CEILING SUPPORT CONSTRUCTION AND METHODS

Abstract

A ceiling construction and method for supporting an upper level of structure using sandwich panels having insulative cores. The ceiling construction has a lower level wall sandwich panel and an upper level wall sandwich panel, each of which with two outer layers and a core separating the outer layers and an upper level wall sandwich panel. Adhered to the lower level wall sandwich panel is a beam configured to support the upper level of the structure.

Description

FIELD OF THE INVENTION

The present invention relates generally to constructing buildings, and more particularly, to a ceiling construction formed from a plurality of adjacent sandwich panels having insulative cores and outer layers and methods of making support beams.

BACKGROUND OF THE INVENTION

There is an increasing global demand for lower cost buildings such as houses, warehouses and office space. The demand for lower cost buildings is particularly strong in developing countries where economic resources may be limited and natural resources and raw materials may be scarce. For example, in areas of the Middle East or Africa, conventional building materials such as cement, brick, wood or steel may not be readily available or, if available, may be very expensive. In other areas of the world, poverty may make it too costly for people to build houses or other buildings with conventional materials.

The demand for lower-cost housing also is high in areas afflicted by war or natural disasters, such as hurricanes, tornados, floods, and the like. These devastating events often lead to widespread destruction of large numbers of buildings and houses, especially when they occur in densely populated regions. The rebuilding of areas affected by these events can cause substantial strain on the supply chain for raw materials, making them difficult or even impossible to obtain. Furthermore, natural disasters often recur and affect the same areas. If a destroyed building is rebuilt using the same conventional materials, it stands to reason that the building may be destroyed or damaged again during a similar event.

It is generally desirable to increase speed of construction and to minimize construction costs. Prefabricated or preassembled components can streamline production and reduce both the time and the cost of building construction. Prefabricated buildings, however, are made from conventional materials that may be scarce or expensive to obtain. Thus, there exists a need for alternative materials and techniques for constructing buildings that use advanced material technologies to increase the speed of construction and also reduce or lower the ownership costs.

BRIEF SUMMARY OF THE INVENTION

According to one aspect of the invention, a ceiling construction includes a lower level wall sandwich panel having two outer layers and a core separating the outer layers; an upper level wall sandwich panel above the lower level wall sandwich panel, the upper level wall sandwich panel having two outer layers and a core separating the outer layers; a beam adjacent to the lower level wall sandwich panel, the beam being configured to support an upper level and having a top, a bottom, two minor sides, two major sides, an outer layer on each of the two major sides, and a core between the two outer layers; and bonding material adhering a minor side of the beam to an outer layer of the lower level wall sandwich panel.

According to another aspect, the first wall sandwich panel may be comprised of at two sandwich panels and the upper level may be partially supported by at least one of the at least two sandwich panels. In addition, the ceiling construction may include a first U-profile wall bracket bonded to the outer layers of the lower level wall sandwich panel and positioned between the lower level wall sandwich panel and the upper level wall sandwich panel; and a second U-profile wall bracket bonded to the outer layers of the upper level wall sandwich panel and positioned between the upper level wall sandwich panel and the lower level wall sandwich panel.

According to another aspect, the ceiling construction may further include bonding material between the first U-profile wall bracket and the second U-profile wall bracket. Also, the first U-profile wall bracket and the second U-profile wall bracket may form a single H-profile wall bracket. The distance that the first U-profile bracket extends along the outer layers of the lower level wall sandwich panel may be at least approximately seven times the thickness of the outer layers of the lower level wall sandwich panel.

According to another aspect, the ceiling construction may further include a U-profile beam bracket bonded to the outer layers of the beam and positioned between the beam and the upper level. Also, the outer layers of the lower level wall sandwich panel may extend beyond the top of the core of the lower wall sandwich panel, and the outer layers of the upper level wall sandwich panel may extend beyond the bottom of the upper level wall sandwich panel, and the space created between the core of the lower level wall sandwich panel and the core of the upper level wall sandwich panel may be filled with bonding material.

According to another aspect of the invention, the outer layers of the lower level wall sandwich panel extend beyond the top of the core of the lower wall sandwich panel a distance that is at least approximately seven times the thickness of the outer layers of the lower level wall sandwich panel.

According to another aspect of the invention, the ceiling construction includes a second lower level wall sandwich panel below the lower level wall sandwich panel. In addition, the ceiling construction may further include a third U-profile wall bracket bonded to the outer layers of the lower level wall sandwich panel and positioned between the lower level wall sandwich panel and the second lower level wall sandwich panel; and a fourth U-profile wall bracket bonded to the outer layers of the second lower level wall sandwich panel and positioned between the second lower level wall sandwich panel and the lower level wall sandwich panel.

Also, the outer layers of the lower level wall sandwich panel may extend beyond the bottom of the core of the lower wall sandwich panel and the outer layers of the second lower level wall sandwich panel may extend beyond the top of the second lower level wall sandwich panel, and the space created between the core of the lower level wall sandwich panel and the core of the upper level wall sandwich panel may be filled with bonding material.

According to another aspect, the distance from top to bottom of the lower level sandwich panel may be approximately the same as the distance from top to bottom of the beam. In addition, the distance from the top to the bottom of the beam may range from approximately 200 mm to approximately 600 mm. The beam may also be a single sandwich panel or include multiple sandwich panels arranged side by side, each sandwich panel having two outer layers and a core separating the outer layers.

According to another aspect of the invention, a method for forming a ceiling construction from a plurality of panels includes: placing an upper level wall sandwich panel having two outer layers and a core separating the outer layers above a lower level wall sandwich panel having two outer layers and a core separating the outer layers; fixing the upper level wall sandwich panel with respect to the lower level wall sandwich panel; placing a beam adjacent to the lower level wall sandwich panel, the beam having a top, a bottom, two minor sides, two major sides, an outer layer on each of the two major sides, and a core between the two outer layers; adhering a minor side of the beam to an outer layer of the lower level wall sandwich panel using bonding material; and placing a second level adjacent the upper level wall sandwich panel such that the second level is at least partially supported by the beam.

In addition, the opposing minor side of the beam may be adhered to another lower level wall sandwich panel. Also, a U-profile wall bracket may be placed between the beam and the second level.

According to another aspect of the invention, the beam is above ground level and may be maintained above ground level primarily by bonding material at the minor sides of the beam. The method may also include placing the lower level wall sandwich panel above a second lower level wall sandwich panel having two outer layers and a core separating the outer layers; and fixing the lower level wall sandwich panel with respect to the second lower level wall sandwich panel.

