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[0001] This application is a continuation-in-part of co-pending application Ser. No. 09/569,693, filed May 11, 2000, which is a divisional of application Ser. No. 09/169,059, filed Oct. 9, 1998, now abandoned, the disclosures of which are expressly incorporated herein by reference.
[0002] The present invention relates generally to structural building components and systems, and more particularly to composite structural building panels, connection systems and related components, and to systems and methods for erecting structures including such panels.
[0003] Traditionally, housing or other building structures are erected one component at a time, i.e., generally at the erection site. This may include separately erecting or installing structural framework, shear sheathing, vapor barriers, protective exterior siding or finishes, and interior finishes or paneling, such as gypsum board. The structural framework may be erected from raw materials, e.g., lumber, and then other components may be successively added to the framework until a finished structure is attained. The various components may be assembled together using a wide range of fasteners, such as, nails, nuts, bolts, screws, and/or other materials, such as gasketing, adhesives and the like.
[0004] Because of the complexity of such structures, highly skilled tradesmen are required, and building them takes substantial time. Further, during construction, ancillary components, such as plumbing, mechanical and electrical systems, architectural features, such as roofmg and trim, interior features and the like, may be added to complete the structure. This may further increase labor and time demands, and consequently result in relatively costly building structures.
[0005] To reduce field costs and accelerate erection of building structures, factory assembled components have been proposed. For example, prefabricated panels, generally made up of plywood applied over a expanded polystyrene (EPS) foam core, may be used to reduce field assembly time. In addition, subassemblies of framing or other structural components may be built in a factory or other offsite environment, where mass production or improved efficiencies may be realized, as compared with field conditions. These components, however, may be bulky, resulting in dramatically increased shipping costs and/or requiring a factory in close proximity to the erection site.
[0006] Another problem with conventional building structures is that they often involve the use of wood products, particularly within the residential industry, which are becoming increasingly scarce and expensive. As an alternative, concrete and steel materials may be used, but these materials generally involve heavy equipment and special labor requirements, which may dramatically increase erection time and cost. Further, steel and concrete materials may not adequately resist corrosion and/or may involve complicated seismic load considerations.
[0007] More recently, plastic or composite materials, i.e., fiber reinforced plastic (“FRP”), have been considered for panel systems. These panels may simply substitute a composite material for one or more elements of the panels, e.g., the outer skins, while using foam or honeycomb core materials between the skins. Other composite panels have been suggested that use extruded or pultruded composite materials. These panel systems, however, generally still require fasteners, e.g., screws or bolts, in order to connect the panels to specially designed trim components, beams, and the like. Thus, many of the components necessary to assemble the panels and erect a building structure may be traditional non-composite materials, which may compromise the structural and durability benefits obtained from the use of composite materials.
[0008] Other composite systems have suggested tongue and groove or “H” strip connectors between panels, but these systems may also require multiple fasteners to provide a structurally integral connection between the panels. Alternatively, other composite systems may use resincatalyst mixtures to bond panels together, but these systems may substantially increase erection time, e.g., due to the curing time of panel joints, and/or may involve specially skilled field labor knowledgeable in working with composite materials.
[0009] Accordingly, structural building components and systems that may be assembled in a more efficient manner, and/or that may overcome problems associated with previous systems would be considered useful.
[0010] The present invention is directed to composite building panels and related connection systems, and to methods for assembling and using such panel systems to create building structures.
[0011] In accordance with one aspect of the present invention, a composite panel for a structural building system is provided that includes a first skin formed from composite material, e.g., FRP including a phenolic resin, defining upper, lower, and side edges, and a second skin defining upper, lower, and side edges spaced apart from the first skin, thereby defining a cavity between the first and second skins. The second skin may be formed from composite material or from drywall material. A foam core is provided within the cavity, for example, a polyisocyanurate foam injected between the first and second skins to substantially fill the cavity.
[0012] A connector formed from plastic or composite material extends along a side edge, and preferably along each of the side edges, of the first and second skins for connecting the composite panel to another composite panel including a mating connector. The connector may include an elongate slot extending generally parallel to the side edges for receiving a pin therein, whereby the composite panel may be connected to another composite panel having a similar connector and slot. In addition, the connector may include an inside face extending generally parallel to a plane defined by the first and second skins, and the slot may extend along the inside face between ends of the connector. Alternatively or in addition, the connector may include at least one of a tongue and a groove extending along a length of the connector.
