U.S. patent application number 13/799482 was filed with the patent office on 2014-03-06 for composite pre-formed building panels.
This patent application is currently assigned to SYNTHEON, INC.. The applicant listed for this patent is Syntheon, Inc.. Invention is credited to Jay J. Bowman, Gregory S. Ralph, Lorenzo L. Salazar.
Application Number | 20140059959 13/799482 |
Document ID | / |
Family ID | 36431348 |
Filed Date | 2014-03-06 |
United States Patent
Application |
20140059959 |
Kind Code |
A1 |
Salazar; Lorenzo L. ; et
al. |
March 6, 2014 |
Composite Pre-Formed Building Panels
Abstract
A composite building panel including a central body,
substantially parallelepipedic in shape, comprised of an expanded
polymer matrix, having a first surface and an opposing second
surface; and one or more structural reinforcing elements
longitudinally extending across the central body between said
opposite faces, having a first side portion embedded in the
expanded polymer matrix, and a second side portion extending away
from the first surface of the central body and one or more
expansion holes located in the reinforcing member between the first
side portion of the reinforcing member and the first surface of the
central body. The central body includes a polymer matrix that
expands through the expansion holes.
Inventors: |
Salazar; Lorenzo L.;
(Gibsonia, PA) ; Bowman; Jay J.; (Florence,
KY) ; Ralph; Gregory S.; (Wexford, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Syntheon, Inc.; |
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US |
|
|
Assignee: |
SYNTHEON, INC.
Leetsdale
PA
|
Family ID: |
36431348 |
Appl. No.: |
13/799482 |
Filed: |
March 13, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11361715 |
Feb 24, 2006 |
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13799482 |
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60656596 |
Feb 25, 2005 |
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60664120 |
Mar 22, 2005 |
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Current U.S.
Class: |
52/309.13 ;
428/138; 52/309.1; 52/588.1 |
Current CPC
Class: |
E04C 2/38 20130101; E04B
5/043 20130101; Y10T 428/25 20150115; Y10T 442/665 20150401; Y10T
428/24331 20150115; E04C 2/044 20130101; E04C 2/34 20130101; E04B
5/19 20130101; Y10T 428/249972 20150401; E04C 2/22 20130101 |
Class at
Publication: |
52/309.13 ;
52/588.1; 52/309.1; 428/138 |
International
Class: |
E04C 2/38 20060101
E04C002/38; E04C 2/22 20060101 E04C002/22; E04C 2/34 20060101
E04C002/34 |
Claims
1. A central body, substantially parallelepipedic in shape,
comprised of an expanded polymer matrix, having a first surface and
an opposing second surface; and one or more reinforcing structural
elements longitudinally extending across the central body, the
reinforcing structural elements comprising: a body having a length,
a width, and a thickness, the body comprising: a first side
portion; and an opposed second side portion, the first side portion
and the second side portion being positioned along a longitudinal
axis of the width of the body, wherein the first side portion
comprises a plurality of expansion holes spaced along the length of
the body, the plurality of expansion holes comprising at least a
first row of equally spaced, elongated holes, a second row of
equally spaced, elongated holes, and a third row of equally spaced,
elongated holes, each row extending longitudinally along a length
of the first side portion, and the holes of the second row are
offset with respect to the holes of the first and third rows, and
the expanded polymer matrix expands through the expansion holes
such that the first side portion of the reinforcing structural
element is embedded in the expanded polymer matrix.
2. A composite building panel comprising: a central body,
substantially parallelepipedic in shape, comprised of an expanded
polymer matrix, having a first surface and an opposing second
surface; and one or more reinforcing structural elements
longitudinally extending across the central body, the reinforcing
structural elements comprising: a body having a length, a width,
and a thickness, the body comprising: a first side portion; and an
opposed second side portion, the first side portion and second side
portion being positioned along a longitudinal axis of the width of
the body, wherein the first side portion comprises a plurality of
expansion holes spaced along the length of the body and the second
side portion comprises at least one utility hole along the length
of the body, and the expanded polymer matrix expands through the
expansion holes such that the first side portion of the reinforcing
structural element is embedded in the expanded polymer matrix.
3. The composite building panel according to claim 2, wherein the
structural reinforcing elements have a CC cross-sectional
shape.
4. The composite building panel according to claim 2, wherein a)
the first side portion of the body comprises: i) a first web having
a first end and a second end; ii) a first flange extending
generally perpendicularly from the first end of the first web, the
first flange having a first end adjacent to the first web and a
second opposing end; and iii) a first return lip extending
generally perpendicularly from the second end of the first flange;
and b) the second side portion of the body comprises: i) a second
flange extending generally perpendicularly from the first web, the
second flange having a first end and a second end; ii) a second web
extending generally perpendicularly from the second end of the
second flange, the second web having a first end and a second end;
iii) a third flange extending generally perpendicularly from the
second end of the second web; and iv) a second return lip extending
generally perpendicularly from the third flange.
5. The composite building panel according to claim 2, wherein the
plurality of expansion holes along the length of the body comprise
at least a first row of equally spaced, elongated holes, a second
row of equally spaced, elongated holes, and a third row of equally
spaced, elongated holes, each row extending longitudinally along a
length of the first side portion.
6. The composite building panel of claim 5, wherein the holes of
the second row are offset with respect to the holes of the first
and third rows.
7. The composite building panel according to claim 2, wherein the
central body has a male end and a female end.
8. The composite building panel according to claim 2, wherein the
male end of the central body comprises a tongue edge and the female
end of the central body comprises a female groove edge that
facilitates a tongue and groove union between a first central body
and a second central body to form one or more combined composite
building panels.
9. The composite building panel according to claim 2, wherein the
expanded polymer matrix comprises one or more polymers selected
from the group consisting of homopolymers of vinyl aromatic
monomers; copolymers of at least one vinyl aromatic monomer with
one or more of divinylbenzene, conjugated dienes, alkyl
methacrylates, alkyl acrylates, acrylonitrile, and/or maleic
anhydride; polyolefins; polycarbonates; and combinations
thereof.
10. The composite building panel according to claim 2, wherein the
polymer matrix comprises carbon black, graphite, or a combination
thereof.
11. The composite building panel according to claim 2, wherein the
reinforcing structural elements comprise a material selected from
the group consisting of construction grade plastics, composite
materials, ceramics, and the like.
12. The composite building panel according to claim 2, wherein the
polymer matrix comprises an interpolymer of a polyolefin and in
situ polymerized vinyl aromatic monomers.
13. The composite building panel according to claim 2, wherein the
reinforcing structural elements comprise a metal selected from the
group consisting of aluminum, steel, stainless steel, tungsten,
molybdenum, iron and alloys, and combinations of such metals.
14. The composite building panel according to claim 2, wherein one
or more surfaces of the reinforcing structural elements have a
texturized surface.
15. A composite building panel comprising: a central body,
substantially parallelepipedic in shape, comprised of an expanded
polymer matrix, having a first surface and an opposing second
surface; and one or more reinforcing structural elements
longitudinally extending across the central body, the reinforcing
structural being a CC-type stud having a first portion embedded in
the expanded polymer matrix, a second portion extending away from
the first surface of the central body, and a plurality of expansion
holes located in the reinforcing structural element between the
first side portion of the reinforcing structural element and the
first surface of the central body, wherein the expanded polymer
matrix expands through the expansion holes and the expansion holes
are arranged in at least two rows on the first side portion that
are offset from each other.
16. The composite building panel according to claim 15, wherein a
space defined by the first surface of the central body and the
second side portion of the reinforcing members is adapted for
accommodating utilities through said space.
17. The composite building panel according to claim 15, wherein the
reinforcing structural element further comprises one or more
utility holes located in the reinforcing structural element between
the first surface of the central body and the second side portion
of the reinforcing structural element and are adapted to receive
utility lines in a transverse direction relative to the reinforcing
structural element.
18. The composite building panel according to claim 17, wherein the
utility lines are one or more selected from the group consisting of
water lines, waste lines, chases, telephone lines, cable television
lines, antenna lines, electrical lines, ductwork, and gas
lines.
19. The composite building panel according to claim 18, wherein the
at least two rows of expansion holes comprise a first row of
equally spaced, elongated holes, a second row of equally spaced,
elongated holes, and a third row of equally spaced, elongated
holes, each row extending longitudinally along a length of the
first side portion.
20. The composite building panel of claim 18, wherein the holes of
the second row are offset with respect to the holes of the first
and third rows.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/361,715 filed Feb. 24, 2006, which claims
the benefit of priority of U.S. Provisional Application Ser. Nos.
60/656,596 filed Feb. 25, 2005 and 60/664,120 filed Mar. 22, 2005,
both entitled "Composite Pre-Formed Building Panels," which are all
herein incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is directed to pre-formed building
panels that include one or more reinforcing structural elements
embedded in a foamed thermoplastic matrix.
[0004] 2. Description of Related Art
[0005] It is known to use construction elements made of expanded
plastics, for example expanded polystyrene, in forms of boards or
section members of suitable shape and size. These members provide
thermal and sound insulation functions and have long been accepted
by the building industry.
[0006] It is also known that, in order to confer adequate
self-supporting properties to such construction elements, one or
more reinforcing section bars of a suitable shape must be
incorporated into the mass of expanded plastics.
[0007] U.S. Pat. Nos. 5,787,665 and 5,822,940 disclose molded
composite wall panels for building construction that include a
regular tetragonal body of polymer foam and at least one light
metal gauge hollow stud in the body. The edges of the studs are
even with a surface of the polymer foam so drywall can be attached
thereto.
[0008] U.S. Pat. No. 6,098,367 discloses a constructive system
applied to buildings to form walls by means of modular foldable
frames that allow for the placement of blocks or plates. The frames
with the resistant channels, rods, blocks or plates, better resist
strong winds and seismic movements.
[0009] U.S. Pat. No. 6,167,624 discloses a method for producing a
polymeric foamed material panel including the steps of providing a
polymeric foamed material, cutting the polymeric foamed material
until reaching a preconfiguration cut point, cutting subsequently
from the preconfiguration cut point a brace-receiving configuration
in the polymeric foamed material, and sliding a brace member into
the brace-receiving configuration to produce a polymeric foamed
material panel.
[0010] U.S. Pat. No. 6,235,367 discloses a molded construction
product, having one or more walls and an inner core section,
including a composition matrix having a resin system, a catalytic
agent, and filler compounds for forming the walls; a foam core
system for forming the inner core section, a curing agent and a
drying agent. A structural reinforcement support system is provided
for reinforcing the structural integrity of the composition. A
locking system is provided for joining one or more of the molded
products.
[0011] EP 0 459 924 discloses a self-supporting construction
element made of expanded plastics material, specifically a floor
element, which includes a substantially parallelepipedic central
body in which a reinforcing section bar, made of a thin metal sheet
shaped as an I-beam, is integrated during the molding step.
[0012] U.S. Pat. No. 5,333,429 discloses a composite panel with a
structural load-bearing wooden framework formed by a substantially
parallelepiped body of expanded synthetic material. The panels have
a plurality of longitudinal channels extending for the whole height
of the panel. A series of channels uniformly spaced and staggered
are open on the adjacent face of the panel and have a T-shaped
cross section. In these open channels fit T-shaped cross section
wooden posts, the stem portion of which emerges out of the open
channels and project from the surface of the panel.
[0013] WO 2002/035020 discloses a composite construction element
that includes a body made of expanded plastics material and a
slab-shaped coating element associated to the body. The slab-shaped
coating element includes a plurality of substantially adjoining and
substantially U-shaped adjacent sections provided with respective
means for mechanically clinching the slab-shaped element to the
expanded plastics material.
[0014] While the construction elements described above have on the
one hand light weight, comparative ease of installation and low
cost, on the other hand their application in the art and
flexibility of use have been restrained heretofore by their poor
fire-resisting properties and/or the propensity for mold to grow on
finished surfaces attached thereto.
[0015] This inadequate resistance to fire is essentially related to
the fact that construction elements made of expanded plastics show
an insufficient capability to securely hold outer covering layers,
such as the plaster layers used for the outer surface finish or
contain the expanded polymer body, in flammable molten or liquid
form, that occurs from the heat generated from a fire.
[0016] When exposed to fire, in fact, the expanded plastic
materials soon shrink into a shapeless mass of reduced volume,
which can flow and burn, and in some cases with the ensuing
separation of the outer covering layers and rapid collapse of the
whole structure.
[0017] In addition, an undesirable separation of the outer covering
layers may be caused in some instances by a premature "aging" of
the plastics surface to which these coverings adhere, a separation
which may be further fostered by exposure to heat sources, dusts,
fumes, vapors, or chemical substances coming from a source close to
the construction elements.
[0018] U.S. Pat. No. 6,298,622 and WO 2004/101905 disclose an
approach to overcoming the above-described problem by using a
self-supporting construction element of expanded plastics for use
as floor elements and walls of buildings. The construction elements
include a central body, substantially parallelepipedic in shape and
having two opposite faces; at least one reinforcing section bar
transversally extending across the central body between the faces
thereof and embedded in the expanded plastics; a lath for
supporting at least one layer of a suitable covering material,
associated to a fin of the reinforcing section bar lying flush with
and substantially parallel to at least one of the faces of the
construction element. However, moisture buildup between the lath
and construction element can lead to mold and mildew growth and the
ability to easily run electrical lines without cutting into the
construction elements have limited the desirability of this
approach.
[0019] Thus there is a need in the art for composite pre-formed
building panels that overcome the above-described problems.
SUMMARY OF THE INVENTION
[0020] The present invention provides a composite building panel
comprising: [0021] a central body, substantially parallelepipedic
in shape, comprising an expanded polymer matrix, having opposite
faces, a first surface and an opposing second surface; and [0022]
one or more reinforcing members longitudinally extending across the
central body between said opposite faces, having a first side
portion embedded in the expanded polymer matrix, and a second side
portion extending away from the first surface of the central body
and one or more expansion holes located in the reinforcing member
between the first side portion of the reinforcing member and the
first surface of the central body; [0023] wherein the central body
includes a polymer matrix that expands through the expansion holes;
and a space defined by the first surface of the central body and
the second side portion of the reinforcing members may accommodate
utilities therethrough.
[0024] Another feature of various embodiments of the present
invention further provides a framing stud comprising: [0025] a body
having a length, a width and a thickness, the body comprising:
[0026] a first side portion; and [0027] an opposed second side
portion, the first side portion and second side portion being
positioned along a longitudinal axis of the width of the body,
[0028] wherein the first side portion comprises a plurality of
holes spaced along the length of the body and the second side
portion comprises at least one utility hole along the length of the
body.
[0029] Various embodiments of the present invention also provide
wall units, floor units, ceiling units, and roofing units
comprising one or more of the various reinforcing members described
herein (and their equivalents) and/or various composite building
panels as described herein (and their equivalents) in combination
form.
[0030] Still other embodiments of the present invention also
provide a method of constructing a building that comprises: [0031]
providing a foundation; [0032] positioning and securing the
above-described composite building panels, adapted for use as a
floor unit, to the foundation; [0033] positioning and securing two
or more of the above described composite building panels, adapted
for use as a wall unit, to at least a part of a top surface of the
floor unit; and [0034] positioning and securing the above-described
composite building panels, adapted for use as a roof and/or ceiling
unit, to the wall units.
[0035] Various embodiments of the present invention also provide a
building constructed according to the various method and/or
buildings as described herein (and their equivalents) that include
one or more of the composite building panels described herein (and
their equivalents).
[0036] Various embodiments of the present invention also further
provide methods of doing business between a composite building
panel manufacturer and a customer for creating custom composite
building panels for use in building or renovating buildings. One
method arrangement includes the steps of: providing an automated
building panel design program to the customer; creating a custom
composite building panel utilizing the automated building panel
design program, where the customer performs a design procedure to
create the custom composite building panel, the design procedure
including the steps of: selecting an architectural design for a
building; specifying at least one custom composite building panel
design; and saving the custom composite building panel design to a
custom design file; and the manufacturer making the custom
composite building panel corresponding to the custom composite
building panel design.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0038] FIG. 2 is a cross-sectional view of a pre-formed building
panel adapted for use with stucco according to various embodiments
of the present invention;
[0039] FIG. 3 is a side elevational view of a pre-formed building
panel according to various embodiments of the present
invention;
[0040] FIG. 4 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0041] FIG. 5 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0042] FIG. 6 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0043] FIG. 7 is a side elevational view of a stud according to
various embodiments of the present invention;
[0044] FIG. 8 is a perspective view of a stud according to various
embodiments of the present invention;
[0045] FIG. 9 is a side elevational view of a stud according to
various embodiments of the present invention;
[0046] FIG. 10 is a perspective view of a stud according to various
embodiments of the present invention;
[0047] FIG. 11 is a side elevational view of a stud according to
various embodiments of the present invention;
[0048] FIG. 12 is a perspective view of a stud according to various
embodiments of the present invention;
[0049] FIG. 13 is a side elevational view of a stud according to
various embodiments of the present invention;
[0050] FIG. 14 is a perspective view of a stud according to various
embodiments of the present invention;
[0051] FIG. 15 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0052] FIG. 16 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0053] FIG. 17 is a side elevational view of a stud according to
various embodiments of the present invention;
[0054] FIG. 18 is a perspective view of a stud according to various
embodiments of the present invention;
[0055] FIG. 19 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0056] FIG. 20 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0057] FIG. 21 is a side elevational view of a stud according to
various embodiments of the present invention;
[0058] FIG. 22 is a perspective view of a stud according to various
embodiments of the present invention;
[0059] FIG. 23 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0060] FIG. 24 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0061] FIG. 25 is a side elevational view of a stud according to
various embodiments of the present invention;
[0062] FIG. 26 is a perspective view of a stud according to various
embodiments of the present invention;
[0063] FIG. 27 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0064] FIG. 28 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0065] FIG. 29 is a side elevational view of a stud according to
various embodiments of the present invention;
[0066] FIG. 30 is a perspective view of a stud according to various
embodiments of the present invention;
[0067] FIG. 31 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0068] FIG. 32 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0069] FIG. 33 is a side elevational view of a stud according to
various embodiments of the present invention;
[0070] FIG. 34 is a perspective view of a stud according to various
embodiments of the present invention;
[0071] FIG. 35 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0072] FIG. 36 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0073] FIG. 37 is a side elevational view of a stud according to
various embodiments of the present invention;
[0074] FIG. 38 is a perspective view of a stud according to various
embodiments of the present invention;
[0075] FIG. 39 is a side elevational view of a stud according to
various embodiments of the present invention;
[0076] FIG. 40 is a perspective view of a stud according to various
embodiments of the present invention;
[0077] FIG. 41 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0078] FIG. 42 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0079] FIG. 43 is a side elevational view of a stud according to
various embodiments of the present invention;
[0080] FIG. 44 is a perspective view of the building panel of FIG.
41;
[0081] FIG. 45 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0082] FIG. 46 is a side elevational view of a portion of a stud
according to various embodiments of the present invention;
[0083] FIG. 47 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0084] FIG. 48 is a side elevational view of a portion of a stud
according to various embodiments of the present invention;
[0085] FIG. 49 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0086] FIG. 50 is a side elevational view of a portion of a stud
according to various embodiments of the present invention;
[0087] FIG. 51 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0088] FIG. 52 is a side elevational view of a portion of a stud
according to various embodiments of the present invention;
[0089] FIG. 53 is a perspective view of a stud according to various
embodiments of the present invention;
[0090] FIG. 54 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0091] FIG. 55 is a side elevational view of a portion of a stud
according to various embodiments of the present invention;
[0092] FIG. 56 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0093] FIG. 57 is a side elevational view of a portion of a stud
according to various embodiments of the present invention;
[0094] FIG. 58 is a perspective view of a stud according to various
embodiments of the present invention;
[0095] FIG. 59 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0096] FIG. 60 is a side elevational view of a portion of a stud
according to various embodiments of the present invention;
[0097] FIG. 61 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0098] FIG. 62 is a side elevational view of a portion of a stud
according to various embodiments of the present invention;
[0099] FIG. 63 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0100] FIG. 64 is a side elevational view of a portion of a stud
according to various embodiments of the present invention;
[0101] FIG. 65 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0102] FIG. 66 is a side elevational view of a portion of a stud
according to various embodiments of the present invention;
[0103] FIG. 67 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0104] FIG. 68 is a side elevational view of a portion of a stud
according to various embodiments of the present invention;
[0105] FIG. 69 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0106] FIG. 70 is a side elevational view of a portion of a stud
according to various embodiments of the present invention;
[0107] FIG. 71 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0108] FIG. 72 is a side elevational view of a portion of a stud
according to various embodiments of the present invention;
[0109] FIG. 73 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0110] FIG. 74 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0111] FIG. 75 is a side elevational view of a portion of a stud
according to various embodiments of the present invention;
[0112] FIG. 76 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0113] FIG. 77 is a cross-sectional view of a stud according to
various embodiments of the present invention;
[0114] FIG. 78 is a side elevational view of a portion of a stud
according to various embodiments of the present invention;
[0115] FIG. 79 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0116] FIG. 80 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0117] FIG. 81 is a cross-sectional view of a portion of a
pre-formed building panel according to various embodiments of the
present invention;
[0118] FIG. 82 is a cross-sectional view of a portion of a
pre-formed building panel according to various embodiments of the
present invention;
[0119] FIG. 83A is a cross-sectional view of a portion of a
pre-formed building panel according to various embodiments of the
present invention;
[0120] FIG. 83B is a cross-sectional view of a portion of a
pre-formed building panel according to various embodiments of the
present invention;
[0121] FIG. 83C is a cross-sectional view of a portion of a
pre-formed building panel according to various embodiments of the
present invention;
[0122] FIG. 84 is a cross-sectional view of pre-formed building
panels connected using a gasket according to various embodiments of
the present invention;
[0123] FIG. 85 is a cross-sectional view of pre-formed building
panels connected using a gasket according to various embodiments of
the present invention;
[0124] FIG. 86 is a cross-sectional view of pre-formed building
panels connected using a gasket according to various embodiments of
the present invention;
[0125] FIG. 87 is a cross-sectional view of pre-formed building
panels connected using a gasket according to various embodiments of
the present invention;
[0126] FIG. 88 is a rear elevational view of a wall system
according to various embodiments of the present invention;
[0127] FIG. 89 is a front elevational view of a wall system
according to various embodiments of the present invention;
[0128] FIG. 90 is a rear perspective view of a wall system
according to various embodiments of the present invention;
[0129] FIG. 91 is a rear view of a portion of a wall system showing
spacer bars according to various embodiments of the present
invention;
[0130] FIG. 92 is a partial top perspective view of a molding
attached to a pre-formed building panel according to various
embodiments of the present invention;
[0131] FIG. 93 is a cross-sectional view of the molding of FIG.