These and further features of the present invention will be apparent with reference to the following description and attached drawings. In the description and drawings, particular embodiments of the invention have been disclosed in detail as being indicative of some of the ways in which the principles of the invention may be employed, but it is understood that the invention is not limited correspondingly in scope. Rather, the invention includes all changes, modifications and equivalents coming within the spirit and terms of the claims appended hereto.

It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof. In addition, features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with, or instead of, the features of the other embodiments.

In the detailed description that follows, like components have been given the same reference numerals regardless of whether they are shown in different embodiments of the invention. To illustrate the present invention in a clear and concise manner, the drawings may not necessarily be to scale and certain features may be shown in somewhat schematic form. Certain terminology is used herein to describe the different embodiments of the invention. Such terminology is used for convenience when referring to the figures. For example, “upward,” “downward,” “above,” “below,” “left,” or “right” merely describe directions in the configurations shown in the figures. Similarly, the terms “interior” and exterior” or “inner” and “outer” may be used for convenience to describe the orientation of the components in the figures. The components can be oriented in any direction and the terminology should therefore be interpreted to include such variations. The dimensions provided herein are exemplary and are not intended to be limiting in scope. Furthermore, while described primarily with respect to house construction, it will be appreciated that the concepts described herein are equally applicable to the construction of any type of structure or building, such as warehouses, commercial buildings, factories, apartments, etc.

The present invention provides an alternative to conventional construction materials and techniques. Buildings, such as houses, commercial buildings, warehouses, or other structures can be constructed by composite sandwich panels (also referred to as “sandwich panels” or “composite panels”), which have an insulative core and one or more outer layers. The buildings can be constructed by gluing several sandwich panels together. Traditional fasteners, such as screws, rivets, nails, etc., are usually not needed for such connections. Generally, composite sandwich panels offer a greater strength-to-weight ratio than traditional materials that are used by the building industry. The composite sandwich panels are generally as strong as, or stronger than, traditional materials including wood-based and steel-based structural insulation panels, while being lighter in weight. Because they weigh less than traditional building materials, the handling and transport of composite sandwich panels is generally less expensive. The composite sandwich panels also can be used to produce light-weight structures, such as floating houses, mobile homes, or travel trailers, etc.

Sandwich panels generally are more elastic or flexible than conventional materials such as wood, concrete, steel or brick and, therefore, monolithic (e.g., unitary or single unit structure) buildings made from sandwich panels generally are more durable than buildings made from conventional materials. For example, sandwich panels also may be non-flammable, waterproof, very strong and durable, and in some cases, able to resist hurricane-force winds (up to 300 Kph (kilometers per hour) or more). The sandwich panels also may be resistant to the detrimental effects of algae, fungicides, water, and osmosis. As a result, buildings constructed from sandwich panels may be better able to withstand earthquakes, floods, tornados, hurricanes, fires and other natural disasters than buildings constructed from conventional materials.

The structures described herein are built with composite materials, such as composite panels (also referred to as “sandwich panels” or “panels”). Panels, which may be formed from synthetic materials, provide a light-weight and potentially less expensive alternative to conventional raw materials, e.g., wood, concrete, metal, etc. Panels are usually connected or joined together with a high-strength bonding material, such as epoxy or glue, and conventional materials, such as nails and screws, are not usually needed. The result is a strong and durable monolithic structure, as described further below.

Sandwich panel structures may be less expensive to build than structures built from conventional materials because of reduced material costs and alternative construction techniques. The ownership and maintenance costs for sandwich panel structures also may be less over the long term because sandwich panel structures may last longer and degrade at a slower rate than buildings made from conventional materials. Structures built from sandwich panels therefore may require less maintenance and upkeep than structures built from conventional building materials, which may reduce the overall ownership costs for end users.

The insulative core of the sandwich panels also may reduce the amount of energy needed to heat and/or cool the building, which may reduce the overall costs to operate the building. The insulative core also may reduce or eliminate the need for additional insulation in the building, as may be necessary to insulate structures built from conventional building materials. Sandwich panel structures therefore may be less expensive to build and operate than buildings constructed from conventional building materials.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a fragmentary environmental view of an exemplary monolithic structure built with composite materials;

FIG. 2A-B are schematic sectional and perspective views of an exemplary ceiling construction;

FIG. 3A-B are schematic sectional and perspective views of another exemplary ceiling construction;

FIG. 4 is an isometric view of a sandwich panel;

FIG. 5 is a fragmentary schematic sectional view of two vertical sandwich panels connected together with U-profile brackets;

FIG. 6 is a fragmentary schematic sectional view of two vertical closed edge sandwich panels connected together;

FIG. 7A is a fragmentary schematic top sectional view of an edge portion of an exemplary sandwich panel;

FIG. 7B is a fragmentary schematic top sectional view of the edge portion of the sandwich panel of FIG. 7A with a portion of the core removed;

FIG. 7C is a fragmentary schematic top sectional view of the edge portion of the sandwich panel of FIG. 7A with a closed edge; and

FIG. 8 is a fragmentary schematic top sectional view of the edge portion of the sandwich panel with U-profile bracket closed edge.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to a novel ceiling construction and a novel method for forming a ceiling construction. The ceiling construction makes use of the advantages of sandwich panels with insulative cores to provide support for a ceiling or level of a structure. More specifically, the present invention involves using one or more sandwich panels as walls on a lower level of a structure and adhering a beam to the lower level sandwich panel(s). The beam may also be sandwich panel having a structure similar to the sandwich panel walls. Once adhered, the beam is capable of providing support for a ceiling or additional level of a structure above the lower level.

Referring to FIG. 1, an exemplary monolithic structure 10, for example, a house, is built from a number of sandwich panels that are connected together with bonding material. A front wall 10f of the house 10 is formed from sandwich panels 11-16. A side wall 10s of the house 10 is formed from sandwich panels 20-23. The sandwich panels are connected together with bonding material to form a number of multi-panel wall segments, which are connected together to form the walls 10f, 10s.

The house 10 includes a top portion 10t and a bottom portion 10b. The top portion 10t of the front wall 10f of the house includes a multi-panel wall segment formed by connecting sandwich panel 13 and sandwich panel 14 together. The top portion 10t of the side wall 10s includes a multi-panel wall segment formed by connecting sandwich panel 22 and sandwich panel 23 together.

The top portion 10t of the house 10 is supported by the bottom portion 10b of the house 10. The bottom portion 10b may be a double wide wall segment that is used to support the top portion 10t. The bottom portion 10b of the side wall 10s may include a number of multi-panel wall segments connected together by a joint 24a. As shown in the cut-away portion 25 of FIG. 1, the double wide wall segment can be used to support a floor 26 and/or other top portion 10t of the house 10, e.g., a ceiling to the lower level. The double wide wall segment includes an outer multi-panel wall segment 30 connected to an inner multi-panel wall segment 31. In addition, a beam 28 may also be used to support a floor 26 and/or other top portion 10t of the house 10.

