STRUCTURE WITH INTEGRATED INSULATION

Abstract

A structure with integrated insulation. The structure with integrated insulation includes a foundation. The foundation is configured to support the structure with integrated insulation and transfer the weight of the structure with integrated insulation to the ground. The structure with integrated insulation also includes a frame attached to the foundation. The structure with integrated insulation further includes a wall. The wall includes at least one wall panel with integrated insulation, the wall panel with integrated insulation being attached to the frame, wherein the attachment between the frame and the wall panel with integrated insulation includes adhesive over the entirety of the surface of the wall panel with integrated insulation in contact with the frame. The wall is also supported by the frame.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to co-pending U.S. patent application Ser. No. ______, filed on Feb. 5, 2014 (Attorney Docket No. 10457.2), and entitled, “ATTACHMENT COMPONENTS FOR SECURING PORTIONS OF A STRUCTURE WITH INTEGRATED INSULATION TO ONE ANOTHER”, which application is incorporated herein by reference in its entirety (hereinafter “first related application”).

This application is related to co-pending U.S. patent application Ser. No. ______, filed on Feb. 5, 2014 (Attorney Docket No. 10457.3), and entitled, “ATTACHMENT COMPONENTS FOR SECURING PORTIONS OF A STRUCTURE WITH INTEGRATED INSULATION TO ONE ANOTHER”, which application is incorporated herein by reference in its entirety (hereinafter “second related application”).

This application is related to co-pending U.S. patent application Ser. No. ______, filed on Feb. 5, 2014 (Attorney Docket No. 10457.4), and entitled, “THERMAL BREAKS WITHIN A STRUCTURE WITH INTEGRATED INSULATION”, which application is incorporated herein by reference in its entirety (hereinafter “third related application”).

BACKGROUND OF THE INVENTION

In most buildings, the design of the structure of the building is divorced from attempts to increase the energy efficiency of the building. That is, the building, including many structural elements, is designed first. Any attempt to increase the energy efficiency of the building is then designed to accommodate the structure. This means that any elements that are intended to improve energy efficiency must be modified to accommodate the already designed structural elements rather than being designed in parallel which would allow the structure to enhance the energy efficiency of the building and vice versa.

In addition, the standard building process is cumbersome and wasteful. For example, when a home is being framed lumber is delivered to the location of the home. The lumber is then cut according to the immediate need. E.g., if a wall is being framed then one end of a board is cut off to make the board the desired length. The end that was removed is generally thrown away or otherwise disposed of. That means that all of the energy and resources used to create the board and deliver it to the home site are wasted. Moreover, costs are higher for wasted materials because the waste must be removed from the site. Additionally, vandalism or theft at the site can mean that more materials than are strictly necessary must be delivered, slowing the building process. This waste drives up the cost of the finished structure.

Further, the need to customize the building material at the job site increases the build time. In most cases, subcontractors must be present at the job site while measurements are made, materials are cut, installation occurs, and then extra materials are disposed etc. Often, one subcontractor may not begin work until other subcontractors have completed work. For example, in home construction drywall cannot be installed until electrical work is complete, painting cannot be started until drywalling is complete, etc. This makes supervision of the site more difficult. In particular, a supervisor may be required to move between job sites leaving most subcontractors at the site unsupervised for a majority of the time that they are present at the build site. This increases the likelihood of installation mistakes, vandalism and theft.

Accordingly there is a need in the art for a structure which is built offsite and assembled on site rather than being built. In addition, there is a need in the art for the structure to incorporate energy efficiency in all design aspects. Further, there is a need in the art for the structure that includes manufactured materials, which can be created with the desired dimensions, reducing materials waste.

BRIEF SUMMARY OF SOME EXAMPLE EMBODIMENTS

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential characteristics of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

One example embodiment includes a structure with integrated insulation. The structure with integrated insulation includes a foundation. The foundation is configured to support the structure with integrated insulation and transfer the weight of the structure with integrated insulation to the ground. The structure with integrated insulation also includes a frame attached to the foundation. The structure with integrated insulation further includes a wall. The wall includes at least one wall panel with integrated insulation, the wall panel with integrated insulation being attached to the frame, wherein the attachment between the frame and the wall panel with integrated insulation includes adhesive over the entirety of the surface of the wall panel with integrated insulation in contact with the frame. The wall is also supported by the frame.

Another example embodiment includes a structure with integrated insulation. The structure with integrated insulation includes a foundation. The foundation is configured to support the structure with integrated insulation and transfer the weight of the structure with integrated insulation to the ground. The structure with integrated insulation also includes a frame attached to the foundation. The structure with integrated insulation further includes a floor. The floor includes at least one floor panel with integrated insulation, the floor panel with integrated insulation being attached to the frame, wherein the attachment between the frame and the floor panel with integrated insulation includes adhesive over the entirety of the surface of the floor panel with integrated insulation in contact with the frame. The floor is supported by the frame. The structure with integrated insulation additionally includes a wall. The wall includes at least one wall panel with integrated insulation, the wall panel with integrated insulation being attached to the frame, wherein the attachment between the frame and the wall panel with integrated insulation includes adhesive over the entirety of the surface of the wall panel with integrated insulation in contact with the frame. The wall is also supported by the frame.