92;
[0132] FIG. 94 is a perspective view of an interior corner post
according to various embodiments of the present invention;
[0133] FIG. 95 is a side elevational view of an interior corner
post according to various embodiments of the present invention;
[0134] FIG. 96 is a cross-sectional view of an interior corner post
according to various embodiments of the present invention;
[0135] FIG. 97 is a cross-sectional view of a stud for the interior
corner assembly of various embodiments of the present
invention;
[0136] FIG. 98 is an interior corner assembly of various
embodiments of the present invention;
[0137] FIG. 99 is a cross-sectional view of building panels
connected by an interior corner assembly according to various
embodiments of the present invention;
[0138] FIG. 100 is a perspective view of an exterior corner post
according to various embodiments of the present invention;
[0139] FIG. 101 is a side elevational view of an exterior corner
post according to various embodiments of the present invention;
[0140] FIG. 102 is a cross-sectional view of an exterior corner
post according to various embodiments of the present invention;
[0141] FIG. 103 is a cross-sectional view of a stud for an outer
corner assembly of various embodiments of the present
invention;
[0142] FIG. 104 is a cross-sectional view of a stud for an exterior
corner assembly of various embodiments of the present
invention;
[0143] FIG. 105 is an exterior corner assembly of various
embodiments of the present invention;
[0144] FIG. 106 is a cross-sectional view of building panels
connected by an exterior corner assembly according to various
embodiments of the present invention;
[0145] FIG. 107 is a side elevational view of a portion of a stud
and spacer bar assembly according to various embodiments of the
present invention;
[0146] FIG. 108 is a cross-sectional view of a stud and spacer bar
assembly according to various embodiments of the present
invention;
[0147] FIG. 109 is a perspective view of a wall system according to
various embodiments of the present invention;
[0148] FIG. 110 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0149] FIG. 111 is a cross-sectional view of a pre-formed building
panel according to various embodiments of the present
invention;
[0150] FIG. 112 is a perspective view of a construction method
according to various embodiments of the present invention;
[0151] FIG. 113 is a partial perspective view of a level track
according to various embodiments of the present invention;
[0152] FIG. 114 is a side elevational view of a pre-formed building
panel and floor connector system according to various embodiments
of the present invention;
[0153] FIG. 115 is a side elevational view of a pre-formed building
panel and floor connector system according to various embodiments
of the present invention;
[0154] FIG. 116 is a cross-sectional view of a concrete composite
pre-formed building panel system according to various embodiments
of the present invention;
[0155] FIG. 117 is a cross-sectional view of a concrete composite
pre-formed building panel system according to various embodiments
of the present invention;
[0156] FIG. 118 is a cross-sectional view of a concrete composite
pre-formed tilt-up insulated panel according to various embodiments
of the present invention;
[0157] FIG. 119 is a cross-sectional view of a reinforced body for
use in making the concrete composite pre-formed tilt-up insulated
panel in FIG. 118;
[0158] FIG. 120 is a perspective view of an embedded metal member
for use in making the reinforced body in FIG. 119 and the concrete
composite pre-formed tilt-up insulated panels in FIGS. 118 and
121;
[0159] FIG. 121 is a cross-sectional view of a concrete composite
pre-formed tilt-up insulated panel according to various embodiments
of the present invention;
[0160] FIG. 122 is a cross-sectional view of a concrete composite
pre-formed tilt-up insulated panel according to various embodiments
of the present invention;
[0161] FIG. 123 is a cross-sectional view of a reinforced body for
use in making the concrete composite pre-formed tilt-up insulated
panel in FIG. 122;
[0162] FIG. 124 is a perspective view of an embedded metal member
for use in making the reinforced body in FIG. 123 and the concrete
composite pre-formed tilt-up insulated panels in FIGS. 122 and
125;
[0163] FIG. 125 is a cross-sectional view of a concrete composite
pre-formed tilt-up insulated panel according to various embodiments
of the present invention;
[0164] FIG. 126A is a perspective view of a floor system according
to various embodiments of the present invention;
[0165] FIG. 126B is a perspective view of a floor system according
to various embodiments of the present invention;
[0166] FIG. 127 is a cross-sectional view of metal members that can
be used in the pre-formed building panels according to various
embodiments of the present invention;
[0167] FIG. 128 is a cross-sectional view of metal members that can
be used in the pre-formed building panels according to various
embodiments of the present invention;
[0168] FIG. 129 is a cross-sectional view of metal members that can
be used in the pre-formed building panels according to various
embodiments of the present invention; and
[0169] FIG. 130 illustrates a manufacturer/customer method of
designing custom composite building panels according to various
embodiments of the present invention;
[0170] FIG. 131 is a cross-sectional view of a wind load resistance
test apparatus for testing panels according to various embodiments
of the present invention;
[0171] FIG. 132 is a perspective view of the wind load resistance
test apparatus for testing panels according to various embodiments
of the present invention;
[0172] FIG. 133 is a top plan view of the test apparatus of FIG.
132;
[0173] FIG. 134 is a side elevational view of the test apparatus of
FIG. 132;
[0174] FIG. 135 is a cross-sectional view of the test apparatus of
FIG. 132 for scenario #2;
[0175] FIG. 136 is a top plan view of a simulated building panel
assembly according to various embodiments of the present
invention;
[0176] FIG. 137 is a top plan view of a simulated building panel
assembly according to various embodiments the present
invention;
[0177] FIG. 138 is a top plan view of a simulated building panel
assembly according to various embodiments of the present
invention;
[0178] FIG. 139 is a top plan view of a simulated building panel
assembly according to various embodiments of the present invention;
and
[0179] FIG. 140 is a top plan view of a simulated building panel
assembly according to various embodiments of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0180] For the purpose of the description hereinafter, the terms
"upper," "lower," "inner", "outer", "right," "left," "vertical,"
"horizontal," "top," "bottom," and derivatives thereof, shall
relate to the invention as oriented in the drawing Figures.
However, it is to be understood that the invention may assume
alternate variations and step sequences except where expressly
specified to the contrary. It is also to be understood that the
specific devices and processes, illustrated in the attached
drawings and described in the following specification, is an
exemplary embodiment of the present invention. Hence, specific
dimensions and other physical characteristics related to the
embodiment disclosed herein are not to be considered as limiting
the invention. In describing the embodiments of the present
invention, reference will be made herein to the drawings in which
like numerals refer to like features of the invention.
[0181] Other than where otherwise indicated, all numbers or
expressions referring to quantities, distances, or measurements,
etc. used in the specification and claims are to be understood as
modified in all instances by the term "about." Accordingly, unless
indicated to the contrary, the numerical parameters set forth in
the following specification and attached claims are approximations
that can vary depending upon the desired properties, which the
present invention desires to obtain. At the very least, and not as
an attempt to limit the application of the doctrine of equivalents
to the scope of the claims, each numerical parameter should at
least be construed in light of the number of reported significant
digits and by applying ordinary rounding techniques.
[0182] Notwithstanding that the numerical ranges and parameters
setting forth the broad scope of the invention are approximations,
the numerical values set forth in the specific examples are
reported as precisely as possible. Any numerical values, however,
inherently contain certain errors necessarily resulting from the
standard deviation found in their respective measurement
methods.
[0183] Also, it should be understood that any numerical range
recited herein is intended to include all sub-ranges subsumed
therein. For example, a range of "1 to 10" is intended to include
all sub-ranges between and including the recited minimum value of 1
and the recited maximum value of 10; that is, having a minimum
value equal to or greater than 1 and a maximum value of equal to or
less than 10. Because the disclosed numerical ranges are
continuous, they include every value between the minimum and
maximum values. Unless expressly indicated otherwise, the various
numerical ranges specified in this application are
approximations.
[0184] Various embodiments of the present invention provide
pre-formed building panels that comprise one or more reinforcing
structural elements or members running longitudinally, which may be
partially exposed, with the remainder of the reinforcing structural
element(s) partially encapsulated in an expanded polymer matrix,
which acts as a thermal break. The reinforcing structural elements
can be flanged lengthwise on either side to provide attachment
points for external objects to the panel. Perforations in the
reinforcing structural elements which are encapsulated in the
expanded polymer matrix allow for fusion perpendicularly.
Perforations in the exposed portion of the reinforcing structural
element provide attachment points for lateral bracing and utility
installation. In some embodiments, a tongue and groove connection
point design provides for panel abutment, weep holes provide for
the draining of moisture or the venting of vapors and attachment
points for external objects. In some embodiments, recessed areas on
opposing panel ends provide an area of member to member connection
with "C" channels running along the top and bottom of the
structural member. In some embodiments, longitudinal holes can be
provided through the expanded polymer matrix to provide areas or
channels for the placement of utilities and/or the venting of
gasses. Such construction also serves to reduce the overall weight
of the panels. The longitudinal holes can be variable in diameter
and location. Panel manufacture can be accomplished through the use
of a semi-continuous or continuous molding process allowing for
variable panel lengths.
[0185] The composite building panels of the present invention will
now be discussed in terms of embodiments providing wall units and
wall systems. However, one skilled in the art would understand that
the composite building panels of the present invention can be used
for a variety of uses, for example flooring units, ceiling units,
etc., such as will be discussed in detail below. Therefore, the
following discussion regarding wall units and wall systems is not
intended to limit the scope of the present invention.
[0186] As shown in FIG. 1, composite building panel or wall unit 10
according to the present invention comprises a central body 9
comprised of an expanded polymer matrix (expanded polymer body
12).
[0187] As used herein, the term "expandable polymer matrix" refers
to a polymeric material in particulate or bead form that can be
impregnated with a blowing agent such that when the particulates
and/or beads are placed in a mold and heat is applied thereto,
evaporation of the blowing agent (as described below) effects the
formation of a cellular structure and/or an expanding cellular
structure in the particulates and/or beads and the outer surfaces
of the particulates and/or beads fuse together to form a continuous
mass of polymeric material conforming to the shape of the mold.
[0188] As used herein, the term "polymer" is meant to encompass,
without limitation, homopolymers, copolymers and graft
copolymers.
[0189] The expanded polymer matrix makes up the expanded polymer
body, panels and/or forms described herein below. The expanded
polymer matrix is typically molded from expandable thermoplastic
particles. These expandable thermoplastic particles are made from
any suitable thermoplastic homopolymer or copolymer. Particularly
suitable for use are homopolymers derived from vinyl aromatic
monomers including styrene, isopropylstyrene, alpha-methylstyrene,
nuclear methylstyrenes, chlorostyrene, tert-butylstyrene, and the
like, as well as copolymers prepared by the copolymerization of at
least one vinyl aromatic monomer as described above with one or
more other monomers, non-limiting examples being divinylbenzene,
conjugated dienes (non-limiting examples being butadiene, isoprene,
1,3- and 2,4-hexadiene), alkyl methacrylates, alkyl acrylates,
acrylonitrile, and maleic anhydride, wherein the vinyl aromatic
monomer is present in at least 50% by weight of the copolymer. In
an embodiment of the invention, styrenic polymers are used,
particularly polystyrene. However, other suitable polymers can be
used, such as polyolefins (e.g. polyethylene, polypropylene),
polycarbonates, polyphenylene oxides, and mixtures thereof.
[0190] As used herein, the terms "(meth)acrylic" and
"(meth)acrylate" are meant to include both acrylic and methacrylic
acid derivatives, such as the corresponding alkyl esters often
referred to as acrylates and (meth)acrylates, which the term
"(meth)acrylate" is meant to encompass.
[0191] In various embodiments of the invention, the expandable
thermoplastic particles are expandable polystyrene (EPS) particles.
These particles can be in the form of beads, granules, or other
particles convenient for the expansion and molding operations.
Particles polymerized in an aqueous suspension process are
essentially spherical and are useful for molding the expanded
polymer body, panels and/or forms described herein below. These
particles can be screened so that their size ranges from about
0.008 to about 0.15 inch (0.20 mm to about 3.81 mm) prior to
expansion.
[0192] The expandable thermoplastic particles can be impregnated
using any conventional method with a suitable blowing agent. As a
non-limiting example, the impregnation can be achieved by adding
the blowing agent to the aqueous suspension during the
polymerization of the polymer, or alternatively by re-suspending
the polymer particles in an aqueous medium and then incorporating
the blowing agent as taught in U.S. Pat. No. 2,983,692. Any gaseous
material or material which will produce gases on heating can be
used as the blowing agent. Conventional blowing agents include
aliphatic hydrocarbons containing 4 to 6 carbon atoms in the
molecule, such as butanes, pentanes, hexanes, and the halogenated
hydrocarbons, e.g. CFC's and HCFC's, which boil at a temperature
below the softening point of the polymer chosen. Mixtures of these
aliphatic hydrocarbon blowing agents can also be used.
[0193] Alternatively, water can be blended with these aliphatic
hydrocarbons blowing agents or water can be used as the sole
blowing agent as taught in U.S. Pat. Nos. 6,127,439; 6,160,027; and
6,242,540 in these patents, water-retaining agents are used. The
weight percentage of water for use as the blowing agent can range
from 1 to 20%. The texts of U.S. Pat. Nos. 6,127,439; 6,160,027;
and 6,242,540 are incorporated herein by reference.
[0194] The impregnated thermoplastic particles are generally
pre-expanded to a density of at least 0.1 lb/ft.sup.3, in some
cases at least 0.25 lb/ft.sup.3, in other cases at least 0.5
lb/ft.sup.3, in some situations at least 0.75 lb/ft.sup.3, in other
situations at least 1 lb/ft.sup.3, and in some instances at least
about 2 lb/ft.sup.3. Also, the density of the impregnated
pre-expanded particles can be up to 12 lb/ft.sup.3, in some cases
up to 10 lb/ft.sup.3, and in other cases up to 5 lb/ft.sup.3. The
density of the impregnated pre-expanded particles can be any value
or range between any of the values recited above. The pre-expansion
step is conventionally carried out by heating the impregnated beads
via any conventional heating medium, such as steam, hot air, hot
water, or radiant heat. One generally accepted method for
accomplishing the pre-expansion of impregnated thermoplastic
particles is taught in U.S. Pat. No. 3,023,175.
[0195] The impregnated thermoplastic particles can be foamed
cellular polymer particles as taught in U.S. Patent Publication No.
2002/0117769, the teachings of which are incorporated herein by
reference. The foamed cellular particles can be polystyrene that
are pre-expanded and contain a volatile blowing agent at a level of
less than 6.0 weight percent, in some cases ranging from about 2.0
wt % to about 5.0 wt %, and in other cases ranging from about 2.5
wt % to about 3.5 wt % based on the weight of the polymer.
[0196] An interpolymer of a polyolefin and in situ polymerized
vinyl aromatic monomers that can be included in the expandable
thermoplastic resin according to various embodiments of the present
invention is disclosed in U.S. Pat. Nos. 4,303,756 and 4,303,757
and U.S. Application Publication No. 2004/0152795, the relevant
portions of which are herein incorporated by reference.
Non-limiting examples of interpolymers that can be used in the
present invention include those available under the trade name
ARCEL.RTM., available from NOVA Chemicals Inc., Pittsburgh, Pa. and
PIOCELAN.RTM., available from Sekisui Plastics Co., Ltd., Tokyo,
Japan.
[0197] The expanded polymer matrix can include customary
ingredients and additives, such as pigments, dyes, colorants,
plasticizers, mold release agents, stabilizers, ultraviolet light
absorbers, mold prevention agents, antioxidants, and so on. Typical
pigments include, without limitation, inorganic pigments such as
carbon black, graphite, expandable graphite, zinc oxide, titanium
dioxide, and iron oxide, as well as organic pigments such as
quinacridone reds and violets and copper phthalocyanine blues and
greens.
[0198] In one embodiment of the invention the pigment is carbon
black, a non-limiting example of such a material is EPS SILVER.RTM.
pigment, available from NOVA Chemicals Inc.
[0199] In another embodiment of the invention the pigment is
graphite, a non-limiting example of such a material is NEOPOR.RTM.
pigment, available from BASF Aktiengesellschaft Corp., Ludwigshafen
am Rhein, Germany.
[0200] When materials such as carbon black and/or graphite are
included in the polymer particles, improved insulating properties,
as exemplified by higher R values for materials containing carbon
black or graphite (as determined using ASTM-C578), are provided. As
such, the R value of the expanded polymer particles containing
carbon black and/or graphite or materials made from such polymer
particles are at least 5% higher than observed for particles or
resulting articles that do not contain carbon black and/or
graphite.
[0201] The pre-expanded particles or "pre-puff" are heated in a
closed mold in the semi-continuous or continuous molding process
described below to form the pre-formed building panels according to
various embodiments of the present invention.
[0202] In some embodiments, portions of the central body 9 can
further comprise materials in addition to the expanded polymer
matrix, as nonlimiting examples ultraviolet (UV) stabilizers, heat
stabilizers, flame retardants, structural enhancements, biocides,
and combinations thereof.
[0203] Generally, the central body 9 is substantially
parallelepipedic in shape, i.e., a polyhedron having six
parallelogram faces that are parallel to the opposite face. As
shown in FIG. 1, the central body 9 comprises opposite faces,
including a first surface or inner surface 30 and an opposing
second surface or outer surface 24, a first end 17 and a second end
19, discussed in detail below.
[0204] In some embodiments of the invention, outer surface 24 of
expanded polymer body 12 can have any desirable type of surface. In
some instances, outer surface 24 will be smooth, in other instances
grooves can be cut into or molded into outer surface 24 to
facilitate the application of finishing surfaces and surface
finishing materials such as stucco and the like. In order to
facilitate the application of stucco to outer surface 24, T-slots
1300 can be cut into or molded into outer surface 24. Any suitable
type of stucco can be used, such as natural material stucco or
polymer based stucco. Thus, by including T-slots 1300 in outer
surface 24, a stucco ready wall panel surface is provided. More
particularly, T-slots 13 provide a mechanical connection for stucco
adhesion and no secondary mesh is required. In a particular
embodiment of the invention, T-slots 1300 allow for the use of
natural material stucco as this type of stucco is able to breathe
and not trap water. When stucco is not applied to outer surface 24,
T-slots 1300 can be used as water condensation channels for other
finishing techniques.
[0205] Referring now to FIG. 1, expanded polymer body 12 has a
width 32. The expanded polymer body 12 can be manufactured in a
variety of different sizes that would facilitate its safe handling
and minimal damage during shipping and installation thereof. The
width 32 of expanded polymer body 12 may be at least 3.28 feet (1
m), in some cases at least 4.92 feet (1.5 m), and in other cases at
least 6.56 feet (2 m) and can be up to 82.02 feet (25 m), in some
cases up to 65.62 feet (20 m), in other cases up to 49.21 feet (15
m), in some instances up to 32.81 feet (10 m) and in other
instances up to 16.40 feet (5 m). The width 32 of expanded polymer
body 12 can be any value or can range between any of the values
recited above.
[0206] The height 33 of expanded polymer body 12 can be any height
that allows for the safe handling and minimal damage to expanded
polymer body 12 during shipping and installation. See FIG. 3. In
various embodiments, the height 33 of expanded polymer body 12 is
generally determined by the length of embedded metal studs 14 and
16. See also FIG. 1. In various embodiments, the height 33 of
expanded polymer body 12 can be at least 3.28 feet (1 m) and in
some cases at least 4.92 feet (1.5 m) and can be up to 9.84 feet (3
m) and in some cases up to 8.20 feet (2.5 m). The height 33 of
expanded polymer body 12 can be any value or can range between any
of the values recited above.
[0207] Referring now to FIG. 1, expanded polymer body 12 can have a
thickness 15, measured as the distance from inner surface 30 to
outer surface 24, of at least 0.79 inches (2 cm), in some cases at
least one inch (2.5 cm), and in other cases at least 1.18 inches (3
cm) and can be up to 3.94 inches (10 cm), in some cases up to 3.15
inches (8 cm), and in other cases up to 2.36 inches (6 cm) from
inner surface 30 of expanded polymer body 12. One skilled in the
art will appreciate that the polymer body 12 could be provided in
other thicknesses without departing from the spirit and scope of
the present invention.
[0208] In some embodiments, expanded polymer body 12 can comprise
one or more openings 18 that traverse all or part of the length
and/or width of expanded polymer body 12, for example holes,
conduits or chases can be molded into and extend along the length
of the expanded polymer body 12. It is conceivable, however, that
the expanded polymer body 12 may also be provided without any such
openings therethrough. In some embodiments of the present
invention, the holes, conduits or chases may be used as access ways
for accommodating utilities, such as wiring, plumbing and exhaust
vents within the walls, ceilings, floors and roofs constructed
according to various embodiments of the present invention.
[0209] Openings 18 can have various cross-sectional shapes,
non-limiting examples being round, oval, elliptical, square,
rectangular, triangular, hexagonal or octagonal. The
cross-sectional size or area of openings 18 can be uniform or they
can vary independently of each other with regard to size and
location relative to inner surface 30 and outer surface 24. The
spacing between each opening 18 can be at least 1.97 inches (5 cm)
and in some cases at least 3.94 inches (10 cm) and can be up to
3.61 feet (110 cm), in some cases up to 3.28 ft (100 cm), in other
cases up to 2.46 ft (75 cm), and in some instances up to 1.97 ft
(60 cm) measured from a midpoint of one opening 18 to a midpoint of
an adjacent opening 18. The spacing between openings 18 can
independently be any distance or range between any of the distances
recited above.
[0210] The cross-sectional area of openings 18 can also vary
independently one from another or they can be uniform. The
cross-sectional area of openings 18 is limited by the dimensions of
expanded polymer body 12, as openings 18 will fit within the
dimensions of expanded polymer body 18. The cross-sectional area of
openings 18 can independently be at least 0.155 in.sup.2 (1
cm.sup.2), in some cases at least 0.775 in.sup.2 (5 cm.sup.2), and
in other cases at least 1.395 in.sup.2 (9 cm.sup.2) and can be up
to 20.15 in.sup.2 (130 cm2), in some cases up to 15.50 in.sup.2
(100 cm.sup.2), in other cases up to 11.625 in2 (75 cm.sup.2). The
cross-sectional area of openings 18 can independently be any value
or range between any of the values recited above.
[0211] Referring now to FIG. 4, in other embodiments of the
invention, the wall units, floor units and expanded polymer panels
or central body have a first end 17, such as a male "tongue" end or
edge, and a second end 19, such as for example a female "groove"
end or edge, that facilitates a "tongue and groove" union of two
matching wall units, floor units and expanded polymer panels. The
tongue and groove union can be non-linear and can provide for a
weep hole and/or larger opening to accommodate plumbing lines.
Typically the tongue and groove union provides a flat surface at
the union to allow for easy application of sealing tape to seal the
union or joint if desired.
[0212] Various embodiments of the present invention further include
reinforcing members to provide strength and rigidity to the panel
and to generally enhance the panel's structural integrity to
thereby enable the panel to withstand the anticipated loads and
stresses that it will likely encounter when installed. The
reinforcing members employed in various embodiments of the present
invention may comprise a variety of different structural members,
bars, joists, studs and other structural profiles without departing
from the spirit and scope of the present invention. FIG. 1
illustrates the use of reinforcing members in the form of
conventional metal studs 14 and 16. As can be seen in that Figure,
the metal studs 14 and 16 are spaced from each other across the
width 32 of the central body 9 and extend longitudinally therein as
illustrated in FIG. 3. As shown in FIG. 1, in one embodiment wall
unit 10 comprises a left facing embedded metal stud 14, and right
facing embedded metal stud 16. One skilled in the art would
understand that in alternative embodiments a single reinforcing
member or more than two reinforcing members can be used as
desired.
