Building Panel Assembly

Abstract

A building panel assembly is provided. The building panel assembly comprises a plurality of pyramidal elements with each pyramidal element having an apex with a plurality of pyramidal feces extending to a base, each face separated from each adjacent face by a face edge, and the base having base edges. A plurality of inverse pyramidal elements are provided with each inverse pyramidal element having inverse pyramidal faces and mateable with the pyramidal elements. A flattened edge is formed along the face edges between each of the pyramidal faces creating a continuous adhesive flow channel and an adhesive substance positionable within the continuous adhesive flow channel. Upon mating, the pyramidal elements with the inverse pyramidal elements, the adhesive travels through the continuous adhesive flow channel and upon hardening the adhesive substance creates a space truss structure thereby strengthening the building panel assembly.

Description

The present application claims benefit of priority of pending provisional patent application Ser. No. 61/583,579, filed on Jan. 5, 2012, entitled “Reinforced Structural Insulated Panel”, and pending provisional patent application Ser. No. 61/533,139, filed on Sep. 9, 2011, entitled “Structural Insulated Panel”.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to a building panel assembly and, more particularly, the invention relates to a building panel assembly forming structural insulated panel created from uniformly sized and shaped pyramidal elements having adhesive flow channels forming a space truss structure.

2. Description of the Prior Art

Structural insulated panels (SIPs) are revolutionizing the structures of buildings. The earliest concept of structural sandwich-panel technology was developed in the 1930s at the Forest Products Laboratory (FPL) in Madison, Wis. FPL engineers proposed that plywood and hardboard sheathing could take a portion of the structural load in wall applications. Their prototype was used to construct test homes that continued to be monitored over thirty years, then disassembled and reexamined. During this time, FPL engineers continued to experiment with new designs and materials.

Famed architect Frank Lloyd Wright used SIPs In his affordable Usonian houses built throughout the 1930s and 1940s. Wright attempted to incorporate beauty and simplicity into relatively low-cost homes. Some of the walls in these houses consisted of three layers of plywood and two layers of tar paper but lacked insulation.

SIPs advanced in technology when one of Wright's students, Alden B. Dow, brother of the founder of Dow Chemical Company, created the first foam core SIP in 1952. Dow, concerned about energy efficiency, was dismayed by the lack of insulation in the Usonian homes. He experimented with the engineering of structural panels with insulation and is now generally credited with producing the first structural insulated panels. His SIP houses were built in Michigan using panels composed of 1⅝ inch Styrofoam cores and 3/16 inch plywood facings for the load-bearing walls and installed over roof framing on 42 inch centers.

By 1959, the Koppers Company converted an auto production plant in Detroit into a SIP production facility and in the 1960s began the first manufacturing effort of structural insulated panels, resulting in the production of SIPs as we know them today.

Today, SIPs offer a high tech solution for residential and low rise nonresidential buildings. Advances in computer aided design and manufacturing allow SIPs to be produced with amazing accuracy to deliver flat, straight, and true walls. SIPs are now made with a variety of structural skin materials, including oriented strand board (OSB), treated plywood, fiber-cement board, and metal. SIPs are available in thickness from 4-inch and 6-inch walls, and thicker roof panels up to 14-inches, depending on climate conditions. The design capabilities, exceptional strength and energy saving insulation make SIPs a twenty-first century building material for high performance buildings.

SUMMARY

The present invention is a building panel assembly. The building panel assembly comprises a plurality of pyramidal elements with each pyramidal element having an apex with a plurality of pyramidal faces extending to a base, each face separated from each adjacent face by a face edge, and the base having base edges. A plurality of inverse pyramidal elements are provided with each inverse pyramidal element having inverse pyramidal faces and mateable with the pyramidal elements. A flattened edge is formed along the face edges between each of the pyramidal faces creating a continuous adhesive flow channel and an adhesive substance positionable within the continuous adhesive flow channel. Upon mating the pyramidal elements with the inverse pyramidal elements, the adhesive travels through the continuous adhesive flow channel and upon hardening the adhesive substance creates a space truss structure thereby strengthening the building panel assembly.

