Building construction method

A building construction unit and a method of constructing a building using wall and ceiling panel assemblies that are made up of traditional framing materials, such as studs and interior walls, coated with insulating foam, except that the typical exterior sheathing is optional. Because the panel assembly is structurally sound and thermally insulated, the only reason to install an exterior sheath or additional roofing material is for aesthetic or practical purposes.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to building construction methods, particularly to a method and unit that provides energy efficiency and structural soundness in buildings through a foam layer shell application.

Background Art

“Light framing” construction is a known construction mode using many small and generally closely spaced members that are assembled by nailing/screwing, and the mode includes balloon, platform and light-steel framing. Light framing building techniques are commonly used, especially in the USA, to erect residential, small commercial or light industrial structures. Light-frame construction using standardized dimensional lumber has become the prevailing light construction method in North America. Use of relatively minimal structural material allows builders to enclose a large area with minimal cost, while achieving a wide variety of architectural styles.

In light platform framing, each floor is framed separately, each floor level being framed as a separate unit or platform. Freed from the need to use heavy timbers (e.g., as with a post-and-beam system), platform framing offers ease of construction. Builders first fabricate a floor, which consists of wood joists and subflooring. The floor often serves as a working platform on which the stud wall frames are fabricated in sections and then lifted into place. A second floor, or the roof, is constructed atop the first-floor wall frame sections. The roof is formed of rafters (e.g., sloping joists) or wood trusses. The standard interior wall sheathing is gypsum board (drywall), which provides fire-resistance, stability, and a surface ready for interior finishing. Light framed structures traditionally have been constructed individually at each construction site; today many of the framing elements are mass-produced elsewhere and assembled on-site.

Modern light-frame structures typically obtain strength from rigid panels (plywood and/or other plywood-like composites such as oriented strand board (OSB) used to form all or part of wall sections). Until recent years, builders often employed any of several types of diagonal bracing techniques to stabilize framed walls. Diagonal bracing remains a vital interior part of many roof systems, and in-wall wind braces are required by building codes in many municipalities or by individual state laws in the USA. Special framed shear walls also are sometimes required to promote building structural strength, especially to foster compliance with earthquake engineering and wind engineering codes and standards.

Thus in commercial and residential construction, walls typically are framed up using vertical wooden or steel studs, to which an interior wall panel made of gypsum drywall (e.g., SHEETROCK® panel), fiberboard, traditional plaster, or the like is attached. Thereafter, exterior wall sheathing is used to enclose the wall and building and provide a surface for application of exterior finish materials, such as stucco, brick façade, shingles, aluminum or vinyl siding, etc. Insulating material, such as fiber glass, rock wool or cellulose, normally is sandwiched between the interior wall panel and exterior wall sheathing in order to thermally insulate the rooms and spaces of the building. Using this traditional method, there disadvantageously is little or no insulation present where the entire length of the vertical stud contacts the interior wall panel on one side, and exterior wall sheathing on the other side, providing a conduit for heat to readily escape the interior rooms, through the studs, to the outside environment.

The present invention solves this thermal insulation problem and also requires significantly less materials to achieve a highly energy efficient and structurally sound building. The presently disclosed method and system offers advantages of structural strength (potentially compliant with many building codes respecting wind and earthquake resistance) using fewer materials and less labor intensive methodology compared to fully conventional light framing construction. Less materials and ease of construction yields benefits of faster construction and reduced construction costs.

The present invention contemplates constructing a building using wall and ceiling panel assemblies that are made up of many traditional framing materials, but which are then coated with an insulating and strengthening foam. The foam layer initially is applied as viscous flowable foam, which may be sprayed in place. After controlled application, the foam layer then hardens into an enveloping shell which provides not only thermal insulation to the completed structure, but which also lends substantial structural strength. Moreover, because the foam shell substantially seals the interior of the structure against exterior weather, an exterior sheathing and an exterior façade are optional. A structure erected according to the present invention may be, if desired, substantially air tight and water tight (except where deliberately provided with doors, windows, vents, and the like). As the structure also is structurally sound and thermally insulated, the only reason to install an exterior sheath or additional roofing material is for aesthetic purposes.