Exemplary panels and methods for forming a monolithic structure, such as the monolithic structure 10, are disclosed in U.S. application Ser. No. 12/101,620, filed Apr. 11, 2008, the entirety of which is incorporated by reference herein.

The sandwich panels, for example, sandwich panels 11-16, may be prefabricated and prepared for installation by cutting the panels to create openings 41, for installing windows, doors, and the like. The sandwich panels typically are manufactured in a rectangular shape, but it will be appreciated that the panels may be manufactured in alternative shapes, as may be desired. While a solid rectangular panel is suitable for solid walls (e.g., the wall formed from the connection of sandwich panels 11 and 12 in FIG. 1), further processing is necessary if openings 41 for windows and doors or other elements are desired. This further processing may be performed at a manufacturing facility or at a construction site.

The sandwich panel 11, for example, may be customized by cutting and removing a portion of the panel 11 to form an opening 41 for a door. The door opening 41 may be cut to any desired size to accommodate the installation of any size door. Similarly, a portion of the panel 12 can be cut and removed to form an opening 41 for a doorway. Also, a top portion of panels 13 or 14 may be removed for installation of an angled eave portion of the roof 40. It will be appreciated that the panel can be customized in any manner desired to meet the specifications of an architectural or design plan. For example, as shown in FIG. 1, the panel 13 includes several window openings 41 and no door opening, while panels 20-23 are solid walls. The sandwich panels also may be cut in other designs to accommodate other roof, wall, etc., arrangements. It also will be appreciated that while the windows, door and roof are described as being cut from a solid sandwich panel, the openings may be molded or otherwise formed in the panel.

Turning next to FIGS. 2A-B a ceiling construction 42 having multiple composite panels is illustrated. The ceiling construction 42 supports an upper level, such as upper level 44 above a lower level, such as lower level 46. Generally, the ceiling construction includes a lower level wall sandwich panel 48 having two outer layers 50a-b and a core 52 separating the outer layers 50a-b. The ceiling construction 42 also includes an upper level wall sandwich panel 54 above the lower level wall sandwich panel 48. The upper level wall sandwich panel 54 also has two outer layers 56a-b and a core 58 separating the outer layers. Adjacent to the lower level wall sandwich panel 48 is a beam 60 that is configured to support the upper level 44. The beam 60 has a top 62, a bottom 64, two minor sides 66 and 68, and two major sides 70 and 72. The beam 60 may also include an outer layer 74a on the first major side 70, an outer layer 74b on the second major side 72 and a core 78 disposed between the outer layers 74a-b.

In addition, the beam 60 may have a lower support 80 on the bottom 64 and may also have an upper support 82. The lower support 80 and upper support 82 may each be formed from multiple layers of composite materials. For example, the lower support 80 and/or the upper support 82 may be formed from the same material as the outer layers 50a-b or 56a-b. In addition, the lower support 80 and/or the upper support 82 may be about 3 to 10 times as thick as the outer layers 50a-b or 56a-b. In addition, bonding material may be used to adhere the upper support 82 to level 44. The materials used to make the beam 60 are described in detail with respect to FIG. 4.

The lower support 80 and/or upper support 82 may also be a U-profile bracket, such as the U-profile bracket 82. The U-profile bracket 82 includes two side walls 84 and 86 connected to one another by a support wall 88. Optionally, the side walls 84 and 86 may be adhered to the outer layers 74a-b by bonding material. The U-profile bracket support wall 88 may also be adhered to the top 62 of the beam. In addition, the top 62 of the beam 60 or the U-profile bracket support wall 88 may be bonded to the upper level 44. The distance that the side walls 84 and 86 of the U-profile bracket 82 extend along the outer layers 74a-b of the beam 60 may vary. In one embodiment, the distance that the side walls 84 and 86 of the U-profile bracket 82 extend along the outer layers 74a-b of the beam 60 is at least approximately seven times the thickness of the outer layers 74a-b of the beam 60. For example, the length of the side walls 84 and 86 may be approximately 40 mm or more. The materials used to make the U-profile bracket 82 are described in detail with respect to FIG. 8.

In addition, the beam 60 may be formed from multiple sandwich panels, such as the beams described in U.S. Application Ser. No. 61/103,379, filed Oct. 7, 2008, the entirety of which is incorporated by reference herein. To provide support for the upper level 44, the beam 60 may be adhered to the lower level wall sandwich panel 48. More specifically, the minor side 66 of the beam 60 may be adhered to the outer layer 50a of the lower level wall sandwich panel 48 using bonding material 67.

The beam 60 and layers 74a-b may vary in size, e.g., height, width and thickness to provide greater support when desired. In a typical application, the beam 60 ranges from approximately 200 mm to approximately 600 mm in height. The lower level wall sandwich panel 48 may also be approximately the same height as the beam 60. In such an embodiment, there is preferably a second lower level wall sandwich panel below the lower level wall sandwich panel 48. Like the lower level wall sandwich panel 48, the second lower level wall sandwich panel 90 may have two outer layers 92a-b and a core 94 separating the outer layers 92a-b.

As shown in FIGS. 2A-B, the lower level wall sandwich panel 48 is joined to the upper level wall sandwich panel 54 with two U-profile brackets 96 and 98. The U-profile bracket 96 includes two side walls 100a-b connected to one another by a support wall 102. Optionally, the side walls 100a-b may be adhered to the outer layers 50a-b by bonding material. The U-profile bracket support wall 102 may also be adhered to the top of the lower level wall sandwich panel 48. In addition, the U-profile bracket support wall 102 may be bonded to the U-profile bracket 98 using bonding material 103. In addition, the distance that the side walls 100a-b of the U-profile bracket 96 extend along the outer layers 50a-b of the lower level wall sandwich panel 48 may vary. In one embodiment, the distance that the side walls 100a-b of the U-profile bracket 96 extend along the outer layers 50a-b of the lower level wall sandwich panel 48 is at least approximately seven times the thickness of the outer layers 50a-b of the lower level wall sandwich panel 48. For example, the length of the side walls 100a-b may be approximately 40 mm or more.