[0213] The reinforcing members used in various embodiments of the
invention can be made of any suitable material. Suitable materials
are those that add strength, stability and structural integrity to
the pre-formed building panels. Such materials provide embedded
framing studs meeting the requirements of applicable test methods
known in the art, as non-limiting examples ASTM A 36/A 36M-05, ASTM
A 1011/A 1011M-05a, ASTM A 1008/A 1008M-05b, and ASTM A 1003/A
1003M-05 for various types of steel.
[0214] Suitable materials include, but are not limited to metals,
construction grade plastics, composite materials, ceramics,
combinations thereof, and the like. Suitable metals include, but
are not limited to, aluminum, steel, stainless steel, tungsten,
molybdenum, iron and alloys and combinations of such metals. In
various particular embodiments of the invention, the reinforcing
members are made of a light gauge metal.
[0215] Suitable construction grade plastics include, but are not
limited to reinforced thermoplastics, thermoset resins, and
reinforced thermoset resins. Thermoplastics include polymers and
polymer foams made up of materials that can be repeatedly softened
by heating and hardened again on cooling. Suitable thermoplastic
polymers include, but are not limited to homopolymers and
copolymers of styrene, homopolymers and copolymers of C.sub.2 to
C.sub.20 olefins, C.sub.4 to C.sub.20 dienes, polyesters,
polyamides, homopolymers and copolymers of C.sub.2 to C.sub.20
(meth)acrylate esters, polyetherimides, polycarbonates,
polyphenylethers, polyvinylchlorides, polyurethanes, and
combinations thereof.
[0216] Suitable thermoset resins are resins that when heated to
their cure point, undergo a chemical cross-linking reaction causing
them to solidify and hold their shape rigidly, even at elevated
temperatures. Suitable thermoset resins include, but are not
limited to alkyd resins, epoxy resins, diallyl phthalate resins,
melamine resins, phenolic resins, polyester resins, urethane
resins, and urea, which can be crosslinked by reaction, as
non-limiting examples, with diols, triols, polyols, and/or
formaldehyde.
[0217] Reinforcing materials that can be incorporated into the
thermoplastics and/or thermoset resins include, but are not limited
to carbon fibers, aramid fibers, glass fibers, metal fibers,
fiberglass, carbon black, graphite, clays, calcium carbonate,
titanium dioxide, woven fabric or structures of the
above-referenced fibers, and combinations thereof.
[0218] A non-limiting example of construction grade plastics are
thermosetting polyester or vinyl ester resin systems reinforced
with fiberglass that meet the requirements of required test methods
known in the art, non-limiting examples being ASTM D790, ASTM D695,
ASTM D3039 and ASTM D638.
[0219] The thermoplastics and thermoset resins can optionally
include other additives, as a non-limiting example ultraviolet (UV)
stabilizers, heat stabilizers, flame retardants, structural
enhancements, biocides, and combinations thereof.
[0220] In an embodiment of the invention, one or more surfaces of
the reinforcing members used herein can have a texturized surface.
As used herein, "texturized surface" refers to a non-smooth surface
that includes surface alterations, non-limiting examples of such
include dimples and corrugation. Methods for texturizing such
surfaces are disclosed, for example in U.S. Pat. Nos. 6,183,879 and
5,689,990, the disclosures of which are herein incorporated by
reference in their entirety. Texturized surfaces can provide
improved strength in the reinforcing members and/or improved
adherence between the reinforcing members and the expanded polymer
matrix and other materials, non-limiting examples of which include
concrete, stucco, cement and mortar.
[0221] The reinforcing members can have a variety of different
thicknesses depending upon the intended use and desired physical
properties of the panel. For example, in various embodiments, the
reinforcing members may have a thickness 41 of at least 0.016 in
(0.4 mm) to up to 0.394 in (10 mm), in some instances at least
0.039 in (1 mm) and in other instances at least up to 0.314 in (8
mm). As indicated above, the reinforcing members that may be
employed in various embodiments of the present invention and may
have a variety of different cross-sectional shapes. For example,
such reinforcing members may comprise studs referred to as C-type
studs, CT-type studs, and CC-type studs. It is also conceivable
that reinforcing members with other cross-sectional shapes and
thicknesses could be employed. In the embodiments depicted in FIGS.
1, 4, and 6, C-type studs are employed.
[0222] Referring now to FIG. 1, there is shown a cross-sectional
view of a preformed building panel 10 that has an expanded polymer
body 12 that includes reinforcing members in the form of metal
studs 14 and 16 that are partially embedded therein. The embedded
metal studs 14 and 16 have embedded side portions 20 and 22, at
least a portion of which is embedded in the expanded polymer
matrix. The portion of the framing stud embedded in the expanded
polymer matrix is referred to as the thermal portion of the stud.
The portion of the embedded framing stud that is not embedded in
the polymer matrix is referred to as the structural portion of the
stud.
[0223] In some embodiments, such as the embodiment depicted in FIG.
1, the embedded side portions 20 and 22 do not extend all the way
through the expanded polymer body 12 to touch the outer surface 24
of expanded polymer body 12. Embedded side portions 20 and 22 can
extend from inner surface 30 any distance into the expanded polymer
body 12 to the outer surface 24.
[0224] Referring now to FIG. 4, in some embodiments, the embedded
side portions 20 and 22 extend all the way through the expanded
polymer body 12 to be flush with the outer surface 24 of expanded
polymer body 12 or, as shown in FIG. 137, emerge through the outer
surface 24 to provide exposed portion 35. Exposed portion 35 of
embedded side portions 20 and 22 can facilitate attachment of
finish surfaces and materials thereto.
[0225] Embedded side portions may extend at least 0.39 inches (1
cm), in some cases at least 0.79 inches (2 cm), and in other cases
at least 1.18 inches (3 cm) into expanded polymer body 12 away from
inner surface 30. Also, embedded side portions 20 and 22 can extend
up to 3.94 inches (10 cm), in some cases up to 3.15 inches (8 cm),
and in other cases up to 2.36 inches (6 cm) away from inner surface
30 into expanded polymer body 12. One skilled in the art will
appreciate that the embedded side portions 20 and 22 can be located
within the expanded polymer body 12 at a variety of different
distances from the inner surface 30 or can range between any of the
distances recited above from the inner surface 30 into the polymer
body 12.
[0226] For example, in still other embodiments of the present
invention, embedded side portions 20 and 22 can be embedded within
the polymer body 12 at distances of about from 1/10 to 9/10, in
some cases 1/3 to 2/3 and in other cases 1/4 to 3/4 of the
thickness of expanded polymer body 12 from the inner surface 30.
However, in other embodiments, side portions 20 and 22 may be
completely exposed to facilitate attachment of finish surfaces or
members thereto.
[0227] In some embodiments of the present invention, embedded metal
studs 14 and 16 have a cross-sectional shape that includes
embedding lengths 34 and 36, embedded side portions 20 and 22 and
exposed side portions 26 and 28. The orientation of embedded metal
studs 14 and 16 is referenced by the direction of open ends 38 and
40. In an embodiment of the invention shown in FIG. 1, open ends 38
and 40 are oriented away from each other. In this embodiment, wall
unit 10 has greater rigidity and is easier to handle without
bending. In other embodiments of the invention shown in FIG. 41,
open ends 38 and 40 may also be oriented facing in the same
direction.
[0228] Referring now to FIGS. 1 and 4, each exposed side portion
26, 28 comprises a web or web 1012, 1014. In some embodiments, each
exposed side portion 26, 28 can further comprise a flange 1016,
1018 extending generally perpendicularly from the web 1012, 1014.
In some embodiments, each exposed side portion 26, 28 can further
comprise a lip portion 1020, 1022 extending generally
perpendicularly from the flange 1004, 1006.
[0229] Referring to FIGS. 6 and 7, there is shown a C-type stud
denoted generally as 1500. As shown in FIG. 7, the stud 1500 has a
body 1502 that has a length 1501 and a width 1503. The stud 1500
also has a thickness 41 as illustrated in FIG. 6. The length 1501,
width 1503, and thickness 41 may vary depending upon the
application and the anticipated loading conditions that the panel
must withstand. For example, in various embodiments, the length
1501 of the body 1502 may be about 3.28 feet (1 m) to 9.84 feet (3
m), for example eight feet (2.44 m). The width 1503 of body 1502
may be about 3.94 inches (10 cm) to about 7.87 inches (20 cm), for
example, about 6 inches (15.24 cm). It is conceivable, however,
that other lengths 1501 and widths 1503 may be employed. In various
embodiments, the body 1502 comprises a first side portion 1504 and
an opposed second side portion 1506. The first side portion 1504
and the second side portion 1506 are positioned along a laterally
extending axis 1507 extending across the width of the body 1502.
The first side portion 1504 of the body 1502 comprises a first
portion 1509 of a web 1508 having an end 1510, a flange 1512
extending generally perpendicularly from the end 1510 of the web
1508 and, optionally, a return lip 1514 extending generally
perpendicularly from the flange 1512 and in a direction generally
away from the end 1510 of the web 1508 making up at least a part if
the thermal portion of the stud.
[0230] The second side portion 1506 of the body 1502 comprises a
second portion 1511 (shown in FIG. 5) of the web 1508 having an end
1516 opposite end 1510, a flange 1518 extending generally
perpendicularly from the end 1516 of the web 1508 and, optionally,
a return lip 1520 extending generally perpendicularly from the
flange 1518 and in the direction of flange 1512. The portion of the
embedded framing stud that is not embedded in the polymer matrix is
referred to as the structural portion of the stud.
[0231] Referring now to FIGS. 15, 16, 17, 20, 24, 28 and 32, a
CT-type stud, denoted generally as 1522, comprises a body 1524
having a length 1523, a width 1525 and a thickness 41. Values of
the length 1523 and width 1525 of the CT-stud 1522 may be similar
to those of the C-stud 1500 discussed above or other lengths and/or
thicknesses may be employed.
[0232] As shown in FIG. 16, the body 1524 comprises a first side
portion 1526 and an opposed second side portion 1528. The first
side portion 1526 and the second side portion 1528 are positioned
along a laterally extending axis 1529 traversing the width of the
body 1524. The first side portion 1526 comprises a first portion
1531 of the first web 1530 (the thermal portion) having a first end
1532, a first flange 1536 extending generally perpendicularly from
the first end 1532 of the first web 1530, a second web 1538 having
a first end 1540 and a second end 1542 extending generally
perpendicularly from the first flange 1536 and positioned generally
parallel to the first web 1530 and a second flange 1544 having a
first end 1546, second end 1548 and a central portion 1550
extending therebetween. The central portion 1550 of the second
flange 1544 is positioned generally perpendicularly to the first
end 1540 of the second web 1538. Generally, the second flange 1544
is positioned to form a T-shape with respect to the second web
portion 1538.
[0233] The second side portion 1528 of the body comprises a second
portion 1533 (the structural portion--shown in FIG. 15) of the
first web 1530 having a second end 1534, a third flange 1552
extending generally perpendicularly from the second end 1534 of the
first web 1530, and, optionally, a return lip 1554 extending
generally perpendicularly from the third flange 1552 (see FIG.
16).
[0234] Some of the differences between the different embodiments of
CT-type studs 1522 are based on the position of the CT-type stud
1522 relative to the expanded polymer body 12, the length of the
first web 1530 and the length of the second web 1538.
[0235] As a non-limiting example, in the embodiment illustrated in
FIG. 15, the first portion 1531 of the first side portion 1526 is
embedded in the expanded polymer body 12 with the second flange
1544 and a portion 1539 of the second web 1538 extending beyond the
outer surface 24 of the expanded polymer body 12. The length of the
first web 1530 may be about 5.12 inches (13 cm) to about 5.90
inches (15 cm), for example 5.51 inches (14 cm). Further, the
length of second web 1538 may be about 1.58 inches (4 cm) to about
2.36 inches (6 cm), for example two inches (5.08 cm). However,
these lengths may vary in other embodiments/applications.
[0236] In the embodiment illustrated in FIG. 19, the first portion
1531 of the first side portion 1526 is embedded in expanded polymer
body 12 with the second flange 1544 flush with the outer surface 24
of expanded polymer body 12. The length of the first web 1530 may
be about 5.51 inches (14 cm) to about 6.30 inches (16 cm), for
example six inches (15.24 cm). Further, the length of second web
1538 may be about 1.58 inches (4 cm) to about 2.36 inches (6 cm),
for example 2 inches (5.08 cm). However, these lengths may vary in
other embodiments/applications.
[0237] In the embodiment illustrated in FIG. 23, similar to the
embodiment of FIG. 15, the first portion 1531 of the first side
portion 1526 is embedded in the expanded polymer body 12 with the
second flange 1544 and a portion of the second web 1538 extending
beyond the outer surface 24 of the expanded polymer body 12. The
length of the first web 1530 may be about 6.30 inches (16 cm) to
about 7.09 inches (18 cm), for example seven inches (17.78 cm).
Further, the length of second web 1538 may be about 1.58 inches (4
cm) to about 2.36 inches (6 cm), for example two inches (5.08 cm).
However, these lengths may vary in other
embodiments/applications.
[0238] The embodiment illustrated in FIG. 27, similar to the
embodiment of FIG. 19, the first portion 1531 of the first side
portion 1526 is embedded in expanded polymer body 12 with the
second flange 1544 flush with the outer surface 24 of expanded
polymer body 12. The length of the first web 1530 may be about 6.30
inches (16 cm) to about 7.09 inches (18 cm), for example seven
inches (17.78 cm). Further, the length of second web 1538 may be
about 0.39 inches (1 cm) to about 1.18 inches (3 cm), for example 1
inch (2.54 cm). However, these lengths may vary in other
embodiments/applications.
[0239] In the embodiment illustrated in FIG. 31 the first portion
1531 of the first side portion 1526 is embedded in expanded polymer
body 12 with the second flange 1544 extending slightly beyond the
outer surface 24 of expanded polymer body 12 such that a bottom
surface of second flange 1544 is adjacent to outer surface 24. The
length of the first web 1530 may be about 6.69 inches (17 cm) to
about 7.48 inches (19 cm), for example 7.25 in (18.42 cm). Further,
the length of second web 1538 may be about 0.39 inches (1 cm) to
about 1.18 inches (3 cm), for example one inch (2.54 cm). However,
these lengths may vary in other embodiments/applications.
[0240] Referring now to FIGS. 36, 42, 45, 47, 49, 51, 54, 56, 59,
63, 65, 69, 71, and 74, in other embodiments of the invention, a
"CC-type" stud, denoted generally as 1556, comprises a body 1558
having a length 1557, a width 1559 and a thickness 41 (see FIGS. 36
and 37). The length 1557 of the body 1558 may be about 3.28 feet (1
m) to 9.84 feet (3 m), for example eight feet (2.44 m). The width
1559 of body 1558 may be about 5.90 inches (15 cm) to about 9.84
inches (25 cm), for example eight inches (20.32 cm). However, these
lengths may vary in other embodiments/applications.
[0241] In various embodiments, the body 1558 comprises a first side
portion 1560 and an opposed, second side portion 1562. The first
side portion 1560 and the second side portion 1562 are positioned
along a laterally extending axis 1561 that traverses the width 1559
of the body 1558. The first side portion 1560 of the body 1558
comprises a first web 1564 having a first end 1566 and a second end
1568. The first flange 1570 extends generally perpendicularly from
the second end 1568 of the first web 1564. The first flange 1570
with a first end 1572 adjacent to the first web 1564 and a second,
opposing end 1574. The first end 1560 of the body 1558 can
optionally comprise a first return lip 1576 extending generally
perpendicularly from the first flange 1570 (see FIG. 36).
[0242] The second side portion 1562 of the body 1558 comprises a
second flange 1578 having a first end 1580 and a second end 1582.
The second flange 1578 extends generally perpendicularly from the
first end 166 of the first web 1564. A second web 1584 extends
generally perpendicularly from the second end 1582 of the second
flange 1578. The second web 1584 having a first end 1586 and a
second end 1588. The second end 1562 of the body 1558 also
comprises a third flange 1590 extending generally perpendicularly
from the second end 1588 of the second web 1584 and, optionally, a
second return lip 1592 extending generally perpendicularly to the
third flange 1590 (see FIG. 36).
[0243] In an exemplary embodiment of the "CC-type" stud 1556, such
as the one illustrated in FIG. 42, the first web 1564 has a length
of about 3.94 inches (10 cm) to about 4.72 inches (12 cm), for
example 4.375 inches (11.11 cm). The first flange 1570 has a length
of about 1.18 inches (3 cm) to about 1.97 inches (5 cm), for
example 1.626 in (4.13 cm). The first return lip 1576 has a length
of about 0.20 inches (0.5 cm) to about 0.79 inches (2 cm), for
example 0.50 inch (1.27 cm). The second flange 1578 has a length of
about 1.18 inches (3 cm) to about 1.97 inches (5 cm), for example
1.626 in (4.13 cm). The second web 1584 has a length of about 3.15
inches (8 cm) to about 3.94 inches (10 cm), for example 3.626 in
(9.21 cm). The third flange 1590 has a length of about 1.18 inches
(3 cm) to about 1.97 inches (5 cm), for example 1.626 in (4.13 cm).
The second return lip 1592 has a length of about 0.20 inches (0.5
cm) to about 0.79 inches (2 cm), for example 0.50 inch (1.27 cm).
However, these lengths may vary in other
embodiments/applications.
[0244] Referring to FIGS. 7-78, the first web 1508, 1530, and 1564
of the embedded reinforcing members which may comprise, for
example, studs, joists, etc. have holes 13 or openings along its
length to facilitate fusion of the expanded plastic material and to
reduce any thermal bridging effects or heat transfer in the
reinforcing bars, studs, joists and/or members.
[0245] Expansion holes 13 are useful in that as expanded polymer
body 12 is molded, the polymer matrix expands through expansion
holes 13 and the expanding polymer fuses. This allows the polymer
matrix to encase and hold embedded studs 16 by way of the fusion in
the expanding polymer. In an embodiment of the invention, expansion
holes 13 can have a flanged and in many cases a rolled flange
surface to provide added strength to the embedded metal studs.
[0246] Expansion holes 13 may be configured in a variety of
different manners, sizes and shapes including, but not limited to,
the following configurations.
[0247] Referring now to FIGS. 7 and 8, the first side portion 1504
of body 1502 comprises a web 1508 with a plurality of generally
circular holes 1594 extending along the length of the body 1502.
The plurality of holes 1594 may be generally evenly spaced along
the length of the body 1502. Each hole of the plurality of holes
1594 may have a diameter of about 0.79 inches (2 cm) to about 1.58
inches (4 cm), for example 1.20 inches (3.05 cm). However, the
sizes, shapes, numbers and spacing arrangement of holes 1594 may
vary without departing from the spirit and scope of the present
invention. The second end 1506 of the body 1502 comprises web 1508
with four elongated, generally oval shaped, utility holes 46. The
utility holes 46 will be discussed in greater detail hereinafter.
Likewise, the sizes, shapes, numbers and spacing arrangement of
these holes may vary without departing from the spirit and scope of
the present invention.
[0248] Referring now to FIGS. 9 and 10, the first side portion 1504
of the body 1502 comprises a web 1508 with a plurality of holes
1596 along the length of the body 1502. The holes 1596 may have a
generally circular shape and comprise a first series of holes 1598
generally evenly spaced along the length of the body 1502 and a
second series of holes 1600 that may be generally evenly spaced
along the length of the body 1502. The first series of holes 1598
may be spaced from the second series of holes 1600 by a central
portion 1602 of the body 1502 that is free of holes. Each of the
holes of the first series of holes 1598 and the second series of
holes 1600 may have a diameter of about 0.79 inches (2 cm) to about
1.58 inches (4 cm), for example 1.20 inches (3.05 cm). However, the
sizes, shapes, numbers and spacing arrangement of these holes may
vary without departing from the spirit and scope of the present
invention.
[0249] The length of the central portion 1602 can vary as desired,
for example, the central portion 1602 can be 1/10 to 1/5 of the
overall length of the stud. In one embodiment, the central portion
1602 is about 1/7 of the total length of the stud. The second side
portion 1506 of the body comprises web 1508 that may have three,
generally oval shaped utility holes 46. Likewise, the sizes,
shapes, numbers and spacing arrangement of these holes may vary
without departing from the spirit and scope of the present
invention.
[0250] Referring now to FIGS. 11 and 12, the side portion end 1504
of body 1502 comprises a web 1508 that may have six generally
circular holes 1604 extending along the length of the body 1502.
The six holes 1604 may be generally evenly spaced along the length
of the body 1502. Each of the six holes 1604 may have a diameter of
about 0.79 inches (2 cm) to about 1.58 inches (4 cm), for example
1.20 inches (3.05 cm). However, the sizes, shapes, numbers and
spacing arrangement of these holes may vary without departing from
the spirit and scope of the present invention. The second side
portion 1506 of the body 1502 comprises web 1508 that may have
three, generally oval shaped utility holes 46. Likewise, the sizes,
shapes, numbers and spacing arrangement of these holes may vary
without departing from the spirit and scope of the present
invention.
[0251] Referring now to FIGS. 13 and 14, the first side portion
1504 of body 1502 may comprise a web 1508 with six generally
circular holes 1606 extending along the length of the body 1502.
The six holes 1606 may be positioned along the length of the body
1502 in a first group of two evenly spaced holes 1608, a second
group of two evenly spaced holes 1610 and a third group of two
evenly spaced holes 1612. The distance between a second hole 1606
of the first group 1608 and a first hole 1606 of the second group
1610 may be the same as the distance from a second hole 1606 of the
second group 1610 to a first hole 1606 of the third group 1612.
Each of the six holes 1606 may have a diameter of about 0.79 inches
(2 cm) to about 1.58 inches (4 cm), for example 1.20 inches (3.05
cm). However, the sizes, shapes, numbers and spacing arrangement of
these holes may vary without departing from the spirit and scope of
the present invention.
[0252] Referring now to FIG. 78, the first side portion 1504 of
body 1502 comprises a web 1508 that may have a first row 1614 of
evenly spaced elongated or oval holes 1616, a second row 1618 of
evenly spaced elongated or oval holes 1620 and a row 1622 of evenly
spaced circular holes 1624 positioned between the first row 1614 of
elongated or oval holes 1616 and the second row 1618 of elongated
or oval holes 1620. Each hole of the row 1622 of circular holes
1624 may have a diameter of about 0.79 inches (2 cm) to about 1.58
inches (4 cm), for example 1.20 inches (3.05 cm). Each hole 1620 of
the second row 1618 of elongated or oval holes 1620 may have a
length that is equal to the length of each hole 1616 of the first
row 1614 of elongated or oval holes 1616, although the relative
lengths of the respective holes may vary. For instance, each hole
1620 of the second row 1618 of elongated or oval holes 1620 and
each hole 1616 of the first row 1614 of elongated or oval holes
1616 may have a length of about 1.97 inches (5 cm) to about 2.76
inches (7 cm), for example 2.5 inches (6.35 cm), and a width of
0.20 inches (0.5 cm) to 0.79 inches (2 cm), for example 0.50 inch
(1.27 cm). However, the sizes, shapes, numbers and spacing
arrangement of these holes may vary without departing from the
spirit and scope of the present invention.