In addition, the present invention includes a building panel assembly having a plurality of pyramidal elements with each pyramidal element having an apex with a plurality of pyramidal faces extending to a base, each face separated from each adjacent face by a face edge, and the base having base edges. A plurality of inverse pyramidal elements is provided with each inverse pyramidal element having inverse pyramidal faces and the pyramidal elements mateable with the inverse pyramidal elements. A flattened edge is formed along the face edges between each of the pyramidal faces creating a continuous adhesive flow channel. Horizontal adhesive flow channels are formed along the pyramidal faces with each of the horizontal adhesive flow channels fluidly connected to the continuous adhesive flow channel. Angled adhesive flow channels are formed along the pyramidal faces with each of the angled adhesive flow channels fluidly connected to the continuous adhesive flow channel and the horizontal adhesive flow channels. An adhesive substance is positionable within the flow channels wherein upon hardening, the adhesive substance creates a space truss structure thereby strengthening the building panel assembly.

The present invention further includes a method for constructing a building panel assembly. The method comprises providing a plurality of pyramidal elements with each pyramidal element having an apex with a plurality of pyramidal faces extending to a base, each face separated from each adjacent face by a face edge, and the base having base edges, providing a plurality of inverse pyramidal elements with each inverse pyramidal element having inverse pyramidal faces, inserting the pyramidal elements into the inverse pyramidal elements, flattening the face edges between each of the pyramidal faces creating a continuous adhesive flow channel, forming horizontal adhesive flow channels along the pyramidal faces, fluidly connecting each of the horizontal adhesive flow channels to the continuous adhesive flow channel, forming angled adhesive flow channels along the pyramidal faces, fluidly connecting each of the angled adhesive flow channels to the continuous adhesive flow channel and the horizontal adhesive flow channels, positioning an adhesive substance within the flow channels, and creating a space truss structure with the hardened adhesive substance.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view illustrating a single unit module of a building panel assembly, constructed in accordance with the present invention, having a right cuboid element and with a pyramidal element extending therefrom receivable within an inverse pyramidal element with adhesive flow channels formed in corner edges of the right cuboid and the edges of the pyramidal element;

FIG. 2 is an exploded perspective view illustrating the building panel assembly, constructed in accordance with the present invention, composed of a plurality of single unit modules;

FIG. 3 is a top view illustrating the adhesive flow channels of the building panel assembly of FIG. 2, constructed in accordance with the present invention, with the adhesive flow channels creating a space truss structure;

FIG. 4 is an elevational side view illustrating the adhesive flow channels of the building panel assembly of FIG. 2, constructed in accordance with the present invention, with the adhesive flow channels creating a space truss structure;

FIG. 5 is a perspective view illustrating the adhesive flow channels of the building panel assembly of FIG. 2, constructed in accordance with the present invention, with the adhesive flow channels creating a space truss structure;

FIG. 6A is a perspective view illustrating another embodiment of the building panel assembly, constructed in accordance with the present invention;

FIG. 6B is an elevational side view illustrating the building panel assembly of FIG. 6A, constructed in accordance with the present invention;

FIG. 7 is an exploded perspective view illustrating another embodiment of the building panel assembly, constructed in accordance with the present invention;

FIG. 8 is a perspective view illustrating the building panel assembly of FIG. 7, constructed in accordance with the present invention;

FIG. 9 is an exploded perspective view illustrating still another embodiment of the building panel assembly, constructed in accordance with the present invention;

FIG. 10 is a semi-exploded perspective view illustrating the building panel assembly of FIG. 9, constructed in accordance with the present invention;

FIG. 11 is perspective schematic view illustrating the building panel assembly of FIG. 9, constructed in accordance with the present invention;

FIG. 12 is a perspective view illustrating yet another embodiment of the building panel assembly, constructed in accordance with the present invention;

FIG. 13 is a schematic perspective view of the building panel assembly of FIG. 12, constructed in accordance with the present invention, with the adhesive flow channels represented;

FIG. 14 is a schematic top view of the building panel assembly of FIG. 12, constructed in accordance with the present invention, with the adhesive flow channels represented;

FIG. 15 is a schematic side view of the building panel assembly of FIG. 12, constructed in accordance with the present invention, with the adhesive flow channels represented; and

FIG. 16 is a schematic end view of the building panel assembly of FIG. 12, constructed in accordance with the present invention, with the adhesive flow channels represented.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As illustrated in FIG. 1-14, the present invention is a building panel assembly, indicated generally at 10, forming a structural insulated panel created from uniformly sized and shaped pyramidal elements having a continuous adhesive flow channel 22 thereby forming a space truss structure. By definition, a space frame truss is a structurally sound, three-dimensional framework of members pinned at their ends. The building panel assembly 10 provides an independent adhesive flow channel 22 creating internal reinforcement of the entire structural insulated panel.

