HIGH PERFORMANCE BUILDING PANEL

Abstract

The present invention discloses a building system comprising a first panel formed of expanded polystyrene with a front surface, a back surface, and an edge surface, and a second panel formed of expanded polystyrene with a front surface, a back surface, and an edge surface, wherein the first panel and the second panel are used to form a portion of a building. In some embodiments the first panel has a tongue, and the second panel has a groove, and the tongue and the groove are used to couple the first panel and the second panel together. In some embodiments the tongue and groove are coupled together with a latch mounted in the tongue of the first panel and a latch receiver mounted in the groove of the second panel. The first panel and the second panel can be formed by molding the expanded polystyrene.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application to Duane Armijo entitled “HIGH PERFORMANCE BUILDING PANEL,” Ser. No. 61/238,080, filed Aug. 28, 2009, the disclosure of which is hereby incorporated entirely herein by reference.

BACKGROUND OF THE INVENTION

1. Technical Field

This invention relates generally to building components and more particularly to panels used to create building walls, floors, and ceilings.

2. State of the Art

Building structures are typically constructed on-site from wood, brick, stucco, and steel, as well as other materials. Wood has always been a favorite because of its easy availability, its hardiness and the ease with which it can be formed and connected to make different shaped building structures. Wood is still the most common element use as the basis for creating building walls and building roofs in homes and smaller industrial buildings. Brick and concrete blocks are also commonly used for walls in homes and commercial buildings. Steel is used as the structural element in some homes and in most commercial construction. In recent years the construction industry has been working to develop building construction techniques and material which are environmentally friendly during both construction and usage of the building.

The use of wood can be discouraged because it uses the natural resource of trees and there is much waste when the wood is cut and some of it discarded on the building site. For both brick and steel, there is a push to reduce the energy consumption of forming these basic building structures and in using recycled material in the fabrication of the mortar and steel components. There is a need for building components which use a minimum of resources and energy to manufacture, which reduce the amount of material waste at the building site, and which are energy efficient once assembled into a building structure.

Typical building construction techniques include sending the basic building blocks of wood, steel, bricks or blocks to the building site, where they are cut, formed, and connected into a building. This can require a high level of manpower and energy consumption at the building site to construct the building, and can result in wasted raw materials. There is a need for building components which are formed to the correct size and shape during manufacture and which can then be quickly and easily connected to create a building at the site, resulting in a minimum of resource usage and labor at the building site.

The construction and maintenance of temporary shelters also pose several problems. When tents are used the tents are not energy efficient and the walls are not sturdy. When wooden structures are used as temporary shelters, the temporary building is difficult to reuse due to the nails and other connecting means which are hard to separate from the building material once the structure is taken down after the first use. Much of the building material is wasted and often the structure can only be used once. There is a need for building components which can be used to create sturdy, energy efficient temporary structures that can be assembled quickly and easily, and reused over and over.

Therefore, building components are proposed which are manufactured to the needed size and shape at the factory, require minimal energy resources to create and sustain a building, can be reused in the case of temporary shelters, and require minimum labor to assemble into a building.

DISCLOSURE OF THE INVENTION

The present invention relates to building components, and more particularly to panels used to form walls, floors, and roofs of buildings. The buildings constructed from these panels can be homes, offices, storage facilities, or any other type of building structure. The present invention discloses a building system comprising a first panel formed of expanded polystyrene with a front surface, a back surface, and an edge surface, and a second panel formed of expanded polystyrene with a front surface, a back surface, and an edge surface, wherein the first panel and the second panel are used to form a portion of a building. In some embodiments the first panel has a tongue, and the second panel has a groove, and the tongue and the groove are used to couple the first panel and the second panel together. In some embodiments the tongue and groove are coupled together with a latch mounted in the tongue of the first panel and a latch receiver mounted in the groove of the second panel. The first panel and the second panel can be formed by molding the expanded polystyrene. In some embodiments the first and the second panel are formed by molding other moldable materials. In some embodiments structural elements are molded into the first or the second panel. The structural element can be formed of light gage steel.

The invention discloses a building system comprising a first panel with a front surface, a back surface, and an edge surface, wherein the panel has a tongue on one of the surfaces. A second panel is disclosed with a front surface, a back surface, and an edge surface, wherein the second panel has a groove formed in one of its surfaces for receiving the tongue from the first panel. A lock located in the tongue couples to a lock receiver mounted in the groove to couple the first panel to the second panel. The first or the second panel can be formed by molding from a moldable material. In some embodiments the first or the second panel are formed of expanded polystyrene material. The first or the second panel can have a structural element molded into the panel. This structural element can be formed of light gage steel. The first or the second panel can have an end cap placed over an edge. The end cap can be formed of light gage steel. In some embodiments a metal mesh is molded into the panel. In some embodiments the first panel has two tongues on a surface, and the second panel has two grooves on a surface, wherein the two tongues mate with the two grooves to couple the first and second panel together.