Another example embodiment includes a structure with integrated insulation. The structure with integrated insulation includes a foundation. The foundation is configured to support the structure with integrated insulation and transfer the weight of the structure with integrated insulation to the ground. The structure with integrated insulation also includes a frame attached to the foundation. The structure with integrated insulation further includes a floor. The floor includes at least one floor panel with integrated insulation, the floor panel with integrated insulation being attached to the frame, wherein the attachment between the frame and the floor panel with integrated insulation includes adhesive over the entirety of the surface of the floor panel with integrated insulation in contact with the frame. The floor is supported by the frame. The structure with integrated insulation additionally includes a wall. The wall includes at least one wall panel with integrated insulation, the wall panel with integrated insulation being attached to the frame, wherein the attachment between the frame and the wall panel with integrated insulation includes adhesive over the entirety of the surface of the wall panel with integrated insulation in contact with the frame. The wall is also supported by the frame. The structure with integrated insulation moreover includes a roof. The roof includes at least one roof panel with integrated insulation, the roof panel with integrated insulation being attached to the frame, wherein the attachment between the frame and the roof panel includes adhesive over the entirety of the surface of the roof panel in contact with the frame. The roof is supported by the frame.

These and other objects and features of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

To further clarify various aspects of some example embodiments of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrated embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1A illustrates an example of a bunk house with integrated insulation;

FIG. 1B illustrates an example of a bunk house with integrated insulation;

FIG. 2A illustrates a floor panel with integrated insulation without a wall connection;

FIG. 2B illustrates a floor panel with integrated insulation with a wall connection;

FIG. 2C illustrates the connection between two floor panels with integrated insulation

FIG. 2D illustrates an access panel in a floor panel with integrated insulation;

FIG. 3A illustrates an example of an interior wall panel with integrated insulation;

FIG. 3B illustrates an example of an exterior wall panel with integrated insulation;

FIG. 3C illustrates an example of an interior wall panel with integrated insulation with a space for utility installation

FIG. 3D illustrates a front view of an example of an interior wall panel with integrated insulation with plumbing installed;

FIG. 3E illustrates a bottom view of an example of an interior wall panel with integrated insulation with plumbing installed;

FIG. 3F illustrates a bottom view of an example of an interior wall panel with integrated insulation with an interior air run;

FIG. 3G illustrates a top view of an example of an interior wall panel with integrated insulation with an alternative interior air run;

FIG. 3H illustrates a front view of an example of an interior wall panel with integrated insulation with an alternative interior air run; and

FIG. 3I illustrates a cross-sectional view along the arrows of FIG. 3H of an example of an interior wall panel with integrated insulation with an alternative interior air run;

FIG. 4A illustrates an example of a roof panel with integrated insulation to be mounted on an exterior wall;

FIG. 4B illustrates an example of a roof panel with integrated insulation to be mounted on an interior wall;

FIG. 4C illustrates an example of a connection between roof panels with integrated insulation; and

FIG. 4D illustrates an example of a ridgeline connection between roof panels with integrated insulation.

DETAILED DESCRIPTION OF SOME EXAMPLE EMBODIMENTS

Reference will now be made to the figures wherein like structures will be provided with like reference designations. It is understood that the figures are diagrammatic and schematic representations of some embodiments of the invention, and are not limiting of the present invention, nor are they necessarily drawn to scale.

FIGS. 1A and 1B (collectively “FIG. 1”) illustrate an example of a structure with integrated insulation 100. FIG. 1A illustrates an example of a bunk house with integrated insulation; and FIG. 1B illustrates an example of a bunk house with integrated insulation. The structure with integrated insulation 100 can include any desired structure. For example, the structure with integrated insulation 100 can include a bunk house, a house, a restaurant, an office building, a storage building, a green house or any other desired structure. In addition, the structure with integrated insulation 100 can be used to create spaces within other buildings. For example, large office buildings often have built in structural elements, such as a large steel frames and concrete floors and walls, but the interior can be customized according to the needs of the tenants. The structure with integrated insulation 100 can be installed within the interior to confer the benefits described below.

The structure with integrated insulation 100 offers numerous advantages over traditional “stick” (i.e., wood frame) builds without sacrificing strength or durability. For example, the structure with integrated insulation 100 is cheaper (15-20% cheaper due to both lower materials cost and less waste), may qualify for energy efficiency tax credits, and is faster to construct than stick builds. The lower overall cost allows more home owners to both be able to purchase a home and qualify for loans, since the borrowed amount can be lower. In addition, the structure with integrated insulation 100 is cheaper to maintain. For example, the structure with integrated insulation is far more energy efficient than a stick build, both in general and because utility use can be targeted (e.g., individual rooms can be heated independent of one another), allowing for lower utility costs and home owner's insurance may be cheaper to reflect lower replacement costs. The structure with integrated insulation 100 offers advantages to builders as well. For example, construction can completed in 30 to 45 days (after the foundation is in), requires fewer inspections (from both the lender and government agencies), fewer sub-contractors are required, less waste removes cleanup and disposal costs, fewer opportunities for theft, shorter construction loans, allows more homes to be built in a designated time frame, fewer suppliers to track/coordinate, lower jobsite risk, higher customer satisfaction, etc. Moreover, the structure with integrated insulation 100 beats or exceeds construction codes both now and that are expected to be implemented well into the future.