Similarly, the U-profile bracket 98 includes two side walls 104a-b connected to one another by a support wall 106. Optionally, the side walls 104a-b may be adhered to the outer layers 56a-b by bonding material. In addition, although not required, the U-profile bracket support wall 106 may also be adhered to the bottom of the upper level wall sandwich panel 54. The U-profile bracket support wall 106 may be bonded to the U-profile bracket 96 using bonding material 103. In addition, the distance that the side walls 104a-b of the U-profile bracket 98 extend along the outer layers 56a-b of the upper level wall sandwich panel 54 may vary. In one embodiment, the distance that the side walls 104a-b of the U-profile bracket 98 extend along the outer layers 56a-b of the upper level wall sandwich panel 54 is at least approximately seven times the thickness of the outer layers 56a-b of the upper level wall sandwich panel 54. For example, the length of the side walls 104a-b may be approximately 40 mm or more. In addition, it will be understood by those of skill in the art that U-profile brackets 96 and 98 may be combined to form a single H-profile bracket. Such combination may be achieved by adhering the brackets together or by framing an H-profile bracket during the construction process.

Also as shown in FIGS. 2A-B, the lower level wall sandwich panel 48 is joined to the second lower level wall sandwich panel 90 with two U-profile brackets 108 and 110. The U-profile bracket 108 includes two side walls 112a-b connected to one another by a support wall 114. Optionally, the side walls 112a-b may be adhered to the outer layers 92a-b by bonding material. In addition, although not required, the U-profile bracket support wall 114 may also be adhered to the top of the second lower level wall sandwich panel 90. The U-profile bracket support wall 114 may be bonded to the U-profile bracket 110 using bonding material 115. In addition, the distance that the side walls 112a-b of the U-profile bracket 108 extend along the outer layers 92a-b of the second lower level wall sandwich panel 90 may vary. In one embodiment, the distance that the side walls 112a-b of the U-profile bracket 108 extend along the outer layers 92a-b of the second lower level wall sandwich panel 90 is at least approximately seven times the thickness of the outer layers 92a-b of the second lower level wall sandwich panel 90. For example, the length of the side walls 112a-b may be approximately 40 mm or more.

The U-profile bracket 110 includes two side walls 116a-b connected to one another by a support wall 118. Optionally, the side walls 116a-b may be adhered to the outer layers 50a-b by bonding material. In addition, although not required, the U-profile bracket support wall 118 may also be adhered to the bottom of the lower level wall sandwich panel 48. The U-profile bracket support wall 118 may be bonded to the U-profile bracket 108 using bonding material 115. The distance that the side walls 116a-b of the U-profile bracket 110 extend along the outer layers 50a-b of the lower level wall sandwich panel 48 may vary. In one embodiment, the distance that the side walls 116a-b of the U-profile bracket 110 extend along the outer layers 50a-b of the lower level wall sandwich panel 48 is at least approximately seven times the thickness of the outer layers 50a-b of the lower level wall sandwich panel 48. For example, the length of the side walls 116a-b may be approximately 40 mm or more. In addition, it will be understood by those of skill in the art that U-profile brackets 108 and 110 may be combined to form a single H-profile bracket. Such combination may be achieved by adhering the brackets together or by framing an H-profile bracket during the construction process.

Turning next to FIGS. 3A-B another embodiment of a ceiling construction having multiple composite panels is illustrated. The ceiling construction 120 supports an upper level, such as upper level 44 above a lower level, such as lower level 46. Generally, the ceiling construction includes two lower level wall sandwich panels 48 and 122. The first lower level wall sandwich panel 48 has two outer layers 50a-b and a core 52 separating the outer layers 50a-b and the additional first lower level wall sandwich panel 122 has two outer layers 124a-b and a core 126 separating the outer layers 124a-b. As shown, the lower level wall sandwich panels 48 and 122 are arranged side by side, e.g., in stacked relation. In other words, the panels 48 and 122 are arranged such that opposing major surfaces of the panels, i.e., the surfaces of the sides 50a and 124b of the panels 48 and 122, face one another, e.g., as shown. The panels 48 and 122 may be joined using bonding material at the surfaces of the sides 50a and 124b.

The ceiling construction 42 also includes the upper level wall sandwich panel 54 above the first lower level wall sandwich panel 48 and the beam 60, which is adjacent to the additional first lower level wall sandwich panel 122. The beam 60 and additional first lower level wall sandwich panel 122 may combine to support the upper level 44. To provide support for the upper level 44, the beam 60 may be adhered to the additional lower level wall sandwich panel 122. More specifically, the minor side 66 of the beam 60 may be adhered to the outer layer 124a of the additional lower level wall sandwich panel 122 using bonding material 67.

As shown in FIGS. 3A-B, the lower level wall sandwich panels 48 and 122 are joined to the upper level wall sandwich panel 54 with two U-profile brackets 134 and 98. The U-profile bracket 134 includes two side walls 136a-b connected to one another by a support wall 138. Optionally, the side walls 136a-b may be adhered to the outer layers 50b and 124a by bonding material. In addition, although not required, the U-profile bracket support wall 138 may also be adhered to the top of the lower level wall sandwich panels 48 and 122. In addition, the U-profile bracket support wall 134 may be bonded to the U-profile bracket 98 using bonding material 103. Also, the distance that the side walls 136a-b of the U-profile bracket 134 extend along the outer layers 124a and 50b of the lower level wall sandwich panels 48 and 122 may vary. In one embodiment, the distance that the side walls 136a-b of the U-profile bracket 134 extend along the outer layers 124a and 50b of the lower level wall sandwich panels 48 and 122 is at least approximately seven times the thickness of the outer layers 124a and 50b of the lower level wall sandwich panels 48 and 122.

Also as shown in FIGS. 3A-B, the ceiling construction 120 includes an additional second lower level sandwich panel 128, which also has two outer layers 130a-b and a core 132 separating the outer layers 130a-b. As shown, the second lower level wall sandwich panels 90 and 128 are arranged side by side, e.g., in stacked relation. In other words, the panels 90 and 128 are arranged such that opposing major surfaces of the panels, i.e., the surfaces of the sides 92a and 130b of the panels 90 and 128, face one another, e.g., as shown. The panels 90 and 128 optionally are joined using bonding material at the surfaces of the sides 92a and 130b. The first lower level wall sandwich panel 48 and the additional first lower level wall sandwich panel 122 may be joined to the second lower level wall sandwich panel 90 and the additional second lower level sandwich panel 128 with two U-profile brackets, such as brackets 142 and 144.

