roof panels 240. As shown in
FIG. 16, the ledge 254 preferably includes a shoulder 256 at the
end adjacent the outer portion of the wall. The shoulder 256 serves
to act as a stop for the roof panel ends 255. In the embodiment
illustrated in FIG. 16, the ledge 254 and shoulder 256 are provided
generally orthogonal to each other. In this embodiment, it is shown
that the outer ends 255 of the roof panels 240 are cut to fit
within the space defined by the ledge 254 and shoulder 256. The
degree of cutting required will depend upon the pitch of the
desired roof. For example, in the case where a flat roof is
desired, it will be understood that no cutting will be necessary.
However, as shown in FIG. 16, where the roof is to include a
certain pitch, the necessary angular cuts may be provided on the
roof panels 240.
[0096] The roof panels 240 may be secured to the roof joint
component 150 using one or more of fasteners, adhesives etc. In
addition, one or more types of anchors or flanges, such as the
flange 258 shown in FIG. 16 may be included in the system of the
invention to further secure the roof panels 240 and/or to provide a
surface for attaching the interior sheathing.
[0097] In the above discussion, a description was provided of some
corner joint components, in the case of corners formed by wall
panels, and ridge joint components, in the case of roof ridges
formed by roof panels. FIGS. 17 and 18 illustrate other embodiments
of these components. In FIG. 17, another embodiment of a corner
joint, or connecting component 270, or corner post, is illustrated.
As shown, the corner joint component 270 serves to form or support
a corner formed by adjacent composite wall panels 202a and 202b.
The structure of the panels 202a and 202b is as described above.
The corner joint component 270 includes opposed slots 272 and 274
adapted to receive panels 202a and 202b, respectively. The slots
272 and 274 in the embodiment shown in FIG. 17 are shown as
including angular base sections to receive the ends of the panels
202a and 202b after such panels are cut to include bevelled ends.
It will be understood that the corner joint component 270 may
alternatively include slots of the same configuration as shown in
FIG. 4. The panels 202a and 202b may be secured to the corner joint
component 270 in any manner as described above.
[0098] As also shown in FIG. 17, the outer edges of the corner
joint component may extend beyond the outer cover layer of the
panels and, thereby, as an edge against which any desired and
optional external cladding, such as siding, shingles etc. may
abut.
[0099] FIG. 18 illustrates a ridge joint, or connecting component
280, which is used to join opposing composite roof panels 240a and
240b to form a pitched roof. The structure of the roof panels 240a
and 240b is the same as that described above. The ridge joint
component 280 includes opposing slots 282 and 284 for receiving
opposed ends of roof panels 240a and 240b, respectively. As shown
in FIG. 18, the slots 282 and 284 are shaped to accommodate the
ends of roof panels after being cut to match the desired pitch of
the roof being constructed. It will be understood that the shape of
the slots and the needed cutting of the panel ends will vary based
on the need and the desired roof pitch.
[0100] The corner joint component 270 and ridge joint component 280
are generally elongate structures and may be extruded from
materials as described above.
[0101] As discussed above, the composite panels used for forming
the roof of the building may be of any dimensions. Although large
sized panels would reduce the number of seams, such panels would be
difficult to manipulate, particularly when building the roof. Where
seams between roof panels are present, various means of sealing
same may be used. Some examples have been described above. The
invention provides another option for connecting adjacent roof
panels apart from the ridge connection previously described. One
example of a roof construction according to an aspect of the
invention is shown in FIG. 19. In this figure, roof panels 300, 302
and 304 are shown. The faces of the panels directed towards the
interior of the building are provided, in one embodiment, with
drywall sheets 306a, b and c. The faces of the panels directed
towards the exterior of the building are provided with metal
sheathing 308a, b and c. Each of the metal sheathing include
externally extending flanges 310. In order to connect adjacent roof
panels together, a cap 312, having a generally inverted "U" shaped
structure when in use, is provided over the adjacent flanges 310 of
adjacent panels. The caps 312 include fastening elements 314 that
extend from the cap 312 and through the seam formed by adjacent
panels, such as between panels 300 and 302 and between panels 302
and 304. The joints between adjacent panels is secured by attaching
tie plates 316 to the fastening elements 314. As shown, the tie
plates 316 are sized to overlap portions of the adjacent panels.