A method of constructing a building is disclosed comprising constructing a floor system for a building, and then assembling a wall system from a plurality of expanded polystyrene panels, wherein a first panel has a tongue on one of its surfaces and a second panel has a groove on one of its surfaces, wherein the tongue couples with the groove to join the two panels. The wall system is connected to the floor system, followed by assembling a roof system and connecting the roof system to the wall system. A door is attached to the wall system to form a building. The method can include many other steps. In some embodiments windows are added. In some embodiments additional doors are added. In some embodiments the expanded polystyrene panels comprising the wall system are formed by molding. In some embodiments the floor system is comprised of expanded polystyrene panels. In some embodiments the roof system is comprised of expanded polystyrene panels. In some embodiments the expanded polystyrene panels can be coupled together with a latch in the tongue and a latch receiver in the groove.

The foregoing and other features and advantages of the present invention will be apparent from the following more detailed description of the particular embodiments of the invention, as illustrated in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view, perspective view, and side view of a panel 100 which is one embodiment of a component of building system 102 according to the invention.

FIG. 2 is a perspective view of panels 100 and 100a according to the invention.

FIG. 3 is a perspective view of panels 100 and 100a of FIG. 2 connected using tongues 112 and grooves 114.

FIG. 4 is a top view, perspective view, and side view of panel 100 of FIG. 1 with end caps 120 added.

FIGS. 5a and 5b are a top view and side view, respectively, of a panel 100 according to the invention with lock assemblies 129 added

FIG. 5c is a perspective view of lock assembly 129 used in panel 100 according to the invention

FIG. 5d shows end and side views of rotating latch 136 and latch receiver 138 of lock assembly 129.

FIGS. 6a and 6b are additional perspective views of panels 100 and panels 100a according to the invention.

FIGS. 7a and 7b are perspective views of panels 100b and 100c according to the invention.

FIG. 8 is a top view, perspective view, and side view of a panel 100d according to the invention.

FIG. 9a shows components of building system 102 as embodiments of panels 100d connected together with hinge 160.

FIGS. 9b and 9c shows embodiments of panels 100d of building system 102 showing tongues 112, grooves, 114, and rotating latches 136 and latch receivers 138 of lock assembly 129.

FIG. 9d shows an embodiment of panel 100d with inner layer 154.

FIGS. 10a and 10b shows components of building system 102 as embodiments of panels 100e including exterior coating 150

FIG. 11a through FIG. 11e shows components of building system 102 as embodiments of panels 100e connected as a wall-to-roof connection.

FIG. 12a shows components of building system 102 as embodiments of panels 100 connected together to form floor system 141.

FIG. 12b shows components of building system 102 as embodiments of panels 100 connected together to form wall system 142, which is connected to floor system 141.

FIG. 12c shows components of building system 102 as embodiments of panels 100 connected together to form roof system 143, which is connected to wall systems 142.

FIG. 12d shows components of building system 102 as embodiments of panels 100 connected together to form building 140 with window 182 and door 183 attached.

FIG. 13 shows components of building system 102 as embodiments of panels 100e connected as a wall-to-roof connection

FIG. 14 shows components of building system 102 as embodiments of panels 100d and how the various embodiments of panels 100d can be connected in wall-to-floor connections, wall-to-wall connections, wall-to-roof connections, and other embodiments.

FIG. 15 shows a method 200 according to the invention where method 200 is a method of constructing a building.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

As discussed above, embodiments of the present invention relate to building components, and more particularly to panels used to form walls, floors, and roofs of buildings.

Conventional building construction materials and techniques result in a high level of waste and energy-inefficiency. Using wood to build structures reduces natural resources and much of the wood is wasted on-site as wooden pieces are cut to fit. On-site construction techniques require high labor costs and low re-use of building materials after the life of the building. There is a need in the construction industry for building components which use resources more efficiently throughout the entire construction chain, from manufacture of construction material and components, through construction of a building, throughout the useful life of a building, and by efficient recycling and reuse of materials after the building life is ended. There is also a particular need for building components for temporary structures and shelters which are configurable, rapidly deployable, energy-efficient, and re-usable many times. The current invention provides a solution to these problems, disclosing panels used for constructing a building made from energy conserving and recycled base materials. The panels according to the invention are manufactured for modular, scalable, and customizable construction, and the resultant structure composed of these panels forms an energy efficient, user-friendly, long life structure.

FIG. 1 shows an embodiment of the invention as panel 100, a component of building system 102 according to the invention. FIG. 1a shows a top view of panel 100 according to the invention. FIG. 1b shows a perspective view of panel 100, and FIG. 1c shows a side view of panel 100.

FIG. 1 shows an embodiment of panel 100 having back surface 122, front surface 124, and four edge surfaces 125, 126, 127, and 128. Panel 100 has tongue 112 on edge 127 and groove 114 on edge 128. Panel 100 also includes four structural elements 116.