The U-profile bracket 142 includes two side walls 146a-b connected to one another by a support wall 148. Optionally, the side walls 146a-b may be adhered to the outer layers 130a and 92b by bonding material. In addition, although not required, the U-profile bracket support wall 148 may also be adhered to the top of the second lower level wall sandwich panel 90 and/or the additional second lower level wall sandwich panel 128. In addition, the U-profile bracket support wall 148 may be bonded to the U-profile bracket 144 using bonding material 115. In addition, the distance that the side walls 146a-b of the U-profile bracket 142 extend along the outer layers 130a and 92b of the second lower level wall sandwich panels 90 and 128 may vary. In one embodiment, the distance that the side walls 146a-b of the U-profile bracket 142 extend along the outer layers 130a and 92b of the second lower level wall sandwich panels 90 and 128 is at least approximately seven times the thickness of the outer layers outer layers 130a and 92b of the second lower level wall sandwich panels 90 and 128. For example, the length of the side walls 146a-b may be approximately 40 mm or more. For instance if the outer layers 130a and 92b, are approximately 2 mm (millimeters) thick, the length of the side walls 146a-b may be approximately 14 mm (millimeters), and may be thicker, if desired. In addition, the length of the side walls 146a-b may be adjusted based upon a desired strength or other factor. In another example, the outer layers 130a and 92b may each be approximately 3 mm (millimeters) thick, the length of the side walls 146a-b may be approximately 21 mm (millimeters) or more.

Similarly, the U-profile bracket 144 includes two side walls 150a-b connected to one another by a support wall 152. Optionally, the side walls 146a-b may be adhered to the outer layers 124a and 50b by bonding material. The U-profile bracket support wall 152 may also be adhered to the bottom of the first lower level wall sandwich panel 48 and/or the additional first lower level wall sandwich panel 122. The U-profile bracket support wall 148 may be bonded to the U-profile bracket 142 using bonding material 115. In addition, the distance that the side walls 150a-b of the U-profile bracket 144 extend along the outer layers 124a and 50b of the second lower level wall sandwich panels 48 and 122 may vary. In one embodiment, the distance that the side walls 150a-b of the U-profile bracket 144 extend along the outer layers 124a and 50b of the second lower level wall sandwich panels 48 and 122 is at least approximately seven times the thickness of the outer layers outer layers 124a and 50b of the second lower level wall sandwich panels 48 and 122. For example, the length of the side walls 84 and 86 may be approximately 40 mm or more. In addition, it will be understood by those 150a-b of skill in the art that U-profile brackets 142 and 144 may be combined to form a single H-profile bracket. Such combination may be achieved by adhering the brackets together.

Turning next to FIG. 4, an exemplary sandwich panel 400 is shown. The sandwich panel 400 includes two outer layers 402 and 404 separated by a core 406. The outer layers 402 and 404 are bonded or adhered to the core 406 with bonding material. The core 406 may be formed from a light-weight, insulative material, for example, polyurethane, expanded polystyrene, polystyrene hard foam, Styrofoam® material, phenol foam, a natural foam, for example, foams made from cellulose materials, such as a cellulosic corn-based foam, or a combination of several different materials. Other exemplary core materials include honeycomb that can be made of polypropylene, non-flammable impregnated paper or other composite materials. It will be appreciated that these materials insulate the interior of the structure and also reduce the sound or noise transmitted through the panels. The core may be any desired thickness and may be, for example, 30 mm (millimeters)-100 mm (millimeters) thick, however, it will be appreciated that the core can be thinner than 30 mm (millimeters) or thicker than 100 mm (millimeters) as may be desired. In one embodiment, the core is about 60 mm (millimeters) thick.

The outer layers 402 and 404 of a panel, e.g., sandwich panel 400 may be made from composite materials that include matrix materials and filler or reinforcement material. Exemplary matrix materials include a resin or mixture of resins, e.g., epoxy resin, polyester resin, vinyl ester resin, natural (or non oil-based) resin or phenolic resin, etc. Exemplary filler or reinforcement materials include fiberglass, glass fabric, carbon fiber, or aramid fiber, etc. Other filler or reinforcement materials include, for example, one or more natural fibers, such as, jute, coco, hemp, or elephant grass, balsa wood, or bamboo.

The outer layers 402 and 404 (also referred to as laminate) may be relatively thin with respect to the panel core 406. The outer layers 402 and 404 may be several millimeters thick and, for example, may be between approximately 1 mm (millimeter)-12 mm (millimeters) thick; however, it will be appreciated that the outer layers can be thinner than 1 mm (millimeter) or thicker than 12 mm (millimeters) as may be desired. In one embodiment, the outer layers are approximately 1-3 mm (millimeter) thick. It will be appreciated that the outer layers 402 and 404 may be made thicker by layering several layers of reinforcement material on top of one another. The thickness of the reinforcement material also may be varied to obtain thicker outer layers 402 and 404 with a single layer of reinforcement material. Further, different reinforcement materials may be thicker than others and may be selected based upon the desired thickness of the outer layers.

The outer layers 402 and 404 may be adhered to the core 406 with the matrix materials, such as the resin mixture. Once cured, the outer layers 402 and 404 of the panel 400 are firmly adhered to both sides of the panel core 406, forming a rigid building element. It will be appreciated that the resin mixture also may include additional agents, such as, for example, flame retardants, mold suppressants, curing agents, hardeners, etc. Coatings may be applied to the outer layers 402 and 404, such as, for example, finish coats, paint, ultraviolet (UV) protectants, water protectants, etc. The outer layers 402 and 404 may function to protect the core 406 from damage and may also provide rigidity and support to the panel 400.

The core 406 may provide good thermal insulation properties and structural properties. The outer layers 402 and 404 may add to those properties of the core 406 and also may protect the core 406 from damage. The outer layers 402 and 404 also provide rigidity and support to the sandwich panel.

The panels 400 may be any shape. In one embodiment, the panels 400 are rectangular in shape and may be several meters, or more, in height and width. The panels 400 also may be other shapes and sizes. The combination of the core 406 and outer layers 402 and 404 create panels with high ultimate strength, which is the maximum stress the panels can withstand, and high tensile strength, which is the maximum amount of tensile stress that the panels can withstand before failure. The compressive strength of the panels is such that the panels may be used as both load bearing and non-load bearing walls. In one embodiment, the panels have a load capacity of at least 50 tons per square meter in the vertical direction (indicated by arrows V) and 2 tons per square meter in the horizontal direction (indicated by arrows H). The panels may have other strength characteristics as will be appreciated in the art.

Internal stiffeners may be integrated into the panel core 406 to increase the overall stiffness of the panel 400. In one embodiment, the stiffeners are made from materials having the same thermal expansion properties as the materials used to construct the panel, such that the stiffeners expand and contract with the rest of the panel when the panel is heated or cooled. The stiffeners may be made from the same material used to construct the outer layers of the panel. The stiffeners also may be made from other composite materials and may be placed perpendicular to the top and bottom of the panels and spaced, for example, at distances of 15 cm (centimeters), 25 cm, 50 cm, or 100 cm. Alternatively, the stiffeners may be placed at different angles, such as a 45-degree angle with respect to the top and bottom of the panel, or at another angle, as may be desired.

