Method of making building panels with support members extending partially through the panels

A building panel for residential and commercial construction uses a plurality of insulating blocks connected together by adhesive. The insulation blocks are typically made of foam. A plurality of support members are disposed on opposite sides of the insulating blocks and offset with respect to the adjacent support member. The support member are typically made of metal and can have different shapes including “T” shape, “U” shape, and “L” shape. Each support member has a head portion in contact with a surface of the insulating block and a stem portion extending into the insulating block and having a length less than a width of the insulating block so that a thermal conduction path of the support member is discontinuous across the insulating block. The panel can be used as a curtain wall panel in high-rise construction, as well as bodies for aircraft, automotive, and marine applications.

FIELD OF THE INVENTION

The present invention relates in general to construction materials and, more particularly, to residential and commercial building panels containing insulating foam and support members extending partially through the insulating foam.

BACKGROUND OF THE INVENTION

Residential and commercial building construction uses a variety of building materials and construction techniques to complete the structure. In some building projects, lumber or metal studs are used for the framing. The frame structure is held together with nails, screws, and bolts. An exterior siding such as stucco, wood, vinyl, brick, or aluminum is placed over the frame structure. Insulation is placed between the studs of the frame structure. The interior coverings such as drywall are affixed to the inside of the frame structure. The entire building project is typically performed on the construction site. The use of interior and exterior siding over frame is costly and labor and time intensive. Wood framing is of inferior quality and subject to insect damage and warping. Metal framing is thermally conductive which is undesirable in view of energy costs. The frame-based structure is susceptible to the effects of aging and storm damage. While frame construction has been dominant in the building industry for many years, other more cost effective and time efficient solutions are becoming more common.

One alternative building approach involves the use of hollow sectional forms, which are put together in the shape of the exterior wall. The hollow forms are filled with concrete and then disassembled when the concrete sets, leaving a concrete wall. The concrete wall is long-lasting and strong against the elements, but the forms are generally expensive to setup.

Another building approach involves the use of pre-fabricated building panels which are manufactured off-site and then assembled together on-site. One such building panel is discussed in U.S. Pat. No. 6,796,093 as having a plurality of I-beam-shaped metal struts spaced about 18 inches apart with insulating foam blocks disposed between the metal struts. The metal struts have cut-outs along the length of the I-beam to reduce the total metal area and associated thermal conductivity.FIG. 1shows exemplary prior art I-beam metal strut12between foam blocks14. While the structural panel has good load-bearing characteristics, the I-beam metal strut12is continuous across foam block14, at least through portions of the metal struts and, consequently, is thermally conductive through the continuous metal areas. Since I-beams12go completely through foam blocks14, heat and cold will conduct from one side to the other side of the wall structure. In the summer, I-beam12conducts heat from the exterior to the interior of the building. In the winter, I-beam12conducts cold from the exterior to the interior of the building. In any case, the I-beam construction decreases the thermal insulation property of the building panels.

A need exists for building panels combining strength with thermal insulating efficiency.

SUMMARY OF THE INVENTION

In one embodiment, the present invention is a method of manufacturing a building panel for use in building a residential or commercial structure off-site at a manufacturing location that is geographically separate from an assembly location where the building panel is incorporated into the residential or commercial structure. The method comprises assembling a plurality of panel forms to form a panel mold having a hollow cavity within the panel mold, an overall size and shape of the hollow cavity substantially defining an overall size and shape of the building panel, a width of the hollow cavity and a height of the hollow cavity substantially defining a width of the building panel and a height of the building panel, respectively.