[0253] Referring now to FIGS. 17 and 18, the first side portion
1526 of body 1524 comprises a plurality of equally spaced,
elongated or oval holes 1626 extending along a length of the second
web 1538 and positioned adjacent to the first flange 1536, and a
plurality of equally spaced, generally circular holes 1628
extending along a length of the first web 1530 on the other side of
the first flange 1536. Each hole of the plurality of elongated or
oval holes 1626 may have a length of about 1.97 inches (5 cm) to
about 2.76 inches (7 cm), for example 2.5 inches (6.35 cm), and a
width of 0.20 inches (0.5 cm) to 0.79 inches (2 cm), for example
0.50 inch (1.27 cm). Each hole of the plurality of circular holes
1628 may have a diameter of about 0.79 inches (2 cm) to about 1.58
inches (4 cm), for example 1.20 inches (3.05 cm). However, the
sizes, shapes, numbers and spacing arrangement of these holes may
vary without departing from the spirit and scope of the present
invention. The second side portion 1528 of the body 1524 may
comprise four, generally oval shaped utility holes 46 extending
along the length of the first web 1530. Likewise, the sizes,
shapes, numbers and spacing arrangement of these holes may vary
without departing from the spirit and scope of the present
invention.
[0254] Referring now to FIGS. 21 and 22, the first side portion
1526 of body 1524 may comprise a plurality of equally spaced,
elongated or oval holes 1630 extending along a length of the second
web 1538 and positioned in the center of the second web 1538, and a
plurality of equally spaced, generally circular holes 1632
extending along a length of the first web 1530. Each hole of the
plurality of elongated or oval holes 1630 may have a length of
about 1.97 inches (5 cm) to about 2.76 inches (7 cm), for example
2.5 inches (6.35 cm), and a width of 0.20 inches (0.5 cm) to 0.79
inches (2 cm), for example 0.50 inch (1.27 cm). Each hole of the
plurality of circular holes 1632 may have a diameter of about 0.79
inches (2 cm) to about 1.58 inches (4 cm), for example 1.20 inches
(3.05 cm). However, the sizes, shapes, numbers and spacing
arrangement of these holes may vary without departing from the
spirit and scope of the present invention. The second side portion
1528 of the body 1524 may comprise four, generally oval shaped
utility holes 46 extending along the length of the first web 1530.
Likewise, the sizes, shapes, numbers and spacing arrangement of
these holes may vary without departing from the spirit and scope of
the present invention.
[0255] Referring now to FIGS. 25 and 26, the first side portion
1526 of body 1524 may comprise a plurality of equally spaced,
elongated or oval holes 1634 extending along a length of the second
web 1538 and adjacent to the first flange 1536, and a plurality of
equally spaced, generally circular holes 1636 extending along a
length of the first web 1530. Each hole of the plurality of
elongated or oval holes 1634 may have a length of about 1.97 inches
(5 cm) to about 2.76 inches (7 cm), for example 2.5 inches (6.35
cm), and a width of 0.20 inches (0.5 cm) to 0.79 inches (2 cm), for
example 0.50 inch (1.27 cm). Each hole of the plurality of circular
holes 1636 may have a diameter of about 0.79 inches (2 cm) to about
1.58 inches (4 cm), for example 1.20 inches (3.05 cm). However, the
sizes, shapes, numbers and spacing arrangement of these holes may
vary without departing from the spirit and scope of the present
invention. The second side portion 1528 of the body 1524 may
comprise three, generally oval shaped utility holes 46 extending
along the length of the first web 1530. Likewise, the sizes,
shapes, numbers and spacing arrangement of these holes may vary
without departing from the spirit and scope of the present
invention.
[0256] Referring now to FIGS. 29 and 30, the first side portion
1526 of body 1524 may comprise a plurality of equally spaced,
elongated or oval holes 1638 extending along a length of the second
web 1538 and positioned in the center of the second web 1538. The
first side portion 1526 may also comprise a plurality of equally
spaced, generally circular holes 1640 extending along a length of
the first web 1530. Each hole of the plurality of elongated or oval
holes 1638 may have a length of about 1.97 inches (5 cm) to about
2.76 inches (7 cm), for example 2.5 inches (6.35 cm), and a width
of 0.20 inches (0.5 cm) to 0.79 inches (2 cm), for example 0.50
inch (1.27 cm). Each hole of the plurality of circular holes 1640
may have a diameter of about 0.79 inches (2 cm) to about 1.58
inches (4 cm), for example 1.20 inches (3.05 cm). However, the
sizes, shapes, numbers and spacing arrangement of these holes may
vary without departing from the spirit and scope of the present
invention. The second side portion 1528 of the body 1524 may
comprise three, generally oval shaped utility holes 46 extending
along the length of the first web 1530. Likewise, the sizes,
shapes, numbers and spacing arrangement of these holes may vary
without departing from the spirit and scope of the present
invention.
[0257] Referring now to FIGS. 33 and 34, the first side portion
1526 of body 1524 may comprise a plurality of equally spaced,
elongated or oval holes 1642 extending along a length of the second
web 1538 and positioned in the center of the second web 1538, and a
plurality of equally spaced, generally circular holes 1644
extending along a length of the first web 1530. Each hole of the
plurality of elongated or oval holes 1642 may have a length of
about 1.97 inches (5 cm) to about 2.76 inches (7 cm), for example
2.5 inches (6.35 cm), and a width of 0.20 inches (0.5 cm) to 0.79
inches (2 cm), for example 0.50 inch (1.27 cm). Each hole of the
plurality of circular holes 1644 may have a diameter of about 0.79
inches (2 cm) to about 1.58 inches (4 cm), for example 1.20 inches
(3.05 cm). However, the sizes, shapes, numbers and spacing
arrangement of these holes may vary without departing from the
spirit and scope of the present invention. The second side portion
1528 of the body 1524 may comprise three, generally oval shaped
utility holes 46 extending along the length of the first web 1530.
Likewise, the sizes, shapes, numbers and spacing arrangement of
these holes may vary without departing from the spirit and scope of
the present invention.
[0258] Referring now to FIGS. 37 and 38, the first side portion
1560 of body 1558 may comprise a first row 1646 of equally spaced,
elongated or oval holes 1648, a second row 1650 of equally spaced,
elongated or oval holes 1652 and a third row 1654 of equally
spaced, elongated or oval holes 1656. Each row 1646, 1650, 1654
extends along a length of the first web 1564. The second row 1650
of equally spaced, elongated or oval holes 1652 may be offset with
respect to the first and third rows 1646, 1654 of equally spaced,
elongated or oval holes 1648, 1656, i.e., the center of holes 1648,
1656 are aligned and the centers of holes 1652 are offset with
respect thereto. Each hole of each row 1646, 1650, 1654 of
elongated or oval holes 1648, 1652, 1656 may have a length of about
1.97 inches (5 cm) to about 2.76 inches (7 cm), for example 2.5
inches (6.35 cm), and a width of 0.20 inches (0.5 cm) to 0.79
inches (2 cm), for example 0.50 inch (1.27 cm). However, the sizes,
shapes, numbers and spacing arrangement of these holes may vary
without departing from the spirit and scope of the present
invention. The second side portion 1562 of the body 1558 may
comprise four, generally oval shaped utility holes 46 extending
along the length of the second web 1584. Likewise, the sizes,
shapes, numbers and spacing arrangement of these holes may vary
without departing from the spirit and scope of the present
invention. Further, the second web portion 1584 has a length that
is greater than the length of the first web portion 1564, as shown
in FIG. 38, thereby creating a notch. The notch allows for secure
attachment to a framing system.
[0259] Referring now to FIGS. 39 and 40, the first side portion
1560 of body 1558 may comprise a first row 1658 of equally spaced,
elongated or oval holes 1660, a second row 1662 of equally spaced,
elongated or oval holes 1664 and a third row 1666 of equally
spaced, elongated or oval holes 1668. Each row 1658, 1662, 1666
extends along a length of the first web 1564. The second row 1662
of equally spaced, elongated or oval holes 1664 may be offset with
respect to the first and third rows 1658, 1666 of equally spaced,
elongated or oval holes 1660, 1668. Each hole of each row 1658,
1662, 1666 of elongated or oval holes 1660, 1664, 1668 may have a
length of about 1.97 inches (5 cm) to about 2.76 inches (7 cm), for
example 2.5 inches (6.35 cm), and a width of 0.20 inches (0.5 cm)
to 0.79 inches (2 cm), for example 0.50 inch (1.27 cm). However,
the sizes, shapes, numbers and spacing arrangement of these holes
may vary without departing from the spirit and scope of the present
invention. The second side portion 1562 of the body 1558 may
comprise three, generally oval shaped utility holes 46 extending
along the length of the second web 1584. Likewise, the sizes,
shapes, numbers and spacing arrangement of these holes may vary
without departing from the spirit and scope of the present
invention.
[0260] Referring now to FIGS. 41-44, the first side portion 1560 of
body 1558 may comprise a first row 1670 of equally spaced,
elongated or oval holes 1672, a second row 1674 of equally spaced,
elongated or oval holes 1676 and a third row 1678 of equally
spaced, elongated or oval holes 1680. See FIG. 43. Each row 1670,
1674, 1678 extends along a length of the first web 1564. The second
row 1674 of equally spaced, elongated or oval holes 1676 may be
offset with respect to the first and third rows 1670, 1678 of
equally spaced, elongated or oval holes 1672, 1680. Each hole of
each row 1670, 1674, 1678 of elongated or oval holes 1672, 1676,
1680 may have a length of about 1.97 inches (5 cm) to about 2.76
inches (7 cm), for example 2.36 inches (6 cm), and a width of 0.20
inches (0.5 cm) to 0.79 inches (2 cm), for example 0.591 in (1.5
cm). However, the sizes, shapes, numbers and spacing arrangement of
these holes may vary without departing from the spirit and scope of
the present invention. The second side portion 1562 of the body
1558 may comprise three, generally oval shaped knockout holes 46
extending along the length of the second web 1584 to be used for
utilities or structural bracing/spacer members. Likewise, the
sizes, shapes, numbers and spacing arrangement of these holes may
vary without departing from the spirit and scope of the present
invention.
[0261] Referring now to FIGS. 45 and 46, the first side portion
1560 of body 1558 may comprise a first row 1682 of equally spaced,
elongated or oval holes 1684, a second row 1686 of equally spaced,
elongated or oval holes 1688 and a third row 1690 of equally
spaced, elongated or oval holes 1692. Each row 1682, 1686, 1690
extends along a length of the first web 1564. The second row 1686
of equally spaced, elongated or oval holes 1688 may be offset with
respect to the first and third rows 1682, 1690 of equally spaced,
elongated or oval holes 1684, 1692. Also, each hole 1688 of the
second row 1686 of elongated or oval holes 1688 may have a length
that is greater than the length of each hole of the first and third
rows 1682, 1690 of elongated or oval holes 1684, 1692. Each hole of
each row 1682, 1690 of elongated or oval holes 1684, 1692 may have
a length of about 1.97 inches (5 cm) to about 2.76 inches (7 cm),
for example 2.5 inches (6.35 cm), and a width of 0.20 inches (0.5
cm) to 0.79 inches (2 cm), for example 0.50 inch (1.27 cm). Each
hole of row 1686 of elongated or oval holes 1688 may have length of
about 7.87 in (20 cm) to about 9.45 in (24 cm), for example 8.50 in
(21.6 cm). However, the sizes, shapes, numbers and spacing
arrangement of these holes may vary without departing from the
spirit and scope of the present invention. The second side portion
1562 of the body 1558 may comprise three, generally oval shaped
knockout holes 46 extending along the length of the second web 1584
to be used for utilities or structural bracing/spacer members.
Likewise, the sizes, shapes, numbers and spacing arrangement of
these holes may vary without departing from the spirit and scope of
the present invention.
[0262] Referring now to FIGS. 47 and 48, the first side portion
1560 of body 1558 may comprise a first row 1693 of equally spaced,
elongated or oval holes 1694, a second row 1695 of equally spaced,
elongated or oval holes 1696, a third row 1697 of equally spaced,
elongated or oval holes 1698, a fourth row 1699 of equally spaced,
elongated or oval holes 1700 and a fifth row 1701 of equally
spaced, elongated or oval holes 1702 extending along a length of
the first web 1564. The second and fourth rows 1695 and 1699 may be
offset with respect to the first, third and fifth rows 1693, 1697
and 1701. Each hole of each row 1693, 1695, 1697, 1699, 1701 of
elongated or oval holes 1694, 1696, 1698, 1700 and 1702 may have a
length of about 4.33 in (11 cm) to about 5.51 inches (14 cm), for
example five inches (12.7 cm), and a width of 0.10 inches (0.25 cm)
to 0.39 inches (1 cm), for example 0.25 inches (0.635 cm). However,
the sizes, shapes, numbers and spacing arrangement of these holes
may vary without departing from the spirit and scope of the present
invention. The second side portion 1562 of the body 1558 may
comprise three, generally oval shaped knockout holes 46 extending
along the length of the second web 1584 to be used for utilities or
structural bracing/spacer members. Likewise, the sizes, shapes,
numbers and spacing arrangement of these holes may vary without
departing from the spirit and scope of the present invention.
[0263] Referring now to FIGS. 49 and 50, the first side portion
1560 of body 1558 may comprise a first row 1703 of equally spaced,
elongated or rectangular holes 1704, a second row 1705 of equally
spaced, elongated or rectangular holes 1706 and a third row 1707 of
equally spaced, elongated or rectangular holes 1708 extending along
a length of the first web 1564. Each hole of the second row of
elongated or rectangular holes 1706 may have a length that is
greater than the length of each hole of the first and third rows of
elongated or rectangular holes 1704 and 1706. Each hole of each row
1703, 1707 of elongated or rectangular holes 1704, 1708 may have a
length of about 1.97 inches (5 cm) to about 2.76 inches (7 cm), for
example 2.5 inches (6.35 cm), and a width of about 0.20 inches (0.5
cm) to about 0.79 inches (2 cm), for example 0.50 inch (1.27 cm).
Each hole of row 1705 of elongated or rectangular holes 1688 may
have length of about 10.63 in (27 cm) to about 15.60 in (32 cm),
for example 11.5 in (29.2 cm) and a width of about 0.20 inches (0.5
cm) to about 0.79 inches (2 cm), for example 0.50 inch (1.27 cm).
However, the sizes, shapes, numbers and spacing arrangement of
these holes may vary without departing from the spirit and scope of
the present invention. The second side portion 1562 of the body
1558 may comprise three, generally oval shaped knockout holes 46
extending along the length of the second web 1584 to be used for
utilities or structural bracing/spacer members. Likewise, the
sizes, shapes, numbers and spacing arrangement of these holes may
vary without departing from the spirit and scope of the present
invention.
[0264] Referring now to FIGS. 51-53, the first side portion 1560 of
body 1558 may comprise a row of generally alternating first
generally triangular slots 1710 and second generally triangular
slots 1712 extending along a length of the first web 1564. The
first triangular slots 1710 may comprise a base 1714 positioned
generally parallel to an intersecting edge between the first web
1564 and the first flange 1570 of the first end 1560 of the body
1558 and an apex 1716 oriented toward the second flange 1578 of the
second end 1562 of the body 1558. The second triangular slots 1712
may comprise a base 1718 positioned generally parallel to an
intersecting edge between the first web 1564 and second flange 1578
of the second end 1562 of the body 1558 and an apex 1720 oriented
toward the first flange 1570 of the first end 1560 of the body
1558. The first triangular slots 1710 and second triangular slots
1712 may generally comprise equilateral triangles with each edge of
each triangular slot 1710, 1712 having a length of about 1.58
inches (4 cm) to about 2.36 inches (6 cm), for example two inches
(5.13 cm). However, the sizes, shapes, numbers and spacing
arrangement of these holes may vary without departing from the
spirit and scope of the present invention. The second side portion
1562 of the body 1558 may comprise three, generally oval shaped
knockout holes 46 extending along the length of the second web 1584
to be used for utilities or structural bracing/spacer members.
Likewise, the sizes, shapes, numbers and spacing arrangement of
these holes may vary without departing from the spirit and scope of
the present invention.
[0265] Referring now to FIGS. 54 and 55, the first side portion
1560 of body 1558 may comprise a first row 1721 of elongated or
oval holes 1722, a second row 1723 of elongated or oval holes 1724
with each hole having a length that is less than the length of each
hole of the first row of elongated or oval holes 1722, a row of
generally alternating first triangular slots 1726 and second
triangular slots 1728, a third row 1729 of elongated or oval holes
1730 with each hole having a length that is equal to the length of
each hole of the second row 1723 of elongated or oval holes 1724,
and a fourth row 1731 of elongated or oval holes 1732 with each
hole having a length that is equal to the length of each hole of
the first row 1721 of elongated or oval holes 1722. Each row of
holes extends along a length of the first web 1564. Each hole of
the first row 1721 of elongated or oval holes 1722 and the fourth
row 1731 of elongated or oval holes 1732 may have a length of about
5.51 inches (14 cm) to about 6.30 inches (16 cm), for example six
inches (15.24 cm), and a width of about 0.10 inches (0.25 cm) to
about 0.39 inches (1 cm), for example 0.25 inches (0.635 cm). Each
hole of the second row 1723 of elongated or oval holes 1724 and the
third row 1729 of elongated or oval holes 1730 may have a length of
about 0.591 in (1.5 cm) to about 1.378 in (3.5 cm), for example one
inch (2.54 cm), and a width of about 0.10 inches (0.25 cm) to about
0.39 inches (1 cm), for example 0.25 inches (0.635 cm). However,
the sizes, shapes, numbers and spacing arrangement of these holes
may vary without departing from the spirit and scope of the present
invention. The first triangular slots 1726 may comprise a base 1734
positioned generally parallel to an intersecting edge between the
first web 1564 and the first flange 1570 of the first end 1560 of
the body 1558 and an apex 1736 oriented toward the second flange
1578 of the second end 1562 of the body 1558. The second triangular
slots 1728 may comprise a base 1738 positioned generally parallel
to an intersecting edge between the first web 1564 and second
flange 1578 of the second end 1562 of the body 1558 and an apex
1740 oriented toward the first flange 1570 of the first end 1560 of
the body 1558. The first triangular slots 1710 and second
triangular slots 1712 may generally comprise equilateral triangles
with each edge of each triangular slot 1710, 1712 having a length
of about 1.58 inches (4 cm) to about 2.36 inches (6 cm), for
example two inches (5.13 cm). However, the sizes, shapes, numbers
and spacing arrangement of these holes may vary without departing
from the spirit and scope of the present invention. The second side
portion 1562 of the body 1558 may comprise three, generally oval
shaped knockout holes 46 extending along the length of the second
web 1584 to be used for utilities or structural bracing/spacer
members. Likewise, the sizes, shapes, numbers and spacing
arrangement of these holes may vary without departing from the
spirit and scope of the present invention.
[0266] Referring now to FIGS. 57 and 58, the first side portion
1560 of body 1558 may comprise a first row 1741 of elongated or
oval holes 1742, a row of generally alternating first triangular
slots 1744 and second triangular slots 1746, and a second row 1747
of elongated or oval holes 1748 with each hole having a length that
is equal to the length of each hole of the first row of elongated
or oval holes 1742. Each row of holes extends along a length of the
first web 1564. Each hole of the first row 1741 of elongated or
oval holes 1742 and second row 1747 of elongated or oval holes 1748
may have a length of about 3.15 inches (8 cm) to about 3.94 inches
(10 cm), for example 3.54 in (9 cm), and a width of about 0.10
inches (0.25 cm) to about 0.39 inches (1 cm), for example 0.25
inches (0.635 cm). However, the sizes, shapes, numbers and spacing
arrangement of these holes may vary without departing from the
spirit and scope of the present invention. The first triangular
slots 1744 may comprise a base 1750 positioned generally parallel
to an intersecting edge between the first web 1564 and the first
flange 1570 of the first end 1560 of the body 1558 and an apex 1752
oriented toward the second flange 1578 of the second end 1562 of
the body 1558. The second triangular slots 1746 may comprise a base
1754 positioned generally parallel to an intersecting edge between
the first web 1564 and second flange 1578 of the second end 1562 of
the body 1558 and an apex 1756 oriented toward the first flange
1570 of the first end 1560 of the body 1558. The first triangular
slots 1710 and second triangular slots 1712 may generally comprise
equilateral triangles with each edge of each triangular slot 1710,
1712 having a length of about 1.58 inches (4 cm) to about 2.36
inches (6 cm), for example two inches (5.13 cm). However, the
sizes, shapes, numbers and spacing arrangement of these holes may
vary without departing from the spirit and scope of the present
invention. The second side portion 1562 of the body 1558 may
comprises three, generally oval shaped knockout holes 46 extending
along the length of the second web 1584 to be used for utilities or
structural bracing/spacer members. Likewise, the sizes, shapes,
numbers and spacing arrangement of these holes may vary without
departing from the spirit and scope of the present invention.
[0267] Referring now to FIGS. 59 and 60, the first side portion
1560 of body 1558 may comprise a first row 1757 of equally spaced,
elongated or oval holes 1758, a second row 1759 of equally spaced,
elongated or oval holes 1760, and a third row 1761 of equally
spaced, elongated or oval holes 1762. Each row of holes extends
along a length of the first web 1564. The second row of holes 1760
may be offset with respect to the first and third rows of hole
1758, 1762. Each hole of each row 1757, 1759, 1760 of elongated or
oval holes 1758, 1760, 1762 may have a length of about 7.48 inches
(19 cm) to about 8.27 in (21 cm), for example eight inches (20.32
cm), and a width of about 0.20 inches (0.5 cm) to about 0.79 inches
(2 cm), for example 0.50 inch (1.27 cm). However, the sizes,
shapes, numbers and spacing arrangement of these holes may vary
without departing from the spirit and scope of the present
invention. The second side portion 1562 of the body 1558 may
comprise three, generally oval shaped knockout holes 46 extending
along the length of the second web 1584 to be used for utilities or
structural bracing/spacer members. Likewise, the sizes, shapes,
numbers and spacing arrangement of these holes may vary without
departing from the spirit and scope of the present invention.