FIG. 1 shows that the structure with integrated insulation 100 can include a foundation 102. The foundation 102 is the lowest and supporting layer of the structure with integrated insulation 100. I.e., the foundation 102 transfers the weight of the structure with integrated insulation 100 to the ground. For example, the foundation 102 can include footings embedded about a meter or so into soil. One type of footing is the spread footing which consists of strips or pads of concrete (or other materials) which extend below the frost line and transfer the weight from walls and columns to the soil or bedrock. Additionally or alternatively, the foundation 102 can include a “slab-on-grade” foundation where the weight of the building is transferred to the soil through a concrete slab placed at the soil surface. Slab-on-grade foundations can be reinforced mat slabs, which range from 25 cm to several meters thick, depending on the size of the building, or post-tensioned slabs, which are typically at least 20 cm for houses, and thicker for heavier structures.

FIG. 1 also shows that the structure with integrated insulation 100 can include a frame 104. The frame 104 rests on the foundation 102. The frame 104 can be directly attached to the foundation 102 or can be placed on the foundation 102 on a temporary basis. The frame 104 provides a base structure on which the rest of the structure with integrated insulation 100 rests. I.e., the frame 104 is the body or support of the structure 104, on which everything else is mounted or attached to create the final structure with integrated insulation 100. The frame 104 can include any suitable material. For example, the frame 104 can include steel beams (as described in second related application). A steel frame 104 provides a high amount of strength; however, a steel frame 104 can lead to higher utility cost (i.e., increases heat transfer) and is more expensive than wood. Nevertheless, other portions of the structure with integrated insulation 100 (described below) make up for these disadvantages.

FIG. 1 further shows that the structure with integrated insulation 100 can include one or more floor panels with integrated insulation 106. The floor panel with integrated insulation 106 forms a subfloor, over which flooring can be laid. I.e., the floor panel with integrated insulation 106 is supported by the frame 104 (or the foundation 102) and provides a solid structure that can be used to support items, including people, within the structure with integrated insulation 100. Multiple floor panels with integrated insulation 106 can interlock with one another (as described below) and the frame (as described in second related application) to create a surface. Flooring, such as tile, hardwood floors, carpet, etc. is then attached to floor panels with integrated insulation 106.

FIG. 1 additionally shows that the structure with integrated insulation 100 can include one or more wall panels with integrated insulation 108. The wall panels with integrated insulation 108 attach to one another (as described below and in second related application), to the frame 104 (as described in first and second related applications) and to the floor panels with integrated insulation 106, or other floor, and the roof (as described in second related application) to create a wall. A wall is a vertical structure, usually solid, that defines and sometimes protects an area. Most commonly, a wall delineates a building and supports its superstructure, separates space in buildings into sections, or protects or delineates a space in the open air. Additionally or alternatively, finish elements or surface (such as drywall or paneling) may be attached to the wall panels with integrated insulation 108. In addition, the wall may house various types of electrical wiring, duct work, plumbing and electrical outlets, lights, fans, smoke detectors, cabinets, etc. are usually mounted in or on walls. In a stick build walls may also contain insulation; however, the wall panel with integrated insulation 108 acts as insulation negating the need for external insulation.

FIG. 1 moreover shows that the structure with integrated insulation 100 can include one or more roof panels with integrated insulation 110. The roof panels with integrated insulation 110 attach to the frame 104 (as described in first related application), to one another (as described below and in first related application), and to the wall panels with integrated insulation 108 (as described in second related application) to create a roof. A roof is the covering on the uppermost part of a building or shelter, to provide protection from the weather, notably rain, but also heat, wind and sunlight. Roofing materials may be attached to the one or more roof panels with integrated insulation 110 for aesthetic or functional purposes. For example, rain gutters, soffit, eaves, tiles or other materials may be attached to the one or more roof panels with integrated insulation 110.

FIGS. 2A, 2B, 2C and 2D (collectively “FIG. 2”) illustrate an example of a floor panel with integrated insulation 106. FIG. 2A illustrates a floor panel with integrated insulation without a wall connection; FIG. 2B illustrates a floor panel with integrated insulation 106 with a wall connection; FIG. 2C illustrates the connection between two floor panels with integrated insulation 106; and FIG. 2D illustrates an access panel in a floor panel with integrated insulation. The floor panel with integrated insulation 106 can be approximately two feet wide (as measured side to side in FIG. 2A), ten inches high (as measured vertically in FIG. 2A) and manufactured to any desired length. The width and height can be critical to provide the desired strength and insulating properties. One of skill in the art will appreciate that the floor panel with integrated insulation 106 may also be a ceiling panel. I.e., the floor panel with integrated insulation 106 may act as a floor for an upper floor and a ceiling for a lower floor. As used in the specification and the claims, the term approximately shall mean that the value is within 10% of the stated value, unless otherwise specified.