[0013] The composite panel may include one or more internal support members, such as an I-beam. The I-beam, which may be formed from plastic or composite material, may space the first and second skins apart to define the cavity. Alternatively or in addition, the connectors may be bonded between the first and second skins to space the first and second skins apart and define the cavity. Optionally, the I-beam may include a chase, e.g., within a tubular segment of the I-beam and extending between its ends.
[0014] In addition, the composite panel may include a top plate, e.g., a “U” shaped channel, extending along the upper edges of the first and second skins. Preferably, the top plate is formed from plastic or composite material, and is bonded between the upper edges of the first and second skins, thereby defining a recess between the upper edges.
[0015] In accordance with another aspect of the present invention, a composite panel system for a building structure is provided that includes first and second composite panels. The first panel includes a first skin including composite material, a second skin including composite or drywall material, a foam core between the first and second skins, and a first side edge. The second panel also includes a first skin including composite material, a second skin including composite or drywall material, a foam core between the first and second skins, and a second side edge.
[0016] A connector is provided for securing the first and second members relative to one another along the first and second side edges. In one embodiment, the connector may include a first connector member bonded to the first edge of the first panel member, and a second connector member bonded to the second edge of the second panel member. Each of the first and second connector members may include a tongue and groove connector including a slot extending along a length thereof. Preferably, the first and second connector members are configured to interlock with one another to secure the first and second panel members to one another in a planar configuration. More preferably, each of the first and second connector members includes a slot extending along a length thereof, the slots defining a passage when the first and second panel members are interlocked. The composite panel system may include an elongate pin insertable into the passage to secure the first and second panel members together.
[0017] Alternatively, the connector may also include a corner connector configured to interlock with the first and second panel members to secure the first and second panel members transversely with respect to one another. In a further alternative, the connector may include a “T” connector configured to interlock with the first and second panel members to secure the first and second panel members in a planar configuration. A third panel member may be provided that is configured to interlock with the “T” connector to secure the third panel member transversely with respect to the first and second panel members.
[0018] In addition, one or more “U” shaped base channel members may be provided that include legs that are spaced for receiving lower edges of the first and second panel members therein.
[0019] In accordance with yet another aspect of the present invention, a method is provided for manufacturing a composite panel that includes bonding a first web of an elongate support member, such as an I-beam formed from plastic, to a first skin, the first skin including composite material. A second web of the support member may be bonded to a second skin including composite or drywall material. A connector may be bonded along side edges of the first and second skins, and a foam core may be injected into a cavity defined between the first and second skins. In addition, a top plate, e.g., a “U” shaped channel, may be bonded between upper edges of the first and second skins.
[0020] In accordance with still another aspect of the present invention, a method is provided for assembling a building structure from a plurality of composite panels including connectors extending along side edges thereof. One or more lengths of “U” shaped base channel may be secured to a foundation, e.g., using fasteners and/or adhesives. A lower edge of a first composite panel may be placed into the base channel in a substantially vertical orientation. A lower edge of a second composite panel may be placed into the base channel adjacent the first panel member. Connectors on the first and second composite panels may be interlocked such that the first and second composite panels are disposed in a substantially planar configuration. The connectors of the first and second composite panels may be secured to one another, for example, by inserting a pin through mating slots in the connectors that define an enclosed passage when the connectors are interlocked. The first and second panels to the base channel, for example, by fasteners and/or adhesives, either before or after interlocking and/or securing the first and second panels together.
[0021] Optionally, the first and second composite panels may include “U” shaped channels between upper edges thereof A top plate may be secured within the channels, and a roof structure may be secured to the top plate.
[0022] In addition, the first composite panel may include an internal chase disposed therein, and a utility accessory may be directed along the chase into the first composite panel. For example, a wire may be inserted into the chase, an opening may be created in a surface of the first composite panel to access the wire within the chase, and an electrical box may be secured to the surface over the opening.
[0023] Other objects and features of the present invention will become apparent from consideration of the following description taken in conjunction with the accompanying drawings.
[0024]
[0025]
[0026]
[0027]
[0028] FIGS.
[0029]
[0030]
[0031] Turning to the drawings,
[0032] A connector
[0033] As shown in FIGS.
