Abstract: A building panel includes a first skin which is bonded to a first face of a first foam sheet. A second face of the first foam sheet is fixed to a cellular network. The cellular network includes a first face, a second face, and a plurality of cells defined by a plurality of cell walls. The second face of the cellular network is fixed to a first face of a second foam sheet. A second skin is bonded to a second face of second foam sheet. In one embodiment, the first skin may include a first portion, a second portion, and a third portion. The first portion of first skin is bonded to the first face of the first foam sheet. The second portion of the first skin extends beyond the first foam sheet and forms a first interlocking member. The third portion of first skin extends beyond the first foam sheet and forms a first complementary interlocking member. The second skin of the building panel may also includes a first portion, a second portion, and a third portion.

Abstract: Modular panels having a foam a core and top and bottom surfaces covered by a metallic skin are interlocked with one another by forming the metal skins so that contiguous panels meet along a tight, substantially immovable seam. Abutting metal parts are bent at an angle slightly greater than ninety degrees so that they meet along a distinct line of contact, forming an ideal seam. The area of contact is small so that contiguous panels are easily slideable with respect to one another in a lateral direction during panel assembly. Another metal part may be bent at differing angles at the time of panel manufacture to vary the amount of force required to interlock contiguous panels. The mating panels form a space protected from the sun within which caulking compound is positioned, and an elongate stiffener enables the panels to be manufactured in elongated sizes.

Abstract: Modular roof panels having sloped top surfaces and flat bottom surfaces are interlocked in edge-to-edge relation to one another to form a monolithic roof where the roof is pitched to provide moisture run off but where the space covered by the roof has a ceiling that is not pitched. Thus, the side walls of the structure have a common height. In a first embodiment, the top and bottom surfaces of the panels are covered with a skin, and in a second embodiment only the top surface is so covered. The first embodiment is used in original roof construction and the second is used in roofover construction. In both embodiments, the core material is preferably expanded polystyrene and the skin is preferably metallic. The skins are bent to interlock contiguous panels.

Abstract: Panels having foam cores covered by metal skins are interlocked along their respective sides by forming bent parts in the metal skins that interlock with one another. A first interconnecting member is generally hook-shaped and projects outwardly. Its counterpart is also generally hook-shaped and extends inwardly. The counterpart slideably receives the first interconnecting member, transiently deforming as the first interconnecting member enters it, and returns to its position of repose when the first interconnecting member is fully received therewithin. The foam cores of abutting panels are also sculpted to interlock with one another. An elongate, channel-shaped stiffener member has a flat base and upstanding side walls, at opposite sides of the base, that are received within the area bounded by the hook-shaped outwardly projecting part of the first interconnecting member. This enables construction of modular panels of up to forty feet in length.

Abstract: Modular building panels having foam cores protected by metal skins are releasably interconnected in edge-to-edge relation to one another. The interconnection is accomplished by bending the metal skins that protect the top and bottom surfaces of the core into complementary shapes so that contiguous panels are snap fit together when the bent metal skins are interlocked with one another. In some embodiments, the cores are grooved and the flexibility of the interlocking members is increased by decreasing the depth of the grooves and the flexibility is decreased by increasing the depths of those grooves because decreasing the groove depth provides less support for the interlocking members and allows them to displace more during the interlocking procedure and increasing the depth increases the support and thus limits their movement.

Abstract: Modular building panels having foam cores protected by metal skins are releasably interconnected in edge-to-edge relation to one another. Each panel has a first panel edge that is flat and a second edge with a pair of parallel grooves formed in it. The interconnection is accomplished by bending the metal skins that protect the top and bottom surfaces of the core so that contiguous panels are snap fit together when the bent metal skins are interlocked with one another. The interlocking skin associated with a first panel edge has a "J" shape and extends outwardly at a forty five degree angle relative to the edge of that panel. The skin associated with a second panel is bent into a ladle shape that includes a cup that receives the curved end of the "J"-shaped part when the panels are interconnected. Each ladle-shaped part extends into its associated groove at a forty five degree angle, in a reverse direction relative to the "J"-shaped part.

Abstract: Building panels having foam cores covered by protective thin sheets of metal are interlocked at abutting edges by mating parts of the metal sheets. In a first embodiment, a first panel has an outwardly projecting tongue formed in an edge wall. The tongue abuts a flat edge wall of a second panel when the respective metal parts of the panels are interlocked. Sufficient play is provided to allow lateral movement of the interlocked panels to facilitate the construction of a structure that employs the panels. One of the interlocking metal plates is in the form of a trough so that if water enters a seam between the panels, such water is directed by the trough to a gutter. In a second embodiment, the tongue is formed in the second panel and channels are provided in the second panel to receive inwardly projecting, curled metal parts that engage complementally formed metal parts of the first panel.