While there are examples in the prior art of applied-foam insulating wall panels, none offer the advantages of the present invention.

SUMMARY OF THE INVENTION

The present invention is a unit and method of residential and commercial building construction. The construction unit is a structure comprised of closed cell polyurethane foam and portions of traditional light framing materials, such as studs, inner wallboard, roof trusses, and inner ceiling wall board. Standoffs are installed on a wall stud or roof truss that creates a gap between the stud/truss and the wall board which allows the foam to more completely coat the wall board. Once it is hardened, the wall board, standoff, stud/truss and foam become a structurally sound, highly insulated, building. The only purpose for the outside wall sheathing materials and roofing (e.g., shingles, tiles) are for aesthetic—not structural—reasons.

The building construction unit and method of the present invention includes arranging two or more (normally a substantial plurality) panel assembly units adjacent to each other to form the walls, ceilings and floors of a building. This erection and arranging of panel assemblies is performed mostly according to known light framing techniques, but once the light framing is realized, the interior panels (e.g., gypsum board are attached to the inside of the framed walls/roof. The framed walls and roofs need not be provided with conventional exterior coverings such as brick or siding. Insulation such as fiberglass batting or blown-in cellulose need not be sandwiched between interior panels and exterior sheathing. Rather, the framed structure, including the installed interior panels, is covered with insulating foam.

Each panel assembly preferably is made of a number of studs with standoffs spaced along one side of the stud and an interior panel. For instance, where a panel assembly is being used as a wall, a number of studs are installed in the upright position a certain distance apart (this distance being calculated to provide adequate structural support for the building), and the standoffs are attached the studs so that the standoffs are between the studs and an interior wall panel. This creates gaps or spaces between the studs and the wall panel where the standoffs are not located. When the insulating foam is applied, it will fill these spaces providing more insulation for the room that is defined by the panel assembly than would be provided by the traditional method of attaching the wall panel directly to the studs.

Not only does the insulating foam provide thermal insulation, it also provides structural support so that an exterior wall panel or sheathing is not required. In a traditional building, an external panel would be attached to the exterior side of the stud, or the opposite side from the standoffs. This exterior panel would cover the studs and foam so that they could not be seen from outside the building, providing additional structural support to the building. In the present invention however, these exterior walls are not required since this method of construction provides enough structural support. Therefore, the exterior walls of a building using this method could have the appearance of insulating foam and the protruding exterior sides of the wall studs. Because this may be unattractive, the user of this method may desire to cover the exterior of the building with some material, but that material would not need to provide any structural support. The material would be for aesthetics only, for instance, the material could be made of solar panels, fabric, wood planks, reflecting material, anything, or nothing.

A combination of the studs with standoffs attached can be pre-fabricated. Further, the stud/standoff combination can be used in conventional construction methods. While not providing the structural support offered by the preferred embodiment of the present invention, the stud/standoff combination can be used such that the exterior sheathing is attached to the studs rather than an interior wall panel. Insulating foam is then sprayed on the interior side of the exterior sheathing so that the foam covers the sheathing and fills the gaps created by the standoffs prior to the installment of the interior wall panel.

In the preferred embodiment of the invention, the insulating foam is a closed-cell spray polyurethane foam (SPF) and is sprayed on such that when hardened, the foam layer is between about 2.0 inches and about 5.0 inches thick, and more preferably approximately 2.5 inches thick on wall panels and approximately 4.0 inches thick on ceiling panels. Preferably, the SPF layer hardens to a medium density (preferably between approximately 1.5 lbs/ft3and approximately 4.0 lbs/ft3, most preferably approximately 2.0 lbs/ft), and is closed-cell to provide structural strength. The SPF layer is applied to the arranged panel assemblies as continuously as practically possible, and so provides continuous coverage at the junction between panel assemblies. When panel assemblies are used as walls, the studs preferably are of 2×4 or 2×6 wood or steel construction. When panel assemblies are used as ceilings, the ceiling joists or roof trusses are of conventional design. A panel assembly preferably is constructed such that the space or gap between the exterior face of a panel (e.g., gypsum board) and the interior side of the stud is, preferably, a minimum of one-half inch, i.e., the depth of a standoff is at least 0.5 inch—although this dimension may vary depending upon particular design requirements.