In this embodiment panel 100 is composed of expanded polystyrene (EPS) material. Using expanded polystyrene allows panels to be formed by molding. These panels can be formed in any size and shape to create buildings of any size and shape, including curved and multi-story structures. Using expanded polystyrene results in panels with excellent thermal protection. The panels are lightweight and can be used for walls, floors, or roof systems. The EPS can be recycled after the useful life of the building is over. Panel 100 is made of EPS material in this embodiment so that panel 100 has weight, strength and thermal characteristics suitable for buildings. Indeed, panel 100 has insulative properties, including at least R12 insulation in the panel 100 that is used in the walls of the building and at least R15 insulation in the panel 100 that is used in the floor or roof of the building. In this embodiment panel 100 is formed from EPS but plastic, fiber, foam, or any other suitable material can be used to form panel 100. In some embodiments panel 100 is formed from material other than expanded polystyrene. In some embodiments panel 100 according to the invention can be made from Neopor® material. In some embodiments panel 100 can be made from an anti-ballistic material.

Panel 100 can be made in any dimension suitable for the building it will be forming. In a particular embodiment panel 100 is 5.5 inches thick, 48 inches wide, and 96 inches tall, or long. In other embodiments panel 100 has other dimensions. The thickness of panel 100 is chosen to provide the thermal and mechanical requirements of the building to be formed. In some houses for example, panel 100 will be thick enough to provide high thermal insulation, high mechanical strength and a long lifetime. In other embodiments, such as where panel 100 is used for temporary shelter or temporary buildings, a thinner panel may be desired so that panel 100 is lightweight and can be carried and assembled easily.

Panel 100 in this embodiment is molded from EPS for ease of manufacture, but in other embodiments panel 100 can be extruded or formed into the correct dimensions using other means. In some embodiments of the invention panel 100 has an air cavity within panel 100. This will result in panels 100 that are lightweight.

Panel 100 as shown in FIG. 1 has tongue 112 on edge 127 and groove 114 on edge 128. Tongue 112 of panel 100 is formed such that it will couple with groove 114 of an adjacent panel 100, as shown in FIG. 2 and FIG. 3. Tongue as used in this document is defined as a protuberance from a structure which couples with a corresponding groove in a mating structure to couple the two structures together. And groove is defined as the corresponding mating channel for the tongue. This is the common definition of tongue and groove as used in the building industry. Tongue 112 and groove 114 are shown in this embodiment as rectangular shaped structures, but any shape can be used which will allow the two panels to repeatably, or non-repeatably, couple together. In some embodiments tongue 112 can be circular or oval shaped. In some embodiments tongue 112 can be shaped with ridges or curves. In some embodiments tongue 112 can include multiple protuberances, and groove 114 can have multiple channels. In the embodiment shown in FIG. 1 tongue 112 has a single protuberance and groove 114 has a single channel.

Panel 100 includes structural elements 116 which provide the function of structural studs within the panels. In this embodiment structural element 116 is made of light gage steel to add structural support to panel 100 and to provide a surface on the front and back of panel 100 to attach or mount other structures to. Structural elements 116 take the place of studs as used in a wood frame building structure. Panel 100 has four square tubular structural elements 116 as shown, two along front surface 124 and two along back surface 122. Structural elements 116 can be formed into panel 100 during molding. In this embodiment structural elements 116 are formed of light gage steel, but in general structural elements 116 can be formed of any suitable material such as metal, plastic, wood, or any other material which will provide the function of adding structural integrity and serving as a wall, ceiling, or floor stud for mounting or attaching to. Structural elements can take many different forms, as will be seen in later figures, and be placed in any desired configuration relative to the structure of panel 100. Creating panel 100 from molding allows the shape and placement of elements within panel 100 to be flexible and configurable during manufacture of panels 100.

Panel 100 can have other items molded into the structure of panel 100 as needed. Tubes or channels can be molded into panel 100 to route wires or pipe through. Wire mesh can be embedded into panel 100 to provide electromagnetic interference (EMI) shielding, radio frequency (RF) shielding, and/or infrared (IR) shielding as needed for the building to be assembled using panel 100. Panel 100 can be molded with openings or holes for windows, air vents, pipes, etc to be installed or pass through. Since molds can be made in any shape, size, and outline, the form of panel 100 is not limited by the starting material as it is with wood or brick building materials.

Panel 100 is shown in FIG. 1 as a flat square panel, with tongue 112 on one edge and groove 114 on another edge. Panel 100 according to the invention, however, can be many different shapes according to the intended use in the building. Panel 100 in some embodiments is square, rectangular, triangular or any other shape necessary in building a particular structure. Panel 100 can have tongues 112 on multiple surfaces, including any of the edges or the front surface 124 or back surface 122. Panel 100 can have grooves 114 on multiple surfaces, including any of the edges or the front surface 124 or back surface 122.