[0268] Referring now to FIGS. 61 and 62, the first side portion
1560 of body 1558 may comprise a first row 1763 of equally spaced,
elongated or oval holes 1764, a second row 1765 of equally spaced,
elongated or oval holes 1766, and a 1767 third row of equally
spaced, elongated or oval holes 1768. Each row of holes extends
along a length of the first web 1564. The second row of holes 1766
may be offset with respect to the first and third rows of holes
1764, 1768. Each hole of each row 1763, 1765, 1767 of elongated or
oval holes 1764, 1766, 1768 may have a length of about 7.48 inches
(19 cm) to about 8.27 in (21 cm), for example eight inches (20.32
cm), and a width of about 0.20 inches (0.5 cm) to about 0.79 inches
(2 cm), for example 0.50 inch (1.27 cm). However, the sizes,
shapes, numbers and spacing arrangement of these holes may vary
without departing from the spirit and scope of the present
invention. The second flange 1578 may comprise additional slots
1769 extending along a length thereof. The additional slots 1769
provide for a thermal break. The second side portion 1562 of the
body 1558 may comprise three, generally oval shaped knockout holes
46 extending along the length of the second web 1584 to be used for
utilities or structural bracing/spacer members. Likewise, the
sizes, shapes, numbers and spacing arrangement of these holes may
vary without departing from the spirit and scope of the present
invention.
[0269] Referring now to FIGS. 63 and 64, the first side portion
1560 of body 1558 may comprise a first row 1771 of equally spaced,
generally elongated or rectangular holes 1770, a second row 1773 of
equally spaced, generally elongated or rectangular holes 1772, a
third row 1775 of equally spaced, generally elongated or
rectangular holes 1774, a fourth row 1777 of equally spaced,
generally elongated or rectangular holes 1776, and a fifth row 1779
of equally spaced, generally elongated or rectangular holes 1778.
Each row extends along a length of the first web 1564. As shown in
FIG. 63, in various embodiments, the holes 1770 may be formed by
punching corresponding tabs 1771' in the first web 1564. Likewise,
the holes 1774 may be formed by punching, cutting, etc.
corresponding tabs 1775' in the first web 1564. Holes 1778 may be
formed by punching, cutting, etc. corresponding tabs 1779' in the
first web 1564. One skilled in the art will appreciate that the
tabs 1771', 1775' and 1779' serve to strengthen the first web 1564.
Each hole of the first, third and fifth rows 1771, 1775, 1779 of
elongated holes 1770, 1774, 1778 may have a smaller cross-sectional
width and shorter length than the holes of the second and forth
rows 1773, 1777 of elongated holes 1772, 1776. Each hole of the
first, third and fifth rows 1771, 1775, 1779 of elongated holes
1770, 1774, 1778 may have a length of about 2.36 inches (6 cm) to
about 3.15 inches (8 cm), for example three inches (7.62 cm), and a
width of about 0.20 inches (0.5 cm) to about 0.30 in (0.75 cm), for
example 0.26 in (0.65 cm) cm. Each hole of the second and fourth
rows 1773, 1777 of elongated holes 1772, 1776 has a length of about
7.48 inches (19 cm) to about 8.27 in (21 cm), for example eight
inches (20.32 cm), and a width of about 0.20 inches (0.5 cm) to
about 0.79 inches (2 cm), for example 0.50 inch (1.27 cm). However,
the sizes, shapes, numbers and spacing arrangement of these holes
may vary without departing from the spirit and scope of the present
invention. The second side portion 1562 of the body 1558 may
comprise three, generally oval shaped or otherwise elongated
knockout holes 46 extending along the length of the second web 1584
to be used for utilities or structural bracing/spacer members.
Likewise, the sizes, shapes, numbers and spacing arrangement of
these holes may vary without departing from the spirit and scope of
the present invention.
[0270] Referring now to FIGS. 65 and 66, the first side portion
1560 of body 1558 may comprise a first row 1781 of equally spaced,
generally elongated or rectangular holes 1780, a second row 1783 of
equally spaced, generally elongated or rectangular holes 1782, a
third row 1785 of equally spaced, generally elongated or
rectangular holes 1784, a fourth row 1787 of equally spaced,
generally elongated or rectangular holes 1786, and a fifth row 1789
of equally spaced, generally elongated or rectangular holes 1788.
Each row extends along a length of the first web 1564. As can be
seen in FIG. 65, in various embodiments, the holes 1780 may be
formed by punching, cutting, etc. corresponding tabs 1781' in the
first web 1564. Likewise, the holes 1784 may be formed by punching,
cutting, etc. corresponding tabs 1785' in the first web 1564. Holes
1788 may be formed by punching cutting, punching, etc.
corresponding tabs 1789' in the first web 1564. One skilled in the
art will appreciate that the tabs 1781', 1785', and 1789' serve to
strengthen the first web 1564. Each hole of the first, third and
fifth rows 1781, 1785, 1789 of elongated holes 1780, 1784, 1788 may
have a smaller cross-sectional width and shorter length than the
holes of the second and forth rows 1783, 1787 of elongated holes
1782, 1786. Each hole of the first, third and fifth rows 1781,
1785, 1789 of elongated holes 1780, 1784, 1788 may have a length of
about 2.36 inches (6 cm) to about 3.15 inches (8 cm), for example
three inches (7.62 cm), and a width of about 0.20 inches (0.5 cm)
to about 0.30 in (0.75 cm), for example 0.26 in (0.65 cm) cm. Each
hole of the second and fourth rows 1783, 1787 of elongated holes
1782, 1786 may have a length of about 7.48 inches (19 cm) to about
8.27 in (21 cm), for example eight inches (20.32 cm), and a width
of about 0.20 inches (0.5 cm) to about 0.79 inches (2 cm), for
example 0.50 inch (1.27 cm). However, the sizes, shapes, numbers
and spacing arrangement of these holes may vary without departing
from the spirit and scope of the present invention. The second
flange 1578 may comprise additional slots 1810 extending along a
length thereof. The additional slots 1810 provide for a thermal
break. The second side portion 1562 of the body 1558 may comprise
three, generally oval shaped or otherwise elongated knockout holes
46 extending along the length of the second web 1584 to be used for
utilities or structural bracing/spacer members. Likewise, the
sizes, shapes, numbers and spacing arrangement of these holes may
vary without departing from the spirit and scope of the present
invention.
[0271] Referring now to FIGS. 67 and 68, the first side portion
1560 of body 1558 may comprise a first row 1791 of equally spaced,
generally elongated or rectangular holes 1790, a second row 1793 of
equally spaced, generally elongated or rectangular holes 1792 and a
third row 1795 of equally spaced, generally elongated or
rectangular holes 1794 extending along the length of the first web
1564. As shown in FIG. 67, in various embodiments, the holes 1790
may be formed by punching, cutting, etc. corresponding tabs 1791'
in the first web 1564. Likewise, the holes 1794 may be formed by
punching, cutting, etc. corresponding tabs 1795' in the first web
1564. One skilled in the art will appreciate that the tabs 1791'
and 1795' serve to strengthen the first web 1564. Each hole of the
first and third rows 1791, 1795 of elongated holes 1790, 1794 may
have a smaller cross sectional width and shorter length than each
hole of the second row 1793 of elongated or rectangular holes 1792.
Each hole of the first and third rows 1791, 1795 of elongated or
rectangular holes 1790, 1794 may have a length of about 2.36 inches
(6 cm) to about 3.15 inches (8 cm), for example three inches (7.62
cm), and a width of about 0.20 inches (0.5 cm) to about 0.30 in
(0.75 cm), for example 0.26 in (0.65 cm) cm. Each hole of the
second row 1793 of elongated or rectangular holes 1792 may have a
length of about 7.48 inches (19 cm) to about 8.27 in (21 cm), for
example eight inches (20.32 cm), and a width of about 0.20 inches
(0.5 cm) to about 0.79 inches (2 cm), for example 0.50 inch (1.27
cm). However, the sizes, shapes, numbers and spacing arrangement of
these holes may vary without departing from the spirit and scope of
the present invention. The second flange 1578 may comprise
additional slots 1810 extending along a length thereof. The
additional slots 1810 provide for a thermal break. The second side
portion 1562 of the body 1558 may comprise three, generally oval
shaped or otherwise elongated utility holes 46 extending along the
length of the second web 1584 to be used for utilities or
structural bracing/spacer members. Likewise, the sizes, shapes,
numbers and spacing arrangement of these holes may vary without
departing from the spirit and scope of the present invention.
[0272] Referring now to FIGS. 69 and 70, the first side portion
1560 of body 1558 may comprise a first row 1797 of elongated or
oval holes 1796, a second row 1799 of elongated or oval holes 1798
and a row of generally trapezoidally shaped holes 1801 positioned
between the first row 1797 of elongated holes 1796 and the second
row 1799 of elongated holes 1798. Each row extends along a length
of the first web 1564. Each hole of the second row of 1799
elongated holes 1798 may have a length that is equal to the length
of each hole of the first row 1797 of elongated holes 1796. Each
hole of the first and second rows 1797, 1799 of elongated holes
1796, 1798 may have a length of about 3.50 in (8.89 cm) to about
7.50 in (19.05 cm), for example six inches (15.24 cm), and a width
of about 0.25 inches (0.635 cm) to about 0.79 inches (2 cm), for
example 0.50 inch (1.27 cm). Each of the trapezoidally shaped
elongated holes 1801 may have an area of about 1.55 in.sup.2 (10
cm.sup.2) to about 9.30 in.sup.2 (60 cm.sup.2), for example 6.665
in.sup.2 (43 cm.sup.2). However, the sizes, shapes, numbers and
spacing arrangement of these holes may vary without departing from
the spirit and scope of the present invention. The second side
portion 1562 of the body 1558 may comprise three, generally oval
shaped or otherwise elongated utility holes 46 extending along the
length of the second web 1584 to be used for utilities or
structural bracing/spacer members. Likewise, the sizes, shapes,
numbers and spacing arrangement of these holes may vary without
departing from the spirit and scope of the present invention.
[0273] Referring now to FIGS. 71 and 72, the first side portion
1560 of body 1558 may comprise a first row 1803 of elongated or
oval holes 1800, a second row 1805 of elongated or oval holes 1802
and a row of generally trapezoidally shaped holes 1804 positioned
between the first row 1803 of elongated holes 1800 and the second
row 1805 of elongated holes 1802. Each row extends along a length
of the first web 1564. Each hole of the second row 1805 of
elongated holes 1802 may have a length that is equal to the length
of each hole of the first row 1803 of elongated holes 1800. Each
hole of the first and second rows 1803, 1805 of elongated holes
1800, 1802 may have a length of about 3.50 in (8.89 cm) to about
7.50 in (19.05 cm), for example 5.50 in (13.97 cm), and a width of
about 0.25 inches (0.635 cm) to about 0.79 inches (2 cm), for
example 0.50 inch (1.27 cm). Each of the trapezoidally shaped
elongated holes 1801 may have an area of about 1.55 in.sup.2 (10
cm.sup.2) to about 9.30 in.sup.2 (60 cm.sup.2), for example 6.665
in.sup.2 (43 cm.sup.2). However, the sizes, shapes, numbers and
spacing arrangement of these holes may vary without departing from
the spirit and scope of the present invention. The second side
portion 1562 of the body 1558 may comprise three, generally oval
shaped or otherwise elongated utility holes 46 extending along the
length of the second web 1584 to be used for utilities or
structural bracing/spacer members. Likewise, the sizes, shapes,
numbers and spacing arrangement of these holes may vary without
departing from the spirit and scope of the present invention.
[0274] Referring now to FIGS. 74 and 75, the first side portion
1560 of body 1558 may comprise a first row 1807 of evenly spaced
elongated or oval holes 1804, a second row 1809 of evenly spaced
elongated or oval holes 1806, and a row 1811 of evenly spaced
circular holes 1808 positioned between the first row 1807 of
elongated holes 1804 and the second row 1809 of elongated holes
1806. Each row extends along a length of the first web 1564. Each
hole of the second row 1809 of evenly spaced elongated holes 1806
may have a length that is equal to the length of each hole of the
first row 1807 of elongated holes 1804. For instance, each hole of
the second row 1809 of elongated holes 1806 and each hole of the
first row 1807 of elongated holes 1804 may have a length of about
1.97 inches (5 cm) to about 2.76 inches (7 cm), for example 2.5
inches (6.35 cm), and a width of 0.20 inches (0.5 cm) to 0.79
inches (2 cm), for example 0.50 inch (1.27 cm). However, the sizes,
shapes, numbers and spacing arrangement of these holes may vary
without departing from the spirit and scope of the present
invention. The second side portion 1562 of the body 1558 may
comprise four, generally oval shaped or otherwise elongated
knockout holes 46 extending along the length of the second web 1584
to be used for utilities or structural bracing/spacer members.
Likewise, the sizes, shapes, numbers and spacing arrangement of
these holes may vary without departing from the spirit and scope of
the present invention.
[0275] The reinforcing member has a second or exposed side portion
extending away from the first surface of the central body. For
example, as shown in FIGS. 1 and 4, embedded metal studs 14 and 16
have exposed second side portions 26 and 28 respectively that
extend from inner surface 30 of expanded polymer body 12.
[0276] Exposed side portions 26 and 28 can extend at least 0.39
inches (1 cm), in some cases at least 0.79 inches (2 cm), and in
other cases at least 1.18 inches (3 cm) away from inner surface 30
of expanded polymer body 12. Also, exposed side portions 26 and 28
can extend up to 1.97 ft (60 cm), in some cases up to 15.748 in (40
cm), and in other cases up to 7.87 in (20 cm) away from inner
surface 30 of expanded polymer body 12. Exposed side portions 26
and 28 can extend any of the distances or can range between any of
the distances recited above from inner surface 30.
[0277] Referring now to FIGS. 79 and 80, inserts can be added to
expanded polymer body 12 to allow for more secure anchoring
positions. For example, with reference to FIG. 79, one or more
attachment members 7900 may be embedded in expanded polymer body 12
to allow for the attachment of a finish surface 475 thereto. In
various embodiments, such attachment members may comprise, for
example, U-channel studs, furring strips, etc. With reference to
FIG. 80, high density foam 7902 may be embedded in expanded polymer
body 12 flush with outer surface 24. The foam provides for a more
secure anchoring position as well as aid in locating the embedded
studs 14 and 16.
[0278] Referring to FIGS. 7-14, 17, 18, 21, 22, 25, 26, 29, 30, 33,
34, 37-40, 43, 46, 48, 50, 52, 53, 55, 57, 58, 60, 62, 64, 66, 68,
70, 72, 75, 78 and 91, embedded metal studs 14 and 16 can have
utility holes 46 spaced along the length of exposed side portions
26 and 28 (i.e., the structural portion of the stud). Utility holes
46 may be useful for running utilities such as wiring for
electricity, telephone, cable television, speakers, and other
electronic devices, gas lines and water lines. Utility holes 46 can
have various cross-sectional shapes, non-limiting examples being
round, oval, elliptical, square, rectangular, triangular, hexagonal
or octagonal. The cross-sectional area of utility holes 46 can also
vary independently one from another or they can be uniform. The
cross-sectional area of utility holes 46 is limited by the
dimensions of embedded metal studs 14 and 16, as utility holes will
fit within their dimensions and not significantly detract from
their structural integrity and strength. The cross-sectional area
of utility holes 46 can independently be at least 1, in some cases
at least 2, and in other cases at least 0.775 in.sup.2 (5 cm.sup.2)
and can be up to 30, in some cases up to 25, in other cases up to
3.10 in.sup.2 (20 cm.sup.2). The cross-sectional area of openings
18 can independently be any value or range between any of the
values recited above. Typically, the number of utility holes ranges
from 1 to 5, for example 3 or 4. However, other sizes, shapes,
numbers and spacing arrangements could conceivable be employed in
alternative embodiments.
[0279] In various embodiments of the invention, utility holes 46
can have a flanged portion around their respective perimeters and
in many cases a rolled flange surface to reinforce the area around
the holes. The flanged holes provide added strength to allow for
the use of lighter gauge materials to achieve the same structural
properties.
[0280] The spacing between each of embedded metal studs 14 and 16
is typically adapted to be consistent with local construction codes
or methods, but can be modified to suit special needs. As such, the
spacing between the metal studs can be at least 25 and in some
cases at least 30 cm and can be up to 110, in some cases up to 100,
in other cases up to 75, and in some instances up to 1.97 ft (60
cm) measured from a midpoint of exposed end 26 to a midpoint of
exposed end 28. The spacing between embedded metal studs 14 and 16
can be any distance or range between any of the distances recited
above.
[0281] As shown in FIG. 1, expanded polymer body 12 can extend for
a distance with alternating embedded metal studs 14 and 16 placed
therein. The length of wall unit 10 can be any length that allows
for safe handling and minimal damage to wall unit 10 while it is
being transported and installed. The length of wall unit 10 can
typically be at least 1, in some cases at least 1.5, and in other
cases at least 6.56 feet (2 m) and can be up to 25, in some cases
up to 20, in other cases up to 15, in some instances up to 10 and
in other instances up to 16.40 feet (5 m). The length of wall unit
10 can be any value or can range between any of the values recited
above. In some embodiments of the invention, each end of wall unit
10 is terminated with an embedded metal stud.
[0282] The height of wall unit 10 can be any height that allows for
safe handling and minimal damage to wall unit 10. The height of
wall unit 10 is determined by the length of embedded metal studs 14
and 16. The height of wall unit 10 can be at least 1 and in some
cases at least 4.92 feet (1.5 m) and can be up to 9.84 feet (3 m)
and in some cases up to 8.20 feet (2.5 m). In some instances, in
order to add stability to wall unit 10, reinforcing cross-members
known as spacer bars (not shown) can be attached to embedded metal
studs 14 and 16. The height of wall unit 10 can be any value or can
range between any of the values recited above.
[0283] As shown in FIG. 1, expanded polymer body 12 has a finite
length and can have a male terminal end 21 that includes forward
edge 23 and trailing edge 25 and a receiving end 27 which includes
recessed section 29 and extended section 31, which is adapted to
receive forward edge 23, and trailing edge 25. Typically, lengths
of wall units 10 are interconnected by inserting a forward edge 23
from a first wall unit 10 into a recessed section 29 a second wall
unit 10. In this manner, a larger wall section containing any
number of wall units can be assembled and/or arrayed.
[0284] Various configurations for interconnecting wall units 10
have been contemplated. Referring now to FIG. 1, the expanded
polymer body 12 of wall unit 10 has a first end 17 configured to
include a male "tongue" or terminal end 21 and a second end 19
configured to include a female "groove" or recessed section 29 that
facilitates a "tongue and groove" union of two matching wall units
10. Typically the tongue and groove union provides a flat surface
at the union to allow for easy application of sealing tape to
further seal the union or joint if desired.
[0285] Referring now to FIG. 4, the first end 17 of expanded
polymer body 12 may include a plurality of "tongue" portions 4000
designed to interconnect with corresponding grooves 4002 formed in
the second end 19 of expanded polymer body 12. "Tongue" portions
4000 may have a generally pyramidal shape that corresponds with the
shape of grooves 4002 thereby providing a smooth flat surface when
two wall units 10 are interconnected.
[0286] Referring now to FIG. 81, the first end 17 of expanded
polymer body 12 may include a protruding portion 8100 adjacent to
outer surface 24 and a recessed portion 8102 adjacent to inner
surface 30 and the second end 19 includes a corresponding
protruding portion (not shown) adjacent to inner surface 30 and a
corresponding recessed portion (not shown) positioned adjacent to
outer surface 30. Each of the protruding portions may have a
generally pyramidal shape that corresponds with the shape of each
of the recessed portions. The protruding portion 8100 is designed
to align with a corresponding recessed portion when two wall units
10 are interconnected thereby providing a substantially smooth flat
wall surface.
[0287] Referring now to FIG. 82, the first end 17 of expanded
polymer body 12 may include a protruding portion 8200 and the
second end 19 includes a corresponding recessed portion (not
shown). The protruding portion may have a generally semicircular
shape that corresponds with a shape of the corresponding recessed
portion. The protruding portion 8200 is designed to align with a
corresponding recessed portion when two wall units 10 are
interconnected thereby providing a substantially smooth flat wall
surface.
[0288] Referring now to FIG. 83A, the first end 17 of expanded
polymer body 12 may include a protruding portion 8300 adjacent to
outer surface 24 and a recessed portion 8302 adjacent to inner
surface 30 and the second end 19 includes a corresponding
protruding portion (not shown) adjacent to inner surface 30 and a
corresponding recessed portion (not shown) positioned adjacent to
outer surface 30. Each of the protruding portions may have a
generally semicircular shape that corresponds with the shape of
each of the recessed portions. The protruding portion 8300 is
designed to align with a corresponding recessed portion when two
wall units 10 are interconnected thereby providing a substantially
smooth flat wall surface.
[0289] Referring now to FIG. 83B, the first end 17 of expanded
polymer body 12 may include a protruding portion 8304 and the
second end 19 includes a corresponding recessed portion (not
shown). The protruding portion may have a generally rectangular
shape that corresponds with a shape of the corresponding recessed
portion. The protruding portion 8304 is designed to align with a
corresponding recessed portion when two wall units 10 are
interconnected thereby providing a substantially smooth flat wall
surface.
[0290] Referring now to FIG. 83C, the first end 17 of expanded
polymer body 12 may include a protruding portion 8306 adjacent to
outer surface 24 and the second end 19 includes protruding portion
(not shown) positioned adjacent to inner surface 30. Each of the
protruding portions may have a generally rectangular shape. The
protruding portion 8306 is designed to adjoin with the protruding
portion of the second end 19 when two wall units 10 are
interconnected thereby providing a substantially smooth flat wall
surface.
[0291] Referring now to FIGS. 84-87, the first end 17 and the
second end 19 of expanded polymer body 12 may each include a
generally semicircular recess 8400. When two wall units 10 are
placed adjacent to each other, the recess on the first end 17 of a
first wall unit 10 and the recess on the second end 19 of a second
wall unit align to form a generally circular opening between the
first and second wall units. A gasket 8402 may be positioned within
the circular opening to provide a secure interconnection between
the first and second wall units.
[0292] Wall unit 10 is typically part of an overall wall system 21
as shown in FIGS. 88-90. A bottom end of embedded metal studs 14
and 16 are seated in and attached to a bottom track 44 and a top
track 42. This configuration leads to the formation of bottom
channel 52 and top channel 54. Channels 52 and 54 can be filled
with correspondingly shaped expanded polymer material, or
alternatively with a molding shaped to fit in channels 52 or
54.
[0293] In various embodiments, the top track 42 may comprise
slotted track such as that slotted track disclosed in U.S. Pat. No.
5,127,760, the disclosure of which is herein incorporated by
reference in its entirety. The portions of the top track 42 and the
bottom track 44 extending between the studs 14, 16 can be filled
with correspondingly shaped expanded polymer material, or
alternatively with a molding shaped to fit in those sections of
tracks 42, 44.