The floor panel with integrated insulation 106 can include two pound (i.e., a density of two pounds per cubic foot) expanded polystyrene (EPS) foam. EPS is a is a rigid and tough, closed-cell foam made of pre-expanded polystyrene (Poly(1-phenylethane-1,2-diyl—molecular formula (C₈H₈)_n) beads. EPS is inert and stable and does not produce methane gas or contaminating leachates. EPS manufacturing uses little energy, in which steam is a component of the manufacturing process. The water from this process is collected and re-used many times. Additionally, only 0.1% of total oil consumption is used to manufacture EPS. Scrap EPS generated during manufacturing or from jobsite waste can be ground up and incorporated into new EPS products. EPS is recyclable and can be turned into new EPS products or thermally processed into a resin to make other products such as garden furniture, coat hangers and crown molding. According to the Environmental Protection Agency (EPA), buildings in the US alone account for 36% of energy use and 30% of greenhouse gas emissions. Using EPS in commercial and residential construction helps to reduce energy consumption and greenhouse gas emissions. EPS has higher, more stable long term R-Values than other insulation alternatives. R-Value measures the thermal resistance. The higher the R-Value the better a product insulates a building. EPS has an R-Value of approximately 4.75 R per inch. The floor panel with integrated insulation 106 can have an R-value of 46. Additionally, EPS has a high compression strength. For example, an eleven inch panel has a compressive strength of approximately two thousand pounds per square foot.

One of skill in the art will appreciate that an advantage of EPS or other integrated insulation includes the ability to add dyes to the insulating material. I.e., the integrated insulation can be dyed to make it any desired color. This allows the material to be customized as desired by a user and provide a desired look.

The floor panel with integrated insulation 106 can create an airtight building envelope which reduces air leakage and heat loss, thus reducing energy consumption and CO₂ emissions in our atmosphere more than with a home built with 2× dimensional lumber. The floor panel with integrated insulation 106 can be fabricated offsite and delivered ready to assemble, meaning onsite cutting and fabrication is virtually eliminated. This reduces onsite waste and space requirements. Leadership in Energy and Environmental Design (LEED) is the nationally accepted benchmark for design, construction and operation of high performance green buildings. Owners of LEED buildings receive tax incentives for reducing the environmental impact on their surroundings. EPS foam formed as a floor panel with integrated insulation 106 provides a stable R-Value without thermal drift, ensuring long term performance and helps ensure compliance with local energy codes and ASHRAE 90.1-1999. Moreover, manufacturing waste can be made into cushions and protects products better than alternative packaging (corrugated cardboard, wood, etc.) from repeat impacts during shipment which reduces waste caused by goods that are broken or damaged in the supply chain saving energy, material and transportation resources. Finally, the light weight of EPS product reduces fuel consumption when materials are transported.

FIG. 2 shows that the floor panel with integrated insulation 106 can include a recess 202. The recess 202 can be configured to allow the floor panel with integrated insulation 106 to be supported by a building frame. For example, the floor panel with integrated insulation 106 can be configured to receive a portion of an I-beam or other structural element. In particular, the recess 202 can be configured to receive the web (vertical portion when viewed from the end as an “I”) of an I-beam. For example, if the web of the I-beam is approximately 0.06 inches wide (˜ 1/16 of an inch) then the recess 202 can be approximately 0.03 inches (the width of the web, 0.06 inches, divided by two). Therefore, the size of the recess 202 can be critical to ensure a snug fit between the floor panel with integrated insulation 106 and the I-beam. As used in the specification and the claims, the phrase “configured to” denotes an actual state of configuration that fundamentally ties recited elements to the physical characteristics of the recited structure. As a result, the phrase “configured to” reaches well beyond merely describing functional language or intended use since the phrase actively recites an actual state of configuration.

FIG. 2 also shows that the floor panel with integrated insulation 106 can include a first notch 204. The size of the first notch 204 can be critical to ensure a snug fit between the floor panel with integrated insulation 106 and the I-beam. I.e., the first notch 204 can allow the first flange (horizontal element when viewed from the end as an “I”) of an I-beam to be recessed, which ensures that the surface is flush. For example, if the portion of the I-beam which is to be inserted into the first notch 204 is approximately two inches wide and one eighth of an inch high, the first notch 204 can be approximately 1.0325 inches wide (

$\frac{2\mathrm{inches}}{2}+1/16-\mathrm{.03}=1.0325;$

2 inch flange divided by two plus one sixteenth inch—to ensure enough room along the edges for the flange to fit—minus 0.03 inches for the recess 202) and one eighth of an inch high so that the top of the I-beam and the top of the floor panel 106 are flush with one another.

FIG. 2 further shows that the floor panel with integrated insulation 106 can include a second notch 206. The size of the second notch 206 can be critical to ensure a snug fit between the floor panel with integrated insulation 106 and the I-beam. I.e., the second notch 206 can allow the second flange of an I-beam to be recessed. For example, if the portion of the I-beam which is to be inserted into the second notch 206 is approximately three inches wide and three sixteenths of an inch high, the second notch 206 can be approximately 1.56 inches wide (1.53 inches relative to the recess 202) and three sixteenths of an inch high. Additionally or alternatively, the second notch 206 can be approximately 7.8725 inches from the top (or 1.94 inches from the bottom; 10 inches minus 7.7825 minus 0.1875—the height of the flange) of the floor panel with integrated insulation 106 to accommodate an I-beam that is approximately 8.06 (˜eight and one sixteenth) inches high.