The method further comprises providing a first metal sheet and bending the first metal sheet to form a first T-shaped support member having a length that is substantially the same as a length of the first metal sheet. Bending the first metal sheet to form the first T-shaped support member consists of bending the first metal sheet by substantially 90 degrees across the length of the first metal sheet to form a first portion of the first metal sheet and a second portion of the first metal sheet that is substantially perpendicular to the first portion of the first metal sheet, a length of the first portion of the first metal sheet less than the width of the hollow cavity. Bending the first metal sheet further consists of bending the second portion of the first metal sheet by substantially 180 degrees across the length of the first metal sheet to form a third portion of the first metal sheet that is substantially parallel to the second portion of the first metal sheet, and further consists of bending the third portion of the first metal sheet by substantially 180 degrees across the length of the first metal sheet to form a fourth portion of the first metal sheet such that the fourth portion of the first metal sheet is parallel to the third portion of the first metal sheet, and such that an end of the first metal sheet lies proximate to where the first metal sheet was bent by substantially 90 degrees across the length of the first metal sheet to form the first portion of the first metal sheet and the second portion of the first metal sheet.

The method further comprises disposing the first T-shaped support member within the hollow cavity such that the length of the first T-shaped support member is substantially parallel to the height of the hollow cavity, such that the third portion of the first metal sheet substantially abuts an interior surface of the panel mold, and such that the first portion of the first metal sheet is substantially parallel to the width of the panel mold.

The method further comprises providing a second metal sheet to form a planar support member having a length that is substantially the same as a length of the second metal sheet and disposing the planar support member within the hollow cavity such that the length of the planar support member is substantially parallel to the height of the hollow cavity, such that the planar support member does not contact the interior surface of the panel mold, and such that the planar support member forms a first angle with the interior surface of the panel mold, wherein the first angle is not a right angle. The method further comprises filling an unoccupied space in the hollow cavity of the panel mold with a semi-fluid insulating material and solidifying the semi-fluid insulating material to form an insulating material that surrounds and encases at least the first T-shaped support member and the planar support member.

In another embodiment, the present invention is a method of making a building panel comprising assembling a plurality of panel forms to form a panel mold having a hollow cavity within the panel mold, an overall size and shape of the hollow cavity substantially defining an overall size and shape of the building panel, the hollow cavity having a width and a height that is substantially the same as a width and a height of the building panel.

The method further comprises providing a first metal sheet, bending the first metal sheet to form a first support member having a length that is substantially the same as a length of the first metal sheet, wherein bending the first metal sheet to form the first support member consists of bending the first metal sheet by a first predetermined angle across the length of the first metal sheet to form a first portion of the first metal sheet, a second portion of the first metal sheet, and a bend connecting the first portion of the first metal sheet to the second portion of the first metal sheet.

The method further comprises disposing the first support member within the hollow cavity such that the length of the first support member is substantially parallel to the height of the hollow cavity and such that the first support member touches an interior surface of the panel mold only at the bend connecting the first portion of the first metal sheet to the second portion of the first metal sheet, filling an unoccupied space in the hollow cavity of the panel mold with a semi-fluid insulating material, and solidifying the semi-fluid insulating material to form an insulating material that surrounds and encases at least the first support member.

In another embodiment, the present invention is a method of manufacturing a building panel comprising providing an insulating block and providing a first metal sheet. The method further comprises bending the first metal sheet no more than three times to form a first support member consisting of a head portion and a stem portion, where the head portion and the stem portion substantially planar in shape, and where the stem portion is disposed substantially perpendicular to the head portion.

The method further comprises attaching the first support member to the insulating block such that a length of the first support member is substantially parallel to a height of the insulating block, and such that the head portion abuts a surface of the insulating block. The first support member is further attached to the insulating block such that the stem portion partially penetrates the insulating block from the surface of the insulating block, wherein the surface of the insulating block is normal to a thickness of the insulating block, and the thickness of the insulating block is less than the height of the insulating block and is less than a width of the insulating block.

In another embodiment, the present invention is a prefabricated building panel comprising an insulating block having a width spanning from a first outer surface of the insulating block to a second outer surface of the insulating block, the width of the insulating block corresponding to a width of the prefabricated building panel.

The prefabricated building panel further comprises a first support member affixed to the insulating block, the first support member having a cross-section in a direction that is perpendicular to a length of the first support member, the first support member affixed to the insulating block such that the length of the first support member is substantially parallel to a height of the insulating block. In this embodiment, the cross-section of the first support member consists of a head and a stem that are both substantially planar in shape, wherein the stem joins the head at substantially a ninety degree angle, wherein the head of the first support member is disposed at the first outer surface of the insulating block and is substantially parallel to the first outer surface of the insulating block, and wherein the stem of the first support member is surrounded and encased by the insulating block.

