CONSTRUCTION SYSTEM USING INTERLOCKING PANELS
A system for constructing a structure, such as a wall, by assembling a plurality of interlocking panels together, is provided. Each of the panels includes a core made of an insulating material, preferably, an expanded polystyrene (EPS). Importantly, the panels include stiffeners (studs) on the outer surfaces; each spaced, preferably, about 24 inches on center (OC), to form a rigid exoskeleton. Unlike in conventional wood framing, the studs do not extend from the exterior surface to the interior surface. Instead, the studs are each structured as C-shaped supports wherein each stud is inserted into a grove pair cut into the core. Accordingly, conduction across the studs from the exterior to the interior, and vice versa, does not occur because the studs do not extend through the panels.
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The present application is a continuation of, and claims priority to and the benefit of, U.S. Ser. No. 12/715,288 entitled “CONSTRUCTION SYSTEM USING INTERLOCKING PANELS” filed on Mar. 1, 2010. The '288 application is related to and claims priority from prior provisional application U.S. Ser. No. 61/157,021 filed by Jeffrey A. Black on Mar. 3, 2009. Both of which are incorporated herein by reference for any purpose.
FIELD OF INVENTIONThe present invention relates to prefabricated building components, and, more particularly, to a construction system using interlocking panels, the panels including a polymeric insulated core and a steel exoskeleton.
BACKGROUND OF THE INVENTIONRecent changes in the construction industry have led to an increased use by builders of prefabricated building components. Despite its many benefits, however, builders have not fully embraced prefabricated building components using alternatives to wood. For example, there has been reluctance to use components made from steel, rather than wood, in the mistaken belief that steel is more costly. However, several studies have actually shown that building a structure using steel costs about the same as using conventional wood framing. Furthermore, another reason that builders have been reluctant to use prefabricated alternatives to wood has been the lack of certification by recognized groups such as the International Code Council (ICC).
SUMMARY OF THE INVENTIONA system for constructing a structure, such as a wall, by assembling a plurality of interlocking panels together, is provided. Each of the panels includes a core made of an insulating material, preferably, expanded polystyrene (EPS). Importantly, the panels include stiffeners (studs) on the outer surfaces; each spaced, preferably to national and international code requirements at 24-inches on center (24″ OC), to form a rigid exoskeleton. Preferably, the studs are made of galvanized steel. Unlike in conventional wood framing, the studs do not extend from the exterior surface to the interior surface. Instead, the studs are each structured as C-shaped supports wherein each stud is inserted into a grove pair cut into the core. Accordingly, conduction across the studs from the exterior to the interior, and vice versa, does not occur because the studs do not extend through the panels.
Preferably, each of the panels has a top track and a bottom track, these tracks made from steel. Preferably, the bottom panels are attachable to a floor, such as a concrete floor, using suitable fasteners. Preferably, the top tracks are attachable to a ceiling using suitable fasteners. Preferably, the panels can be joined together by fitting complementary L-shaped edges together. However, any suitable mating or attachment method can be used to join adjacent panels. Accordingly, workers can build a wall, for example by connecting a series of panels together, and fastening the bottom and top tracks. Panels can be assembled to form a comer by trimming a portion of a first track to allow a second track to overlap. Preferably, the comer portion is secured to the floor with an additional fastener for extra strength. Preferably, the panels are marked with indicia to assist in assembly of the wall structure and/or identify the maker and/or seller of the wall system.
A notable feature of the present invention is that each of the panels can have pre-molded (or cut) channels useable to receive utility runs, such as, for example, wires, cables, and plumbing. In one embodiment, each panel has a vertical channel and two horizontal channels along the entire width of the panel. Preferably, the horizontal channels have a depth greater than the depth of the groove pairs holding the studs, so as to prevent the studs from impeding utility runs through the horizontal channels.
Another notable feature of the present invention is that for added structural support, a splice plate can be used to connect one top track to an adjacent top track. The splice plate can be made of any suitably strong and stiff material and secured to the top tracks by known methods, such as, for example, using adhesive bonding or fasteners. The dimensions of the splice plate depend on the dimensions of the top track.
Another notable feature of the present invention is that the studs preferably include inwardly extending tabs to assist in securing the studs to the panel.
Another notable feature of the present invention is that the components used to create each of the panels are made in accordance with ICC and ICBO code requirements.
Additional components of the present invention include jam sections that can be inserted between the panels to create window openings or entrance ways such as doorways, and trim tracks that can be used to trim window areas.
These and other aspects, features, and advantages of the present invention will become apparent from the following detailed description of preferred embodiments, which is to be read in connection with the accompanying drawings.
As shown in
In an embodiment of the present invention, groove pairs are positioned on the panel 1 so that the studs 2 are spaced about 24 inches apart from each other. In prior art wall construction, insulating material is placed between studs which extend the depth of the wall. This permits conduction from one side (interior or exterior) to the opposite side (interior or exterior) of the wall. In contrast, wall structures created with the wall system of the present invention do not allow conduction of heat (and transmission of sound, vibration, etc.) through the studs since the studs do not extend from one side to the opposite side. In other words, having the studs 2 on both sides 12, 13, without contacting each other, prevents conduction from the one side 12 to the other side 13 through the studs 2. Panel 1 does not have any conductive components passing through the core A from one side 12 to the other side 13 which results in superior insulative properties.
One of the front rear sides 12, 13, depending on which will face the interior of the structure to be constructed, can have one or more horizontal channels 20, 22 and/or vertical channels 24 to receive utility runs, such as, for example, electric and plumbing. In one embodiment, shown in
Preferably, each panel 1 includes a left side 30 and a right side 32 having complementary mating members 34, 36 such that adjacent panels 1 can interlock or mate to form a continuous wall surface.