FIG. 2 additionally shows that the floor panel with integrated insulation 106 can include a c-channel indentation 208. A c-channel indentation 208 (as described in first related application) is a notch or groove that is shaped like a square “C”. I.e., it is rectangular with one side missing. The c-channel indentation 208 can receive a wall panel or some other structural element. For example, the c-channel indentation 208 can be approximately 2 inches deep and approximately 6.5 inches wide to receive a 6 inch wall or approximately 4.5 inches to receive a 4 inch wall. One of skill in the art will appreciate that the c-channel indentation 208 can be either on the top or the bottom of the floor panel with integrated insulation and the c-channels indentation 208 need not be offset from one another. I.e., because the c-channel indentation 208 is approximately 2 inches deep in a 10 inch high floor panel with integrated insulation 106 a first c-channel indentation 208 on the top of the floor panel with integrated insulation 106 and a second c-channel indentation 208 on the bottom of the floor panel with integrated insulation 106 at the same location, approximately six inches of floor panel with integrated insulation remain between the first c-channel indentation 208 and the second c-channel indentation 208.

FIG. 2 moreover shows that the floor panel with integrated insulation 106 can include a panel attachment 210. The panel attachment 210 can be configured to ensure that adjacent floor panels with integrated insulation 106 are flush with one another and snug with one another (i.e., no gap between them). For example, the panel attachment 210 can include a vertical tongue and grove (T&G) connection (as described in first related application). I.e., the T&G connection can be on a portion of the floor panel with integrated insulation 106 that protrudes from the main body of the floor panel with integrated insulation 106 so that the T&G joint is aligned vertically, rather than horizontally. A vertical T&G connection ensures that a vertical force on the floor panel with integrated insulation 106 does not cause adjacent panels to become misaligned (i.e., not flush) one to another. Additionally or alternatively, the panel attachment 210 can create a c-channel indentation 208 that is configured to receive a wall panel or other structural element. For example, the protrusion that includes the male end of the T&G in FIG. 2C has a portion missing on the bottom. This c-channel indentation 208 can be approximately 4 inches wide and 2 inches deep to receive a 4 inch wall panel.

FIG. 2 also shows that the floor panel with integrated insulation 106 can include an access panel 212. The access panel 212 can include a portion of the floor panel 106 that is removable. I.e., the access panel 212 can be removed, creating an opening in the floor panel 106. The opening can be used to access an attic, crawlspace or any other space on the other end of the floor panel with integrated insulation 106.

FIGS. 3A, 3B and 3C (collectively “FIG. 3”) illustrate an example of a wall panel with integrated insulation 108. FIG. 3A illustrates an example of an interior wall panel with integrated insulation 108; FIG. 3B illustrates an example of an exterior wall panel with integrated insulation 108; FIG. 3C illustrates an example of an interior wall panel with integrated insulation 108 with a space for utility installation; FIG. 3D illustrates a front view of an example of an interior wall panel with integrated insulation 108 with plumbing installed; FIG. 3E illustrates a bottom view of an example of an interior wall panel with integrated insulation 108 with plumbing installed; FIG. 3F illustrates a bottom view of an example of an interior wall panel with integrated insulation 108 with an interior air run; FIG. 3G illustrates a top view of an example of an interior wall panel with integrated insulation 108 with an alternative interior air run; FIG. 3H illustrates a front view of an example of an interior wall panel with integrated insulation 108 with an alternative interior air run; and FIG. 3I illustrates a cross-sectional view along the arrows of FIG. 3H of an example of an interior wall panel with integrated insulation 108 with an alternative interior air run. The wall panel with integrated insulation 108 can be used to form either full walls, pony walls, or partial walls (such as on the side of a stair case). The wall panel with integrated insulation 108 can be approximately four feet wide (as measured side to side in FIG. 3A), approximately four inches thick for interior walls and approximately six inches thick for exterior walls (i.e., as measured vertically in FIG. 2A) and manufactured to any desired length. The width and height can be critical to provide the desired strength and insulating properties. The wall panel with integrated insulation 108 can include 2 pound EPS, conferring the same benefits as described relative to the floor panel with integrated insulation 106 in FIG. 2. The interior wall can have an R-value of 17 and the exterior wall can have an R-value of 27.

FIG. 3 shows that the wall panel with integrated insulation 108 can include a T&G connection 302. The T&G connection 302 can allow adjacent wall panels with integrated insulation 108 to be aligned with one another (or with another external element, such as a post as described in first related application). Once the wall panels with integrated insulation 108 are aligned an adhesive can be applied to retain the position of the wall panels with integrated insulation 108 relative to one another. The T&G connection 302 assures that while the adhesive cures that the panels remain in position and provides resistance to a shearing force (as described in first related application). One of skill in the art will appreciate that although FIG. 3 shows that the T&G connection 302 can be on the edges of the wall panel with integrated insulation 108, the wall panel with integrated insulation 108 can include a T&G connection 302 along the surfaces as well. I.e., the wall panel with integrated insulation 108 can include a T&G connection 302 on the surface to receive an intersecting wall panel with integrated insulation 108.

FIG. 3 also shows that the wall panel with integrated insulation 108 can include a T-beam notch 304. The T-beam notch 304 can be configured to receive a T-beam which acts as a stud in the framing (as described in second related application). For example, in the exterior wall of FIG. 3A if the T-beam has a flange that is approximately 2 inches wide and ⅛ of an inch high and a web that is approximately 2 inches high and ⅛ of an inch wide, the T-beam notch 304 can include a recess of approximately ⅛ of an inch high and 2.125 inches wide and a groove approximately 2.25 inches deep (for a total of 2.375 inches from the surface) and ⅛ of an inch wide. In contrast, in the interior wall of FIG. 3B if the T-beam has a flange that is approximately 2 inches wide and ⅛ of an inch high and a web that is approximately 1.5 inches high and ⅛ of an inch wide, the T-beam notch 304 can include a recess of approximately ⅛ of an inch high and 2.125 inches wide and a groove approximately 1.5 inches deep (for a total of 1.625 inches from the surface) and ⅛ of an inch wide. The recess ensures that the T-beam is flush with the surface of the wall panel with integrated insulation 108 and the groove receives the whole of the T-beam web.

