Composite structural panel

Abstract

An improved composite structural panel and method of fabrication are provided. In one embodiment, the panel generally includes two outer layers or sheets arranged in substantially facing relationship to each other and an intermediate layer spacing the outer layers apart. The intermediate layer includes a generally rigid stiffening or reinforcing core that preferably is bonded to outer layers to form a unified composite structure. In one embodiment, the core has an open structure defining a plurality of open cells 15. An insulating material is preferably disposed in the cells, and in one embodiment is a rigid foam that structurally reinforces the core 14 and strengthens the panel.

Description

BACKGROUND OF THE INVENTION [0001] The present invention generally relates to modular structural panels, and more particularly to an improved structural panel, joint, and method of fabricating the same for constructing interconnected panel systems. [0002] Modular building components such as composite structural panels with the ability to be interconnected have been used to construct various types of residential, commercial, and industrial structures. For example, the panels may be interconnected to create walls, floors, ceilings, and partitions of a building or various types of enclosures within a building. [0003] One type of composite panel, commonly known as structural insulated panels (SIPS), has an insulating core that is disposed between an exterior and interior facing sheets. In one method of fabricating a composite panel, a preformed rigid sheet of insulating material such as polystyrene or urethane is sandwiched between the facing sheets. In another type of fabrication used,...

AI Technical Summary

Benefits of technology

[0007] The present invention is directed to an improved composite structural panel and joint, and a method of fabricating the same that overcomes the shortcomings of foregoing known panels and joining systems. The invention provides a modular composite structural building panel with increased strength, non-leaking joints, and a unique fabrication process. When combined in a modular system comprising multiple adjacent units coupled together with the joining system disclosed herein, a building or other enclosure may be constructed that is strong, thermally efficient, and weather resistant. Typical applications, without limitation and for illustrative purposes only, may include residential, commercial, and industrial buildings; equipment enclosures; partitions; etc. The invention provides numerous advantages over known panel systems as further described herein.

Problems solved by technology

These types of joints, however, may be weak.

The panels and / or joints between adjacent panels may lack sufficient strength to resist axial, torsional, or shear loads imposed by the dead weight of the structure, impact forces, or wind loadings.

The foregoing known joining methods often are not sufficiently waterproof or airtight, thereby allowing air and water to infiltrate through the joint and into the panel and / or building formed by the panels without an adequate means of intercepting, directing, or stopping the through-flow of these elements.

Water infiltration may result in structural damage to the panel or reduce its thermal efficiency by wetting the insulating material.

Air infiltration or exfiltration, depending on whether ambient air pressure is greater inside or outside of the structure, results in heat loss and energy inefficiency that translates into higher utility costs for heating and air conditioning.

In inclement weather situations, ambient pressure differentials between the exterior or interior of a structure may cause panels to bow and joints to partially or completely open and fail.

Existing panel fabrication methods are also often complicated and time-consuming, thereby resulting in higher manufacturing and final product costs.

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