The building panel assembly 10 of the present invention includes a first rigid diaphragm panel 12 having a first side surface and a second side surface and a second rigid diaphragm panel 14 having a first side surface and a second side surface. A right cuboid element 16 is mounted to the first side surface of the first rigid diaphragm panel 12 with each right cuboid 16 element having a pyramidal element 18 extending therefrom. An inverse pyramidal element 20 is mounted to the first side surface of the second rigid diaphragm 14. Preferably, the right cuboid element 16 and the inverse pyramidal element 20 are mounted to the first rigid diaphragm panel 12 and the second rigid diaphragm panel 14 by an adhesive material or the like.

It should be noted that while the building panel assembly 10 has been described as having a right cuboid element 16 mounted directly to the first side surface of the first rigid diaphragm panel 12, it is within the scope of the present invention to completely remove the right cuboid element 16 from the construction of the building panel assembly 10. In this instance, the base of the pyramidal element 18 will be mounted directly to the first rigid diaphragm panel 12 or to another pyramidal element, as described in further detail below.

Preferably, the building panel assembly 10 of the present invention has a plurality of uniformly sized and shaped pyramidal elements 18 and a plurality of uniformly sized and shaped inverse pyramidal elements 20. The pyramidal elements 18 and the inverse pyramidal elements 20 are preferably both constructed of an insulating material with the pyramidal elements 18 mateable with the inverse pyramidal elements 20 to form the structural insulated panel of the building panel assembly 10 with the first rigid diaphragm panel 12 and the second rigid diaphragm panel 14 sandwiching the mated pyramidal elements 18 and the inverse pyramidal elements 20. The mating of the pyramidal elements 18 and the inverse pyramidal elements 20 inhibits lateral movement of the pyramidal element 18 relative to the inverse pyramidal element 20.

In a preferred embodiment, the right cuboid element 16 of the building panel assembly 10 of the present invention has twelve edges. Each pyramidal element 18 has an apex with four side edges extending to a square base with a first horizontal edge between the right cuboid element 16 and the pyramidal element 18 and four vertical base edges extending from the first horizontal edge to a second horizontal edge at the base of the right cuboid element 16. In an embodiment of the present invention, all of the edges of the pyramidal elements 18 are removed. In another embodiment of the present invention, the first horizontal edge and/or the second horizontal edge are removed. In still another embodiment of the present invention, in addition to the removal of the edges of the pyramidal elements 18, all of the vertical edges of the right cuboid element 16 are also removed. The removed edges create a continuous adhesive flow channel when the pyramidal elements 18 and the inverse pyramidal elements 20 are mated together. Additional angled, horizontal and/or vertical adhesive flow channels 22 can be formed in the pyramidal elements for additional structural enhancements of the structural insulated panel.

The building panel assembly 10 of the present invention further includes an adhesive applied to the pyramidal elements 18 and the inverse pyramidal elements 20. The adhesive collects in and flows through the adhesive flow channels 22 created by the removed edges. Basically, upon hardening of the adhesive substance, the adhesive flow channels 22 create internal reinforcement of the structural insulated panel by effectively forming the struts of a space truss structure within the building panel assembly 10. With the struts of the space truss structure in place, the structural insulated panel of the building panel assembly 10 has greater strength with lower cost than conventional structural insulated panels

Further embodiments of the building panel assembly 10 of the present invention can be formed using the principals of pyramidal elements 18 and inverse pyramidal elements 20, as described above. For instance, as best illustrated in FIGS. 7 and 8, an additional pyramidal element 18 is added in addition to additional side elements 24 to finish the edges of the building panel assembly 10. The side elements 24 have pyramidal elements 18 with adhesive flow channels 22 allowing the adhesive to further construct and strengthen the space truss structure. As best illustrated in FIGS. 9-11, the building panel assembly 10 includes an additional pyramidal element mounted in an opposite fashion to the other pyramidal elements 18 with additional inverse pyramidal elements 20. As with the teachings above, the edges of the pyramidal elements 18 are removed creating the adhesive flow channels 22. As best illustrated in FIGS. 12-16, similar to FIGS. 7 and 8, the building panel assembly 10 has side elements. The adhesive flow channels 22 creating the space truss structure are visible when the other elements are removed.