DETAILED DESCRIPTION OF THE DRAWINGS

Residential, commercial, and industrial building construction can be done much more efficiently and cost effectively with pre-manufactured wall, roof, floor, and ceiling panels. The pre-manufactured panels can be made in a controlled environment, such as a manufacturing facility, shipped to the construction site, and then assembled together to form the walls and roof of the building. The pre-manufactured panels stand strong against adverse environmental conditions, such as wind, rain, snow, hurricane, flood, and earthquake. The wall and roof panels are easy to assemble into the complete building structure on the job site. As will be demonstrated, the wall and roof panels of the present invention provide improved insulation, i.e., higher R-value insulation factor, as compared to the prior art.

To construct a building with the wall and roof panels as described herein, an architect or builder will design and layout the building structure. The building may be a home, office, industrial, hotel, or commercial structure of any size and shape and as tall as the local building codes permit. The building designer will specify a blueprint of the building, including dimensions for the walls and roof. The designer then selects wall and roof panels to conform to the building blueprint, i.e., the walls and roof are made with a plurality of building panels assembled together according to the design. The panels can be round, rectangle, triangle, curved, polygon, or any other convenient shape. The selected panels are connected together on the job site to form the walls and roof of the building. The building panels can be stacked on-end with appropriate support for multi-story structures.

FIG. 2illustrates a portion of building structure20with two building panels or sections22connected together at joint26. Building panels are each made with one or more insulating blocks28. The insulating blocks28may be made with expanded polystyrene (EPS) foam formed in 48-inch blocks. Alternatively, the blocks28can have other lengths and be made with fiberglass, paper, or any other thermally insulating material. The height of each insulating block depends on the building design, typically ranging from 8-10 feet. The thickness of the insulating blocks ranges from 4-8 inches. In other embodiments, the insulating blocks may range from 2 to 12 inches in thickness. For walls greater than 48 inches in length, a plurality of insulating blocks28are interconnected to run the length of the wall. Adjacent insulating blocks28are held together with an adhesive, e.g., urethane glue. Building panel22may have side end caps34for support and protection of the foam block. Building panel22may also have top and bottom end caps (not shown). The top cap is a metal angle or “L”-shaped brace running along the top perimeter of panel22, contacting the top and sides of the insulating blocks. The bottom cap is a metal angle or “L”-shaped brace running along the bottom perimeter of panel22, contacting the bottom and sides of the insulating blocks. For the wall panels, the bottom cap may be formed in or attached to the foundation of the building structure to aid in aligning the walls and to meet hurricane and earthquake standards.

Support members or struts30are inserted into insulating blocks28to provide structural support and withstand the environmental elements, e.g., wind, rain, and snow. The building panels22are also resistant to water, mold, mildew, insects, fire, hurricanes, and earthquakes. Support members30and insulating blocks28complement one another to provide a strong yet thermally isolating building panel. Support member30can be made from a variety of materials capable of providing structural support with the insulating block, such materials including metal (steel, aluminum or composite metal), ceramic, concrete, fiberglass, graphite, wood, plastic, cardboard, rubber, and composites of such materials.

In one embodiment, support members30are formed in the shape of a “T” and run the height of the wall, from top to bottom. The stem of support member30extends partially into the insulating block28but does not extend completely through the insulating block. The support members30are installed on opposite sides of panel22, in an alternating pattern and offset or staggered with respect to the adjacent support members on the other side of the building panels, as shown inFIG. 2. The support members are about 12-18 inches apart on center of each member, and about 24-36 inches apart on each side of the building panel.