Thus, when secured to the fastening elements, the tie plates 316
and the caps 312 are urged together and locked. As will be
understood, the interlocking of the inverted "U" shaped caps 312
and the upwardly extending flanges 310 of the adjacent panels serve
to prevent separation of adjacent panels. The tie plates 316 may be
secured to the fastening elements 314 by various means. For
example, at least the terminal portion of the fastening elements
314 may be provided with an external thread and cooperating nuts
may be provided to secure the tie plates 316 thereto.
[0102] FIGS. 20 to 27 illustrate a method of how a building may be
constructed using, for example, the panels and joint components
described above, and in particular, as shown in FIGS. 16 to 19. As
shown in FIG. 20, a concrete pad 400 is first poured in the
location where the building is to be erected. Corner posts, or
corner joint components 402 are then provided at the corners of the
building. The corner posts 402 may be embedded in the concrete or
may be secured to the formed concrete. In the next phase, wall
panels 404 are inserted into the respective slots in the corner
posts 402. In FIG. 20, the walls are shown as being formed of a
single panel 404. However, it will be understood that each wall may
be comprised of multiple panels where needed.
[0103] In FIG. 21, the building is shown having three walls
erected. As shown, one wall 405, is provided with a gable shaped
top portion. It will be understood that, if needed, all the panels
may have the same shape as shown at 404.
[0104] FIGS. 22 and 23 illustrates the addition of wall caps, or
wall cap components 406 to the upper ends of the wall panels 404
and the installation of ceiling joists 410. In this embodiment, the
wall caps 406 include slots 412 that are adapted to receive the
ceiling joists 412.
[0105] As shown in FIG. 24, once the wall caps 406 and ceiling
joists 410 are installed, the roof joint, or connecting components
414 are then secured to the upper ends of the ceiling joists 410.
In the embodiment shown, roof joint components 414 are only
required on the two opposed walls since the remaining two walls are
shown as including gable ends. For the gable wall panels, gable
joint components such as the gable plates 92c and 92d as described
in reference to FIGS. 6 and 7, may be used. As shown in FIG. 16,
the roof joint component 414 include slots 416 for receiving ends
of roof panels. As shown in FIG. 7, similar engagement structures
are provided in the gable plates.
[0106] FIG. 25 illustrates the addition of roof framing members 418
and the installation of the ridge joint component 420. Ridge joint
component 420 is generally the same as that shown and described in
FIG. 18.
[0107] FIG. 26 illustrates the next step wherein roof panels 422
are installed, with each panel extending longitudinally between the
ridge joint component 420 and respective roof joint component 414.
As described above with regard to FIG. 19, the seams between
adjacent panels 422 would preferably be connected or locked in
place.
[0108] Finally, in FIG. 27, the step of installing facia 424 or
other types of commonly known covering is shown.
[0109] FIG. 4 discussed above illustrated one embodiment of
connecting panels that form a corner between two panels, such as
wall panels. A variation in the corner joint between two panels is
illustrated in FIGS. 28 to 30. In FIGS. 28-30, the panels of the
invention will be understood as having the structure as described
above. In FIGS. 28-30, the panels forming the corner joint are
adapted to be connected together by means of a pin and keyhole
arrangement, which serves to interlock the panels and to provide
the building with further structural integrity to the building
being constructed. FIG. 28 shows a plan view illustrating four
walls forming a building. In construction, two opposing wall panels
500 and 502 are first erected in the manner described above.
Subsequently, two opposing end wall panels 504 and 506 are
positioned. As shown, the ends of each wall and end wall panel are
provided with cooperating profiles to provide mutual engagement
between adjacent panels. Specifically, as shown in FIG. 29, the
wall panels are provided with internal cut-outs resulting in each
end to have an "L" shaped structure. Thus, the ends of each pair of
wall and end panels combine to form a corner having a zigzag shaped
joint there-between. As shown in FIGS. 28 and 29, the internal
faces 505 and 506 of the end panels 504 and 506 are sized to be
received between the internal faces 501 and 503 of the two wall
panels 500 and 502.