The T-beam notch 304 can include any desired spacing. For example, the bottom surface of the wall panel with integrated insulation 108 as shown in FIG. 3A can include a first T-beam notch 304 approximately 8 inches from the right end (9.0625 inches to the center of the T-beam notch groove—8 inches plus 2.125/2). The distance along the bottom side from the center of one T-beam notch 304 groove to the center of the next T-beam notch 304 groove can be approximately 24 inches (i.e., 24 inches on center). Likewise, the top side of the wall panel with integrated insulation 108 as shown in FIG. 3A can include identical spacing, but measured from the left end. This ensures that the T-beam notches 304 are offset relative to one another, creating a thermal break (as described in third related application).

FIG. 3 further shows that the wall panel with integrated insulation 108 can include a river 306. The river 306 is a space that utilities can be installed. For example wiring, plumbing, duct work, etc. can be installed in the river 306. The river 306 ensures that holes do not have to be created in the wall panel with integrated insulation 108 to run utilities. This increases the insulating properties of the wall panel with integrated insulation 108. The river 306 can extend vertically, horizontally or diagonally as needed in the wall panel with integrated insulation 108. For example, the river 306 can include a horizontal portion that allow for utilities that run from room to room and vertically for utilities that extend up/down from/into the floor or ceiling. E.g., FIG. 3D shows that the river 306 can extend horizontally, allowing for installation of a plumbing trap and then vertically allowing for water to drain down where it is finally removed from a building.

FIG. 3 additionally shows that the wall panel with integrated insulation 108 can include a cover 308. The cover 308 can be configured to close the opening to the river 306 after installation of utilities. For example, a piece of material (made of the same material as the wall panel with integrated insulation 108) can be glued into the opening of the river 306. The cover can be custom designed to fit around the installed utilities. This ensures that the river 306 does not create a thermal bridge (as described in third related application). Additionally or alternatively, the cover can reduce the noise created by the utilities. I.e., water running through a pipe will have insulation surrounding it, reducing the noise which can be heard external to the wall. Moreover, the cover can allow the wall to have a complete and smooth surface.

FIG. 3 moreover shows that the wall panel with integrated insulation 108 can include an air run 310. For example, the air run 310 acts as an opening for delivering conditioned (heated or cooled) air to a room or removing air to be conditioned and to prevent pressure differentials between rooms. A common installation today for builders is to use an undercut door to eliminate the installation of the return air path in a room. This practice is commonly use in the bedrooms today. The undercuts in the door help the air from the supply registers get back to the return when the doors are closed. This has been the easiest way to lower pressure if the return air ducts were not installed in the room. The air flows under the door to the nearest return air, commonly placed in the hallway.

Lack of return air is a very common problem for those systems that were poorly designed. Placing the air run 310 in the center of the room as an air run to each room allows for greater supply air into a room, resulting in better airflow and. The benefits by taking care of this problem include: quieter operation, better airflow, fewer repairs, longer life of equipment, lower utility bills and greater comfort. Therefore, the air run 310 can be installed in the wall panel 108 allowing the return air runs to be placed into individual rooms. Putting the return air duct into the center of the wall allows the duct to be insulated on all sides. Additional return air ducts can be added into the any wall depending on the room requirements.

One of skill in the art will appreciate that the air run 310 can eliminate the need for ductwork. I.e., because the air run 310 is created directly within the wall panel with integrated insulation 108 there is no need to create a pathway via ductwork through the walls. This reduces installation costs. Additionally or alternatively, the insulating properties of the wall panel with integrated insulation 108 ensures that the air run 310 delivers the conditioned air more effectively. I.e., the air run 310 is highly insulated and, therefore, less heat is lost or introduced into the conditioned air.

One of skill in the art will appreciate that the air run 310 can include one or more features to reduce turbulence. For example, the air run 310 can include a curved portion which “turns” air traveling through the air run 310 to exit through the heat register. I.e., the air run 310 need not be straight and bends or turns can allow air flow to proceed with less resistance.

FIGS. 4A, 4B, 4C and 4D (collectively “FIG. 4”) illustrate an example of a roof panel with integrated insulation 110. FIG. 4A illustrates an example of a roof panel with integrated insulation 110 to be mounted on an exterior wall; FIG. 4B illustrates an example of a roof panel with integrated insulation 110 to be mounted on an interior wall; FIG. 4C illustrates an example of a connection between roof panels with integrated insulation 110; and FIG. 4D illustrates an example of a ridgeline connection between roof panels with integrated insulation 110. The roof panel with integrated insulation 110 can be approximately two feet wide (as measured into or out of the page in FIG. 4A), ten inches thick and manufactured to any desired length. The width and height can be critical to provide the desired strength and insulating properties. The roof panel with integrated insulation 110 can include 2 pound EPS, conferring the same benefits as described relative to the floor panel with integrated insulation 106 in FIG. 2. The roof panel with integrated insulation 110 can have an R-value of 46.