The use of panel22provides several advantages for building construction. The building panels can be made off-site, in a controlled environment such as a manufacturing facility, and then transported to and assembled at the building site. The off-site manufacturing provides cost saving efficiencies in terms of accessibility to mass production equipment, sheltered work environment, and ready access to raw materials. The building panels can be formed to any size and shape in accordance with the building design. The panels can be straight, curved, angled, etc. The insulating blocks28provide exceptional insulation properties against the outside elements. Each inch of thickness of the insulating block yields about R-4 insulation factor. A 6-inch thick foam panel would provide about R-24 value of insulation. The support members30provide structural strength to panel22. With support members30, an 8-foot by 8-foot by 6-inch section of panel22can withstand in excess of 27,000 lbs. of total axial loading directed against surface32.

In most if not all prior designs, the support struts in the foam blocks are continuous through the panel, see exemplary I-beam12inFIG. 1. The continuous metal structure of I-beam12through foam block14provides a continuous thermal conduction path from the interior surface to the exterior surface that reduces the R-value insulation factor of the prior art panel.

An important feature of building panel22is its thermal non-conductivity properties in combination with the structural strength it provides. The thermal non-conductivity property of panel22arises from the fact the support members extend only partially through the building panel. As seen inFIG. 2, each support member30, on both sides of panel22, stops in the interior portion of the insulating block28and does not extend completely through from the interior surface to the exterior surface of the building panel. In one embodiment, the support member extends about half way through the insulating block. In a 6-inch insulating block, the “T” support member extends about 3 inches into the insulating block. Support members30are typically made with metal and as such have high thermal conductive properties. The support members30inherently exhibit a thermal conduction path through the metal. The foam portion of panel22has high thermal insulation properties. Since the support members30do not extend all the way from the interior surface to the exterior surface of panel22, there is no channel of high thermal conductivity from the interior surface to the exterior surface in the body of the building panel. Thus, the thermal conduction path associated with the support members is discontinuous through panel22as the insulating material blocks the thermal transfer at the point where the support member stops in the interior of the insulating block28.

It is understood that thermal transfer through panel22is not completely eliminated with the use of support members30as insulating blocks28are not perfect thermal isolators. However, the high thermal transfer associated with the metal support members is certainly discontinuous across the wall panel22and as such significantly improves its R-value insulation factor for the wall panel as a whole.

The structural strength of building panel22arises from the arrangement of the support members30in the insulating blocks28. Each “T”-shaped support member30has a head portion parallel to and in contact with the interior and exterior surfaces of panel22. The stem of the “T”-shaped support member extends into the insulating block28. The “T”-shaped support members30are positioned on opposite sides of panel22, in an alternating pattern and offset or staggered with respect to the adjacent support members on the opposite side of the building panel. The embedded stem of support members30, arranged as shown inFIG. 2, increases the structural strength of panel22.

The support member30is shown inFIG. 3having head portion40and stem portion42. The support member is formed from a rolled sheet of steel that is bent to the desired “T” shape. The steel is 20 gauge thickness, although other gauge steel could be used as well. The “T”-shape of the support member is formed using a sheet metal bending machine and process. At about 1 inch into the width of the steel plate a first 180° bend is made at point44, commonly known as a “double-hem.” At another 2 inches into the width of the steel plate a second 180° bend is made at point46. At another 1 inch into the width of the steel plate a third bend at 90° is made at point48. The steel plate is cut at about 3 inches past point48to form stem42. The result is the double-hem “T”-shaped support member30having head portion40width of 2 inches, stem portion42of 3 inches, and a length the same as the height of panel22, i.e., 8-10 feet. In other embodiments, the head portion40can range from 2-4 inches and the stem portion42can range from 1-6 inches.

A support member50is shown inFIG. 4having the same dimensions as support member30including head portion52and stem portion54. The support member50has a plurality of cut-outs or openings56formed in the stem portion52.FIG. 5shows that support member50can have cut-outs or openings56of different sizes, shapes, and patterns. The cut-outs reduce the thermal conductivity and weight of the support member without significantly reducing its structural strength for panel22.

FIG. 6illustrates in cross-section groove or slot58cut into a side surface of insulating blocks28from the bottom to the top of panel22. For a 6-inch thick insulating block, the groove58is about 3 inches deep into the insulating block. An adhesive60such as urethane glue is disposed into groove58. A groove58is cut into insulating blocks28of panel22for each support member30. The stem portion42of support members30are then inserted into the groove58until the head portion40contacts the surface of insulating block28. The stem portion42cures with adhesive60and forms a secure union between support member30and insulating block28.