[0110] As shown in FIGS. 29 and 30, the wall panels 500 and 502 are
provided with a number of keyholes 508 having a larger upper
opening and a narrower lower opening. The end panels 504 and 506
are provided with pins 510 adapted to interact with the keyholes
508. More specifically, the pins 510 have heads that are capable of
being inserted into the larger opening of the keyholes 510 but not
the narrower opening thereof. To further facilitate this
arrangement, each of the panels 504 and 506 may be provided with
end caps as shown in FIG. 29 into which the pins 510 and keyholes
508 are provided. In constructing the wall structure shown in FIG.
28, the end wall panels 504 and 506 are slightly lifted during
placement between wall panels 500 and 502 so as to insert the pins
510 into the larger openings of the respective keyholes 508. The
end wall panels 504 and 506 are then lowered, thereby engaging the
pins 510 within the respective keyholes 508. In such arrangement,
it will be understood that the wall panels 500, 502, 504 and 506
will be interlocked. In dismantling the building, the reverse
process is followed. That is, once the roof structures have been
removed, the end wall panels 504 and 506 are lifted slightly so as
to draw the pins 510 into the larger opening of the keyholes 508
and then laterally moved away from the wall panels 500 and 502.
[0111] It will be understood that a similar pin and keyhole
arrangement as described in reference to FIGS. 28-30 may be used
for any other corner joint of the panels of the invention. For
example, such an arrangement may be provided between wall and roof
panels. It will be appreciated that in such example, connecting the
respective pins and keyholes is facilitated by the fact that the
roof panels would generally be lowered onto existing wall panels
and, therefore, insertion of pins on the roof panels into
corresponding keyholes in the wall panels is rendered possible.
[0112] In the above description, various examples of connecting
members have been described for connecting the panels of the
invention in a number of ways. A few other examples of possible
connecting members will now be described with reference to FIGS. 31
to 36. As will be understood, any combination of the connecting
members disclosed herein can be used in the invention depending on
the specific need. The need or desirability of one component over
another will be known to persons skilled in the art. Some
considerations in the choice may include cost, speed of
construction, required structural integrity, etc., and combinations
thereof. The invention is not limited to any particular combination
of panels or connecting components.
[0113] FIG. 31 illustrates a variant of a corner connection of two
wall panels according to another aspect of the invention. As with
the embodiment shown in FIGS. 28 to 30, in the embodiment of FIG.
31, the panels are adapted to avoid the need for a separate corner
joint component. That is, as shown, and using the numbering
convention of FIGS. 28 to 30, the corner arrangement of FIG. 31
comprises an intersection of two wall panels 502a and 504a. The
panels 502a and 504a are designed to include end reinforcement
members 512 and 514, respectively. Reinforcement members 512 and
514 may comprise generally elongate, rectangular tubular members as
shown in FIG. 31. For example, reinforcement member 512 is
comprised of spaced apart side walls, 516 and 517, which are
connected by opposing end walls 518 and 519 to define a hollow
interior. Similarly, reinforcement member 514 is comprised of side
walls 520 and 521, which are separated by end walls 522 and 523. As
shown, side walls 517 and 521 form the ends of the panels 502a and
504a, respectively. Although reinforcement members 512 and 514 are
described as being hollow tubular members, it will be understood
that such structure may be preferred for a high strength to weight
ratio. However, the reinforcement members may equally be solid
structures depending upon the need. The reinforcement members may
be made of any variety of materials such as metal, plastic, wood or
any combination thereof.
[0114] The reinforcement members 512 and 514 are positioned within
each wall panel so that the layers, or skins, of the panels 502a
and 504a, extend over the end walls of the respective reinforcement
members 512 and 514 as shown in FIG. 31.
[0115] One of the pair of reinforcement members, for example 514,
is provided with a flange 524 that is connected to or, preferably,
integral with end wall 522, which faces the outer side of the panel
505a. Flange 524 is sized to extend beyond the side wall 521 and,
preferably, extends beyond the side wall 521a distance roughly
equal to the thickness of the adjacent panel 502a forming the
corner structure. As shown in FIG. 31, when the panels 502a and
504a are arranged to form the corner, the end of panel 502a is
positioned within the corner formed by the flange 524 and the side
wall 521 of the reinforcement member 514. As also shown, the outer
layer, or skin, 526 of the panel 504a having the flange 524 also
preferably extends over the flange 524. In this way the outer
appearance of the structure along the wall panel 504a would appear
without seams.