The roof panel with integrated insulation 110 can be attached to an I-beam in a similar manner to the connection between an I-beam and a floor panel with integrated insulation shown above in FIG. 2. I.e., the roof panel with integrated insulation 110 is glued to an I-beam which is configured to support the weight of the roof panel with integrated insulation 110. Likewise, the roof panel with integrated insulation 110 can be glued to adjacent roof panels using a T&G connection 404 in a similar manner to the connection between wall panels with integrated insulation shown above in FIG. 3.

FIG. 4 shows that the roof panel with integrated insulation 110 can include a c-channel indentation 402. A c-channel indentation 402 (as described above) is a notch or grove that is shaped like a square “C”. I.e., it is rectangular with one side missing. The c-channel indentation 402 can receive a c-channel attached to a wall panel or some other structural element. For example, the c-channel indentation 402 can be approximately 2 inches deep and approximately 6 inches wide to receive a 6 inch wall or approximately 4 inches wide to receive a 4 inch wall. One of skill in the art will appreciate that because the c-channel indentation 402 is approximately 2 inches deep in a 10 inch high roof panel with integrated insulation 110 approximately eight inches of roof panel with integrated insulation 110 remain between the first c-channel indentation 402 and the second c-channel indentation 402. One of skill in the art will appreciate that the that the “width” of the c-channel indentation 402 will be the horizontal width and which is not necessarily the same as the size of the c-channel indentation 402 as measured along the surface of the roof panel 110 (as described in first related application).

By way of example, the roof panel with integrated insulation 110 supplied by the manufacture will come in multiple roof panel sections to cover the span of the roof. E.g., in the example structure with integrated insulation 100 of FIG. 1 described above, the roof span on one side of the roof is approximately fifteen feet one inch (15′ 1″) long (i.e., from ridge to eave). Two roof panels with integrated insulation 110 ten inches (10″) thick, approximately twenty four inch (24″) wide and approximately seven feet six and one half inches (7′ 6½″) in length will be used span the fifteen feet one inch (15′ 1″). Each roof panel with integrated insulation 110 is precut to for fit the eight (8″) inch I-Beam into the roof panel with integrated insulation 110. Each I-Beam will be attached and glued to the length of each of the two (2) sides of the fifteen feet one inch (15′ 1″) length of the 10 inch thick EPS floor panels.

The I-Beam installed at the manufacturing plant will be glued and pressed into each roof panel with integrated insulation 110. Each vertical side of the I-Beam allows a large surface to be glue and attached the roof panel with integrated insulation 110. Adhesive will be applied to entire surface of the I-Beam that is to be in contact with the roof panel with integrated insulation 110 to ensure a good attachment and create a thermal break (as described in third related application). The opposite ten inch (10″) side of the roof panel with integrated insulation 110 will be cut to receive the same eight (8″) inch I-Beam that was installed at the manufacturing plant. The roof panel with integrated insulation 110 is ten inches (10″) thick and the I-Beam is eight inches (8″) in height. This leave two (2″) inches of material to be used at the bottom of each roof panel with integrated insulation 110 that will create a thermal break (as described in third related application).

When the first roof panel with integrated insulation 110 is ready to be installed, the top of the exterior wall and any interior walls should be clean (free of dirt and debris). The top of the exterior wall and any interior walls will be sprayed with adhesive and the underside of the non-air-transfer (thermal break) on the roof panel with integrated insulation 110 will also be sprayed with adhesive. The roof panel with integrated insulation 110 will be set onto the exterior wall (and/or interior wall). After placing the roof panel with integrated insulation 110 onto the exterior wall the I-Beam it will be secured to the sill plate (as described in second related application). Rivets will be used to secure the roof panels with integrated insulation 110 and will be supplied by the installer of the roof panel with integrated insulation 110s.

Spraying the adhesive confers a number of advantages. In particular, spraying the adhesive creates a tight seal, which creates a better thermal break (as described in third related application). Further, the adhesive is stronger than the insulating material (i.e., if two roof panels with integrated insulation 110 are glued together and separation is attempted, the insulating material will break before the adhesive fails) which eliminates the need for shear bracing or other structural supports that are required using current construction techniques.

When the second roof panel with integrated insulation 110 is ready to be installed, this roof panel with integrated insulation 110 will likewise be attached to the I-beam. The top of the exterior wall (or interior wall) should be clean of dirt and debris. The top of the exterior wall (and/or interior wall) will be sprayed with adhesive and the underside of the non-air-transfer (thermal break) on the roof panel with integrated insulation 110 will also be sprayed with adhesive. The exposed side of the first EPS roof panel with integrated insulation 110 and the second roof panel with integrated insulation 110s I-Beam will have adhesive sprayed onto it and pressed together and secured with clamps until the adhesive has been set. After placing the roof panel with integrated insulation 110 into place the I-Beam it will be secured to the exterior wall (and/or interior wall).

The roof rake and the eave are specific parts of a building's roof. The eave is the horizontal edge that sticks out past the exterior wall. Most often, it is the bottom part of the roof that slopes. The rake is the sloped connection between the roof and the wall. The main purpose of the eave is to carry water away from the building and keep it from draining inside the structure. Many eaves also serve a decorative purpose. The eave and the rake both play key roles in keeping water from entering the home. They also help to protect buildings from wind. Because the rake and eaves are vulnerable areas, they need reinforcements to help keep a structure from sustaining water damage. One way to avoid this issue is to install gutters along all of the eaves.