Referring to
To create a wall structure, one or more bottom tracks 3 can be secured to a floor, the number of bottom tracks 3 depending on the length to be spanned by the wall structure. After studs 2 have been inserted in the groove pairs of the core A, a panel 1 can be mounted in the bottom track 3, and fastened thereto using adhesives or fasteners. Bottom and top tracks 3, 4 can receive one or more panels 1 depending on the respective size of the panels 1 and tracks 3, 4. In the embodiment shown in
The top track 4 can be secured to the panels 1 in a similar fashion, such as by screwing the leg members 5, 6 of the top track 4 to each stud 2 on each of the front and back sides 12, 13, with sheet metal screws, for example. Referring to
As shown in
Referring to
The wall system once assembled can be finished on the internal and external surfaces with suitable covering materials along with paint or using other finishing methods. In one embodiment, the inside surface of the wall system can be finished with dry wall attached thereto with any suitable means. Such means can include fasteners such as bolts or screws and/or adhesives. The outer surface likewise can be finished with dry wall, concrete sheets, stucco or other covering material, for example.
Multiple wall systems can be combined to form structures such as a habitable building capable of bearing significant loads and be structurally sound for its intended purpose.
While this invention has been described in conjunction with the various exemplary embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention.
Claims
1. A panel, comprising:
- a polymeric insulated core comprising a first groove and a second groove cut out of the core configured to receive a first stud; and
- the polymeric insulated core further comprising a third groove and a fourth groove cut out of the core configured to receive a second stud, wherein the first stud and the second stud are attached to opposing outer surfaces of the core such that the first stud is not in contact with the second stud, wherein the first stud and the second stud are C-shaped with a first inwardly extending tab and a second inwardly extending tab configured to be friction fit in the first groove and the second groove respectively.
2. The panel of claim 1, wherein the polymeric insulated core is expanded polystyrene (EPS).
3. The panel of claim 1, wherein at least one of the first stud and the second stud is made from galvanized steel.
4. The panel of claim 1, wherein the polymeric insulated core is flame retardant.
5. The panel of claim 1, wherein each of the panels includes at least one channel useable to receive utility runs.
6. The panel of claim 5, wherein the channel depth in the core is greater than depth of the first groove.
7. The panel of claim 1, wherein the panel further comprises a vertical channel and a first horizontal channel and a second horizontal channel, wherein each channel is configured to span the respective length or width of the panel.
8. The panel of claim 1, wherein the panel is configured to be coupled to a second panel.
9. The panel of claim 1, wherein polymeric insulated core material is removed from between the first groove and a second groove to receive the first stud flush mounted with the face of the panel.
10. The panel of claim 1, wherein the panel is constructed from parts in accordance with ICC code requirements.
11. The panel of claim 1, wherein the interior of the C shaped first stud defines a channel, and wherein a portion of core material between the first groove and the second groove substantially fills the channel upon the insertion of the C shaped first stud in the first groove and the second groove.
12. The panel of claim 1, wherein the panel is attachable to a bottom track, the bottom track attachable to a floor.
13. The panel of claim 1, wherein the panel is attachable to a top track, the top track attachable to a structure above the top track.
14. The panel of claim 1, wherein the panel comprises L-shaped edges.
15. The panel of claim 1, wherein the tabs are configured to at least one of crush and catch the polymeric insulated core upon insertion of the C shaped first stud to the polymeric insulated core.
16. The panel of claim 1, wherein the panel is configured to be coupled to a jamb section.
17. The panel of claim 1, wherein the polymeric insulated core further comprises carbon fiber.
18. A method for constructing a structure, comprising:
- assembling a plurality of panels together, each of the panels including a polymeric insulated core comprising a first groove and a second groove cut out of the core configured to receive a first stud; and
- each of the panels comprising a third groove and a fourth groove cut out of the core configured to receive a second stud, wherein the first stud and the second stud are attached to opposing outer surfaces of the core such that the first stud is not in contact with the second stud, wherein the first stud and the second stud are C-shaped with a first inwardly extending tab and a second inwardly extending tab configured to be friction fit in the first groove and the second groove respectively.
19. The method of claim 18, wherein each panel further comprises a vertical channel and a first horizontal channel and a second horizontal channel, wherein each channel is configured to span the respective length or width of the panel, wherein the channel depth in the polymeric insulated core of the first horizontal channel and the second horizontal channel are greater than depth of the first groove as measured from the face of the panel.
20. A method for constructing a structure, comprising:
- assembling a plurality of panels together, each of the panels including a polymeric insulated core comprising a first groove and a second groove cut out of the core configured to receive a first stud; and
- each of the panels comprising a third groove and a fourth groove cut out of the core configured to receive a second stud, wherein the first stud and the second stud are attached to opposing outer surfaces of the core such that the first stud is not in contact with the second stud, wherein the first stud and the second stud are C-shaped with a first inwardly extending tab and a second inwardly extending tab configured to be friction fit in the first groove and the second groove respectively, wherein the polymeric insulated core between the first groove and the second groove is configured to receive the flush mounted first stud by polymeric insulated core material being removed between the first groove and the second groove.
Type: Application
Filed: Mar 13, 2012
Publication Date: Oct 4, 2012
Applicant: IFRAME BUILDING SOLUTIONS, LLC (Scottsdale, AZ)
Inventor: Jeffrey Black (Scottsdale, AZ)
Application Number: 13/418,849
International Classification: E04B 1/62 (20060101); E04B 2/00 (20060101); E04C 2/52 (20060101); E04C 2/22 (20060101); E04B 2/46 (20060101); E04C 2/20 (20060101);