The foregoing exemplary descriptions and the illustrative preferred embodiments of the present invention have been explained in the drawings and described in detail, with varying modifications and alternative embodiments being taught. While the invention has been so shown, described and illustrated, it should be understood by those skilled in the art that equivalent changes in form and detail may be made therein without departing from the true spirit and scope of the invention, and that the scope of the present invention is to be limited only to the claims except as precluded by the prior art. Moreover, the invention as disclosed herein may be suitably practiced in the absence of the specific elements which are disclosed herein.

Claims

1. A building panel assembly comprising;

a plurality of pyramidal elements, each pyramidal element having an apex with a plurality of pyramidal faces extending to a base, each face separated from each adjacent face by a face edge, the base having base edges;

a plurality of inverse pyramidal elements, each inverse pyramidal element having inverse pyramidal faces, the pyramidal elements mateable with the inverse pyramidal elements:

a flattened edge formed along the face edges between each of the pyramidal faces creating a continuous adhesive flow channel; and

an adhesive substance positionable within the continuous adhesive flow channel;

wherein upon mating the pyramidal elements with the inverse pyramidal elements with the pyramidal faces contacting the inverse pyramidal faces, the adhesive travels through the continuous adhesive flow channel; and

wherein upon hardening, the adhesive substance creates a space truss structure thereby strengthening the building panel assembly.

2. The building panel assembly of claim 1 and further comprising:

a first rigid diaphragm panel having a first side surface and a second side surface, the base of the pyramidal elements mounted to the first side surface of the first rigid diaphragm panel; and

a second rigid diaphragm panel having a first side surface and a second side surface, the inverse pyramidal elements mounted to the second side surface of the second right diaphragm panel.

3. The building panel assembly of claim 1 and further comprising:

a cuboid secured to the base of each first pyramidal element, each cuboid having flattened edges;

wherein the flattened edges of the cuboid create an additional adhesive flow channel; and

wherein the additional adhesive flow channel is fluidly connected and continuous with the continuous adhesive flow channel thereby creating additional struts for the space truss structure.

4. The building panel assembly of claim 3 wherein each pyramidal element has an apex with four first pyramidal faces extending to a square base with four base edges and each cuboid is a right cuboid.

5. The building panel assembly of claim 3 and further comprising:

a first rigid diaphragm panel having a first side surface and a second side surface, the first right cuboid element mounted to the first side surface of the first rigid diaphragm panel.

6. The building panel assembly of claim 1 and further comprising:

horizontal adhesive flow channels formed along the pyramidal faces, each of the horizontal adhesive flow channels fluidly connected to the continuous adhesive flow channel.

7. The building panel assembly of claim 1 and further comprising;

angled adhesive flow channels formed along the pyramidal faces, each of the angled adhesive flow channels fluidly connected to the continuous adhesive flow channel.

8. The building panel assembly of claim 1 and further comprising:

vertical adhesive flow channels formed along the pyramidal faces, each of the vertical adhesive flow channels fluidly connected to the continuous adhesive flow channel.

9. The building panel assembly of claim 1 and further comprising:

a plurality of side elements, each of the side elements having side element adhesive flow channels in fluid communication with the continuous adhesive flow channel.

10. The building panel assembly of claim 1 and further comprising:

a plurality of additional pyramidal elements, the additional pyramidal elements being identical to the pyramidal elements;

a plurality of additional inverse pyramidal elements, the additional inverse pyramidal elements being identical to the inverse pyramidal elements, the pyramidal elements mateable with the inverse pyramidal elements; and

additional adhesive flow channel created by flattening edges of the additional pyramidal elements;

wherein the base of the pyramidal elements is secured to the base of the additional pyramidal elements and the additional adhesive flow channel is fluidly connected to the continuous adhesive flow channel.