[0116] Various fasteners, 528, may be used to connect the wall
panels 502a and 504a together. In one aspect, the fasteners 528 may
comprise nails, screws or the like, that are provided through the
outer layer 526 and the flange 524 of the panel 504a and through
the side wall 517 of the adjacent panel 502a. In this way, the two
panels are secured together to form a corner of a structure.
[0117] FIG. 32 illustrates a variant of the embodiment shown in
FIGS. 5 and 16 and shows a joint between a roof panel 550 and a
wall panel 552. The panels 550 and 552 have the same general
construction as described above, namely, comprising a core
positioned between two layers or skins. The wall panel 552 includes
an elongate reinforcement member 554 positioned at the top edge of
the panel 552. The reinforcement member is generally as described
previously with respect to reinforcement members 512 and 514.
[0118] In the embodiment of FIG. 32, the wall panel 552 is further
provided with a top plate 556, which includes a top wall 558, a
bottom wall 560 that are separated and joined by opposed side walls
562 and 564. As shown, the bottom wall 560 includes an open
channel. Side wall 564 is shorter that side wall 564 and is
positioned facing outwardly of the structure being erected. In the
result, the top wall 558 is angularly provided with respect to the
bottom wall 560. As will be understood by persons skilled in the
art having regard to the present specification, the angle provided
for the top wall 558 will preferably correspond to the pitch of the
roof being erected. The top plate 556 may be connected to the roof
panel 550 by any means. By way of example, fasteners, such as shown
at 566 may be provided through the top wall 558 and into the roof
panel 550.
[0119] The top plate is further preferably adapted to receive and
retain the wall panel 552. For this purpose, the side walls 562 and
564 are provided with downwardly extending flanges, 568 and 570,
respectively. In this way, a channel is formed with the flanges 568
and 570 and the underside of the bottom wall 560, which is
preferably sized to receive the upper end of the wall panel 552.
Preferably, the length of the flanges 568 and 570 is sufficient
enough to allow a surface through which fasteners 572 may be
extended. As shown, the fasteners 572 preferably extend through the
respective flange and the outer layers of the wall panel. As shown,
the wall panel 552 is also provided with the reinforcement member
554. Thus, the fasteners 572 also extend through the adjacent wall
of the reinforcement member 554. In this way, a corner is formed
between the wall panels 550 and the wall panels 554.
[0120] The roof panel 550 also includes a reinforcement member
shown at 574. As with the previously described reinforcement
members, member 574 is preferably an elongate hollow structure;
however, the invention contemplates member 574 being solid as well.
Similarly, member 574 may be formed of any of the materials
discussed above. The roof panel reinforcement member 574 includes
an outer wall 576 and a lower wall 578, which preferably form a
generally 90.degree. angle at the bottom, outside corner of the
member 574. The outer wall 576 preferably includes a groove 580 on
the upper end thereof. As shown, the groove 580 is adapted to
receive a hooking portion of a soffit element 582. Soffit element
582 may be formed of any material as would be apparent to persons
skilled in the art. For example, soffit element 582 may comprise a
sheet of aluminum etc. The soffit element 582 may be secured to the
roof reinforcement member 574 using, for example, fasteners 584 or
the like.
[0121] The lower portion 586 of the soffit element extends towards
the wall panel 552. In a preferred embodiment, the lower edge of
the flange 570 extends outwardly away from the outer face 588 of
wall panel 552, thereby defining a channel 590 for receiving a
"hook" portion 592 of the soffit. In this arrangement, the soffit
is secured to the corner formed by the wall and roof panels.