Referring next to FIG. 5, an exemplary connection 559 between sandwich panels 512 and 514 is shown. Sandwich panels 512 and 514 may be the same types of sandwich panels illustrated in FIGS. 2A-B and 3A-B at 48, 54, 90, 122 and 128. The sandwich panels 512 and 514 are connected to one another by bonding material 560 between two U-profile brackets 561 and 562. The edge 543 of sandwich panel 512 is closed by U-profile bracket 561. The U-profile bracket 561 has two side walls 563 and 564 connected by a bottom wall 565. The U-profile bracket 561 is bonded to the outer layers 540 and 541 by bonding material 565 and 566, such that a gap 567 may be created between the edge 543 of the core 542 and the bottom wall 565 of the U-profile bracket 561. It will be appreciated, however, that the edge 543 of the panel 514 may be in contact with the bottom wall 565 of the U-profile bracket 561. The edge 548 of sandwich panel 514 is closed in a similar manner with the U-profile bracket 562.

The U-profile bracket 562 includes two side walls 570 and 571 connected to one another by a bottom wall 572. The side walls 570 and 571 are connected to the outer layers 545 and 546 by bonding material 573 and 574, such that a gap 575 may be formed between the edge 548 and the bottom wall 572. It will be appreciated, however, that the edge 548 of the panel 514 may be in contact with the bottom wall 572 of the U-profile bracket 562. As described above, the gaps 567 and 575 and the bonding material 565, 566, 573 and 574 between the outer walls 540, 541, 545 and 546 of the sandwich panels 512 and 514 and the side walls 563, 564, 570 and 571 of the U-profile brackets 561 and 562 generally transfer or direct the forces in the panels to the outer layers of the panels and generally not to the panel cores.

Although FIGS. 2A-B and 3A-B illustrate sandwich panels (e.g., 48, 54, 90, 122 and 128) connected using brackets, it is also possible to connect the sandwich panels using a straight joint without brackets. FIG. 6 illustrates an exemplary non-bracket connection between panels 612 and 614, which may be the same types of sandwich panels illustrated in FIGS. 2A-B and 3A-B at 48, 54, 90, 122 and 128. The sandwich panels 612 and 614 generally are coplanar or coextensive with one another when connected edge to edge to form a straight connection 639 as shown in FIG. 6. Sandwich panel 612 includes two outer layers 640 and 641 separated from one another by a core 642. The edge 643 of the sandwich panel 612 is closed by removing a portion 644 of the core 642 and replacing it with a bonding material. Similarly, sandwich panel 614 has two outer layers 645 and 646 that are separated by a core 647, and a closed edge 648 is formed by removing a portion 649 of the core 647 and replacing it with bonding material. The closed edges 643 and 648 of the sandwich panels are connected to one another with bonding material 650, and any forces acting between the two sandwich panels are directed towards the outer layers of the sandwich panels and generally not through the panel cores.

The methods of closing the edges of the sandwich panels are described in more detail in FIGS. 7A-C and 8.

FIG. 7A depicts a top view of an edge portion of the sandwich panel 790. As shown in FIG. 7A, an edge 793a of the panel core 793 is generally flush with, even with, or coplanar to edges 791a and 792a of the outer layers 791 and 792. The outer layers 791 and 792 may be formed from composite materials, for example, the composite materials used to construct the outer layers 402 and 404, as described above. The edge 793a of the panel core 793 is exposed or open and may be subject to compression forces or damage if the panel is connected to another construction element. The panel edge, therefore, is closed to protect the core from damage and to distribute the forces acting on the panel in the general direction of the outer layers. It will be appreciated that while the illustrated embodiment has a generally straight edge, the edge may be jagged or shaped, for example as an “S”, or another shape.

The method of closing of the edge of the sandwich panel is illustrated in more detail in FIGS. 7B-C. With initial reference to FIG. 7B, a portion 793a of the panel core 793 is removed from the edge 793a of the panel 790. The portion 793b removed creates a cavity or void in the panel core 793 that is partially defined by the outer layers 791 and 792 and the remaining portion of the panel core 793.

The portion 793b removed from the core 793 extends along the outer layers 791 and 792 from the outer layer edges 791a and 792a, as designated generally by the dimension “A” in FIG. 7B. The portion 793b removed from the core 793 also extends in a generally perpendicular direction from the outer layers 791 and 792 and toward the center of the core 793, as designated generally by the dimension “B” in FIG. 7B.

The dimensions A, B of the portion 793b removed from the core 793 are several millimeters in length, and may, for example be approximately 7-25 mm (millimeters) long or more. The length of dimensions A, B may be selected based upon the thicknesses of the outer layers 791 and 792 according to a desired ratio. The desired ratio of the dimensions A, B to the thickness of the outer layers 791 and 792 may be about seven to one (7:1), or more, e.g., 8:1 or an even larger ratio. For instance if the outer layers 791 and 792 are about 2 mm (millimeters) thick, the dimensions A, B would be at least approximately 14 mm (millimeters), and may be thicker, if desired, or adjusted based upon a desired strength or other factor. In another example, if the outer layers 791 and 792 may be 3 mm (millimeters) thick and the dimensions A, B would be at least approximately 21 mm (millimeters) or more.

The portion 793b removed from the core 793 extends along the width of the panel 790 between the outer layers 791 and 792. The remaining portion of the core 793 forms a new edge 793c. The new edge 793c of the panel core 793, therefore, is recessed from the edges 791a and 792a of the outer layers 791 and 792, as indicated by dimension “C” in FIG. 7B. The edges 791a and 792a of the outer layers 791 and 792 are not cut or removed from the panel, and therefore, the edges 791a and 792a overhang or extend beyond the new edge 793c of the panel core 793 by dimension C.

The length of dimension C may be any desired length and may, for example, be selected based upon the strength of the bonding material. The length of dimension C may be based on a desired ratio. The desired ratio of the dimension C to the thickness of the outer layers 791 and 792 may be about two to one (2:1), or more, e.g., 3:1 or an even larger ratio. The length of dimension C may be approximately the same as the thickness of the outer layers 791 and 792. For instance, if the outer layers 791 and 792 are approximately 2-3 mm (millimeters) thick, then the new edge 793c of the core 793 may be recessed approximately 2-3 mm (millimeters). It will be appreciated, however, the dimension C and, therefore, the amount that the new edge 793c is recessed may be any desired length, and may, for example, be greater or less than the thickness of the outer layers 791 and 792. More core material may be removed for larger (e.g., thicker) outer layers or less core material may be removed for smaller (e.g., thinner) outer layers. It will be appreciated that the core 793 and outer layers 791 and 792 may be formed in the configuration of FIG. 7B prior to adhering the outer layers 791 and 792 to the core 793, or the sandwich panel may be molded to the desired shape.