11. A building panel assembly comprising:

a plurality of pyramidal elements, each pyramidal element having an apex with a plurality of pyramidal faces extending to a base, each face separated from each adjacent face by a face edge, the base having base edges;

a plurality of inverse pyramidal elements, each inverse pyramidal element having inverse pyramidal faces, the pyramidal elements mateable with the inverse pyramidal elements;

a flattened edge formed along the face edges between each of the pyramidal faces creating a continuous adhesive flow channel;

horizontal adhesive flow channels formed along the pyramidal faces, each of the horizontal adhesive flow channels fluidly connected to the continuous adhesive flow channel;

angled adhesive flow channels formed along the pyramidal faces, each of the angled adhesive flow channels fluidly connected to the continuous adhesive flow channel and the horizontal adhesive flow channels; and

an adhesive substance positionable within the flow channels;

wherein upon applying the adhesive substance within the adhesive flow channels, the adhesive substance, when hardened, creates a space truss structure thereby strengthening the building panel assembly.

12. The building panel assembly of claim 11 and further comprising:

a first rigid diaphragm panel having a first side surface and a second side surface, the base of the pyramidal elements mounted to the first side surface of the first rigid diaphragm panel; and

a second rigid diaphragm panel having a first side surface and a second side surface, the inverse pyramidal elements mounted to the second side surface of the second right diaphragm panel.

13. The building panel assembly of claim 11 and further comprising:

a cuboid secured to the base of each first pyramidal element, each cuboid having flattened edges;

wherein the flattened edges of the cuboid create an additional adhesive flow channel; and

wherein the additional adhesive flow channel is fluidly connected and continuous with the continuous adhesive flow channel thereby creating additional struts for the space truss structure.

14. The building panel assembly of claim 13 and further comprising:

a first rigid diaphragm panel having a first side surface and a second side surface, the first right cuboid element mounted to the first side surface of the first rigid diaphragm panel.

15. The building panel assembly of claim 11 and further comprising:

vertical adhesive flow channels formed along the pyramidal faces, each of the vertical adhesive flow channels fluidly connected to the continuous adhesive flow channel.

16. A method for constructing a building panel assembly, the method comprising:

providing a plurality of pyramidal elements, each pyramidal element having an apex with a plurality of pyramidal faces extending to a base, each face separated from each adjacent face by a face edge, the base having base edges;

providing a plurality of inverse pyramidal elements, each inverse pyramidal element having inverse pyramidal faces;

inserting the pyramidal elements into the inverse pyramidal elements;

flattening the face edges between each of the pyramidal faces creating a continuous adhesive flow channel;

forming horizontal adhesive flow channels along the pyramidal faces;

fluidly connecting each of the horizontal adhesive flow channels to the continuous adhesive flow channel;

forming angled adhesive flow channels along the pyramidal faces;

fluidly connecting each of the angled adhesive flow channels to the continuous adhesive flow channel and the horizontal adhesive flow channels;

positioning an adhesive substance within the flow channels; and

creating a space truss structure with the hardened adhesive substance.

17. The method of claim 16 and further comprising:

providing a first rigid diaphragm panel having a first side surface and a second side surface;

mounting the base of the pyramidal elements to the first side surface of the first rigid diaphragm panel;

providing a second rigid diaphragm panel having a first side surface and a second side surface; and

mounting the inverse pyramidal elements to the second side surface of the second right diaphragm panel.

18. The method of claim 16 and further comprising:

securing a cuboid to the base of each first pyramidal element, each cuboid having flattened edges;

creating additional adhesive flow channels with the flattened edges; and

fluidly connecting the additional adhesive flow channels with the continuous adhesive flow channel thereby creating additional struts for the space truss structure.

19. The method of claim 18 and further comprising:

providing a first rigid diaphragm panel having a first side surface and a second side surface; and

mounting the first right cuboid element to the first side surface of the first rigid diaphragm panel.

20. The method of claim 16 and further comprising:

forming vertical adhesive flow channels along the pyramidal faces; and

fluidly connecting each of the vertical adhesive flow channels to the continuous adhesive flow channel.