[0122] One example of a ridge joint at the apex of a roof structure
was described in connection with FIG. 18. FIG. 33 illustrates yet
another embodiment of a roof ridge wherein the panels include
reinforcement members, such as those shown in FIGS. 31 to 32. As
shown in FIG. 33, a pair of roof panels 600 and 602 are provided to
form a roof. As with the previously described embodiment, the
panels 600, 602 are arranged in an angular manner so as to form an
apex, or ridge 603, on the roof. It will be understood that the
ridge 603 may assume any desired angle, or pitch and that such
angle will depend on the desired drainage requirements, the span of
the panels, any height clearance limitations etc. The invention is
not limited to any specific pitch. As in the embodiments previously
described, the panels 600 and 602 include respective longitudinal
reinforcement members 604 and 606. As also described above, the
reinforcement members 604, 606 may comprise hollow or solid,
generally rectangular beams or elements which form the ends of the
respective panels.
[0123] In the roof structure shown in FIG. 33, the ridge 603 is
preferably provided over a bearing wall 608 for support. In one
case, the bearing wall 608 is comprised of one or more of the wall
panels of the invention or may comprise a wall of commonly known
construction as well. In a preferred embodiment, however, the
bearing wall 608 shown in FIG. 33 comprises a sandwich panel such
as those described above. Further, in the preferred embodiment, the
panel 608 is provided with an elongate reinforcement member 610
that extends across the top edge of the panel 608 and forms the top
end thereof. As with the aforementioned reinforcement members, the
member 610 may also be hollow or solid for the same reasons
provided above. The reinforcement member 610 is embedded within the
top edge of panel 608 within the layers 611, 612 thereof. The
reinforcement member 610 is provided in one embodiment with a
generally pentagonal cross shape in end cross section. That is, as
shown in FIG. 33, the reinforcement member 610 includes a bottom
wall 614 that is positioned within the core of the panel 608. Side
walls 616 and 618 extend upwardly from the bottom wall 614, on
opposite sides thereof. As shown in FIG. 33, in a preferred
embodiment, the side walls 616 and 618 are covered by the
respective layers 611 and 612. A top wall is comprised of two
sections 620a and 620b that are angled upwardly to form an angle
that preferably approximates the desired pitch of the roof. It will
be understood that in some cases, the angle provided between the
top wall sections 620a and 620b may not need to be that of the
desired roof pitch. The apex of the top wall extends above the
layers 611 and 612 and includes a locating flange 622, the purpose
of which will be described below.
[0124] As illustrated in FIG. 33, in forming the roof, the ends of
the roof panels 600 and 602 are positioned in an opposed
arrangement with the ends thereof facing each other. The ends of
the panels, formed by reinforcement members 604 and 606,
respectively, are positioned on the reinforcement member 610 of the
wall panel 608. As can be seen, the angle preferably formed by the
top wall sections 620a and 620b of the reinforcement member 610
serves to align the roof panels 600 and 602 in the desired pitch.
The panels 600 and 602 are positioned on the top wall sections 620a
and 620b such that the ends thereof abut the locating flange 622.
In one embodiment, such as shown in FIG. 33, opposed, lower side
walls 626 and 628 of the panels 600 and 602, respectively, are
provided with extended flanges 630 and 632. The flanges 630 and 632
serve to assist the location of the panels 600 and 602 with respect
to the locating flange 622 and also to provide a surface through
which fasteners such as shown at 634 can be passed to secure the
roof panels 600, 602 to the reinforcement member 610 of the wall
panel 608.
[0125] In order to close the ridge 603 of the roof, a ridge cap 636
is provided. The ridge cap 636 generally comprises an elongate
member preferably having opposed arms 638 and 639 angularly
arranged so as to conform to the pitch of the roof being
constructed. The arms are provided with locating flanges 640, 641,
respectively, which abut the ends of the roof panels. The terminal
ends of the arms 638, 639 preferably extend over at least portion
of the upper ends of the reinforcement members 604, 606 of the wall
panels 600, 602. In this way, fasteners such as shown at 644 may be
used to secure the ridge cap 636 to the roof panels 600, 602. As
will be understood, in addition to the fasteners mentioned above,
any other means may be used to secure and seal the various members
of the roof components together. These include additional
fasteners, joint compounds, weather stripping, caulking, sealants
and the like.
[0126] FIG. 34 illustrates a further mounting arrangement of roof
structures, which has particular advantages in flat roof
structures. As shown, a roof panel 650 is provided above a wall
panel 652. The panels 650, 652 will be understood to have the same
general structure as described above. In this embodiment, the roof
panel 650 is provided with two reinforcement members 654 and 656.