Panel 100 does not have to be flat. FIG. 2 and FIG. 3 shows how panel 100 and panel 100a are mated together to form a portion of a building wall with corner 118. Panel 100a has corner 118 which can form a corner in a wall. Corner 188 can also form a corner on a roof, floor, or any other building surface. Panel 100a has structural element 116a molded into the interior of corner 118 and structural element 116 molded into the exterior of corner 118 to add strength and structural integrity to corner 118. Panel 100 a shows a 90-degree corner 118, but in some embodiments corners can be molded into panel 100 which have different angles, typically ranging from 0 to 180 degrees. Whatever angle is needed for the building to be assembled can be molded into panel 100. It should be understood that panel 100 can be constructed in any particular size and shape needed to form any portion of a building as needed.

Tongue 112 of adjacent panels 100 mount into groove 114 of panel 100 as shown in FIG. 2 and FIG. 3. In some embodiments tongue 112 and groove 114 can be formed so that this coupling is a one-time coupling which can not be reversed. In some embodiments tongue 112 and groove 114 are formed so that the coupling is repeatable and reversible. In other embodiments tongue 112 and groove 114 are coupled so that the attachment is not permanent but may be difficult to reverse. The permanency of coupling is determined by the building and its use. For temporary structures which may be assembled and disassembled many times during the life of the panels, couplings for tongue 112 and groove 114 which are reversible may are used. For permanent structures it may be desirable in some embodiments to couple tongue 112 and groove 114 in a permanent fashion. In other embodiments where the building is long-term but changes might be desirable, the coupling can be durable and reversible but not necessarily be quick to reverse.

FIG. 4 shows components of building system 102 according to the invention including panel 100 with end caps 120. FIG. 4a shows a cross-section of two end caps 120. End caps 120 in this embodiment are formed of light gage steel and provide protection to edges 127 and 128 of panel 100. FIG. 4b shows a top edge view of panel 100 with end caps 120 mounted to respective ends 127 and 128. FIG. 4c and FIG. 4d shows a perspective view and side view, respectively, of panel 100 with end caps 120 mounted to edges 127 and 128. Tongue 112 and groove 114 of edges 127 and 128 can be the weakest elements of panel 100 due to the small structural width and the stresses they experience during shipping and assembling. End caps 120 protect tongue 112 and groove 114 from chipping, breaking, bending, mis-shaping, etc. and add structural strength after assembling. End caps 120 can be formed into panel 100 during manufacturing or added to panel 100 after forming panel 100. End caps 120 can be any shape needed to match the contours of panel 100. End caps 120 in this embodiment are made of light gage steel, but end caps 120 can be formed of any material capable of protecting the edges of panel 100. End caps 120 can be made of plastic, metal, or other durable material. The end caps 120 may run the length of the panel 100 along the edges 127 and 128 or, alternatively, the end caps 120 may cover only a portion of the edges 127 and 128. Where the end caps 120 run the entire length of the edges 127 and 128, the end caps 120 can have openings therein to accommodate a latch 136 and latch receiver 138, to be discussed in more detail below.

FIG. 5 shows components of building system 102 according to the invention including panel 100 with lock assemblies 129. In this embodiment lock assembly 129 is an R2-0267-02 lock from Allegis Corporation. In other embodiments different lock assemblies 129 are used. FIG. 5a shows a top view of two panels 100 coupled with lock assemblies 129. FIG. 5b shows a side view of two panels 100 coupled with lock assemblies 129. FIG. 5c shows a perspective view of lock assembly 129, and FIG. 5d shows side cross-sections of lock assembly 129. Lock assembly 129 is used to couple tongue 112 and groove 114. In some embodiments lock assembly 129 can repeatably couple tongue 112 and groove 114. In this embodiment lock assembly 129 includes latch 136, which includes rotating tumbler 131 and latch actuator 135, and latch receiver 138. Panel 100 includes latch hole 132, latch receiver hole 134, and lock access hole 130 (see FIG. 10). Latch 136 is positioned in panel 100 next to groove 114, in latch hole 132. Latch receiver 138 is positioned in panel 100 in latch receiver hole 134, in tongue 112 (see FIG. 10). Latch 136 and latch receiver 138 are positioned in panel 100 so that when tongue 112 and groove 114 are mated for assembly, latch 136 can be accessed through lock access hole 130 to activate latch 136, which will couple latch 136 to latch receiver 138, which couples tongue 112 to groove 114. In this way latch 136 couples to latch receiver 138 of an adjacent panel 100, coupling adjacent panels 100 together. In this way tongue 112 is coupled to groove 114, coupling adjacent panels 100 together. FIG. 5 shows panel 100 comprising six latches 136 and six latch receivers 138, three on each of two sides, but any number of latch 136 and latch receivers 138 can be used along any appropriate edges to couple panels 100 together. FIG. 5 shows latch 136 and latch receiver 138 being used to couple together two panels 100 which are both flat, but latches 136 and latch receivers 138 can be used with any type or shape of panel 100, such as corner panel 100a of FIG. 2 and FIG. 3, or any other type or shape of panel 100.

