Insulated wall panel for building construction and method and apparatus for manufacture thereof

Abstract

Pre-fabricated wall, ceiling and roof panels for use in building construction have a metal framework, metal interior bracing as needed and may include internal electrical, water and gas supply conduits enabling simple and efficient building construction. A method for manufacturing the pre-fabricated building panels includes constructing a metal panel framework with internal structural bracing and placing the framework in a machine having relatively moveable foam containment plates. Polyurethane foam panel filler material having efficient thermal insulating quality is injected into the panel frame between the foam containment plates and expands during curing to fill the voids within the panel frame and define parallel exterior and interior panel surfaces. The light-weight polymer foam filled panels are then secured to the panel connectors of a building foundation and are secured to one another to define the walls, ceiling and roof a building structure and provide resistance to storm damage, insect and water damage and heat reflection.

Description

BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] This invention relates generally to pre-fabricated wall, ceiling and roof panel structures for use in building construction. The invention also concerns a method of manufacturing pre-fabricated building panel structures incorporating metal panel framework and structural bracing and having polymer foam panel filler material that is installed in finished metal panel frames enhances the structural integrity of the panels and provides excellent thermal insulation characteristics that minimize the energy requirements for air-conditioning and heating the interior of a building to maintain a comfortable thermal environment. More particularly, the present invention also concerns a machine and manufacturing system for manufacturing the building construction panels and a method for manufacturing pre-fabricated insulated wall and roof panels. [0003] 2. Description of the Prior Art [0004] It is well known that various types of ...

AI Technical Summary

Benefits of technology

[0006] It is a principle feature of the present invention to provide pre-fabricated building panels that incorporate a panel framework composed of lightweight metal sheet material that is formed to desired configuration and have internal structural braces as desired that are also composed of formed metal sheet material and further having a thermal insulating polyurethane foam material formed in situ and filling the voids of the framework and defining exterior and exterior substantially parallel panel surfaces;

[0007] It is also a feature of the present invention to provide structural insulated panels that can be used effectively in timber framed, steel framed, and log homes and can be employed in multi-unit buildings and light commercial buildings;

[0008] It is a feature of the present invention to provide structural insulated panels that can be used effectively to define interior supporting walls of a building and for adding seismic strength, sound absorption and fire separation to building structures and to provide storm resistant wall, roof and ceiling structures for buildings;

Problems solved by technology

It is known, however, that uncured polyurethane foam material tends to expand non-uniformly, so that it is virtually impossible for polyurethane foam insulation to create planar interior and exterior polymer foam panel surfaces without subsequent panel preparation after the polyurethane foam material has become completely cured.

It is also known that curing and expanding polyurethane foam material will generate very high pressure if curing and expansion takes place within a confined space.

Significant panel manufacturing problems will typically occur if wall and roof framework closure panels are applied to the panel framework in order to confine the expanding polyurethane foam in an attempt to create parallel exterior and exterior planar panel surfaces.

When wood and other organic materials are employed for the development of structural insulated panels for the wall and roof structures of buildings, insect damage, water damage and dry rot are significant problems that affect the durability of such structures.

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