In an alternative embodiment, a shallow trench or recess62is cut into insulating block28to sufficient depth to contain head portion40, as shown in cross-section inFIG. 7. The stem portion42is inserted into groove58to cure with adhesive60. The top surface of head portion40is co-planar with the side surface of insulating blocks28and provides a flush surface for panel22.

Another embodiment for the support member is shown in cross-section inFIG. 8. The “L”-shaped support member70has head portion72and stem portion74. The support member is formed from a rolled sheet of steel that is bent to the “L” shape. About 1 inch into the width of the steel plate a first 180° bend is made at point75. At another 1 inch into the width of the steel plate a third bend at 90° is made at point77. The steel plate is cut at about 3 inches past point77to form stem74. The result is an “L”-shaped support member70having head portion72width of 1 inch, stem portion74of 3 inches, and a length the same as the height of panel22, i.e., 8-10 feet.

A shallow trench or recess76is cut into insulating block28to sufficient depth to contain head portion72. A groove78cut into a side surface of insulating blocks28from the bottom to the top of panel22. For a 6-inch thick insulating block, the groove78is cut about 3 inches deep into the insulating block. An adhesive80such as urethane glue is disposed into groove78. A groove78is cut into insulating blocks28of panel22for each support member30. The stem portion74of support members70are then inserted into the grooves78until the top surface of head portion74is co-planar with the side surface of insulating blocks28. The recessed head portion provides a flush surface for panel22.

FIG. 9shows a cut-away of insulating block28with support member30in place. Note that the cut-outs or openings56in the support member30also improve the adhesive of the stem portion to the insulating block28. Alternatively, the stems portions can be textured, roughened, corrugated, or partially punched for better adhesion in groove58to the insulating block.

FIGS. 10a-10fillustrate alternative embodiments of the support members. Each figure is a cross-sectional view of panel22.

FIG. 10ashows “U”-shaped support members90disposed in insulating block28extending the height of panel22. The “U”-shaped support members90are formed by making two 90° bends in the sheet of steel. The “U”-shaped support member90has a head portion and two stem portions extending partially into insulating block28, but does not extend all the way through from the interior surface to the exterior surface of panel22. Accordingly, the thermal conduction path through panel22, attributed to the metal support members, is discontinuous. The support members90are installed on opposite sides of panel22, in an alternating pattern and offset or staggered with respect to the adjacent support members on the other side of the building panel. The support members are about 12-18 inches apart on center of each member. The “U”-shaped support member90can also be recessed into insulating block28as described inFIG. 7.

FIG. 10bshows “T”-shaped support members100disposed in insulating block28extending the height of panel22. Opposing “T”-shaped support members100are directly opposite one another, but still do not extend all the way through from the interior surface to the exterior surface of panel22. In the embodiment ofFIG. 10b, there is a break or gap between opposing “T” support members100, the space being filled with foam to block the thermal conduction path from the interior surface to the exterior surface of panel22. Accordingly, the thermal conduction path through panel22, attributed to the metal support members, is discontinuous.

FIG. 10cillustrates the “T”-shaped support members100ofFIG. 10bwith thermally insulating connectors102placed between opposing “T”-shaped support members100. The thermal insulating connectors102are made of plastic or other rigid thermally isolating material. The thermal insulating connectors102provide additional strength for the support members100, while blocking the thermal conduction path from the interior surface to the exterior surface of panel22. Accordingly, the thermal conduction path through panel22, attributed to the metal support members, is discontinuous.