FIG. 6a and FIG. 6b show additional illustrations of components of building system 102 as panels 100 and 100a according to the invention, including panel 100 and 100a formed of EPS, tongue 112 and groove 114 molded into panel 100 and 100a, and structural elements 116 molded into panel 100 and 100a.

FIG. 7a and FIG. 7b shows additional embodiments of panel 100 according to the invention, including corner panel 100b and flat panel 100c. Panels 100b and 100c can be formed of molded EPS, with tongue 112 and groove 114 on edges 127 and 128. Panels 100b and 100d have structural elements 116 which consist of square tubular structural element 116, corner structural elements 116a, and v-shaped structural elements 116b. Panel 100b and 100c can have a smaller thickness than panels 100 and 100a. It should be understood that panel 100 can be made any suitable thickness according to the strength, weight, and thermal and structural characteristics needed for specific buildings. Panel 100b and 100c can be used when lighter and thinner panels are desired. Any type or placing of structural elements 116 can be used to provide the desired structural or attachment requirements.

FIG. 8 shows additional components of building system 102 according to the invention including panel 100d having two tongues 112 on edge 127 and two grooves 114 on edge 128. Multiple tongues 112 and grooves 114 add strength and durability to the coupling of adjacent panels 100d. FIG. 8a shows a top edge view of panel 100d, FIG. 8b a perspective view of panel 100d, and FIG. 8c a side view of panel 100d. Panel 100d as shown includes lock assembly 129. In some embodiments panel 100d does not include lock assembly 129. FIG. 9a shows multiple panels 100d coupled together using tongues 112, grooves 114, and lock assembly 129. In some embodiments panel 100d can include end caps 120 as shown in FIG. 9a. Panel 100d includes structural elements 116c molded into panel 100d. Structural elements 116c have a different shape than structural elements 116, 116a, and 116b shown earlier. Structural elements 116c have a wing-shape as shown. Panel 100d can in some embodiments include structural elements 116, 116a, or 116b shown in other figures, or different shaped structural elements 116. It should be understood that structural element 116 can take many different shapes and forms as desired.

Panel 100 according to the invention can be formed in any shape and connected in many ways to create a structure. Panels 100 can be used to form walls, floors or roofs of a building, or any other structure. Panel 100 can be formed with a thickness that fits the thermal and mechanical needs of the building to be formed. Panel 100 can be formed with many different numbers and shapes of structural elements 116 embedded therein, to provide the needed attachment, support and strength.

FIG. 9a shows an additional embodiment of components of building system 102 according to the invention, including panels 100d and coupled together with hinge 160. Hinge 160 allows panels 100d to rotate with respect to one another at a corner. Hinge 160 can be used to couple two panels 100 to form a wall-to-wall corner. Hinge 160 can also be used to couple two panels 100 to form a wall-to-floor corner. Hinge 160 can be used to couple two panels 100 together to form a door-to-wall corner. Hinge 160 can be used to couple two panels 100 together to form a wall-to-roof corner. Hinge 160 is only one example of how multiple panels 100 can be coupled together. Multiple panels 100 can be coupled together using tongue 112 and groove 114, or multiple panels can be coupled together using hinge 160. In some embodiments multiple panels can be coupled together using different coupling means. These coupling means can include screws, glue, bolts, nails, staples, locks, hinges, etc.

FIG. 9b and FIG. 9c shows additional embodiments of panels 100d coupled together with tongues 112, grooves 114, and lock assembly 129, which includes latch 136 and latch receiver 138.

Panels 100 according to the invention can be made with one or more inner layers 154, as shown in FIG. 9d. FIG. 9d shows panel 100d with a single inner layer 154. Inner layer 154 can be made of many different materials. In some embodiments inner layer 154 can be air. In some embodiments inner layer 154 can be a Kevlar® material as made by DuPont. In some embodiments inner layer 154 can be plastic, EPS, rubber, or other material. In some embodiments inner layer 154 can be an anti-ballistic material. FIG. 9d shows a single inner layer 154, but some embodiments have multiple inner layers 154.