As discussed previously, the reinforcement members may have a solid
or hollow structure and may be made of a variety of materials. The
first reinforcement member 654 is provided at the terminal end of
the wall panel and preferably forms the outer edge thereof. In the
specific embodiment shown in FIG. 34, the outer edge of the roof
panel 650 extends beyond the wall panel 652 so as to form a gable
for the structure being constructed. It will be understood that the
length of the gable may vary depending on the need.
[0127] The second reinforcement member 656 is provided internally
within the roof panel 650 and is located at the position of the
wall panel 652. As will be understood, reinforcement member 656
serves to provide a structural support at the load point where the
roof panel 650 rests on the upper edge of the wall panel 652. In
one embodiment, the wall panel may include a reinforcement member
as described above. In such case, the connection between the roof
panel and wall panel may be accomplished with various types of
fasteners and the like. For example, angle iron or similar
components may be used. FIG. 34 provides a further means for
facilitating the connection process between the panels 650, 652. As
shown, the upper edge of the wall panel 652 is provided preferably
with a generally rectangular "U" shaped reinforcement member 658,
having a bottom wall 660 and opposed side walls 662 and 664. The
reinforcement member 658 thereby forms a channel at the top edge of
the wall panel 652. Although a generally "U" shaped structure for
the reinforcement member 658 is preferred to form the channel,
various other forms will be understood to provide the same result
and such other forms are contemplated by the invention. In a
preferred embodiment, the channel of the reinforcement member 658
is sized, or adapted, to receive a mounting block 666 that is
attached to the roof panel 650. The mounting block 666 includes an
upper wall 668 and opposed, downwardly depending side walls 670,
671. As shown, the mounting block 666 is first attached to the
second reinforcement member 656 within the roof panel 650 by means
of fasteners 672 and the like, that are passed through the upper
wall 668 and into the second reinforcement member 656. Once the
mounting block 666 is attached to the roof panel 650, the roof
panel 650 is then lowered onto the wall panel 652 so as to insert
the mounting block 666 into the channel of the of the reinforcement
member 658. In a preferred embodiment, as shown in FIG. 34, the
side walls 670, 671 of the mounting block 666 may be optionally
provided with tapered lower ends so to facilitate insertion of the
mounting block 666 within the channel of the reinforcement member
658. Once the roof panel 650 is positioned, fasteners such as shown
at 674 may be used to secure the roof and wall panels together. As
shown, the fasteners are provided through opposite sides of the
wall panel 652 and extend through the side walls 662 and 664 of the
reinforcement member 658 and through the side walls 670 and 671 of
the mounting block 666.
[0128] FIG. 35 illustrates an embodiment of the invention wherein
two abutting panels, such as roof panels 680, 682, are connected.
Although reference is made to roof panels, it will be understood
that the following description may equally apply to any of the
aforementioned panels. However, it will be apparent to persons
skilled in the art that the following connection method may be
particularly suited for roof panel applications. As shown in FIG.
35, the roof panels 680 and 682 are provided with respective
reinforcement members 684 and 686, which will be understood to have
the same general characteristics as the reinforcement members
previously described. However, for this embodiment, the opposed
outer walls 688 and 690, respectively, of the reinforcement members
684, 686 are provided with oppositely directed locking flanges 692
and 694, respectively. As shown, the locking flanges 692 and 694
are adapted, that is sized and arranged, to engage each other when
the panels 680, 682 are assembled together. The engagement between
the locking flanges 692, 694 may be by a "snap fit" or any other
known manner, such as by first providing one panel in an angled
arrangement and the orienting such panel to the desired linear
arrangement when the locking flanges 692, 694 engage each other. In
addition, to form the required seals between the roof panels 680,
682, the opposite side walls of the reinforcement members may
include sealing flanges that extend beyond the ends of the roof
panels 680, 682. For example, as shown in FIG. 35, the lower side
wall 696 of the reinforcement member 684 of one roof panel 680 is
provided with a sealing flange 698. Similarly, the upper side wall
700 of the reinforcement member 686 of the other roof panel 682 is
also provided with a sealing flange 702. When the panels 680, 682
are assembled, the sealing flanges 698, 702 overlap at least a
portion of the reinforcement members 684, 686 of the opposed panel.
