Building system utilizing integrated technology with molded expanded polystryrene cores
The disclosure pertains to a method of constructing structures and the resulting structures with SEP technology but with additional building components that create very strong buildings, including the ability to withstand high winds. The disclosure includes the option of constructing vertical concrete columns and horizontal concrete beams within the joined panel walls. This results in combining structural insulated panel technology with insulated concrete form technology. The disclosure also teaches use of compression fasteners that extend through both layers of the panel skin to achieve a mechanical attachment of the panel skins and not relying totally on the adhesive bond found on the typical SIP thus creating a “true” box beam effect of the panel itself. The fasteners have large chambered heads. These fasteners can be used at the junction of abutting panels. The panels are block lap cut and the fastener extends through both block extensions.
This application claims priority to and the benefit of the provisional application Ser. No. 60/901,738 filed Feb. 17, 2007 entitled “Building System Utilizing Integrated Technology with Molded Expanded Polystyrene Cores.” The text and the drawings of the provisional application Ser. No. 60/901,738 are incorporated by reference herein.
BACKGROUND OF INVENTION1. Field of Use
The invention pertains to modular constructed building systems that employ green technology and little, if any, wood products.
2. Related Technology
Off site manufacturing of building components such as wood roof trusses are known.
SUMMARY OF DISCLOSUREThe disclosure pertains to a plurality of wall panels fabricated of molded expanded polystyrene (MEPS) with an outer layer or “skin” of cement board, oriented strand board, metal or magnesium oxide. In one example the panels can be 4 feet wide by 8 feet high and 3½ inches to 11½ inches thick. Other dimensions are possible. The vertical ends of the panels may be cut to form block and tongue lap joints with the next adjoining panel. The resulting lap joint allows for increased surface area for bonding the panels together. Adhesives are used to “weld” the MEPS at the panel lap joint to create a “continuous like” structural wall. The panels are secured with compression fasteners that traverse through the thickness of both panels at the block and tongue lap joint and anchor at the outer surface.
The structure can be anchored to a concrete pad. The roof structure can be made of the panel material and attached to the walls with attachment connectors.
The panels may also contain preformed voids creating forms for pouring and shaping internal vertical concrete columns and horizontal concrete beams thereby combining structural insulated panel (SIP) technology with insulated concrete form (ICF) technology.
The horizontal ends of the panels may also be similarly cut and shaped to form block and tongue lap joints.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention. These drawings, together with the general description of the invention given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
It will be appreciated that the foregoing drawings illustrate only one embodiment of the invention and that numerous other variations may be created within the scope of the described invention. Further, the accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention. These drawings, together with the general description of the invention given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
DETAILED DESCRIPTION OF INVENTIONThe building structure and method described herein incorporates structural insulated panel technology (hereinafter “SIPs”) and may include a concrete pad or foundation, wall panels that are adhesive bonded and secured together with compression fasteners, optional internal concrete beams and a roofing system attached to the wall system. The structure and the building method come in two versions, one that integrates concrete and one that does not.
Utilization of the concrete column and beam technology achieves a combination of structural insulated panel technology with insulated concrete form technology. Both versions utilize structural insulated panels (hereinafter “SIPs”). In the embodiments disclosed, the concrete columns and beams are installed within the interior of the SIP panels.
The panel is a structural insulated wall or roof panel 11 which has a core made of molded expanded polystyrene (hereinafter “MEPS”) of various thicknesses from 3½″ to 11½″. The outer layers 110 are cement board (CB) or oriented strand board (OSB), metal or Magnesium Oxide (MgO) board which may be pressure adhered with a Type II, Class 2 structural adhesive or similar. One embodiment of a SIP panel is illustrated in
The CB and MgO outer materials also have fire retardant properties.
Other components of the structure system, e.g., fiberglass, may be made from an extrusion process. This can allow fabrication of components in custom shapes.
The system utilizes a 3-4″ block projecting tongue fabricated on the vertical edge, and in some cases the top horizontal edge, of each panel and which butt and lap together with the similar edge of a second panel. A series of compression fasteners are placed vertically and horizontally along the butt joint forming the lap juncture. The compression fasteners attach to each panel skin, whether cement board, OSB, metal or MgO of each panel. The compression fastener therefore incorporates both skins of the SIP panels. The compression fasteners are placed horizontally at gables and 2 story walls. This strengthens the bond between the panels.