FIG. 10dshows straight support members110embedded within the interior of insulating material108. In this embodiment, the panel22can be made by creating a form of the outline of the building panel. The support members110are placed into the form, and the form is filled with the insulating material108, e.g., paper, foam, or fiberglass. The insulating material108is mixed with an adhesive to create a semi-fluid mixture that surrounds and encases the support members110as the form is filled. When the insulating material hardens, the panel forms are removed, leaving panel22. The support members110do not extend all the way through from the interior surface to the exterior surface of panel22. In the embodiment ofFIG. 10d, there is a break or gap on either end of the support member110before the interior and exterior surfaces of panel22. The space of the gap is filled with the insulating material108to block the thermal conduction path from the interior surface to the exterior surface of panel22. Accordingly, the thermal conduction path through panel22, attributed to the metal support members, is discontinuous.

FIG. 10eshows straight support members110in combination with “T”-shaped support members112embedded within the interior of insulating material108. As withFIG. 10d, the panel22can be made by creating a form of the outline of the building panel. The support members110and112are placed into the form, and the form is filled with the insulating material108in its semi-fluid state to surround and encase the support members110and112as the form is filled. When the insulating material hardens, the panel forms are removed, leaving panel22. The support members110and112do not extend all the way through from the interior surface to the exterior surface of panel22, which blocks the thermal conduction path from the interior surface to the exterior surface of panel22. Accordingly, the thermal conduction path through panel22, attributed to the metal support members, is discontinuous.

FIG. 10fshows angled support members114embedded within the interior of insulating material108. As withFIG. 10d, panel22can be made by creating a form of the outline of the building panel. The support members114are placed into the form, and the form is filled with the insulating material108. The insulating material108is mixed with an adhesive to create a semi-fluid mixture that surrounds and encases the support members114as the form is filled. When the insulating material hardens, the panel forms are removed, leaving panel22. The support members114do not extend all the way through from the interior surface to the exterior surface of panel22. In the embodiment ofFIG. 10f, there is a break or gap on either end of the support member114before the interior and exterior surfaces of panel22. The space of the gap is filled with the insulating material108to block the thermal conduction path from the interior surface to the exterior surface of panel22. Accordingly, the thermal conduction path through panel22, attributed to the metal support members, is discontinuous.

Another embodiment of panel22is shown inFIG. 11. The stem of “T”-shaped support members116and118extend only partially into the insulating material. However, the support members do not extend the complete height of panel22. Instead, panel22has a row of vertical support members116, followed by a row of horizontal support members118, followed by a row of vertical support members116, and another row of horizontal support members118, and so on. In areas120, there are horizontal support members118on the opposite surface of panel22.

Wall panel22can be formed with horizontal and vertical conduits or air channels to run electric wire and plumbing pipes. Doors and windows can be cut into wall panel22in the manufacturing facility or at the construction site. The wall panel can be formed to any shape.FIG. 12ashows a curved wall panel122with “T” support members124.FIG. 12bshows an “S” shaped wall panel126with “T” support members128.

Roof panels for the building structure20can be manufactured as described for building panel22. The same is true for floor and ceiling panels. Since roof panels rest at an angle or flat, these panels may include additional support for vertical loads bearing into the surface of the panel.

Another application for panel22involves high-rise construction. Most high-rise buildings have a frame structure with curtain wall panels placed between columns of the frame structure. Building panels like22are ideally suited to be disposed between the frame structure of a high-rise building. InFIG. 13, frame structure130has columns132made of red iron or steel. Curtain wall panels22are placed between columns132and rest on ears134or are pinned to columns132. Once in position, curtain wall panels22are welded to columns132. The curtain wall panel has an exterior surface that can be covered with mesh, sto, dinsglass, and an exposure surface such as stucco, granite, brick, or slate. The interior surface of the curtain wall panel has sheet rock and decorative covering such as paint or wall paper. Curtain wall panel22can be formed with horizontal and vertical conduits or air channels or chases to run electric wire and plumbing pipes. Alternatively, foam-filled panel22can be formed within another panel that acts as the curtain wall panel. The electric and plumbing lines can be placed in gaps between the curtain wall panel and the inner foam-filled panel22.

Panels like22have applications in many other industries, such as aircraft fuselage, automobile bodies, and marine hulls. The panels are strong, exhibit high thermal insulation properties, and can be formed to any size and shape, which would be well-suited to such applications.