High-strength insulated building panel with internal stud members

Abstract

The invention is directed to a building panel which has structural integrity. A plurality of stud members with opposed side surfaces and opposed end surfaces extend from a first face of the panel toward a second face. The plurality of stud members are spaced from each other and extend in a direction which is essentially parallel to each other. A rigid foam fills the volume of the panel which is not filled by the plurality of stud members. The rigid foam is bonded to at least one side surface of each of the plurality of stud members. The bonding of the rigid foam to the plurality of stud members results in a stable and strong panel which is capable of accommodating large shear loads.

Description

FIELD OF THE INVENTION[0001]The present invention relates to a building panel which has structural integrity. In particular, the invention is directed to a panel in which a foam is bonded to at least one side surface of each of a plurality of stud members resulting in a stable and strong panel which is capable of accommodating large shear loads.BACKGROUND OF THE INVENTION[0002]The construction industry is continuously attempting to find ways to reduce the time, cost, and labor associated with the construction of a structure, such as a wall, room, floor, ceiling and roof. Conventional stick building is labor-intensive, involving as separate steps, building the frame, erecting the frame, applying external sheathing and building wrap, followed by installing thermal insulation, typically fiberglass batts or blown-in cellulose. This practice generally results in less than optimal insulation because materials are inherently limited in insulating properties and construction practices are v...

AI Technical Summary

Benefits of technology

[0012]One aspect of the invention is directed to a building panel which has structural integrity. The panel has a first face and an oppositely facing second face. A pair of panel end walls and a pair of panel sidewalls extend between the first face and the second face. A plurality of stud members with opposed side surfaces and opposed end surfaces extend from the first face toward the second face. The plurality of stud members are spaced from each other and extend in a direction which is essentially parallel to each other. A rigid foam fills the volume of the panel which is not filled by the plurality of stud members. The rigid foam is bonded to at least one side surface of each of the plurality of stud members. The bonding of the rigid foam to the plurality of stud members results in a stable and strong panel which is capable of accommodating large shear loads.

[0013]Another aspect of the invention is directed to a panel having structural integrity for use in floors, ceilings, walls and / or roofs of a structure. The panel has a first face and an oppositely facing second face. A pair of panel end walls and a pair of panel sidewalls extend between the first face and the second face. A plurality of stud members with opposed side surfaces and opposed end surfaces extend from the first face toward the second face. The plurality of stud members are spaced from each other and extend in a direction which is essentially parallel to each other. A rigid foam fills the volume of the panel which is not filled by the plurality of stud members. A facing material extends across the first face of the panel. The facing material is bonded to the rigid foam. The bonding of the rigid foam to the plurality of stud members and to the facing material results in a stable and strong panel which is capable of accommodating large shear loads.

[0014]Another aspect of the invention is directed to a method of manufacturing a building panel. A plurality of stud members is positioned in a mold in a direction which is essentially parallel to each other, each stud of the plurality of stud members having opposed side surfaces and opposed end surfaces. The plurality of stud members are spaced from each. Foam is injected into the mold to fill the volume of the mold which is not filled by the plurality of stud members. Increased pressure and temperature are applied to allow the foam to cure, become rigid and bond to at least one side surface of each of the plurality of stud members. The panel is removed from the mold. The bonding of the rigid foam to the plurality of stud members results in a stable and strong panel which is capable of accommodating large shear loads.

Problems solved by technology

Conventional stick building is labor-intensive, involving as separate steps, building the frame, erecting the frame, applying external sheathing and building wrap, followed by installing thermal insulation, typically fiberglass batts or blown-in cellulose.

This practice generally results in less than optimal insulation because materials are inherently limited in insulating properties and construction practices are variable.

One problem with such techniques is that the prefabricated portion of the structure is constructed with conventional materials using the techniques that would be used on the construction site.

Another problem with these techniques is that the prefabricated portion is subject to damage during its transportation to the construction site.

Although the axial and bending strengths of SIPs are known to be high, conventional SIPs typically require additional support along both their top and bottom surfaces.

While the plates and bands contribute to the overall strength of the SIPs, they add to the quantity of material used in their construction and thereby increase cost.

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