In one option, concrete may be used in the structure. The panel contains a vertically oriented void that forms the various shapes of the concrete column internal to the panel. A panel is placed on the cement pad of the structure where a vertical concrete column is to be placed. The reinforcing bar (rebar) placed in the column is tied to rebar extending from the concrete pad. Compression fasteners are utilized to stabilize the sides of the form (within the panel wall) when the concrete is poured. The form for the concrete column is a void created in the interior MEPS and extends the length of the SIP panel.
A horizontal beam that sits on top of the vertical column can be created by a second void in the top of the SIP panel or by use of an installed or “detachable” beam form. The rebar of the horizontal beam will be tied to the vertical rebar extending from and attached to the structure's concrete pad. (See information below).
Block projecting tongue lapping is used on all vertical panel joining and at gable ends and when structure side walls have a greater height than the standard SIP wall panels
Block projecting tongue lapping or lap juncture is illustrated in
Waterproof construction adhesive 5 may be applied to both sides of the lap joint. A ⅛ inch air gap 130 is recommended between the joined SIP wall panels. The horizontal off set 135 of the block projecting tongue combination may be approximately 4 inches.
Panel lapping of three roof panels 20A, 20B, 20C is also illustrated in
The SIP panel 20D, 20E illustrated in
SIP panel lapping is used on all vertical (wall) panel joining and may be used horizontally at gable ends of the structure.
The system utilizes a unique compression fastener comprising a bolt that can be mounted flush to the SIP panel surface or “skin”. The compression fastener is illustrated in
The large chamfer or square sided head on both bolt and nut ends of the compression fastener and engage with the SIP panel skins facilitates compression of the SIP panel. The head and nut components are threaded and can be tightened. This is a more secure connection that staples, nails or screws. This also enhances the stability of the structure, including stability in earth movement or high wind conditions. The construction technique forms a box beam effect on the panel wall connection.
Composition of fasteners can be either non-metallic, e.g., fiberglass, or metallic, e.g., stainless steel. The compression fasteners may be of any appropriate length consistent with the thickness of the SIP panel. In one embodiment, the fasteners are 7 inches to 10 inches in length. The diameter of the rod portion of the fastener may, in one embodiment, be ¼ inch. In one embodiment, the chamfer or square ends may have a 1 inch diameter. The chamfer ends may include hex slot for tightening.
The system described herein permits the installation of vertically oriented concrete columns within constructed SIP panels. See
A rectangular or other shaped void 140 is placed vertically in a wall panel for the purpose of pouring a structural concrete column. The void extends the entire length of the SIP panel. If a horizontal concrete beam is to be installed, the concrete column will not extend to the top of the panel. The form or void may be 5¼ inches by 13½ inches in a panel that is 7¼ inch wide. The rectangular shape is shown as an example only and is not a limitation.
Recall that compression fasteners and adhesive will be applied at each lap joint. The compression fasteners may be placed vertically every two feet. The series of joined wall panels, having fasteners traversing through the thickness of the lapped panels and the large chamfered ends engage the outer surface of each skin of the joined panels to pull them together which thereby becomes rigid and unified.
In addition to the building of vertical concrete columns, horizontal concrete beams may be constructed across the top of some or all panels. Two options are illustrated.
In the second variation,
To assist securing the detachable beam form, compression fasteners 3 are utilized to stabilize and secure the sides of the form 145 when concrete is poured as illustrated in
Note that the form fits over the top of the SIP wall panel 215. This can be a method for raising the wall height as well as increasing the wall strength and wind resistance.
The use of concrete columns and beam can allow the construction of multi-story structures. Appropriate engineering of the column, beam and wall thickness dimensions would be required.
The structural connector is tied to the concrete bean by a bolt 311 vertically oriented within the concrete 312. A U shaped collar 313 extends from the structural fastener over the I-beam. The mechanism may include a flat plate bolted 310 over the I-beam.
It will be appreciated that the same manufacturing techniques are used in creating the wind resistant roof system. The result is a structurally unified roof system strongly connected to the wall system (optionally containing concrete columns and beams). The complete structure is well adapted to area subject to earth movement and to storm prone areas where wind damage is experienced. The manufacturing system also permits rapid construction of structures. Since components are factory manufacture, costs are minimized.