FIG. 10 shows an embodiment of components of building system 102 as panel 100e, which has exterior coating 150 applied to the outer surface. Exterior coating 150 can be added to protect the outside of panel 100, protecting the surfaces from chipping, wearing, denting, deteriorating, and damage from people, insects, and animals during the lifetime of panel 100. Exterior coating 150 can be or can include a fire resistant coating to improve the fire prevention capabilities of panels 100e. In some embodiments exterior coating 150 can be an anti-ballistic material. Exterior coating can be applied over top of panel 100 and in some embodiments, over at least a portion of the end caps 120, as shown in FIG. 10. Exterior coating 150 can be a hard coating, or it can be a pliable coating. Exterior coating 150 can be applied over panel 100 so that exterior coating 150 on a first panel 100 can come into contact with the exterior coating 150 on a second panel 100 connected to the first panel 100. For example, the exterior coating 150 can be formed on the horizontal panel 100e, shown in FIG. 10a, except over the groove 114. The exterior coating 150 can also be formed on the vertical panel 100e, shown in FIG. 10a, except over the edge surface and tongue. When the tongue 112 of vertical panel 100e is placed within the groove 114 of horizontal panel 100e and the lock assembly 129 is actuated, the exterior coating 150 of the vertical panel 100e can come into contact with the exterior material 150 of the horizontal panel 100e, such that the resulting building is completely covered with exterior coating 150. FIG. 10b shows a close-up cross section showing lock assembly 129 including latch 136, latch hole 132, latch receiver 138, latch receiver hole 134, and lock access hole 130. Once tongue 112 is inserted into groove 114, lock access hole 130 can be used with a locking tool to activate latch 136 and couple it to latch receiver 138, maintaining the coupling of the two panels 100e. The coupling shown in FIG. 10 can be a wall-to-wall coupling, a floor-to-wall coupling, a wall-to-roof coupling, or a coupling between other types of panels 100. FIG. 10 also illustrates how groove 114 does not have to be on an end edge surface of panel 100. In FIG. 10 groove 114 is on surface 122 and tongue 112 is on edge 127. Tongue 112 and groove 114 can be on any surface of panel 100 to create a coupling between any of the surfaces.

FIG. 11 shows additional components of building system 102 according to the invention including panels 100e and illustrating how two panels 100e can be connected to make a wall-to-roof connection, where the roof is slanted. FIG. 11a shows a cross-section of two panels 100e connected via tongue 112, groove 114, and lock assembly 129. The edges of the two panels 100e are angled so that one can be a slanted roof of a building. It should be evident that panels 100 according to the invention can be any shape, size, or angle to form whatever shape and size of building structure is needed. FIG. 11b shows a close up of the corner section with lock assembly 129. FIG. 11c shows a close up of ‘c’ channel 171 used on the interior of panel 100e used as a portion of a roof. ‘C’ channel 171 is adjustable and can add to the structural integrity and strength of the building structure, specifically the structural integrity of the roof and the adjoining walls. ‘C’ channel 171 includes wingnut 172 and slot 173. The length of the ‘c’ channel 171 running along the interior of the roof may be adjusted using the wingnut 172 and slot 173. FIG. 11d shows a close up of support piece 174 which is molded into panel 100e. Support piece 174 has three studs 175 which couple support piece 174 to panel 100e. Support piece 174 is connected by wingnut 172 and slot 173 to ‘c’ channel 171. After coupling wall panel 100e to roof panel 100e, wingnuts 172 can be adjusted and tightened in slots 173 to provide additional attachment and structural integrity between wall panel 100e and roof panel 100e. For example, the pitch of the ‘c’ channel 171 referenced from the support piece 174 can be adjusted using the wingnuts 172 in slots 173.

FIG. 12 illustrates components of building system 102 as used to create building 140. FIG. 12a shows how panels 100 according to the invention are used to create floor system 141. FIG. 12b shows panels 100 according to the invention being used to create wall systems 142 connected to floor system 141. FIG. 12c shows panels 100 according to the invention being used to create roof system 143. FIG. 12d shows building 140 built from panels 100 after door 183 and window 182 have been added.

To create floor system 141 as shown in FIG. 12a, the ground is prepared and leveled if required, and panels 100 laid out to the proper size. Each panel 100 is connected to adjacent panels 100 using tongues 112 and grooves 114 and lock assemblies 129 if used. It should be understood that panels 100 as shown can be any embodiment of panel 100 including panels 100a, 100b, 100c, 100d, or 100e as shown and discussed earlier. Some panels 100 used in floor 141 may be different embodiments. Any combination and number of panels 100 can be used to create floor 141 of the desired shape, thickness, and size.

Wall systems 142 are created by coupling adjacent panels 100 as shown in FIG. 12b. Adjacent panels 100 can be coupled by connecting tongues 112 to grooves 114 and actuating lock assemblies 129 if used. Not all panels in FIG. 12b are labeled panel 100, but it should be understood that each panel can be a panel 100 according to the invention. Each panel can be an embodiment of panel 100 as discussed and shown earlier, such as panel 100a, 100b, 100c, 100d, 100e, or any combination of these panels. Some panels may be different embodiments of panel 100 according to the invention. Wall systems 142 can be assembled and connected while laying on the ground and then raised and connected to floor system 141 and adjacent wall systems 142. Or, wall systems 142 can be assembled in place by starting with a panel 100 used as a corner piece, connecting tongues 112 and groove 114 between panel 100 and floor system 141, and continuing by attaching each successive panel 100 to create wall system 142.

Roof system 143 can be assembled separately from panels 100 and then raised and attached to wall systems 142. Or roof 143 can be assembled in place on wall system 142. Not all panels in FIG. 12c are labeled panel 100, but it should be understood that each panel can be a panel 100 according to the invention. Each panel can be an embodiment of panel 100 as discussed and shown earlier, such as panel 100a, 100b, 100c, 100d, 100e, or any combination of these panels. Each tongue 112 is coupled to appropriate groove 114 and lock systems 129 are activated if used.