[0294] As a non-limiting example molding 58 can be inserted into
top channel 54 and attached to top track 42 by inserting fasteners
60 into holes 62 in top track 42 as shown in FIG. 92. Molding 58
provides a thermal break to the exposed metal track 42. In various
embodiments, both sides of each of the embedded metal studs 14 and
16 are exposed at the ends of the panels. This feature overcomes a
basic structural problem in the prior art by providing a positive
mechanical connection to both sides of the embedded metal studs
when top track 42 and bottom track 44 are installed. Further, when
slotted top tracks are employed, the combined composite building
panels can move relative to the top track 42 when the panels are
attached to the top track 42 by mechanical fasteners extending
through the slots therein.
[0295] Wall system 21 is shown in FIGS. 88-91, in which three wall
units are connected. Where the ends of two wall units meet to form
a corner, an outside corner attachment 47 secures the ends of the
two wall units together. The outside corner attachment may be
either an interior corner post assembly 9800 or an exterior corner
post assembly 9900. Referring now to FIGS. 94-99, an interior
corner post assembly 9800 includes an interior corner post 9802, a
first corner stud 9804, a second corner stud 9806 and a plurality
of fastening members 9807 for securing the first corner stud 9804
to the interior corner post 9802 and the second corner stud
9806.
[0296] Interior corner post 9802 comprises a body 9808 with a
length 9810 and a width 9812. The body 9808 comprises a web 9814
with a first end 9816 and a second end 9818, a first flange 9820
extending generally perpendicularly from the second end 9818 of the
web 9814, and a second flange 9822 extending generally
perpendicularly from a central portion between the first end 9816
and the second end 9818 of the web 9814 in a direction opposite to
the first flange 9820. First flange 9820 may comprise a plurality
of holes 9824 extending longitudinally along a length of the body
9808. The holes 9824 allow fastening members 9807 to be inserted
therethrough to secure the first corner stud 9804 to the interior
corner post 9802.
[0297] First corner stud and second corner stud, denoted generally
as 9804 and 9806, respectively, each comprises a body 9826 having a
length and a width. In various embodiments, the first and second
corner studs 9804, 9806 may comprise those studs manufactured by
Dietrich Industries, Inc. of Pittsburgh, Pa. under the trademark
HDS.TM.. As shown in FIGS. 97 and 98, the body 9826 comprises a web
9828 having a first end 9830 and a second end 9832, a first flange
9834 extending generally perpendicularly from the first end 9830 of
the web 9828, a return lip 9836 extending generally perpendicularly
from the first flange 9834 and in a direction generally away from
the first end 9830 of the web 9828, and a second flange 9838
extending generally perpendicularly from the return lip 9836 and
towards the web 9828.
[0298] The body 9826 also comprises a third flange 9840 extending
generally perpendicularly from the second end 9832 of the web 9828,
a return lip 9842 extending generally perpendicularly from the
third flange 9840 and in a direction generally away from the second
end 9832 of the web 9828, and a fourth flange 9844 extending
generally perpendicularly from the return lip 9842 and towards the
web 9828.
[0299] As shown in FIG. 98, interior corner post assembly 9800 is
constructed by providing an interior corner post 9802, a first
corner stud 9804 and a second corner stud 9806. The web 9828 of the
first corner stud 9804 is positioned adjacent to the first flange
9820 of the interior corner post 9802 and attached thereto using
one or more fastening members 9807. A first channel, indicated
generally as 9846, for receiving a wall unit 10 is thereby formed
by a portion of the web 9828 of the first corner stud 9804, the
second flange 9822 of the interior corner post 9802 and the web
9814 of the interior corner post 9802. The web 9828 of the second
corner stud 9806 is positioned adjacent to the third flange 9840 of
the first corner stud 9804 and secured thereto using a fastening
member 9807. A second channel, indicated generally as 9848, for
receiving a second wall unit 10' is thereby formed by a portion of
the web 9828 of the second corner stud 9806, a portion of the web
9828 of the first corner stud 9804 and the web 9814 of the interior
corner post 9802. First wall unit 10 and second wall unit 10' are
positioned in first channel 9846 and second channel 9848,
respectively, such that the exposed end of embedded studs are
positioned parallel to the first corner stud 9804 and the second
corner stud 9806. A finish surface 475, such as dry wall, can then
be secured to the exposed ends of the embedded studs, the first
corner stud 9804 and the second corner stud 9806 using a suitable
fastening member.
[0300] The fastening member 9807 is any suitable fastener
including, but not limited to, screws, nails, pins or the like.
[0301] In an embodiment of the invention, corner attachment can be
a corner post assembly as shown in FIGS. 100-106, where an exterior
corner post assembly, indicated generally as 9900, includes an
exterior corner post 9902, a first corner stud 9904, a second
corner stud 9906 and a plurality of fastening members 9907 for
securing the first corner stud 9904 to the exterior corner post
9902 and the second corner stud 9906. In various embodiments, the
first and second corner studs 9904, 9906 may comprise those studs
manufactured by Dietrich Industries, Inc. of Pittsburgh, Pa. under
the trademark HDS.TM..
[0302] The exterior corner post 9902 comprises a body 9908 with a
length 9910 and a width 9912. The body 9908 comprises a web 9914
with a first end 9916 and a second end 9918, a first flange 9920
extending generally perpendicularly from the second end 9918 of the
web 9914, and a lip portion 9922 extending generally
perpendicularly from the first flange 9920. The body 9908 also
includes right-angled tabs 9924 positioned along the length 9910 of
the body 9908. The number of tabs 9924 can vary as needed provide
structural integrity. For example, as shown in FIG. 100, eight tabs
9924 can be used. However, it will be understood that other
quantities, sizes and shaped tabs 9924 may be employed.
[0303] First corner stud, denoted generally as 9904, comprises a
body 9926 having a length and a width. The body 9926 comprises a
web 9928 having a first end 9930 and a second end 9932, a first
flange 9934 extending generally perpendicularly from the first end
9930 of the web 9928, a return lip 9936 extending generally
perpendicularly from the first flange 9934 and in a direction
generally away from the first end 9930 of the web 9928, and a
second flange 9938 extending generally perpendicularly from the
return lip 9836 and towards the web 9928.
[0304] The body 9926 also comprises a third flange 9940 extending
generally perpendicularly from the second end 9932 of the web 9928,
a return lip 9942 extending generally perpendicularly from the
third flange 9940 and in a direction generally away from the second
end 9932 of the web 9928, and a fourth flange 9944 extending
generally perpendicularly from the return lip 9942 and towards the
web 9928.
[0305] The second corner stud, denoted generally as 9906, comprises
a body 9946 having a length and a width. The body 9946 comprises a
web 9948 having a first end 9950 and a second end 9952, a first
flange 9954 extending generally perpendicularly from the first end
9950 of the web 9948, a first return lip 9956 extending generally
perpendicularly from the first flange 9954 and in a direction
generally away from the first end 9950 of the web 9948.
[0306] The body 9946 also comprises a second flange 9958 extending
generally perpendicularly from the second end 9952 of the web 9948
and a second return lip 9960 extending generally perpendicularly
from the second flange 9958 and in a direction generally away from
the second end 9952 of the web 9948.
[0307] The exterior corner post assembly 9900 may be constructed by
providing an exterior corner post 9902, a first corner stud 9904
and a second corner stud 9906. The web 9928 of the first corner
stud 9904 is then positioned adjacent to the web 9914 of the
exterior corner post 9902 and attached thereto using a fastening
member 9907. The web 9948 of the second corner stud 9906 is
positioned adjacent to the return lip 9936 of the first corner stud
9904 and secured thereto using a fastening member 9907. A first
channel 9960 for receiving a wall unit 10 is formed by the lip
portion 9922, the first flange 9820 and the web 9914 of the
exterior corner post 9902. A second channel 9862 for receiving a
second wall unit 10' is formed by a portion of the web 9914 of the
exterior corner post 9902, the tab 9924 of the exterior corner post
9902, the first flange 9954 of the second corner stud 9906 and the
first flange 9934 of the first corner stud 9904. First wall unit 10
and second wall unit 10' are positioned in first channel 9960 and
second channel 9962, respectively, such that the exposed end of
embedded studs are positioned parallel to the first corner stud
9904 and the second corner stud 9906. A finish surface 475, such as
dry wall, can then be secured to the exposed ends of the embedded
studs, the first corner stud 9904 and the second corner stud 9906
using a suitable fastening member to form an inside wall.
[0308] The fastening member 9807 is any suitable fastener
including, but not limited to, screws, nails, pins or the like.
[0309] Also, additional metal studs 49 can be included to add
strength to the formed corners. Thus the wall system includes
interconnecting bottom 44 and top 42 tracks that may be of the type
and construction described above and embedded metal studs 51
secured together at corner attachment units that extend along the
height of each wall unit.
[0310] Openings for windows and doors are provided by framing the
ends of the opening with two or more embedded metal studs placed
adjacent to each other (shown as 53). Upper member 55 and lower
member 57 are connected to the embedded metal studs to form a
framed opening. The openings can be adapted to readily accept
pre-manufactured windows and doors.
[0311] The strength and integrity of wall system 21 can be enhanced
by including spacer bars 61 that are arranged to pass through
openings, such as utility holes 46 in embedded metal studs 14 and
16. Referring now to FIGS. 107 and 108, spacer bars 61 are attached
to embedded metal studs 14 and 16 and are arranged, as shown, in a
generally perpendicular relationship to metal studs 14 and 16,
although spacer bars 61 can be arranged to form any suitable angle
with embedded metal studs 14 and 16 that enhances the strength and
integrity or wall system 21. Spacer bars and metal studs that can
be incorporated in the invention include those available under the
trademarks TRADE READY.RTM. SPAZZER.RTM. available from Dietrich
Industries, Inc., Pittsburgh, Pa. as well as those disclosed in
U.S. Pat. Nos. 5,784,850, 6,021,618 and 6,708,460, the relevant
portions of which are herein incorporated by reference. In one
embodiment, SPAZZER.RTM. bar Model No. 5400 is used. Retainer clips
such as SPAZZER.RTM. BAR GUARD.TM. retainer clips, also available
from Dietrich Industries, Inc., can be used for load bearing
applications, if desired.
[0312] The various metal structural parts in wall system 21 can be
secured or attached to one another by way of welds 71 and/or screws
73. It is conceivable, however, that other forms of mechanical
fasteners may also be employed without departing form the spirit
and scope of the present invention.
[0313] Some advantages of the present wall units and wall systems
include the ability to easily run utilities prior to attaching a
finish surface to the exposed ends of the embedded metal studs. The
exposed metal studs facilitate field structural framing changes and
additions and leave the structural portions of the assembly exposed
for local building officials to inspect the framing.
[0314] Referring to FIG. 109, in an embodiment of the invention,
wall unit 10 includes expanded polymer body 12 (central body),
right facing embedded metal studs 16, which include flanges 11 and
have utility holes 46 located in an exposed portion of embedded
studs 16, expansion holes 13 in an embedded portion (thermal
portion) of embedded studs 16 and embedded end 22, which does not
touch outer surface 24 of expanded polymer body 12. The embedded
metal studs 16 also have exposed end 28 (structural portion)
respectively that extends from inner surface 30 of expanded polymer
body 12. While C-type embedded studs are illustrated in FIG. 109,
this is not to be construed as limiting the present invention as
the use of other types of studs, such as CC-type embedded studs and
CT-type embedded studs, may be successfully employed in similar
manners.
[0315] A utility space defined by inner surface 30 of expanded
polymer body 12 and flanges 11 adapted for running utilities is
provided. Flanges 11 may have a finish surface or material attached
to them, a side of which further defines the utility space.
[0316] In an embodiment of the invention, the utility space may be
adapted and dimensioned to receive a variety of commercially
available standard and/or pre-manufactured components, such as
windows, doors and medicine cabinets as well as customized
cabinets, shelving, etc.
[0317] In an embodiment of the invention, utility holes 46 may be
adapted to allow utilities (as shown, electrical line 15) to be
installed in a transverse direction through embedded studs 16.
[0318] The utilities can be one or more selected from water lines
(either potable, or as a non-limiting example hot water lines for
radiant heating), waste lines, chases, telephone lines, cable
television lines, computer lines, fiber optic cables, satellite
dish communication lines, antenna lines, electrical lines,
ductwork, gas lines, etc.
[0319] In a particular embodiment of the invention, wall unit 10 is
attached to bottom track 44. In this embodiment, bottom track 44 is
adapted to hold a volume at least equivalent to the volume of the
expanded polymer matrix in expanded polymer body 12, in liquid or
molten form. In some instances, this volume can be defined by
bottom 101 and sides 103 of bottom track 44 and the portions of
embedded bars 16 within the space defined by bottom track 44.
[0320] Non-limiting examples of suitable finish surfaces include
wood, rigid plastics, wood paneling, concrete panels, cement
panels, drywall, sheetrock, particle board, rigid plastic panels, a
metal lath, or any other suitable material having decorating and/or
structural functions.
[0321] Further, the air space between the inner surface of the
expanded polymer body and the finish surface allows for improved
air circulation, which can minimize or prevent mildew.
Additionally, because the metal studs are not in direct contact
with the outer surface, thermal bridging via the highly conductive
embedded metal studs is avoided and insulation properties are
improved.
[0322] The present invention also provides composite building
panels useful for floor units and floor systems. As shown in FIG.
110, floor unit 90 includes expandable polymer panel 92 (central
body) and embedded metal joists 94 and 96 (embedded framing studs).
Expandable polymer panel 92 includes openings 98 that traverse all
or part of the length of expanded polymer panel 92 (as described
regarding openings 18 in expanded polymer body 12). The embedded
metal joists 94 and 96 have embedded ends 104 and 106,
respectively, that are in contact with top surface 102 of expanded
polymer panel 92. The embedded metal joists 94 and 96 also have
exposed ends 108 and 110, respectively, that extend from bottom
surface 100 of expanded polymer panel 92.
[0323] Embedded metal joists 94 and 96 include first transverse
members 124 and 126, respectively, extending from embedded ends 104
and 106, respectively, which are generally in contact with top
surface 102 and exposed ends 108 and 110 include second transverse
members 128 and 129, respectively, which extending from exposed
ends 108 and 110, respectively. The space defined by bottom surface
100 of expanded polymer panel 92 and the exposed ends 108 and 110
and second transverse members 128 and 129 of embedded metal joists
94 and 96 can be oriented to accept ductwork or other members
placed between embedded metal joists 94 and 96 adjacent bottom
surface 100.
[0324] Expanded polymer panel 92 can have a thickness, measured as
the distance from top surface 102 to bottom surface 100 similar in
dimensions to that described above regarding expanded polymer body
12. See FIG. 110.
[0325] Exposed ends 108 and 110 extend at least 1, in some cases at
least 2, and in other cases at least 1.18 inches (3 cm) away from
bottom surface 100 of expanded polymer panel 92. Also, exposed ends
108 and 110 can extend up to 60, in some cases up to 40, and in
other cases up to 7.87 in (20 cm) away from bottom surface 100 of
expanded polymer panel 92. Exposed ends 108 and 110 can extend any
of the distances or can range between any of the distances recited
above from bottom surface 100.
[0326] In an embodiment of the invention, embedded metal joists 94
and 96 have a cross-sectional shape that includes embedding lengths
114 and 116, embedded ends 104 and 106, and exposed ends 108 and
110. The orientation of embedded metal joists 94 and 96 is
referenced by the direction of open ends 118 and 120. In an
embodiment of the invention, open ends 118 and 120 are oriented
toward each other. In this embodiment, floor unit 90 is adapted to
accept ductwork. As a non-limiting example, a HVAC duct can be
installed along the length of embedded metal joists 94 and 96.
[0327] As used herein, the term "ductwork" refers to any tube,
pipe, channel or other enclosure through which air can flow from a
source to a receiving space; non-limiting examples being air
flowing from heating and/or air-conditioning equipment to a room,
make-up air flowing from a room to heating and/or air-conditioning
equipment, fresh air flowing to an enclosed space, and/or waste air
flowing from an enclosed space to a location outside of the
enclosed space. In some embodiments, ductwork includes generally
rectangular metal tubes that are located below and extend generally
adjacent to a floor.
[0328] The spacing between each of embedded metal joists 94 and 96
can be as described regarding embedded metal studs 14 and 16 in
wall unit 10.
[0329] Openings 98 can have various cross-sectional shapes and
similar spacing and cross-sectional area as described regarding
openings 18 in expanded polymer body 12.
[0330] As shown in FIG. 110, expanded polymer panel 92 can extend
for a distance with alternating embedded metal joists 94 and 96
placed therein. The length of floor unit 90 can be any length that
allows for safe handling and minimal damage to floor unit 90 as
described regarding the length of wall unit 10. In some
embodiments, an end of floor unit 90 can be terminated with an
embedded metal joist.
[0331] As shown in FIG. 110, expanded polymer panel 12 has a finite
length and has a male terminal end 91 that includes forward edge 93
and trailing edge 95 and a receiving end 97 which includes recessed
section 99 and extended section 101, which is adapted to receive
forward edge 93, and trailing edge 95. Typically, lengths of floor
units 90 are interconnected by inserting a forward edge 93 from a
first floor unit 90 into a recessed section 99 from a second floor
unit 90. In this manner, a larger floor section containing any
number of floor units can be assembled and/or arrayed.
[0332] The width of floor unit 90 can be any width that allows for
safe handling and minimal damage to floor unit 90. The width of
floor unit 90 may be determined by the length of embedded metal
joists 94 and 96. The width of floor unit 90 can be at least 1 and
in some cases at least 4.92 feet (1.5 m) and can be up to 9.84 feet
(3 m) and in some cases up to 8.20 feet (2.5 m). In some instances,
in order to add stability to floor unit 90, reinforcing
cross-members (not shown) can be attached to embedded metal joists
94 and 96. The width of floor unit 90 can be any value or can range
between any of the values recited above.
[0333] Floor unit 90 may comprise a typically part of an overall
floor system, which may include, for example, a plurality of
composite floor panels as described herein, ductwork attached to
the reinforcing members of at least one floor panel, and a flooring
material attached to one or more of the first transverse members of
the composite floor panels.
[0334] The floor panels interconnect with the male ends, which
include a forward edge or tongue edge, and the female ends, which
include a groove or recessed section, arrayed such that the tongue
(male) and/or groove (female) of each panel is in sufficient
contact with a corresponding tongue and/or groove of another panel
to form a structure having a planar surface.
[0335] In the present floor system, ductwork can be attached to the
reinforcing members of at least one composite floor panel.
[0336] Additionally, a flooring material can be attached to one or
more of the first transverse members of the composite floor panels.
Any suitable flooring material can be used in the invention.
Suitable flooring materials are materials that can be attached to
the transverse members and cover at least a portion of the expanded
polymer panel. Suitable flooring materials may include, but are not
limited to, plywood, wood planks, tongue and grooved wood floor
sections, sheet metal, sheets of structural plastics, stone,
ceramic, cement, concrete, and combinations thereof.
[0337] Generally, the floor system forms a plane that extends
laterally from a foundation and/or a structural wall.
[0338] FIGS. 126A and 126B show floor system components 140 and 141
respectively. As shown in FIGS. 126A and 126B, the floor system is
established by contacting forward edge 93 with recessed section 99
to form a continuous floor 142. Like features of the individual
floor panels are labeled as indicated above. As described above,
various shaped types of ductwork can be secured in the space
defined by bottom surface 100 of expanded polymer panel 92 and the
exposed ends 108 and 110 and second transverse members 128 and 129
of embedded metal joists 94 and 96. As non-limiting examples,
rectangular ventilation duct 147 is shown in FIG. 126A and oval air
duct 148 is shown in FIG. 126B.
[0339] The composite building panels, wall units, floor units, tilt
up insulated panels and I-beam panels described herein contain
variations that are not meant as limitations. Any of the variations
discussed in one embodiment can be used in another embodiment
without limitation.
[0340] The embodiments of the invention shown in FIGS. 126A and
126B show a non-limiting example of combinations of the composite
panels described herein combining features of the various panels.
This embodiment combines I-beam panel 140 and floor panel 90 (shown
as 92 and 92A). In this embodiment, receiving end 176 of I-beam
panel 140 accepts forward edge 93 of floor panel 92 and recessed
section 99 of floor panel 92A accepts forward edge 172 of I-beam
panel 140 to provide tongue and groove connections to establish
continuous floor system 141. In this embodiment, circular ductwork
148 is installed along bottom surface 100 of floor panel 92 between
embedded metal joists 94 and 96. In this embodiment, the flooring
material is concrete layer 145, which covers top surface 102 of
floor panels 92 and 92A and outer face 162 of I-beam panel 140.
I-beam channel 182 extends from and is open to outer face 162 and
is filled with concrete and the thickness of concrete layer 145 is
sufficient to encase exposed ends 158 and 160 of I-beam panel 140.
The combination shown in this embodiment provides an insulated
concrete floor system where utilities can be run under an
insulation layer.
[0341] As shown in FIG. 112, an end of embedded metal joists 94 and
96 are seated in and attached to a joist rim 122 and a second joist
rim is attached to the other end of embedded metal joists 94 and
96. A floor base 149, typically plywood, particle board or other
supporting surface or flooring material, can be attached to the
exposed ends 108 and 110. Alternatively, floor base 149 can be
attached to embedded ends 104 and 106.
[0342] Referring now to FIGS. 114 and 115, a first wall unit 10
with a first end and a second end is positioned with the first end
adjacent to a surface and the second end positioned in a level
track 128. A joist rim 122 of a floor system is fixedly connected
to the level track 128. In various embodiments, the joist rims
manufactured by Dietrich Industries of Pittsburgh, Pa. under the
trademark TRADE READY.RTM. may be employed. A plurality of metal
joists 94 are attached to the joist rim 122 and support a floor
base 149. A bottom track 44 is also provided in connection with
joist rim 122 opposite to level track 128. A second wall unit 10'
with a first end and a second is positioned with the first end in
the bottom track 44. When the first and second wall units 10, 10'
are constructed in this manner, a gap 117 between the expanded
polymer body 12 of the first wall unit 10 and the expanded polymer
body 12' of the second wall unit is created. This gap 117 can be
filled with any suitable material 115, such as insulation. The
material 115 may be secured to the structure using an adhesive,
nails, screws or any other suitable securing method.
[0343] In this manner, a multi-story structure can be constructed
using the building panels of the present invention.
[0344] Referring back to FIG. 112, embedded metal joists 94 and 96
have utility holes 127 spaced along their length. Utility holes 127
are useful for running wiring for electricity, telephone, cable
television, speakers, and other electronic devices. Utility holes
127 can have various cross-sectional shapes, non-limiting examples
being round, oval, elliptical, square, rectangular, triangular,
hexagonal or octagonal. The cross-sectional area of Utility holes
127 can also vary independently one from another or they can be
uniform. The cross-sectional area of utility holes 127 is limited
by the dimensions of embedded metal joists 94 and 96, as utility
holes 127 will fit within their dimensions and not significantly
detract from their structural integrity and strength.
[0345] Expansion holes 13, as mentioned above are useful in that as
expanded polymer body 92 is molded, the polymer matrix expands
through expansion holes 113 and the expanding polymer fuses. This
allows the polymer matrix to encase and hold embedded studs 94 and
96 by way of the fusion in the expanding polymer. In an embodiment
of the invention, expansion holes 13 can have a flanged and in many
cases a rolled flange surface to provided added strength to the
embedded metal studs.