Like label numerals are used to denote like or similar elements throughout the various views.

DESCRIPTION OF PREFERRED EMBODIMENTS

There is disclosed hereafter a method for erecting a structure, and a construction unit erected thereby. Initial steps of erection may be similar to known techniques, including for example the provision of foundation components such as reinforced poured concrete footings and/or stem walls. The method and structure of the inventive method also may be practiced upon conventional concrete masonry unit (CMU) substructures. Conventional subflooring may be installed generally according to known techniques, including the pouring of concrete slab-on-grade, and/or the installation of truss-supported subflooring upon supporting substructure. The present invention exploits and then improves upon basic processes borrowed from light framing construction.

As used herein, certain terms have the following definitions:

A “stud” is a metal or wood post used in the framework of a structure for supporting interior wall panels such as wallboard or similar material. A stud also provides structural support for a ceiling panel or roof top in the form of a ceiling joist, rafter, roof truss, or the like.

A “panel assembly” is a portion of the building construction unit, namely, a plurality of studs, and standoffs, and a panel attached to the studs, as shown generally inFIG. 7.

Where the subscript “n” is used, “n” equals a positive integer and refers to the “nth” element of the apparatus and system that includes a plurality of such elements of indefinite number “n,” (e.g., “nth” wall panel assembly in a construction unit having a plurality of panel assemblies).

The disclosed method, and a construction unit according thereto, is intended to provide an airtight envelope that completely surrounds the habitable spaces within residential structures and/or temperature and environmentally controlled portions of commercial structures, including high rise buildings. The airtight characteristic of the envelope is subject mainly to deliberate apertures and openings in the envelope, such as doors, vents, stacks, windows, and the like, which may be disposed through/in the envelope.

Reference first is made toFIGS. 1, 4, and 7, showing an example portion of a building construction unit12(FIG. 1) and a simple panel assembly42(FIG. 7) erected according to an embodiment of the present invention. There is provided a plurality of first studs13,13nwhich in a preferred embodiment are disposed substantially vertically. Each of such first studs has an interior side14,14n(FIGS. 4, 7) and an exterior side15,15n(also shown inFIG. 7). The studs13,13nmay be composed of metal or preferably wood, generally according to conventional light frame construction.

A plurality of first standoffs16,16nare attached (e.g., with adhesive or nails) to the interior side14of each first stud13. The first standoffs16may be composed of wood, plastic, or composite, but preferably constitute a generally rigid yet thermally insulating material. Each panel assembly according to this disclosure includes a panel, and panel assembly42features first panel17. The panels of panel assemblies, including the first panel17, have a first (e.g., upper) end18, and second (e.g., lower) end19, an interior face20(seeFIGS. 1, 2) and an exterior face21. The exterior face21of the first panel17is attached to the first standoffs16to define spaces22between the exterior face21of the first panel17and the interior side14of the first studs13.

Combined reference is made toFIGS. 1 and 2. For illustrative purposes inFIGS. 1 and 2, the first panel assembly is shown in the vertical plane and the second panel assembly is shown in the horizontal plane, the first panel assembly being attached at a right angle to the second assembly. Despite this illustrative representation, any number of panel assemblies, connected or arranged at any of various angles (but most typically orthogonally), are contemplated and their arrangement in various constructive configurations is within the capability of a person skilled in the art.

FIG. 2is a vertical cross section of portions of adjoining first (e.g. vertical) and second (e.g., horizontal) panel assemblies, in the vicinity where they come together, showing single first stud13and single second stud53. There thus also are provided a plurality of second studs53, the second studs53having an interior side54and an exterior side55. The second studs are similar in general configuration to first studs13, but may serve as beams/joists and thus more preferably and likely have larger moments of inertia, or are integrated as the bottom chord in a truss (see stud53ninFIG. 9). The second studs53thus may be disposed substantially horizontally and may be, or be a part of, a roof joist system. A plurality of second standoffs56are attached to the interior side54of each second stud53of the plurality of second studs, similarly as described and shown for the first studs13.