In addition, this specification is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the manner of carrying out the invention. It is to be understood that the forms of the invention herein shown and described are to be taken as the presently preferred embodiments. As already stated, various changes may be made in the shape, size and arrangement of components or adjustments made in the steps of the method without departing from the scope of this invention. For example, equivalent elements may be substituted for those illustrated and described herein and certain features of the invention maybe utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the invention.
While specific embodiments have been illustrated and described, numerous modifications are possible without departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying claims.
Claims
1. A structure comprising
- a) at least one wall comprising a plurality of SIP wall panels each comprised of a core of molded expanded polystyrene contained between a first and opposing second outer skin of cement board, OSB, metal or MgO and the panels are joined together to form the wall with lap junctures and adhesive and further comprising compression fasteners wherein the compression fastener extends through the thickness of the wall panel and comprises a male threaded portion and a female nut portion wherein each end comprises a large chambered component facilitating holding each skin layer.
- b) a roof comprised of a plurality of panels comprising a core of molded expanded polystyrene and first and second outer skins of cement board, OSB, metal or MgO and the panels are joined together utilizing lap joints, compression fasteners extending through the thickness of the skins of the panel and adhesives; and
- c) the roof is attached to the wall panels comprising structural connectors attached to the top of the wall panel with compression fasteners extending through the attachment device and the skins of the wall panel and the attachment device is attached to the roof panel with a bolt.
2. The structure of claim 1 further comprising at least one SIP wall panel containing a void vertically oriented through the panel that can be filled with concrete.
3. The structure of claim 1 further comprising a horizontally oriented mold oriented proximate to the top of the SIP wall that can be filled with concrete.
4. A method of constructing a structure comprising
- a) assembling at least one wall comprised of separate wall panels of molded expanded styrene with a least one first outer skin of MgO, cement board, metal or OSB and the adjoining panels have a lap joint joined with adhesive and at least one compression fastener extending through the thickness of the lap joint wall thickness to join the second skin of the joined panels;
- b) attaching a plurality of a roof support components having two side panels fitting over the outer skin of the wall with a compression fastener extending through the wall skin and the side panels of the components;
- c) attaching roof panels joined together with lap joints, compression fasteners and adhesive wherein the individual roof panels are joined together to form a single roof surface that is wind resistant.
5. The method of claim 4 further comprising:
- a) creating vertically oriented voids in the molded expanded styrene core of the wall panel;
- b) assembling rebar that can fit within the void;
- c) pouring concrete into the void containing rebar to create a vertical column extending from a foundation pad;
- d) installing a plurality of compression fasteners through the both the first and second skins of the wall panel through the void.
6. The method of claim 5 further comprising the rebar of the vertical column connected to rebar extending from the foundation pad.
7. The method of claim 5 further comprising:
- a) creating a horizontally oriented void within the molded expanded styrene core at the top of one or more wall panels;
- b) assembling rebar that can fit within the void spanning multiple wall panels;
- c) pouring concrete into the void containing rebar creating a horizontal concrete column; and
- d) installing a plurality of compression fasteners through both the first and second skins of the wall panel through the void.
8. The method of claim 7 further comprising the horizontal concrete column attached to at least one of the vertical concrete columns.
9. A method of manufacturing expanded wall panels comprised of a core of molded expanded polystyrene and a first and second outer skin of cement board, OSB, metal or MgO further comprising:
- a) balancing twin hydraulic “T” presses or other cold presses wherein one vertical structural member is used for two presses retracting rollers located in the base of one or more presses that allow a rack of panels to enter at the end of the press and be removed after the panel curing, the press base is made of wide flange steels beams placed perpendicular to the panel length, and the roller flange steels beams placed perpendicular to the panel length;
- b) placing roller assemblies on steel lifting rails on each side of the press, wherein two hydraulic cylinders or high tension springs are placed under each lifting rail to raise or lower the roller assemblies between the wide flange beams, and when the rails/rollers assemblies are raised or the high tension springs rise it allows for the cured panels to be removed from the press;
- c) feeding product from the front and discharging cured product from the rear of the press; and
- d) flexibility to install multiple presses within the T-formation alignment of lay-up and laminating line and the ability to cycle presses for continuous operation.
10. The method of claim 9 wherein hydraulic type cold presses are used.
Type: Application
Filed: Feb 14, 2008
Publication Date: Aug 21, 2008
Inventor: Dan Williams (Carolina, PR)
Application Number: 12/070,038
International Classification: E04C 2/34 (20060101); E04B 7/22 (20060101);