The removal of the portion 793b from the core 793 may leave excess or loose material in the cavity, e.g., powder or remnants from cutting or removing the portion 793b of the core 793 that inhibit the effect of the bonding material that is used to close the edge. Any of a number of techniques can be used to remove the excess material from the cavity. For example, the remnants can be blown out of the cavity by blowing air into the cavity and across the new edge 793c. The air may be supplied from a high pressure air source or blowing mechanism. Other mechanisms may be used to remove the excess material from the cavity as will be appreciated by one of skill, for example, a vacuum or other device may be used. The outer layers 791 and 792 may also to be cleaned at the cavity from remaining core material e.g. by a metal brush.

Referring now to FIG. 7C, the cavity formed by the removal of the portion 793b from the core 793 is filled with bonding material. The bonding material is spread to form an edge 793a′ that generally is coplanar with the edges 791a and 792a of the outer layers.

The bonding material 793b solidifies or cures to close the edge of the panel, resulting in a new edge 793a′ that is generally flush with, even with, or substantially coplanar to the edges 791a and 792a of the outer layers 791 and 792. The edge of the panel, therefore, is reinforced with the bonding material and the forces acting on the panel are directed towards the outer layers 791 and 792 and generally not through the panel core 793, which may not have the same strength, e.g., stiffness or rigidity to support a load on the panel, as the outer layers.

Referring to FIG. 8, a view of a sandwich panel 790 closed with a bracket 800 is provided. The bracket 800 has a U-profile and includes a bottom wall 801 and two side walls 802 and 803 that are connected to form the general shape of a “U.” The edge 793a of the sandwich panel 790 is insertable into the U-profile bracket 800. The side walls 802 and 803 may be spaced slightly wider than the width of the sandwich panel 790 to accommodate insertion of the panel 790 and to provide a gap into which bonding material may be applied. For instance, the space, or gap between the outer layers 791 and 792 and the side walls 801 and 802 may be about 1-3 mm (millimeters) wide. The walls 802 and 803 may be spaced nearer or farther from each other for wider or narrower sandwich panels, and/or based upon a desired tolerance. For instance, if the sandwich panel 790 is about 62 mm (millimeters) wide, the side walls 802 and 803 may be spaced about 64 mm (millimeters) to 68 mm (millimeters) apart, or more.

The U-profile bracket 800 may be made from any suitable material. For example, the U-profile bracket 800 could be made composite materials that include matrix materials and filler or reinforcement material. Exemplary matrix materials include a resin or mixture of resins, e.g., epoxy resin, polyester resin, vinyl ester resin, natural (or non oil-based) resin or phenolic resin, etc. Exemplary filler or reinforcement materials include fiberglass, glass fabric, carbon fiber, or aramid fiber, etc. Other filler or reinforcement materials include, for example, one or more natural fibers, such as, jute, coco, hemp, or elephant grass, balsa wood, or bamboo. In addition, the U-profile bracket could be made from other types of plastic or metal materials.

The U-profile bracket 800 may be formed from composite materials, for example, the composite materials used to construct the outer layers 402 and 404, as described above. The walls 801, 802 and 803 of the U-profile bracket 800 also may be relatively thin with respect to the panel 790, and may, for example be the same thickness as the outer layers 791 and 792, or may be approximately two or three times thicker than the outer layers 791 and 792 of the panel 790. For instance, the walls 801, 802 and 803 may be several millimeters thick and may, for example, be between approximately 1 mm (millimeter)-12 mm (millimeters) thick, however, it will be appreciated that the outer layers can be thinner than 1 mm (millimeter) or thicker than 12 mm (millimeters) as may be desired.

To close the edge of the sandwich panel 790, the edge 793a of the core 793 and the edges 791a and 792a of the outer layers 791 and 792 (e.g., a first outer layer 791 and a second outer layer 792) are inserted into the open end of the U-profile bracket 800. Bonding material 804 and 805 is applied, injected or otherwise placed into the gap between the outer layers 791 and 792 and the respective side walls 802 and 803 (e.g., a first side wall 802 and a second sidewall 803) of the U-profile bracket 800. The bonding material adheres or connects the U-profile bracket 800 to the sandwich panel 790 and closes the edge 793a of the panel 790 and also facilitates the transfer of the forces through the U-profile bracket 800 and to the outer layers 791 and 792 when the sandwich panel is connected to another construction element. The U-profile bracket 800 extends along the length of the sandwich panel and, therefore, closes the entire edge 793a of the panel. The U-profile bracket also may have end walls.

The side walls 802 and 803 extend along a length of the outer layers 791 and 792 as indicated generally by dimension “D.” The length of dimension D may be based on a desired ratio. The desired ratio of the dimension D to the thickness of the outer layers 791 and 792 may be about seven to one (7:1), or more, e.g., 8:1 or an even larger ratio. The length of the side walls 802 and 803 may be about 7 mm (millimeters) to 50 mm (millimeters) or more and may compensate for unevenness in, for example, sandwich panels with respect to one another.

The edge 793a of the panel 790 may be spaced from the bottom wall 801 of the U-profile bracket 800 to form a gap 805. The width of the gap 805 may be about the same as the thickness of the outer layers 791 and 792 of the sandwich panel 790, and may, for example, be about 1-3 mm (millimeters). It will be appreciated that a larger or smaller gap 805 may be selected based upon the size of the sandwich panel 790 and/or the size of the U-profile bracket 800 or other criteria. As indicated above, the gap 805 may be zero, e.g., the edge 793a may be in contact with the bottom wall 801 and may be substantially free from bonding material.

The gap 805 is generally free from bonding material and the edge 793a and the bottom wall 801 are spaced from one another, which facilitates the transfer of the forces acting on the panel 790 to the outer layers 791 and 792 and minimizes transfer of forces through the panel core 793. The bottom wall 801 also provides a surface for connecting the sandwich panel 790 to another construction element, such as bracket as described above.

It will be appreciated that each edge 793a of the sandwich panel 790 may be closed using either of the methods described above, e.g., by removing a portion of the panel core and filling the resulting cavity with a boding material or by a U-profile bracket at each edge. For instance, if the sandwich panel is rectangular, any or all of the four edges of the panel can be closed as described above.