[0346] In an embodiment of the invention, the floor system can be
placed on a foundation. However, because foundations are rarely
perfectly level, a level track 128 can be attached to foundation
130 prior to placement of the floor system (see FIGS. 112 and 113).
Level track 128 can be placed on foundation 128 and leveled
utilizing conventional techniques. The level is made permanent by
fastening level track 128 to foundation 130 by using fasteners 131
(nails shown, although screws or other suitable devices can be
used) via fastening holes 132. Screws 133 can also be used to
attach level track 128 to foundation 130 via screw holes 135.
Screws 133 can also maintain the level position of level track 128
until a more permanent positioning is achieved. Alternatively or
additionally mortar can be applied via mortar holes 134 to fill the
space between level track 128 and the top of foundation 130. After
level track 128 has been attached and/or the mortar has
sufficiently set, the flooring system can be fastened to the
foundation.
[0347] In various embodiments, level track 128 includes side rails
137, which are adapted to extend over a portion of foundation 130.
The width of level track 128 is the transverse distance of a top
portion of level track 128 from one side rail 137 to the other. The
width of level track 128 is typically slightly larger than the
width of foundation 130. The width of level track 128 can be at
least 3.94 inches (10 cm), in some cases at least 5.90 inches (15
cm), in other cases at least 7.87 in (20 cm) and in some instances
at least 8.27 in (21 cm). Also, the width of level track 128 can be
up to 15.748 in (40 cm), in some cases up to 13.78 in (35 cm), and
in other cases up to 11.81 in (30 cm). The width of level track 128
can be any value or range between any of the values recited
above.
[0348] The length of side rail 137 is the distance it extends from
the top portion of level track 128 and is sufficient in length to
allow for proper leveling of level track 128 and attachment to
foundation 130 via fasteners 131 and fastening holes 132. The
length of side rail 137 can be at least 1.58 inches (4 cm), in some
cases at least 1.97 inches (5 cm), and in other cases at least 2.76
inches (7 cm). Also, the length of side rail 137 can be up to 7.87
in (20 cm), in some cases up to 5.90 inches (15 cm), and in other
cases up to 4.72 inches (12 cm). The length of side rail 137 can be
any value or range between any of the values recited above.
[0349] An embodiment of the invention relates to a floor or tilt up
insulated panel that is adapted to act as a concrete I-beam form.
As shown in FIG. 111, I-beam panel 140 includes expanded polymer
form 142 (central body) and embedded metal members 144 and 146
(embedded reinforcing bars). Expanded polymer form 142 includes
openings 148 that traverse all or part of the length of expanded
polymer form 142. The embedded metal members 144 and 146 have
embedded ends 152 and 156 respectively that are in contact with
inner face 150 of expanded polymer form 142. The embedded metal
members 144 and 146 also have exposed ends 158 and 160,
respectively, that extend from outer face 162 of expanded polymer
form 142.
[0350] Expanded polymer form 142 can have a thickness, measured as
the distance from inner face 150 to outer face 162 of at least 8,
in some cases at least 10, and in other cases at least 4.72 inches
(12 cm) and can be up to 100, in some cases up to 75, and in other
cases up to 1.97 ft (60 cm). The thickness of expanded polymer form
142 can be any distance or can range between any of the distances
recited above.
[0351] Exposed ends 158 and 160 extend at least 1, in some cases at
least 2, and in other cases at least 1.18 inches (3 cm) away from
outer face 162 of expanded polymer form 142. Also, exposed ends 158
and 160 can extend up to 60, in some cases up to 40, and in other
cases up to 7.87 in (20 cm) away from outer face 162 of expanded
polymer form 142. Exposed ends 158 and 160 can extend any of the
distances or can range between any of the distances recited above
from outer face 100.
[0352] In an embodiment of the invention, embedded metal members
144 and 146 have a cross-sectional shape that includes embedding
lengths 164 and 166, embedded ends 152 and 156, and exposed ends
158 and 160. The orientation of embedded metal members 144 and 146
is referenced by the direction of open ends 168 and 170. In an
embodiment of the invention, open ends 168 and 170 are oriented
toward each other. In this embodiment, I-beam panel 140 is adapted
to be embedded in the concrete that is applied to outer face
162.
[0353] The spacing between each of embedded metal members 144 and
146 can be as described regarding embedded metal studs 14 and 16 in
wall unit 10.
[0354] Openings 148 can have various cross-sectional shapes and
similar spacing and cross-sectional area as described regarding
openings 18 in expanded polymer body 12.
[0355] As shown in FIG. 111, expanded polymer panel 140 has a
finite length and has a male terminal end 170 that includes forward
edge 172 and trailing edge 174 and a receiving end 176 which
includes recessed section 178, which is adapted to receive forward
edge 172, and protruding edge 180. Typically, lengths of I-beam
panels 140 are interconnected by inserting a forward edge 172 from
a first I-beam panel 140 into a recessed section 178 of a second
I-beam panel. In this manner, a larger roof or wall section
containing any number of I-beam panels can be assembled and/or
arrayed. The width of I-beam panel 140, measured as the distance
from protruding edge 180 to trailing edge 174 can typically be at
least 20, in some cases at least 30, and in other cases at least
13.78 in (35 cm) and can be up to 150, in some cases up to 135, and
in other cases up to 4.10 ft (125 cm). The width of I-beam panel
140 can be any value or can range between any of the values recited
above.
[0356] As can also be seen in FIG. 111, I-beam panel 140 includes
I-beam channel 182. Various forms of the present I-beam panel are
advantageous when compared to prior art systems in that the
connection between adjacent panels in the prior art is provided
along the thin section of expanded polymer below I-beam channel
182. The resulting thin edge of those prior panels is prone to
damage and/or breakage during shipment and handling. The I-beam
panel of the present invention eliminates this problem by providing
a connection between adjacent panels at ends 170 and 176.
Therefore, when the I-beam channel 182 is molded with concrete or
the like, damage resulting from the concrete seeping through a gap
created by the connection is eliminated.
[0357] In an embodiment of the invention, rebar or other concrete
reinforcing rods can be placed in I-beam channel 182 in order to
strengthen and reinforce a concrete I-beam formed within I-beam
channel 182.
[0358] In another embodiment of the invention shown in FIG. 116,
instead of I-beam channel 182, I-beam panel 141 includes channel
183. Channel 183 is adapted to accept ductwork or other mechanical
and utility parts, devices and members.
[0359] An example of an I-beam system 200 according to various
embodiments of the present invention is shown in FIG. 117, where
four I-beam panels 140 are connected by inserting a forward edge
172 from a first I-beam panel 140 into a recessed section 178 of a
second I-beam panel. Concrete is poured, finished and set to form a
concrete layer 202 that includes concrete I-beams 204, which are
formed in I-beam channels 182. The embodiment shown in FIG. 117 is
an alternating embodiment, where the direction of I-beam channel
182 of each I-beam panel 140 alternately faces toward concrete
layer 202 and includes concrete I-beam 204 or faces away from
concrete layer 202 and I-beam channel 182 does not contain
concrete. In an embodiment of the invention, the facing away I-beam
panel can be I-beam panel 141. Alternatively, every I-beam panel
140 could face concrete layer 202 and include concrete I-beam
204.
[0360] In the embodiment shown in FIG. 117, exposed ends 158 and
160 are either embedded in concrete layer 202 or are exposed. The
exposed ends 158 and 160 are available as attachment points for a
finish surface such as wood, rigid plastics, wood paneling,
concrete panels, cement panels, drywall, sheetrock, particle board,
rigid plastic panels, or any other suitable material having
decorating and/or structural functions or other construction
substrates 210. The attachment is typically accomplished through
the use of screws or other suitable fastener arrangements.
[0361] In various embodiments of the invention, I-beam system 200
is assembled on a flat surface and a first end is lifted while a
second end remains stationary resulting in orienting I-beam system
200 generally perpendicular to the flat surface. This is often
referred to as "tilting a wall" in the art and in this embodiment
of the invention, I-beam system 200 is referred to as a
"tilt-wall."
[0362] In another embodiment of the invention, I-beam system 200
can be used as a roof on a structure.
[0363] An embodiment of the invention relates to a tilt up
insulated panel that is adapted for use as a wall or ceiling panel.
As shown in FIGS. 118-121, one-sided wall panel 340 includes a
reinforced body 341 that includes expanded polymer form 342
(central body) and embedded metal members 344 and 346 (embedded
reinforcing bars). Expanded polymer form 342 can include openings
348 and utility chases 349, which traverse all or part of the
length of expanded polymer form 342. The embedded metal members 344
and 346 have embedded ends 352 and 356, respectively, that are not
in contact with inner face 350 of expanded polymer form 342. The
embedded metal members 344 and 346 also have exposed ends 358 and
360, respectively, that extend from outer face 362 of expanded
polymer form 342.
[0364] Expanded polymer form 342 can have a thickness similar to
that described regarding expanded polymer form 142. Exposed ends
358 and 360 extend at least 0.39 in (1 cm), in some cases at least
0.79 inches (2 cm), and in other cases at least 1.18 inches (3 cm)
away from outer face 362 of expanded polymer form 342. Also,
Exposed ends 358 and 360 can extend up to 2.36 in (60 cm), in some
cases up to 15.748 in (40 cm), and in other cases up to 7.87 in (20
cm) away from outer face 362 of expanded polymer form 342. Exposed
ends 358 and 360 can extend any of the distances or can range
between any of the distances recited above from outer face 362.
[0365] In an embodiment of the invention, embedded metal members
344 and 346 have a cross-sectional shape that includes embedding
lengths 364 and 366, embedded ends 352 and 356, and exposed ends
358 and 360. The orientation of embedded metal members 344 and 346
is referenced by the direction of embedded ends 352 and 356. In a
particular embodiment of the invention, embedded ends 352 and 356
are oriented away from each other. In this embodiment, one-sided
wall panel 340 is adapted so that exposed ends 358 and 360 of
embedded metal members 344 and 346 are embedded in concrete 370
that is applied to outer face 362.
[0366] The spacing between each of embedded metal members 344 and
346 can be as described regarding embedded metal studs 14 and 16 in
wall unit 10.
[0367] Referring now to FIGS. 118 and 120, in an embodiment of the
invention, one-sided wall panel 340 includes expanded polymer body
342 (central body), embedded metal members 344 and 346 (embedded
framing studs), which include flanges 311, cornered ends 312,
utility holes 346 located in an exposed portion of embedded metal
members 344 and 346, expansion holes 313 in an embedded portion of
embedded metal members 344 and 346, and embedded ends 344 and 346,
which do not touch inner face 350.
[0368] In an embodiment of the invention, inner face 350 can have a
corrugated surface, which can be molded in or cut in, which
enhances air flow between inner face 350 and any surface attached
thereto.
[0369] With continuing reference to FIGS. 118 and 120, expansion
holes 313 are useful in that as expanded polymer body 342 is
molded, the polymer matrix expands through expansion holes 313 and
the expanding polymer fuses. This allows the polymer matrix to
encase and hold embedded metal members 344 and 346 by way of fusion
in the expanding polymer. In an embodiment of the invention,
expansion holes 313 can have a flanged and in many cases a rolled
flange surface to provided added strength to the embedded metal
members.
[0370] Openings 348 can have various cross-sectional shapes and
similar spacing and cross-sectional area as described regarding
openings 18 in expanded polymer body 12.
[0371] Referring now to FIGS. 118 and 119, reinforced body 341 has
a finite length and has a male terminal end 371 that includes
forward edge 372 and a receiving end 376 which includes recessed
section 376, which is adapted to receive forward edge 372.
Typically, lengths of one-sided wall panel 340 are interconnected
by inserting a forward edge 372 from a first one-sided wall panel
340 into a recessed section 378 of a second one-sided wall panel.
In this manner, a larger wall or ceiling section containing any
number of one-sided wall panels can be assembled and/or arrayed.
The width of one-sided wall panel 340, measured as the distance
from protruding edge 380 to trailing edge 374 can typically be at
least 20, in some cases at least 30, and in other cases at least
13.78 in (35 cm) and can be up to 150, in some cases up to 135, and
in other cases up to 4.10 ft (125 cm). The width of one-sided wall
panel 340 can be any value or can range between any of the values
recited above.
[0372] An example of a one-sided wall panel 340 according to
various embodiments of the present invention is shown in FIG. 118,
where four embedded metal members 344 and 346 are used. Concrete is
poured, finished and set to form a concrete layer 370 that encases
exposed ends 358 and 360 of embedded metal members 344 and 346.
[0373] The embedded ends 350 and 356 of embedded metal members 344
and 346 are available as attachment points for a finish surface
such as wood, rigid plastics, wood paneling, concrete panels,
cement panels, drywall, sheetrock, particle board, rigid plastic
panels, or any other suitable material having decorating and/or
structural functions or other construction substrates sheetrock 375
as shown in FIG. 118. The attachment is typically accomplished
through the use of screws or other suitable fastener
arrangements.
[0374] Another embodiment of the invention is shown in FIG. 121. In
this embodiment, reinforcement mesh 371 is attached to exposed ends
358 and 360 of embedded metal members 344 and 346. Reinforcement
mesh 371 can be made of any suitable material, non-limiting
examples being fiberglass, metals such as steel, stainless steel
and aluminum, plastics, synthetic fibers and combinations thereof.
Desirably, after reinforcement mesh 371 is attached to exposed ends
358 and 360, concrete layer 370 is poured, finished and set so as
to encase reinforcement mesh 371 and exposed ends 358 and 360. In
this embodiment, reinforcement mesh 371 increases the strength of
concrete layer 370 as well as increasing the strength of the
attachment of concrete layer 370 to reinforced body 341.
[0375] In an embodiment of the invention, one-sided wall panel 340
is assembled on a flat surface and a first end is lifted while a
second end remains stationary resulting in orienting one-sided wall
panel 340 generally perpendicular to the flat surface. This is
often referred to as "tilting a wall" in the art and in this
embodiment of the invention, one-sided wall panel 340 is referred
to as a "tilt-up wall."
[0376] An embodiment of the invention relates to another tilt up
insulated panel that is adapted for use as a wall or ceiling panel.
As shown in FIGS. 122-125, two-sided wall panel 440 includes a
reinforced body 441 that includes expanded polymer form 442
(central body) and embedded metal members 444 and 446 (embedded
reinforcing bars). Expanded polymer form 442 can include openings
448 that traverse all or part of the length of expanded polymer
form 442. The embedded metal members 444 and 446 have a first
exposed end 452 and second exposed end 456 respectively that extend
from first face 462 of expanded polymer form 442. The embedded
metal members 444 and 446 also have second exposed ends 458 and 460
respectively that extend from second face 450 of expanded polymer
form 442.
[0377] Expanded polymer form 442 can have a thickness, measured as
the distance from second face 450 to first face 462 similar to that
described regarding expanded polymer form 142.
[0378] The exposed ends can extend at least 1, in some cases at
least 2, and in other cases at least 1.18 inches (3 cm) away either
face 450 or face 462 of expanded polymer form 442. Also, the
exposed ends can extend up to 60, in some cases up to 40, and in
other cases up to 7.87 in (20 cm) away from either face of expanded
polymer form 442. The exposed ends can extend any of the distances
or can range between any of the distances recited above from either
face of expanded polymer form 442.
[0379] In an embodiment of the invention, exposed ends 452, 456,
458, and 460 are embedded in first concrete layer 469 and second
concrete layer 470 that are applied to faces 450 and 462.
[0380] The spacing between each of embedded metal members 444 and
446 can be as described regarding embedded metal studs 14 and 16 in
wall unit 10.
[0381] In an embodiment of the invention, two-sided wall panel 440
includes expanded polymer body 442 (central body), embedded metal
members 444 and 446 (embedded framing studs), which cornered ends
412, utility holes 446 located in an exposed portion of embedded
metal members 444 and 446, and expansion holes 413 in an embedded
portion of embedded metal members 444 and 446.
[0382] Expansion holes 413 are useful in that, as expanded polymer
body 442 is molded, the polymer matrix expands through expansion
holes 413 and the expanding polymer fuses. This allows the polymer
matrix to encase and hold embedded metal members 444 and 446 by way
of fusion in the expanding polymer. In an embodiment of the
invention, expansion holes 413 can have a flanged portion around
their respective perimeters and in many cases a rolled flange
surface to reinforce the area around the holes.
[0383] Openings 448 can have various cross-sectional shapes and
similar spacing and cross-sectional area as described regarding
openings 18 in expanded polymer body 12.
[0384] Reinforced body 441 has a finite length and has a male
terminal end 471 that includes forward edge 472 and a receiving end
476 which includes recessed section 478, which is adapted to
receive forward edge 472. Typically, lengths of two-sided wall
panel 440 are interconnected by inserting a forward edge 472 from a
first two-sided wall panel 440 into a recessed section 478 of a
second two-sided wall panel. In this manner, a larger wall or
ceiling section containing any number of two-sided wall panels can
be assembled and/or arrayed. The width of one-sided wall panel 440,
measured as the distance from forward edge 472 to recessed section
478 can typically be at least 20, in some cases at least 30, and in
other cases at least 13.78 in (35 cm) and can be up to 150, in some
cases up to 135, and in other cases up to 4.10 ft (125 cm). The
width of two-sided wall panel 440 can be any value or can range
between any of the values recited above.
[0385] An example of a two-sided wall panel 440 according to
various embodiments of the present invention is shown in FIG. 122,
where four embedded metal members 444 and 446 are used. Concrete is
poured, finished and set to form concrete layers 469 and 470 that
encases exposed ends 452, 456, 458, and 460 of the embedded metal
members.
[0386] Alternatively, as shown in FIG. 125, a two-sided wall panel
439 includes variations of two-sided wall panel 440. In two-sided
wall panel 439 one (or alternatively both, which is not shown) of
exposed ends 452 and 456 (and alternatively also 458 and 460) are
available as attachment points for a finish surface 475 such as
wood, rigid plastics, wood paneling, concrete panels, cement
panels, drywall, sheetrock, particle board, rigid plastic panels,
or any other suitable material having decorating and/or structural
functions or other construction substrates. The attachment is
typically accomplished through the use of screws. However, other
suitable fastener arrangements may be employed. In this embodiment,
the space 476 defined by the finished surface, the exposed ends 444
and 446 and the expanded polymer body 442 can be used to run
utilities, insulation and anchors for interior finishes as
described above.
[0387] In this alternative embodiment, reinforcement mesh 471 is
attached to exposed ends 458 and 460 of embedded metal members 444
and 446. Reinforcement mesh 471 can be made of any suitable
material, non-limiting examples being fiberglass, metals such as
steel, stainless steel and aluminum, plastics, synthetic fibers and
combinations thereof. Desirably, after reinforcement mesh 471 is
attached to exposed ends 458 and 460, concrete layer 470 is poured,
finished and set so as to encase reinforcement mesh 471 and exposed
ends 458 and 460. In this embodiment, reinforcement mesh 471
increases the strength of concrete layer 470 as well as increasing
the strength of the attachment of concrete layer 470 to reinforced
body 441.
[0388] In another embodiment of the invention, two-sided wall panel
440 is assembled on a flat surface and a first end is lifted while
a second end remains stationary resulting in orienting two-sided
wall panel 440 generally perpendicular to the flat surface. This is
often referred to as "tilting a wall" in the art and in this
embodiment of the invention, two-sided wall panel 440 is referred
to as a "tilt-up wall."
[0389] In embodiments of the tilt-up walls described herein, the
exposed ends of the embedded metal members can act as a chair for
the proper placement of reinforcing wire mesh and/or rebar or other
reinforcing rods to the center of a concrete layer, poured,
finished and set to encase the exposed ends.
[0390] As used herein, the term "concrete" refers to a hard strong
building material made by mixing a cementitous mixture with
sufficient water to cause the cementitous mixture to set and bind
the entire mass as is known in the art.
[0391] In an embodiment of the invention, the concrete can be a so
called "light weight concrete" in which light weight aggregate is
included with the cementitous mixture. Exemplary light weight
concrete compositions that can be used in the present invention are
disclosed in U.S. Pat. Nos. 3,021,291, 3,214,393, 3,257,338,
3,272,765, 5,622,556, 5,725,652, 5,580,378, and 6,851,235, JP 9 071
449, WO 98 02 397, WO 00/61519, and WO 01/66485 the relevant
portions of which are incorporated herein by reference.
[0392] In an embodiment of the invention, when the exposed ends of
the one-sided wall panel and the two sided wall panel are encased
in concrete as described above, utility holes 346 and 446 act as
sites where the set and hardened concrete fuses through the holes
and thereby holds and attaches to the embedded metal members.
Additionally, reinforcing rods can be placed through utility holes
346 and 446 connecting embedded metal members, thus further
strengthening the formed wall panel.
[0393] The wall units, floor units, tilt up insulated panels and
I-beam panels described herein contain variations that are not
meant as limitations. Any of the variations discussed in one
embodiment can be used in another embodiment without
limitation.
[0394] In an embodiment of the invention, a lath can be attached to
the exposed ends of the metal studs, metal joists or metal members
of the wall units, floor units, and expanded polymer panels; i.e.
construction elements, of the invention. The lath is capable of
supporting a covering layer constituted by a suitable construction
material. The lath can include one or more portions extending flush
on opposite lateral sides of the construction element, which can be
embedded in and anchored also to the concrete used for
incorporating and/or joining together one or more adjacent
construction elements.
[0395] The lath can support one or more covering layers and is
typically a stretched metallic lath including a rhomb-shaped mesh
having a length-to-height rhomb ratio of about 2:1. The rhomb
length can vary between 0.79 and 2.36 in (20 and 60 mm), while the
rhomb width can vary between 0.39 and 1.18 in (10 and 30 mm). The
stretched metallic lath can have a thickness of from 0.0157 and
0.0591 in (0.4 and 1.5 mm) and, in some cases of from 0.0157 and
0.0394 in (0.4 and 1.0 mm). However, other configurations and sizes
may be employed.
[0396] The covering layers can, for example, include one or more
coating layers of plaster, stucco, cement, etc. as it is or,
optionally, reinforced with fibers of a suitable material.
[0397] A particular advantage of the construction panels, wall
units, floor units, and expanded polymer panels according to
various embodiments of the present invention is directed to fire
protection and safety. As described above, a portion of the
reinforcing members in the form of embedded framing studs are
exposed and can include a web of holes formed along their length.
By exposing a section of the web of holes in the embedded framing
studs, air flow is encouraged and in a fire situation, cooling of
the web section of the embedded framing studs takes place. This can
be very important to prolonging the failure time of a loaded wall
section. Typically, in a fire test, an insulated metal stud will
fail before a non-insulated stud in the center web area.
[0398] Locating spacer bars, as described above, in the exposed web
section, the embedded framing studs act as a heat sink, helping to
dissipate heat from the center web section of the embedded framing
studs as well as adding to the structural properties of the
wall.