A gable is the generally triangular portion of a wall between the edges of a sloping roof. The gable can be glued to the exterior wall below the eave and along the rake. The fascia is an architectural term for a frieze or band running horizontally and situated along the outer surface of the eave, visible to an observer. Soffit in architecture, describes the underside of the eave. At the ridge (peak of the roof) of each roof panel with integrated insulation 110 the roof panel with integrated insulation 110 is cut to match the pitch of the roof. This allows both sides of the roof panel with integrated insulation 110 to match up and create a smooth and straight ridge line at the top of the peak of the roof. The eave, rake, gable and any other portion can be panels that are part of the roof panel 110 or attached thereto.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

1. A structure with integrated insulation, the structure with integrated insulation comprising:

a foundation, wherein the foundation is configured to: support the structure with integrated insulation; and transfer the weight of the structure with integrated insulation to the ground;

a frame attached to the foundation; and

a wall, wherein the wall: includes at least one wall panel with integrated insulation; the wall panel with integrated insulation being attached to the frame, wherein the attachment between the frame and the wall panel with integrated insulation includes adhesive over the entirety of the surface of the wall panel with integrated insulation in contact with the frame; and is supported by the frame.

2. The structure with integrated insulation of claim 1, wherein the wall panel with integrated insulation includes expanded polystyrene.

3. The structure with integrated insulation of claim 2, wherein the density of the expanded polystyrene is at least two pounds per cubic foot.

4. The structure with integrated insulation of claim 1, wherein the wall panel with integrated insulation can include a recess configured to receive the flange of a T-beam.

5. The structure with integrated insulation of claim 4, wherein the wall panel with integrated insulation includes a groove configured to receive the web of a T-beam.

6. The structure with integrated insulation of claim 5, wherein the wall panel with integrated insulation includes a second groove configured to receive the web of a second T-beam, the second groove being disposed on the surface opposite the groove.

7. The structure with integrated insulation of claim 1, wherein the wall panel with integrated insulation is approximately 48 inches wide.

8. The structure with integrated insulation of claim 1, wherein the wall panel with integrated insulation is approximately 4 inches thick.

9. The structure with integrated insulation of claim 1, wherein the wall panel with integrated insulation is approximately 6 inches thick.

10. The structure with integrated insulation of claim 1, wherein the wall panel with integrated insulation includes a river configured to allow for the placement of a utility line within the wall panel with integrated insulation.

11. A structure with integrated insulation for, the structure with integrated insulation comprising:

a foundation, wherein the foundation is configured to: support the structure with integrated insulation; and transfer the weight of the structure with integrated insulation to the ground;

a frame attached to the foundation; and

a floor, wherein the floor: includes at least one floor panel with integrated insulation; the floor panel with integrated insulation being attached to the frame, wherein the attachment between the frame and the floor panel with integrated insulation includes adhesive over the entirety of the surface of the floor panel with integrated insulation in contact with the frame; and is supported by the frame; and

a wall, wherein the wall: includes at least one wall panel with integrated insulation; the wall panel with integrated insulation being attached to the frame, wherein the attachment between the frame and the wall panel with integrated insulation includes adhesive over the entirety of the surface of the wall panel with integrated insulation in contact with the frame; and is supported by the frame.

12. The structure with integrated insulation of claim 11, wherein the floor panel with integrated insulation includes a recess configured to receive the web of an I-beam.

13. The structure with integrated insulation of claim 12, wherein the floor panel with integrated insulation includes a notch configured to receive a flange of the I-beam.

14. The structure with integrated insulation of claim 13, wherein the floor panel with integrated insulation includes a second notch configured to receive a second flange of the I-beam.

15. The structure with integrated insulation of claim 11, wherein the floor panel with integrated insulation is approximately 24 inches wide.

16. The structure with integrated insulation of claim 11, wherein the floor panel with integrated insulation is approximately 10 inches thick.

17. The structure with integrated insulation of claim 11, wherein the floor panel with integrated insulation includes an access panel, the access panel configured to allow a portion of the floor panel with integrated insulation to be removed as desired.

18. A structure with integrated insulation for, the structure with integrated insulation comprising:

a foundation, wherein the foundation is configured to: support the structure with integrated insulation; and transfer the weight of the structure with integrated insulation to the ground;

a frame attached to the foundation;

a floor, wherein the floor: includes at least one floor panel with integrated insulation; the floor panel with integrated insulation being attached to the frame, wherein the attachment between the frame and the floor panel with integrated insulation includes adhesive over the entirety of the surface of the floor panel with integrated insulation in contact with the frame; is supported by the frame;

a wall, wherein the wall: includes at least one wall panel with integrated insulation; the wall panel with integrated insulation being attached to the frame, wherein the attachment between the frame and the wall panel includes adhesive over the entirety of the surface of the wall panel in contact with the frame; and is supported by the frame; and

a roof, wherein the roof: includes at least one roof panel with integrated insulation; the roof panel with integrated insulation being attached to the frame, wherein the attachment between the frame and the roof panel includes adhesive over the entirety of the surface of the roof panel in contact with the frame; and is supported by the frame.

19. The structure with integrated insulation of claim 18, wherein the roof panel with integrated insulation is approximately 24 inches wide.

20. The structure with integrated insulation of claim 18, wherein the roof panel with integrated insulation is approximately 10 inches wide.