Completed building 140 according to the invention as shown in FIG. 12d is an embodiment of a rapidly deployable building 140 after a door 183 and a window 182 have been added. This particular embodiment of building 140 constructed from a plurality of panels 100 can be constructed quickly and efficiently with a minimum of labor costs. Panels 100 are made to the correct size and shape at the factory and received ready to install. Moreover, each of the panels 100 can be identified as a floor panel, a wall panel, a roof panel, a door panel, a window panel, or other applicable panel within the building 140. Also, each of the panels 100 can be labeled within the building system to assist the user in assembling the panels into the building 140. Each panel 100 can have a set position within the building 140, and this position can be marked on the panel 100, for example, in color code or numerical code, to ease assembly. This minimizes material waste at the site and speeds construction. FIG. 12d shows a particular size and shape building 140, but it should be understood that the size and shape of building 140 is configurable. In addition, internal wall systems using panels 100 can be added to divide interior space into any number of rooms and structures. Integrated power systems can be added to provide power to building 140. Panels 100 can be used to construct a building of any footprint that is durable, affordable, and energy efficient. When the useful life of building 140 as shown in FIG. 12d is over, it can be quickly and easily dismantled and the panels 100 used again in another structure. After the useful life of panel 100 is over it can be recycled. Ease of re-use and recycling is designed into panels 100 by virtue of their modular design, long life material, and integral coupling structure.

Panels 100 can be used to construct structures used as homes and residences, commercial buildings, offices, storage facilities, etc. The structures constructed from panels 100 can be temporary or long-term structures. The examples provided here of components of building system 102 and structures formed from building system 102 and panels 100 are not exhaustive of the possibilities. Many other embodiments are possible. For instance, walls or other building structures can be formed of multiple layers of panels 100. This will add to the structural integrity and thermal characteristics of the structure being created. In some embodiments layers of panels 100 can be coupled together with an air gap in between. In some embodiments this air gap can be further filled with material such as foam or additional EPS.

FIG. 13 shows additional embodiments of components of building system 102 including using panel end cap mounting assembly 165 to provide the capability to mount additional structures to a building constructed from panels 100. FIG. 13 shows a cross-section of two panels 100e connected in a wall-to-roof configuration using lock assembly 129 and tongue 112 and groove 114. In addition to having end caps 120 over panel edges, panel end cap mounting assembly 165 is inserted between the coupled edges of the two panels 100e. Panel end cap mounting assembly 165 can be used to mount many different structures to panels 100e. In this embodiments panel end cap mounting assembly 165 provides a mount for truss 166 internal to the structure, and for roof structure 164 mounted outside the structure. Roof structure 164 is mounted to panel end cap mounting assembly 165 using roof structure mounting arm 163. Roof structure 164 can be many different items, including but not limited to antennae, solar panels, shade structures, water collectors, etc. It should be understood that panels 100 can be configured to include different forms of mounting structures to connect and mount items needed for the operation, safety, and comfort of the building constructed from panels 100.

FIG. 14 shows multiple embodiments of panels 100d and accessories, including end caps 120 and lock assembly 129. Various embodiments of panel 100d are shown which illustrate how coupling between multiple panels 100d are made for wall-to-wall connections, wall-to-floor connections, wall-to-roof connections, and others.

FIG. 15 illustrates a method 200 of constructing a building according to the invention, comprising steps 201 assembling a floor system, and step 202 assembling a wall system from a plurality of expanded polystyrene panels, wherein a first panel has a tongue on a first surface, and a second panel has a groove on a second surface, wherein the tongue and the groove couple the first panel to the second panel. Method 200 also includes step 203 connecting the wall system to the floor system, step 204 assembling a roof system, step 205 connecting the roof system to the wall system, and step 206 attaching a door to the wall system to form a building. Method 200 according to the invention can include many other steps. Step 201 can include using any embodiment of panels 100 as components of the floor system, including panels 100a, 100b, 100c, 100d, 100e, or a different embodiment of panel 100 according to the invention. Step 201 can in some embodiments include connecting multiple panels 100 using tongue 112 and groove 114 or lock assembly 129. Step 201 can include using multiple embodiments of panel 100 to assemble a floor system.

Step 202 can include using any embodiment of panels 100 to assemble a wall system, including panels 100a, 100b, 100c, 100d, 100e, or a different embodiment of panel 100 according to the invention. Step 202 can in some embodiments include connecting multiple panels 100 using lock assembly 129. Step 202 can include using multiple embodiments of panel 100 as components of the wall system. Step 202 can include using panels 100 according to the invention that have an opening for windows, pipes, electronics or other items which must pass through the wall system or reside within the wall system.

Step 203 can include connecting the wall system to the floor system using tongue 112 and groove 114. Step 203 can in some embodiments include connecting the wall system to the floor system using lock assembly 129. In some embodiments other means for connecting the wall system to the floor system are used.