[0399] The melting properties of the polymer matrix in a fire
situation further facilitates the cooling of the embedded framing
studs web section by melting away from the web as the temperature
exceeds 200.degree. F. (93.33.degree. C.), allowing further air
circulation and cooling of the web.
[0400] The bottom track of the wall panel, as described above, can
be designed to act as a drip and containment pan in a fire event.
The bottom track area is designed to contain the solids that melt
when the polymer matrix burns. The bottom track is adapted to hold
a volume at least equivalent to the volume of the expanded polymer
matrix in the expanded polymer body in liquid or molten form. Each
track section can be designed to have a holding capacity of from at
least 0.2 ft.sup.3 (5.66 L), in some instances at least 0.25
ft.sup.3 (7.08 L), in some cases at least 0.3 ft.sup.3 (8.5 L) and
in other cases at least 0.4 ft.sup.3 (11.33 L) and the holding
capacity can be up to 0.75 ft.sup.3 (21.24 L), in some cases up to
0.65 ft.sup.3 (18.41 L) and in other cases up to 0.1 ft.sup.3 (2.83
L) of liquid or molten material. The containment volume in the
bottom track can be any value or range between any of the values
recited above. The holding capacity of the bottom track is
typically designed to contain the solids contained in a typical
48''.times.96'' (1.22 m.times.2.44 m) construction panel.
[0401] In larger construction panels, for example those of greater
height, the exterior portion of the bottom track can be slotted,
allowing for the evacuation of melt materials to the exterior of
the building. This design greatly diminishes the interior fire
spread and improves the safety of the interior environment of the
structure during initial fire spread and rescue operations.
[0402] The wall units, floor units, and expanded polymer panels of
the present invention can be made using batch shape molding
techniques. However, this approach can lead to inconsistencies and
can be very time intensive and expensive.
[0403] In an embodiment of the invention, the wall units, floor
units, and expanded polymer panels of the present invention can be
made using an apparatus for molding a semi-continuous or continuous
foamed plastic element that includes [0404] a) a mold including:
[0405] i) a bottom wall, a pair of opposite side walls and a cover,
and [0406] ii) a molding seat, having a shape mating that of the
element, defined in the mold between the side walls, the bottom
wall and the cover; [0407] b) means for displacing the cover and
the side walls of the mold towards and away from the bottom wall to
longitudinally close and respectively open the mold; and [0408] c)
first means for positioning in an adjustable manner said cover away
from and towards said bottom wall of the mold to control in an
adjustable and substantially continuous manner the height of the
molding seat.
[0409] The apparatus is configured to include reinforcing members
which may comprise, for example, embedded framing studs, metal
bars, embedded metal joists and other metal profiles which may be
configured as discussed above. As a non-limiting example, the
methods and apparatus disclosed in U.S. Pat. No. 5,792,481 can be
adapted to make the wall units, floor units, and expanded polymer
panels of the present invention. The relevant parts of U.S. Pat.
No. 5,792,481 are incorporated herein by reference.
[0410] In an embodiment of the invention, the reinforcing members
220 can be molded into the wall units, floor units, and expanded
polymer panels having a formed embedded end 222 and a straight
exposed end 224 as shown in FIG. 127. Subsequently, the straight
exposed end can be formed, worked and/or modified to provide a
shaped end 228A as shown in shaped member 226A in FIG. 128 or a
shaped end 228B as shown in shaped member 226B FIG. 129. Embedded
ends 226A and 226B can remain unchanged from embedded end 222.
Equipment and machinery for subsequently bending, working, forming
or modifying the exposed end are well known in the art.
[0411] In an embodiment of the invention, the inner surface, bottom
surface, or inner face of the wall units, floor units, and expanded
polymer panels described above can have a grooved surface, either
molded in or applied mechanically, to improve air flow through the
annular space between the expanded plastic and any materials
attached to the exposed ends of the metal studs, metal joists or
metal members of the wall units, floor units and expanded polymer
panels described above.
[0412] One aspect of various embodiments of the present invention
is directed to a method of constructing a building in a first
embodiment including: [0413] providing a foundation having a series
of walls having top surfaces; [0414] positioning and securing any
of the floor units or systems described above, such that the floor
unit spans at least some of the top surfaces of the foundation
walls to the walls; [0415] positioning and securing any of the wall
systems described above to the floor unit or system; and [0416]
positioning and securing a roof system as described above to a top
surface of the wall system.
[0417] Another aspect of various embodiments of the present
invention provides a method of constructing a building that
includes: [0418] providing a foundation having a series of
foundation walls having top surfaces; [0419] positioning and
securing the composite building panels described above, adapted for
use as a floor unit, to at least some of the top surfaces of the
foundation walls; [0420] positioning and securing two or more of
the composite building panels described above, adapted for use as a
wall unit, to at least part of a top surface of the floor unit,
wherein a bottom track and a top slip track are attached to a
bottom end and a top end respectively of the composite building
panels; and [0421] positioning and securing the composite building
panels described above, adapted for use as a roof unit, to at least
some of the top slip track of the wall units.
[0422] Still another aspect of various embodiments of the present
invention is directed to a method of constructing a multi-story
building that further includes: [0423] positioning and securing the
composite building panels described above, adapted for use as a
second floor unit, to at least some of the top slip track of the
wall units; and [0424] positioning and securing two or more of the
composite building panels described above, adapted for use as a
second wall unit, to at least part of a top surface of the second
floor unit, wherein a bottom track and a top slip track are
attached to a bottom end and a top end respectively of the
composite building panels; [0425] where the roof unit is secured to
at least some of the top slip track of the second wall units.
[0426] Thus, various forms of the present invention also provide a
building that contains one or more of the floor units, wall systems
and roof systems described above.
[0427] The wall units, floor units and expanded polymer panels of
the present invention provide a number of advantages. For example,
they can eliminate the need for house wrap. The expanded polymers
used in the present invention may also have at least an equivalent
rating as required by local building codes for house wraps.
[0428] Also, no insulation subcontractors may be required during
construction as the wall units, floor units and expanded polymer
panels of the invention already include adequate insulation. The
materials of construction may also effectively block low frequency
sound waves resulting from exterior noise.
[0429] The acoustical properties of the construction panels, wall
units, floor units and expanded polymer panels are particularly
advantageous. Typically, metal studded structures have major
acoustical or sound transmission problems. The metal studs will
generally amplify sound through their ability to vibrate. When the
metal studs are encapsulated in the polymer matrix, vibration is
reduced, which results in reduced vibration and desirable
acoustical and sound transmission properties. A non-limiting
example of a suitable test method for determining acoustic sound
insulative properties of various panels according to the present
invention is ASTM E 413-04.
[0430] The panels of the present invention can have good fire
resistance properties. Fire resistance of various wall assemblies
according to the present invention may be evaluated according to
ASTM E 119-00a.
[0431] Also, various panel embodiments of the present invention can
have good strength and resistance to shear forces, such as wind
resistance. Shear stiffness, shear strength and ductility of
various wall assemblies according to the present invention can be
evaluated according to ASTM E 2126-05. Horizontal and vertical
transverse load, horizontal concentrated/point load and vertical
compressive/axial load for various wall or floor assemblies of the
present invention can be evaluated according to ASTM E 72-05.
[0432] The wind load resistance at the joint between two panel
assemblies of various embodiments of the present invention (foam
adhesion strength at the wall panel joint) can be determined
according to the following method. The nominal size of each test
panel is 4 ft wide by 8 ft long and consists of EPS foam with 2
embedded steel studs at 2 ft on center.
[0433] Suitable testing equipment is shown in FIGS. 131-135. Two
wooden panel supports, each with the 35/8'' track and 1/2 ''dia.
bolts at 16'' on centers, are arranged as shown in FIGS.
131-135.
[0434] Marked concrete slabs with known weights are used to
simulate uniformly distributed load on the foam. The approximate
size of each slab is 1 ft by 1 ft by 3.5'' thick at 110
lb/ft.sup.3, a total weight of 32 lb/slab. A 3/4'' thick plywood
panel, 1 ft wide by 7 ft long is used to support the slabs on top
of the test panels, as discussed below. Pieces of 2.times.4 lumber
are used for bracing as shown in FIGS. 131-135. A rotary laser is
used for leveling.
[0435] Data on Applied Loads versus Foam deflection is determined
for two testing scenarios. The two testing scenarios are scenario
#1 in which the test panels have the foam side oriented as the top
surface and scenario #2 in which the test panels have the steel
stud side without foam oriented on the top.
[0436] The testing apparatus in assembled as shown in FIGS.
131-135. Two 4 ft.times.8 ft panels are placed inside the track
side by side such that both panels have the foam side oriented on
the top and the steel stud side without the foam facing downward.
Weigh the 1 ft wide.times.7 ft long.times.3/4'' thick plywood panel
and place it longitudinally over the length of the test panels, 6''
off each panel edge. Using a rotary laser, establish the horizontal
line for taking the measurements. Measure the distance between the
horizontal to the top of plywood surface at the mid-span and note
it as reading 1 (or the baseline measurement), for unloaded wall
panel joint. Place the known weights/slabs of approx. 32 lb/ft
starting with two slabs (64 lb total) at the center on the plywood
panel and move towards the edges of the panel at increment of two
slabs/reading time. Record the exact total weight placed on the
plywood and its mid-span deflection. Provide some room at mid-span
panel joint for taking foam deflection measurements. Keep adding a
load increment of 64 lb; measure the distance between the steel
cable to the top of plywood and the total weight on the plywood
panel. Repeat step #6 and 7 until foam failure. The estimated
maximum load range is 250 lb to 560 lb. Record the total weight and
the corresponding foam deflection for each load change.
[0437] Repeat the above steps for testing scenario #2 (FIG. 135)
namely, having both wall panels oriented with steel studs without
foam on top and the foam with embedded studs facing downward. The
loads will be placed on the 3/4'' plywood on foam at the panel
joint.
[0438] The ultimate strength of the panel joint is determined by
foam separation or failure. In order to prevent the wall finishes
(i.e. plaster) from cracking or spalling, the wall panel deflection
is limited to L/240, where L is the height of the wall panel or the
length of the panel in the orientation of the test. For example,
when the wall panel height is 8 ft or 96 inches, the wall panel
deflection is the height divided by 240, i.e., 8 ft.times.12 in/240
or 0.4 in.
[0439] Another potential advantage of various embodiments of the
present invention is that less framing is required on a job site
because of the prefabricated nature of the present wall units,
floor units and expanded polymer panels.
[0440] The generally faster construction time resulting from using
the present wall units, floor units and expanded polymer panels
allows for earlier enclosure and protection from the elements
leading to less water damage during construction. Additionally, the
provided holes, openings, conduits, chases and spaces in the
present wall units, floor units and expanded polymer panels results
in faster wiring and plumbing and less job site scrap.
[0441] The present invention also relates to a method of doing
business that allows an architectural design layout to be accessed
by the apparatus for molding a semi-continuous or continuous foamed
plastic element in order to customize the size, shape and
dimensions of the various elements of the construction panels, wall
units, floor units, and expanded polymer panels of the invention.
The architectural design layout can be provided via software from a
disk or via an Internet connection. For those customers with
Internet capabilities, access to the present method is convenient
and provides an efficient and time saving method to design and
manufacture building and/or housing units.
[0442] In a non-limiting exemplary embodiment, a customer selects
an architectural design for a building. The architectural design
includes the unique features of each composite building panel to be
used in the building. The architectural design is loaded into a
processing unit that translates the design into instructions for
the apparatus for molding a semi-continuous or continuous foamed
plastic element. The instructions direct the apparatus to
continuously or semi-continuously mold panels as described above
and what customizing features to include in each panel.
[0443] The architectural design can include, as non-limiting
examples the dimensions of and the location of openings and holes
required in each reinforcing embedded bar as well as any
indentations in each composite building panel needed to build the
building; the dimensions of each composite building panel to
include thickness, width, height, spacing between the reinforcing
members in the form of, for example, embedded framing studs,
dimensions and shape for each embedded framing studs, any channels
that need to be cut into or formed in the central body of each
composite building panel, any of the design features described
above, any other unique features for each composite building panel,
as well as gable ends accommodating any roof pitch or slope, bay
window floor cuts and other design specified architectural
features.
[0444] The processing unit can be any computer or device capable of
reading instructions and translating them into instructions for the
apparatus for molding a semi-continuous or continuous foamed
plastic element.
[0445] The customizing features can include any of the
architectural design features described above. As a non-limiting
example, the customizing features can include forming a straight
exposed end as shown in FIG. 127 to a shaped end as shown in either
of FIGS. 128 and 129.
[0446] In another embodiment of the invention, an interactive
computer program can be used to provide the architectural designs
described above. In an embodiment of the invention, the
architectural design can be inputted using a series of computer
screen menus, where a user selects choices made available on a
computer screen. When the design button is selected, a screen
appears for additional choices for modifying the central body, the
embedded framing studs, and/or the spatial relationship between the
two. Selecting any of the menus directs to another screen where
specific architectural design features as described above can be
inputted as well as the number of panels required that have those
features. Upon selection, additional customized panels can be
inputted. The user then verifies the order by selecting an "order
panels" button. The instructions are then relayed to the apparatus
for molding a semi-continuous or continuous foamed plastic element
and each of the requested number of panels having each of the
architectural design features are molded and cut to the order
specifications. In an embodiment of the invention, all panels are
automatically labeled and marked for placement in their proper
position.
[0447] In a further embodiment, the customer requests access to an
interactive program that steps the customer through the design
process. Once the design is complete, the customer can save the
design for future use. The customer may also choose to submit the
design for an order.
[0448] The use of a design program on an Internet site benefits the
manufacturer in a variety of ways including a method of gathering
customer profiles that can later be used for mailings, etc. In
addition, an Internet site that includes this unique method of
doing business reaches worldwide and generates name recognition for
the manufacturer, particularly where the construction panel
manufacturer is the is the only manufacturer to offer an accessible
and convenient method of designing and ordering composite
construction panels.
[0449] Various embodiments of the design program of the present
invention provide an advantage for the user in his or her own
business in that it raises the level of professionalism of the user
by allowing prompt and on-the-spot service for his or her own
customers. For example, a customer may bring a sketch or layout for
an architectural design a composite construction panel shop
requesting construction panels to use in the layout or design. In
response, the panel shop owner, i.e., user, can utilize the design
program to build a series of composite construction panels on a
computer screen with the customer by his side, and explain to the
customer the benefits of the custom composite construction panels.
This process provides a first rate service to the customer,
eliminates guessing, increases interaction between the panel shop
and the end customer, and enhances business reputation in the
field.
[0450] FIG. 130 illustrates a method of doing business 400 between
a composite construction panel manufacturer 420 and a customer 414,
416 requiring the manufacture of custom composite construction
panels. A composite construction panel design program is provided
to a customer 414, 416 via a hard copy 418, e.g., a disk containing
a copy of the program, or via electronic access, e.g., the Internet
or e-mail. The composite construction panel design software is
utilized by a customer on the customer's personal computer 414,
416. The customer designs one or more composite construction panels
and delivers the completed design to the manufacturer 420. The
design can be printed to provide a hard copy 418 to the
manufacturer 420. In a particular embodiment of the present
invention, the finished design is uploaded to a central computer
406 located at the manufacturer 420. In another particular
embodiment, compatibility between the design program software and
the software of the apparatus for molding a semi-continuous or
continuous foamed plastic element 408 allows the finished design
specifications to be entered into the apparatus 408 directly
through a connection to the central computer. In another
embodiment, the design specifications are entered manually by an
apparatus operator. The design software stores and sorts the data
based on particular panel design types, and identifies the most
efficient sequence for making panels. Thus, the software is usable
as a management tool to simplify the work of the apparatus
operator, including specifying what order to make the panels and
how to maneuver parts of the apparatus to change from one panel
design to the next. The method of doing business as illustrated in
FIG. 130 reduces the time and cost to design and manufacture custom
construction panels.
[0451] Various embodiments of the invention will now be described
by the following examples. The examples are intended to be
illustrative only and are not intended to limit the scope of the
invention.
Example
Thermal Resistance
[0452] The thermal resistance or R-value for wall assemblies that
include various wall panels according to the present invention was
determined using three-dimensional computer modeling simulation.
Each determination was based upon a simulated section of wall
assembly 24 inches (61 cm) wide and inches (30.5 cm) high. Each
simulated wall assembly consisted of an outer layer of 0.50 inch
(1.27 cm) thick OSB board in facing engagement with a foam section
of a wall panel according to various embodiments of the present
invention in which the stud was positioned in the center of the
wall assembly area, as shown in FIGS. 136-140. The foam used in the
computer modeling simulation was conventional rigid cellular
polystyrene whose thermal insulation property met type 1
classification as per ASTM C578-04a. The simulated assembly also
included an outer layer of 0.50 inch (1.27 cm) thick gypsum board
positioned in facing engagement with the exposed, opposite end of
the stud.
[0453] The thermal conductivity values for each of the wall
assembly materials used for calculations in the computer thermal
modeling simulation is set forth in Table 1 below. The average
thermal conductivity of the above expanded polymer matrix or foam
material was determined according to ASTM C-518-98
(Tmean=75.degree. F. (25.degree. C.) and temperature difference
between test plates .DELTA.T=40.degree. F. (7.degree. C.)) of a
12''.times.12''.times.1.5'' (30.5 cm.times.30.5 cm.times.3.8 cm)
using two samples of foam. Twenty (20) gauge steel was used for
simulations of all steel profiles.
TABLE-US-00001 TABLE 1 Thermal Conductivity Wall Material
(Btu-in/hr ft.sup.2 .degree. F.) Steel 3.18e.sup.3 OSB Board 0.80
Gypsum board 1.11 Foam 0.28
[0454] The above thermal conductivity values were used to calculate
theoretical thermal resistance or R-value for each of five
simulated wall assemblies A-E.
[0455] Referring now to FIG. 136, simulated Wall Assembly A
included a wall panel according to the present invention having a
C-shaped stud as discussed above with reference to FIGS. 5 and 13.
Simulated Wall Assembly A consisted of the above-described foam
1900 having a thickness of 3.375 inches (8.6 cm), a C-shaped stud
1902 embedded such that the outer side of the flange 1904 of the
first end 1906 of the stud 1902 was one inch (2.5 cm) from the top
surface 1908 of the foam 1900 and gypsum board 1910 in facing
engagement with the outer side 1912 of the flange 1914 of the
second end 1916 of the stud 1902.
[0456] Referring now to FIG. 137, simulated Wall Assembly B
included a wall panel according to the present invention having a
CT-shaped stud as discussed above with reference to FIGS. 31-34.
Simulated Wall Assembly B consisted of the above-described foam
1918 having a thickness of 4.441 inches (11.28 cm), a CT-shaped
stud 1920 embedded such that the inner side 1922 of the flange 1924
of the first end 1926 of the stud 1920 was flush with the top
surface 1928 of the foam 1918 and gypsum board 1930 in facing
engagement with the outer side 1932 of the flange 1934 of the
second end 1936 of the stud 1920.
[0457] Referring now to FIG. 138, simulated Wall Assembly C
included a wall panel according to the present invention having a
CT-shaped stud as discussed above with reference to FIGS. 31-34.
Simulated Wall Assembly C consisted of the above-described foam
1938 having a thickness of 4.375 inches (11.11 cm), a CT-shaped
stud 1940 embedded such that the inner side 1942 of the flange 1944
of the first end 1946 of the stud 1940 was 0.25 inch (0.635 cm)
above the top surface 1948 of the foam 1938 and gypsum board 1950
in facing engagement with the outer side 1952 of the flange 1954 of
the second end 1956 of the stud 1940.
[0458] Referring now to FIG. 139, simulated Wall Assembly D
included a wall panel according to the present invention having a
CC-shaped stud as discussed above with reference to FIGS. 35, 39
and 40. Simulated Wall Assembly D consisted of the above-described
foam 1958 having a thickness of 4.375 inches (11.11 cm), a
CC-shaped stud 1960 embedded such that the outer side 1962 of the
flange 1964 of the first end 1966 of the stud 1960 was flush with
the top surface 1968 of the foam 1958 and gypsum board 1970 in
facing engagement with the outer side 1972 of the flange 1974 of
the second end 1976 of the stud 1960.
[0459] Referring now to FIG. 140, simulated Wall Assembly E
included a wall panel according to the present invention having a
CC-shaped stud as discussed above with reference to FIGS. 35 and
51-53. Simulated Wall Assembly D consisted of the above-described
foam 1978 having a thickness of 4.375 inches (11.11 cm), a
CC-shaped stud 1980 embedded such that the outer side 1982 of the
flange 1984 of the first end 1986 of the stud 1980 was flush with
the top surface 1988 of the foam 1978 and gypsum board 1990 in
facing engagement with the outer side 1992 of the flange 1994 of
the second end 1996 of the stud 1980.
[0460] Thermal modeling of the wall area directly surrounding the
wall stud was performed on the above simulated wall assemblies
using HEATING 7.3, a three-dimensional finite difference computer
code by Oak Ridge National Laboratories. The computer modeling
enabled analysis of theoretical temperature distribution in the
analyzed wall systems and calculation of local heat fluxes, which
were utilized to calculate face-to-face R-values for the above wall
assembly configurations. The results of the computer modeling are
presented in Table 2 below.
TABLE-US-00002 TABLE 2 Simulated R-value Wall Assembly (ft.sup.2
.degree. F. Hr/Btu) A 11.97 B 13.3 C 13.56 D 14.01 E 13.97
[0461] As shown in Table 2, Wall Assemblies D and E had higher
simulated R-values compared to Wall Assemblies A-C.
[0462] Using the above simulated R-values, the framing effect on
each of simulated Wall Assemblies A-E was determined. As used
herein, "framing effect" means the reduction of the nominal wall
R-value caused by application of steel structural components, and
is described by the following formula:
f.sub.e=1-R.sub.eff/R.sub.nom
where:
[0463] f.sub.e is framing effect;
[0464] R.sub.eff is effective simulated R-value of the wall
assembly; and
[0465] R.sub.nom is nominal "in-series" R-value of cavity
insulation and sheathing materials.
[0466] The results of the calculations of framing effect based upon
the above simulated R-values are presented in Table 3 below.
TABLE-US-00003 TABLE 3 Wall R-value of Framing Assembly foam
R.sub.nom R.sub.eff Effect (%) A 12.15 13.22 11.97 9.5 B 15.75
16.82 13.3 20.9 C 15.75 16.82 13.56 19.4 D 15.75 16.82 14.01 16.7 E
15.75 16.82 13.97 16.9
[0467] As shown in Table 3, Wall Assembly D had the highest
simulated R-value and second lowest framing effect of Wall
Assemblies A and C.
[0468] While the present invention has been described in
conjunction with the specific embodiments set forth above, many
alternatives, modifications and other variations thereof will be
apparent to those of ordinary skill in the art. All such
alternatives, modifications and variations are intended to fall
within the spirit and scope of the present invention.
* * * * *