To facilitate the overlapping of the sealing flanges 698, 702, the
reinforcement members 684, 686 may include respective recesses,
such as shown at 704 and 706, to receive such sealing flanges 698,
702. Various attachment means such as fasteners 708 and the like,
may be provided to connect the reinforcement members 684, 686
together. For example, as shown, the fasteners 708 may be provided
through the sealing flange 698 and through the adjacent wall of the
opposite reinforcement member 686. In roof applications such as
shown in FIG. 35, fasteners would preferably only be provided on
the underside of the panel assembly. The sealing flange on the
upper surface of the roof panel assembly would then preferably be
provided with any type of sealing means to prevent ingress of
moisture, insects, etc. as may be needed. The invention is not
limited to any particular sealing means.
[0129] FIG. 36 illustrates an embodiment of the invention wherein a
wall panel 720 is secured to a concrete base 722, such as a
foundation wall or a concrete slab etc. The embodiment illustrated
in FIG. 36 provides a means of securing the wall panel 720 to the
concrete base 722. As shown, the bottom end of the wall panel 720
is provided with a reinforcement member 724, which preferably a
generally rectangular "U" shaped structure, defining a channel. For
example, the reinforcement member 724 comprises a top wall 726 and
downwardly depending side walls 728 and 730. As will be understood,
the reinforcement member 724 may comprise any other shape while
still providing the aforementioned channel. As also shown, the
reinforcement member 724 is also preferably provided within the
wall panel 720, whereby the layers 732, 733, forming the panel,
extend over the side walls 728 and 730 of the reinforcement
member.
[0130] A mounting block 734 is provided on the concrete base 722 to
which the wall panel 720 is to be secured. The mounting block 734
includes a bottom wall 736 and opposed, upwardly extending side
walls 738, 740. The mounting block 734 is secured to the concrete
base 722 by inserting anchor bolts 742 through bolt holes (not
shown) provided in the bottom wall 736. The anchor bolts 742 will
be understood to preferably be provided within the concrete before
it hardens, in a manner that is commonly known in the art. Once the
anchor bolts 742 are inserted into the aforementioned bolt holes in
the bottom wall 736, and the after the mounting block 734 is
properly positioned, the mounting block 734 is secured in position
by nuts 744 that are tightened on the bolts 742.
[0131] Once the mounting block 734 is secured to the concrete base
722, the wall panel 720 is lowered thereon so as to allow mounting
block 734 to be received within the channel provided by the
reinforcement member 724. Once the wall is thus positioned, various
fasteners 746 and the like may be used to connect the wall panel
720 to the mounting block 734. As shown, the fasteners 746 are able
to extend through the layers 732, 733 forming the panel 720,
through the side walls 728, 730 of the reinforcement member 724,
and through the side walls 738, 740 of the mounting block 734. In
this manner, the wall panel 720 is then secured to the mounting
block 734 and, therefore, to the concrete base 722. It will be
understood that reference has been made herein to concrete base
722. However, as will be understood by persons skilled in the art,
the connection system described above can be used for any other
base. For example, the base may comprise a floor panel such as
described above or a wood panel. In such cases, the anchor bolt 742
will assume the needed structure to enable the securing of the
mounting block 734.
[0132] FIGS. 37 and 38 illustrate uses of panels of the present
invention as joists or I-beams, or similar structural support
members. As shown in FIG. 37, an example of a joist includes a web
comprised of a panel 800 having the same structure as discussed
above. Specifically, the panel 800 includes a core 802 sandwiched
by two layers 804, 806. The materials from which the core and
layers may be formed have been described above. However, for the
formation of the joist discussed below, the core may also comprise
a composite wood material. On opposed top and bottom ends of the
panel 800 are provided joist ends 808 and 810. As can be seen, the
panel 800 and ends 808, 810 combine to form a generally "I" shape
in end cross section. As such, the joist described herein may also
be commonly referred to as an "I" beam. The joist ends, or support
elements 808, 810 may in one embodiment be formed of composite
lumber, as shown in FIG. 37. In order to accommodate the ends of
the panel 800, the joist ends 808, 810 would preferably be provided
with respective grooves or channels 812, 814 to receive the end of
the panel 800 therein. The support elements may also be formed of
wood or other material as would be known to persons skilled in the
art. The support elements 808, 810 may be of the same or different
material.