[0034] Returning to
[0035] Each I-beam
[0036] Optionally, the upper edges
[0037] Returning to
[0038] The resin may be selected from a number of thermoset plastics, such as polyvinyl chloride (PVC) or PVC derivatives, and/or thermoplastic materials, such as phenolics, polyesters, vinylesters, polypropylenes, epoxies, and polycarbonates. Ultraviolet inhibitors may be added, if desired, to all or selected components, such as exterior skins, to protect the components from damage due to exposure to sunlight. Phenolic resins may be preferred as they have a higher resistance to fire as compared to other resins, i.e., they have relatively low coefficients of flame spread and smoke generation during combustion, and may be formulated such that they will not support substantial combustion at all. Phenolic resins also do not include styrenes, which may provide an improved environment during manufacturing and/or pre-assembly of the panels over other resins. Phenolic resins, however, may be corrosive and consequently may require special protection of manufacturing equipment and/or panel components during manufacturing. In a preferred form of the present invention, fiberglass is impregnated within a phenolic resin in proportions of about 15-60% fiberglass by volume, and more preferably about 25-35% fiberglass, to provide a preferred composite material.
[0039] The second skin
[0040] The connector(s)
[0041] To manufacture a panel in accordance with the present invention, the first skin
[0042] Alternatively, “open mold” wet lay-up methods may be used during which one or more of the components may be manufactured individually. This may reduce output volume, but may allow special textures, such as an architectural finish, e.g., a stone or brick pattern, a stucco pattern, a tile pattern, a wooden panel pattern, and the like, to be incorporated into finished components, such as an outer skin. For example, sheet molding compound or “pre-preg” may be used, in which resin is pre-applied to the fiber reinforcement and provided in an uncured sheet form. The sheet may be placed in a mold having a surface finish thereon, and heat and/or pressure may be applied to cure the material and mold the surface finish directly into the sheet.
[0043] No matter what method is used, the first skin(s)
[0044] The first skin
[0045] The second skin
[0046] With the skins
[0047] Other accessories for the panel system, such as the special connectors, channels, and/or trim, may also be manufactured, for example, using a pultrusion method or using an extrusion process, as described above. Although an extrusion process may be performed on phenolic resin composites, PVC or PVC derivative materials may be extruded more easily, and may be preferred for accessory components that are not likely to be exposed upon erection of the structure. For exposed accessories, such as the comer connector
[0048] For example, as shown in
[0049] Turning to
[0050] Turning to
[0051] Turning to
[0052] Optionally, composite panels may be manufactured for use as internal walls, such as the representative panel
[0053] The composite panels are preferably manufactured and assembled at a manufacturing site where efficiencies may be realized and/or labor costs controlled more effectively. Thus, upon delivery to an erection site, no assembling individual panels may be required. Alternatively, if shipping volume is an important consideration, the panel components may be shipped unassembled, and assembled and bonded into panels at or near the erection site.
[0054] With reference to
[0055] As shown in
[0056] A lower edge of a second panel (not shown) may be placed into the base channel
[0057] Generally, with particular reference to
[0058] Turning to
[0059] A roof structure (not shown) may be secured to the trusses that may be provided from conventional materials. Alternatively, as shown in
[0060] Turning to
[0061] The electrical box
[0062] A significant advantage of composite panels, as compared to wood or other traditional materials, is that the composition of composite materials may be modified in a predetermined manner to optimize the structural characteristics of components or systems formed using them. For example, the fiber reinforcement content of the material may be increased to generally increase the strength of the resulting structure, particular arrangements of fibers may be selected to provide selected structural properties, and the like. In addition, the spacing and construction of internal support members may be selected to provide desired structural properties.
[0063] In addition, an exterior skin of composite material may be manufactured with a desired architectural finish, thereby reducing exterior finish work on the exterior of the structure. Similarly, composite panels including drywall inner skins may provide a rough finish for the interior of the structure, only requiring painting or other finishes.
[0064] Another advantage of connection systems in accordance with the present invention is that special tools and fasteners may be eliminated. Although fasteners may be required to secure the wall panels to base channel or to connect a roof structure to wall panels, the connectors of the present system may only require a single pin to assemble and secure adjacent wall panels. Thus, a substantial volume of hardware generally required for erecting building structures may be eliminated.
[0065] While the invention is susceptible to various modifications, and alternative forms, specific examples thereof have been shown in the drawings and are herein described in detail. It should be understood, however, that the invention is not to be limited to the particular forms or methods disclosed, but to the contrary, the invention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the appended claims.