As described above with respect to FIGS. 2-9, the bonding material (e.g., 67, 103, 115, etc.) connecting the respective construction elements together may be a layer that is approximately 1-5 mm (millimeters) thick, or more. In addition, the layer of bonding material 67, for example, may be thicker than the layers of bonding material 103 and 115. It will be appreciated, however, that thicker or thinner amounts bonding material may be selected as desirable. The bonding material may be more flexible than the sandwich panels, and may be, for example, four or five times more flexible than the panels. The flexibility of the bonding material, therefore, reduces the likelihood than the panels of the monolithic structure will break or split apart, and also transfers loads from one panel to another and towards the outer layers each respective panel.

The bonding material may be any suitable bonding material such as epoxy, epoxy resin, glue, adhesive, adhering material or another bonding material (these terms may be used interchangeably and equivalently herein). The bonding material may be a glass fiber reinforced epoxy and may have the same general thermal expansion characteristics as the materials used to construct the sandwich panel. The bonding material may include filling components, such as, fiberglass or a fiberglass and resin mixture, and may be, for example, microfiber and Aerosil®.

It also will be appreciated that while FIGS. 2A-B and 3A-B depict multiple separate U-profile brackets (e.g., 96 and 98, 108 and 110, and 142 and 144) that may be combined to form single brackets in the form of an “H.” In such an embodiment, the sandwich panels may be connected to one another without the bonding material 103 or 115 between the two U-profile brackets.

Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings.

While the present invention has been described in association with exemplary embodiments, the described embodiments are to be considered in all respects as illustrative and not restrictive. Such other features, aspects, variations, modifications, and substitution of equivalents may be made without departing from the spirit and scope of this invention which is intended to be limited only by the scope of the following claims. Also, it will be appreciated that features and parts illustrated in one embodiment may be used, or may be applicable, in the same or in a similar way in other embodiments.

Claims

1. A ceiling construction comprising:

a lower level wall sandwich panel having two outer layers and a core separating the outer layers;

an upper level wall sandwich panel above the lower level wall sandwich panel, the upper level wall sandwich panel having two outer layers and a core separating the outer layers;

a beam adjacent to the lower level wall sandwich panel, the beam being configured to support an upper level and having a top, a bottom, two minor sides, two major sides, an outer layer on each of the two major sides, and a core between the two outer layers; and

bonding material adhering a minor side of the beam to an outer layer of the lower level wall sandwich panel.

2. The ceiling construction of claim 1 wherein the first wall sandwich panel is comprised of at least two sandwich panels and wherein the upper level is partially supported by at least one of the at least two sandwich panels.

3. The ceiling construction of claim 1 further comprising:

a first U-profile wall bracket bonded to the outer layers of the lower level wall sandwich panel and positioned between the lower level wall sandwich panel and the upper level wall sandwich panel; and

a second U-profile wall bracket bonded to the outer layers of the upper level wall sandwich panel and positioned between the upper level wall sandwich panel and the lower level wall sandwich panel.

4. The ceiling construction of claim 3 further comprising bonding material between the first U-profile wall bracket and the second U-profile wall bracket.

5. The ceiling construction of claim 3 wherein the first U-profile wall bracket and the second U-profile wall bracket form a single H-profile wall bracket.

6. The ceiling construction of claim 3 wherein the distance that the first U-profile bracket extends along the outer layers of the lower level wall sandwich panel is at least approximately seven times the thickness of the outer layers of the lower level wall sandwich panel.

7. The ceiling construction of claim 1 further comprising a U-profile beam bracket bonded to the outer layers of the beam and positioned between the beam and the upper level.

8. The ceiling construction of claim 1 wherein outer layers of the lower level wall sandwich panel extend beyond the top of the core of the lower wall sandwich panel, wherein the outer layers of the upper level wall sandwich panel extend beyond the bottom of the upper level wall sandwich panel, and further comprising bonding material in a space created between the core of the lower level wall sandwich panel and the core of the upper level wall sandwich panel.

9. The ceiling construction of claim 8 wherein the distance that the outer layers of the lower level wall sandwich panel extend beyond the top of the core of the lower wall sandwich panel is at least approximately seven times the thickness of the outer layers of the lower level wall sandwich panel.

10. The ceiling construction of claim 1 further comprising a second lower level wall sandwich panel below the lower level wall sandwich panel.

11. The ceiling construction of claim 10 further comprising:

a third U-profile wall bracket bonded to the outer layers of the lower level wall sandwich panel and positioned between the lower level wall sandwich panel and the second lower level wall sandwich panel; and

a fourth U-profile wall bracket bonded to the outer layers of the second lower level wall sandwich panel and positioned between the second lower level wall sandwich panel and the lower level wall sandwich panel.

12. The ceiling construction of claim 10 wherein the outer layers of the lower level wall sandwich panel extend beyond the bottom of the core of the lower wall sandwich panel and wherein the outer layers of the second lower level wall sandwich panel extend beyond the top of the second lower level wall sandwich panel, and further comprising bonding material in a space created between the core of the lower level wall sandwich panel and the core of the second lower level wall sandwich panel.

13. The ceiling construction of claim 1 wherein the distance from top to bottom of the lower level sandwich panel is approximately the same as the distance from top to bottom of the beam.

14. The ceiling construction of claim 1 wherein the distance from the top to the bottom of the beam ranges from approximately 200 mm to approximately 600 mm.

15. The ceiling construction of claim 1 wherein the beam is a sandwich panel having two outer layers and a core separating the outer layers.

16. The ceiling construction of claim 1 wherein the beam comprises multiple sandwich panels arranged side by side, each sandwich panel having two outer layers and a core separating the outer layers.

17. The ceiling construction of claim 1 wherein the lower level wall sandwich panel and the upper level wall sandwich panel are a single wall sandwich panel, part of which is in a lower level and part of which is in an upper level.

18. A method for forming a ceiling construction from a plurality of panels comprising:

placing an upper level wall sandwich panel having two outer layers and a core separating the outer layers above a lower level wall sandwich panel having two outer layers and a core separating the outer layers;

fixing the upper level wall sandwich panel with respect to the lower level wall sandwich panel;

placing a beam adjacent to the lower level wall sandwich panel, the beam having a top, a bottom, two minor sides, two major sides, an outer layer on each of the two major sides, and a core between the two outer layers;

adhering a minor side of the beam to an outer layer of the lower level wall sandwich panel using bonding material; and

placing a second level adjacent the upper level wall sandwich panel such that the second level is at least partially supported by the beam.

19. The method of claim 18 further comprising adhering an opposing minor side of the beam to another lower level wall sandwich panel.

20. The method of claim 18 further comprising placing a U-profile wall bracket between the beam and the second level.

21-24. (canceled)