[0133] Alternatively, as shown in FIG. 38, the joist ends 808a,
810a may be formed of, for example, and extrusion of metal or
composite material. In such case, the extrusion may be formed with
a groove or channel such as shown at 812a, 814a, to receive the
ends of the panel 800 therein.
[0134] In either of the cases illustrated in FIGS. 37 and 38, the
joist ends 808, 810, 808a, 810a may be secured to the ends of the
panel 800 using various forms of adhesive and the like as would be
apparent to persons skilled in the art.
[0135] As will be understood, the aspects of the invention
described herein are based on the strength of the composite or
"sandwich" panels and the unique methods of joining same using
modular components. The panels incorporate a core of foam, such as
expanded polystyrene (although other materials may equally be used
depending on the desired strength of the foam or other attributes).
The foam is sandwiched between cover layers, which are preferably
fibre reinforced thermoplastic sheets, in order to form a
structural member. These layers may in turn optionally be covered
with any appropriate material, sheathing, or coating to provide
desired interior and exterior finishes. In one preferred aspect,
the panels are large enough to completely form an entire side of
the structure without any seams or joints. As will be understood,
this feature is desirable in order to minimize thermal losses that
normally occur in the case of seams. Of course, it will be
understood, that in the case of large buildings, some seams would
need to be provided.
[0136] In accordance with the system of the invention, the panels
are joined by a variety of attachment or joint components, or
"nodes", that provide several functions. The nodes are preferably
made of a composite material with high compressive strength and the
ability to withstand point loads. Thus, the joint components form
mechanical connections between the panels via either mechanical
fasteners and/or adhesives. The joint components also complement
the panels in providing structural integrity to the building being
constructed. In the latter case, this is the result of the
combination of the high torsion strength of the panels and the load
distribution ability of the joint components.
[0137] The system of the invention serves to encapsulate the
perimeter of building (comprised of the panels and nodes), thus
providing a method of attachment while simultaneously distributing
all point loads evenly throughout the panel. In the invention, each
panel is preferably designed to have sufficient strength so as to
maximize absorption of deflection loads and to minimize or
eliminate potential bending and buckling loads to which the nodes
or joint components may be subjected. In this manner, all point
loads are evenly distributed throughout the adjoining panels,
thereby resulting in a structure having a high structural
strength.
[0138] The system of the invention can be easily and quickly
assembled on site. As mentioned above the panels are preferably as
large as feasibly possible and may be manufactured to include one
or both interior and exterior finishes, including roofing. This
feature also minimizes the time required assemble the building
under construction. As also mentioned above, the invention also
contemplates various kits comprising any number of components
described above. For example, a "simple" structure kit may comprise
a plurality of panels, such as the wall panels, roof panels and
floor panels described above, the necessary connecting members for
such panels and suitable instructions for assembly. Such kits may
then be dispatched to any desired location and the needed
structures erected. As will be understood by persons skilled in the
art, the systems and kits of the present invention will have
particular utility in emergency situations where shelters are
needed rapidly to protect life and/or property.
[0139] In some of the figures included herein, the roof panels is
shown as including a metal exterior cladding. Such roof panels may
preferably be 4 feet in width and extend from the ridge joint
component to the outer walls without any other support members
being required. In one embodiment, the upwardly extending seams on
the metal cladding meet at the joints between adjacent roof panels,
in which case, a sealing and locking mechanism may be used to join
such panels together.
[0140] Although the invention has been described with reference to
certain specific embodiments, various modifications thereof will be
apparent to those skilled in the art without departing from the
purpose and scope of the invention as outlined in the claims
appended hereto. Any examples provided herein are included solely
for the purpose of illustrating the invention and are not intended
to limit the invention in any way. Any drawings provided herein are
solely for the purpose of illustrating various aspects of the
invention and are not intended to be drawn to scale or to limit the
invention in any way. The disclosures of all prior art recited
herein are incorporated herein by reference in their entirety.
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