FIGS. 1 and 2also illustrate that a second panel57(similar to panel17, such as a gypsum board) is arranged adjacent to the first panel17. The second panel57has a first end58, a second end59, an interior face60and an exterior face61. The exterior face61of the second panel57is attached to the second standoffs56to define spaces62between the exterior face61of the second panel57and the interior side54of the second studs53. A first end58of the second panel57preferably is in contact with a portion of an upper edge of the first panel17. A layer of insulating foam30is applied to cover the exterior face61of the second panel57and the exterior face21of the first panel17, filling the spaces22defined between the exterior face21of the first panel17and the interior side14side of the first studs13, also filling the spaces62defined between the exterior face61of the second panel57and the interior side54of the second studs53. The foam layer30thus contacts and adheres to both the exterior faces21,61, as well as to the interior sides14,54of the studs to constitute a shell-like layer incorporating the studs.

FIG. 2offers an enlarged, cross-sectional, diagrammatic view of the connection of a first panel assembly (including first studs13, first standoffs16, first panel17, and first spaces22), with a second panel assembly (including second studs53, second standoffs56, second panel57, and second spaces62), with the layer of insulating foam30also shown. This corner connection is at the joist band area of a framed construction, where the ends of roof joists (e.g., second studs53) rest atop the top plate (not shown for sake of simplicity of illustration) that typically runs horizontally along the top ends of vertical wall studs (e.g., first studs13).

FIG. 3illustrates that multiple standoffs16npreferably are attached to the interior side14of a representative single first stud13n, where n equals a positive integer and refers also to the nth element in a multiplicity of studs usable in a building construction unit according to this disclosure; description of a single stud serves substantially to describe a plurality of similar studs. The exterior side15is the side to which a first panel17is affixed.FIG. 4shows the single first stud13nwith standoffs16nattached the stud's interior side14. The standoffs may be composed of polymers, wood, high density expanded polystyrene, or a wood-polymer composite. Each first stud13nhas a top end68that ordinarily connects to a top plate (not shown, but generally according to light framing convention), and a bottom end69that connects to a toe plate (not shown, but also generally according to convention).FIG. 5illustrates that there is a plurality of the single first studs13n(with standoffs16non the studs' interior sides14n) whileFIG. 6is a view of the plurality of studs13nwith standoffs16nextending from the studs' exterior sides15n. Each panel assembly (e.g. assembly42inFIG. 7) includes a plurality of spaced studs13n.

Specific reference is made toFIG. 7, which depicts a representative panel assembly42according to the present disclosure. A plurality of panel assemblies are interconnected and juxtaposed as walls and roofs to erect a construction unit (e.g., unit12ofFIG. 1) having two or more walls and a roof. Doors and windows can be defined as desired in any given panel assembly. Any particular panel assembly42preferably includes a panel17n, with the exterior face21of the panel attached to standoffs16, which standoffs are in turn attached to the interior sides14of a plurality of studs13n. Space22nis defined in one direction between adjacent standoffs, and (in a second direction) between the exterior face21of the panel17nand the interior side14nof the studs13n.

Attention is invited toFIG. 8, showing the representative panel assembly42nseen inFIG. 7, but after the application of a layer of insulating foam30to cover the exterior face21nof a panel17nand also to fill the spaces22ndefined between the exterior face21nof the panel17nand the interior sides14nof the studs13n. The foam layer30preferably is polymer foam (e.g., an aromatic isocyanate) that is applied by spraying. The layer30preferably is sprayed into place (using known spray application systems) as viscous foam, but cures to a hard layer of medium density (e.g., approximately two pounds per cubic foot).FIG. 8also indicates that the foam layer30contacts and adheres to the lateral sides of the studs13n, as well as to the interior sides of the studs. There accordingly is defined a structural shell that includes a structural integration of the studs13nwith a panel17n, with the standoffs and spaces22nenhancing thermal insulation between the studs and panel without compromising structural integrity. The polymer foam preferably is applied so as to compile a layer that cures substantially integrally, preferably to define a layer30that is generally continuous over the exterior face21of a single panel assembly (but between the studs13n), as well as wrapping around the junctures (near/along wall corner stanchions, and near/along wall top plates) between adjacently juxtaposed panel assemblies.