Step 204 can include assembling a roof system using panels 100 according to the invention. Step 204 can include using any embodiment of panels 100 to assemble roof system, including panels 100a, 100b, 100c, 100d, 100e, or a different embodiment of panel 100 according to the invention. Step 204 can in some embodiments include connecting multiple panels 100 using tongue 112 and groove 114. Step 204 can in some embodiments include connecting multiple panels 100 using lock assembly 129. Step 204 can include using multiple embodiments of panel 100 to assemble a roof system. Step 204 can include assembling the roof system separately from the wall system and then raising the roof system over the wall system and connecting them together as in step 205. In other embodiments step 205 connecting the roof system to the wall system can be accomplished as the roof system is being assembled in step 204. In this embodiment the roof system is assembled in place on top of the wall system.

Step 205 can include connecting the roof system to the wall system using tongue 112 and groove 114. Step 205 can including connecting the roof system to the wall system using lock assembly 129. In some embodiments other coupling means are used to connect the roof system to the wall system according to the invention.

Method 200 according to the invention can include many other steps. Method 200 can include the steps of adding windows to the building. Method 200 can include the steps of adding walls to the interior of the building using embodiments of panels 100. Method 200 can include adding an integrated power system to the building. Method 200 can include adding a plumbing system to the building. Method 200 can include adding an air handling system to the building.

The embodiments and examples set forth herein were presented in order to best explain the present invention and its practical application and to thereby enable those of ordinary skill in the art to make and use the invention. However, those of ordinary skill in the art will recognize that the foregoing description and examples have been presented for the purposes of illustration and example only. The description as set forth is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the teachings above without departing from the spirit and scope of the forthcoming claims.

Claims

1. A building system comprising:

a first panel having a front surface, a back surface, and an edge surface;

a tongue on one of the surfaces;

a second panel having a front surface, a back surface, and an edge surface;

a groove in the second panel for receiving the tongue of the first panel; and

a locking mechanism that couples the tongue to the groove, wherein the first and second panel are used to form a portion of a building.

2. The building system of claim 1, wherein the tongue of the first panel runs the length of the surface and the length of the groove of the second panel corresponds to the length of the tongue.

3. The building system of claim 1, wherein the first and second panel are formed of expanded polystyrene.

4. The building system of claim 1, wherein the first and second panel are molded or extruded.

5. The building system of claim 1, wherein at least one of the first and second panels includes a structural element integral with the panel, the structural element running substantially parallel with the edge surface.

6. The building system of claim 5, wherein the structural element is made of light-gauge steel.

7. The building system of claim 1, wherein at least one of the first and second panels includes a plurality of structural elements set at predetermined intervals in the panel, the plurality of structural elements running substantially parallel to the edge surface.

8. The building system of claim 1, wherein an end cap encases the edge surface.

9. The building system of claim 8, wherein the end cap is formed of light-gauge steel.

10. The building system of claim 1, wherein the front surface and the back surface of at least one of the first and second panels define a cavity therebetween.

11. The building system of claim 1, wherein a material is molded within the panel between the front surface and the back surface.

12. The building system of claim 1, wherein the first panel has two tongues on one of its surfaces and the second panel has two grooves on one of its surfaces.

13. The building system of claim 12, wherein the two tongues are parallel with one another and run the length of the surface, and the length of the grooves corresponds to the length of the tongues, the grooves being structured to receive the tongues upon the condition that the first panel is coupled to the second panel.

14. The building system of claim 1, one of the surfaces is molded to appear like one of bricks, siding, wood, and stucco.

15. The building system of claim 1, wherein the panel defines an opening in the front and back surfaces.

16. The building system of claim 1, the locking mechanism further comprising:

a latch integral to the tongue; and

a latch receiver integral to the groove,

wherein the latch and the latch receiver are configured to repeatedly and releasably couple the tongue to the groove.

17. The building system of claim 1, further comprising:

an exterior coating covering each of the panels,

wherein under the condition that the panels are coupled together to form a building, the exterior coating of the respective panels contacts one another to substantially cover the complete exterior surface of the building.

18. A building system, comprising:

a plurality of panels configured to be assembled together to construct a building;

each of the plurality of panels having a front surface, a back surface, and two sets of opposing edge surfaces;

each of the plurality of panels having a tongue on one of the surfaces and a groove on another of the surfaces;

each of the plurality of panels having identifying features to identify the panel as at least a floor panel, a wall panel, or a roof panel,

wherein the identified panels are labeled within the system to assist the user in releasably coupling the appropriate panels to one another to form the building.

19. The building system of claim 18, wherein each of the plurality of panels includes a plurality of structural elements integral to the panel and set at predetermined intervals in the panel, the plurality of structural elements running substantially parallel to one of the edge surfaces.

20. The building system of claim 18, wherein each of the plurality of panels is formed of expanded polystyrene and each of the plurality of structural elements is formed of light-gauge steel.