A person skilled in the art recognizes that the mutual orientation of the studs and panel can be substantially reversed, that is, to turn the arrangement “inside out” with the studs on the inside of the construction unit and the panel on the outside. In such an alternative embodiment, the interior face of a panel faces outward with respect to the interior of the construction unit, and the spaces are defined by the spacers between the panel and the studs, whose interior sides also face inward toward the enclosed space of the structure. Thus the representative panel assembly42nseen inFIG. 7, is merely flipped, and the layer of insulating foam is applied to cover the exterior face21nof the panel17n(but now facing the opposite direction) also to fill the spaces22ndefined between the exterior face21nof the panel17nand the interior sides14nof the studs13n.

FIG. 9depicts a single second stud53nin the form of, or being a chord of, a roof truss, with multiple second standoffs56nattached to the interior side54nof the second or roof truss stud53n.FIG. 9is best considered in combination withFIG. 10, illustrating a building construction unit12according to this disclosure and as suggested byFIG. 1. The construction unit12ofFIG. 10is shown covered with the foam layer30and having second studs53arranged the form of a roof truss.

Taking reference toFIG. 11, it is seen that an example self-supporting building construction unit32according to this disclosure features a unit similar to the unit12ofFIG. 1. The construction unit32provides a third panel assembly disposed, for example, as a wall parallel to the first (wall) panel assembly and perpendicular to the second (roof) panel assembly. However, it is to be understood that a third panel assembly could be disposed or arranged orthogonally with respect to the first and second panel assemblies, i.e., to “close” the open end of the structure ofFIG. 11, with all three panel assemblies mutually perpendicular in three dimensions to define a 3-D corner. A foam layer30is in such a case applied to substantially integrate into a structural shell all three juxtaposed panel assemblies.

The third panel assembly includes a plurality of third studs73, each of the third studs73having an interior side and an exterior side, a plurality of third standoffs attached to the interior side of each third stud73, generally in accordance with those elements and features as described hereinabove for first plurality of studs13and second plurality of studs53, as well as the first and second panels17,57. Likewise, a third panel77is provided, the third panel77having a first upper end, a second lower end, an interior face80and an exterior face, the exterior face being attached to the third standoffs in a manner like unto that previous described above for the first and second panels. There also are side or lateral end edges to the third panel. Spaces are defined between the exterior face of the third panel77and the interior side of the third studs73. The first or upper end of the third panel77is adjacent to, preferably abuts, at least a portion of the second end59of the second panel57(see alsoFIG. 1).

And again, as seen inFIG. 11a layer of insulating foam30is provided on the exterior face of the third panel77, the layer30substantially covering the exterior face of the third panel77, and filling the spaces defined between the exterior face of the third panel77and the interior sides of the third studs83.FIG. 11thus depicts three of the representative panel assemblies42ofFIG. 7arranged as two parallel walls and a roof. There is a substantially continuous layer of insulating foam30, the layer30covering the exterior faces of all the panels, and filling the spaces defined between the exterior faces of the panels and the interior sides of all the studs, and bonding together the studs and panels.

It accordingly is understood that, although not depicted, according to the disclosed method two panel assemblies42may have their respective side ends placed together and with the planes of the panels disposed to define an angle (typically 90 degrees) between them, so to define two walls of a construction unit. The side ends of the panel assemblies may be connected structurally at a corner stanchion according to known principles of light framing. However, the respective side edges of the panels (e.g., a pair of panels17) of the respective panel assemblies preferably are adjacent, preferably abutted together, to define a vertical juncture that can be covered with an applied foam layer30.

A construction unit32according to the present disclosure can be self-supporting, even with only the three panel assemblies depicted inFIG. 11, due to the structural integrity and enhancement provided by the cured foam layer30—potentially even in the absence of diagonal bracing within the walls and at the corners of two walls, as commonly required in the art. The foam layer30adheres securely to all the panels and all or substantially all the studs and, when cured, with the studs and panels defines a generally integrated thermally insulating shell or envelope of the construction unit.

Still referring toFIG. 11, it is noted that there is a first juncture90defining the corner (generally in the vicinity of the joist band) whereat the first panel17and the second panel57come substantially adjacently together or in actual abutment. Similarly, the construction unit32ofFIG. 11has a second juncture91(in the vicinity of the joist band) along a corner defined where the second panel assembly57and the third panel assembly77preferably abut adjacently together. Referring also toFIG. 2, and as described further hereinafter, a construction unit32according to the present disclosure has the advantageous feature that the layer of insulating foam30is applied to wrap continuously over the outside of the junctures90,91, to cover that juncture and all other junctures similarly defined between other panels throughout a construction unit. The insulating layer30is applied substantially continuously between the first studs13, and between the second studs53, and between the third studs73as well as over the junctures90,91running perpendicular to the studs. As mentioned, the insulating foam30also is applied so to fill all the spaces (provided by the use of the standoffs, e.g.,16,56) defined between the exterior faces (e.g.,21,61) of the several panels (e.g.,17,57,77) and the interior sides (e.g.,14,54) of the studs13,53,73. When a plurality of panel assemblies are joined to erect a construction unit (typically to enclose a hollow interior habitation special volume), the application of the insulating foam layer30thereby constitutes a mostly continuous, unbroken (i.e., accounting yet for doors, windows, and other intended structural and functional openings) envelope which seals the interior of the structure from significant penetration by weather, including moisture and air.

It is readily understood by a person skilled in the art that fourth and fifth panel assemblies (substantially the same as those described) could be arranged with and against the first three panel assemblies seen inFIG. 11, to close the open ends of the structure, and thereby to compose a five-sided construction unit enclosing an open hollow interior, the overall construction unit defining a generally parallelepiped shape. All the junctures (including, e.g., junctures90,91) at the abutments of adjacent panels of adjoining panel assemblies preferably are covered with the layer of foam30. The layer30thus is essentially seamless where adjacent panel assemblies come together (i.e., at and along wall corner stanchions where to wall panel assemblies are connected, and along joist bands at the top plates where wall panel assemblies connect to a roof panel assembly.

FIGS. 12A through 12Dserve to illustrate further a method of erecting a construction unit structure in accordance with the present disclosure. It is noted that some initial steps of the method are similar to erecting a structure according to known light framing construction techniques, such as conventional frame-on-slab construction. Known techniques may be adapted to accommodate the more specific disclosure of the inventive method as described herein.

There is installed a foundation generally according to convention, which may be footings with stem walls40(e.g. reinforced concrete) as shown inFIG. 12A. A concrete slab41or other floor is provided.FIG. 12Ashows that first studs13are provided, the first studs each having an interior side and an exterior side (FIGS. 3 and 4), and may be provided vertically to define partially a wall. The first studs13with other framing elements may, according to convention, define window/doors, as suggested inFIG. 12A. First standoffs (FIGS. 5 and 6) are attached to the interior sides of the first studs13. Second studs53also are provided, the second studs likewise each having an interior side and an exterior side. InFIG. 12Athe second studs53are disposed horizontally to define partially a roof, and optionally may be part of a roof trussing system (FIGS. 9, 10). Second standoffs (FIG. 9) are attached to the interior sides of the second studs53.FIG. 12Aalso shows that third studs73are provided, the third studs each having an interior side and an exterior side (FIGS. 3 and 4); the third studs73may be provided vertically to define partially a wall. Third standoffs (FIGS. 5 and 6) are attached to the interior sides of the third studs13.

FIG. 12Bshows that a first panel17is provided, the first panel having a first end, a second end, an interior face and an exterior face. The second panel57also is provided, the second panel having a first end, a second end, an interior face and an exterior face. A first panel assembly thus is provided by connecting the exterior face of the first panel17to the first standoffs on the first studs13to define spaces between the exterior face of the first panel and the interior sides of the first studs13. The first panel assembly may define a vertical wall, and includes the first studs13, the first standoffs, and the first panel17. Similarly, a second panel assembly is provided by connecting the exterior face of the second panel57to the second standoffs to define spaces between the exterior face of the second panel57and the interior sides of the second studs53. The second panel assembly thus may define a horizontal roof, and includes the second studs53, the second standoffs, and the second panel57. A plurality of third studs73preferably was provided. A third panel77accordingly is provided, the third panel likewise having a first end, a second end, an interior face and an exterior face. As with the provision of the first and second panel assemblies, a third panel assembly thus is provided by connecting the exterior face of the third panel77to third standoffs attached on the third studs73to define spaces between the exterior face of the third panel77and the interior sides of the third studs73. The third panel assembly may define a vertical wall, and includes the third studs73, third standoffs, and the third panel77.

Reference toFIGS. 12B and 12Cindicate generally the step of adjoining together the first two panel assemblies (i.e., panel assemblies42,44ofFIG. 13), of what may eventually be a plurality of panel assemblies that are positioned with ends adjacent and adjoined together. A first panel assembly (for instance, wall panel assembly including studs13and panel17) and second panel assembly (for instance roof panel assembly including studs53and panel57) are adjoined end to end. The adjoining may be by generally conventional means, such as by nailing or framing anchors, with/to a corner stanchion (between two wall panel assemblies) or a top plate (to join a wall panel assembly to a roof panel assembly). The step of adjoining two panels assemblies preferably includes placing the first end of a first panel17adjacent to the first end of a second panel57to define a first juncture90, and applying continuously the layer of insulating foam30over the first juncture. Application of the foam layer30includes covering the exterior face of the first panel17and covering the exterior face of the second panel57, and filling the spaces defined between the exterior face of the first panel17and the interior sides of the first studs13, and filling the spaces defined between the exterior face of the second panel57and the interior sides of the second studs53, and with the same continuous application also wrapping the layer of insulating foam30over the first end of the first panel and over the first end of the second panel to cover the first juncture90.

By these steps a sealing envelope comprised of the foam layer30covers the first panel assembly and the second panel assembly. The method also preferably includes placing the first end of the third panel77adjacent to a second end of the second panel57to define a second juncture91, as also seen inFIG. 12C. Thereafter, the step of applying continuously the layer of insulating foam30preferably further comprises covering with the foam layer the exterior face of the third panel77, filling with the foam layer the spaces defined between the exterior face of the third panel77and the interior sides of the third studs73, and wrapping the layer of insulating foam over the first end of the third panel77and over a second end of the second panel57to cover the second juncture91. In this manner a sealing envelope or shell covers the first panel assembly, the second panel assembly, and the third panel assembly. This forgoing process can be successively or simultaneously repeated to juxtapose and join additional fourth, fifth, sixth or more panel assemblies (e.g. elements42n,44n,46ofFIG. 13) to erect a construction unit of practically any desired layout or configuration.

FIG. 12Dillustrates that any of a variety of suitable exterior sheathings33may optionally then be installed, e.g., to the exterior sides of the various studs, to aesthetically cover the structure and/or provide a surface for application of exterior finish materials, such as stucco, brick façade, shingles, aluminum or vinyl siding, etc. However, the installation of exterior sheathings in the inventive method and structure is optional, and primarily for aesthetics; the sealing envelope provided by the application of the continuous foam layer30in the process described provides for a sealing of the space within the structure against the weather, sound, vermin, etc.

The method of the present disclosure is further explained by reference toFIG. 13, which is an enlarged view of the construction unit ofFIG. 12C. A construction unit completed according to the basic steps of the inventive method includes a plurality of panel assemblies arranged and connected to comprise the construction unit; there are at a minimum a first panel assembly42, a second panel assembly44, and a third panel assembly46erected and configured as explained hereinabove, and as seen inFIG. 13. Fourth and fifth panel assemblies are not depicted inFIG. 13for the sake of simplicity, but may be provided to close the sides appearing to be open in the figure. The panel assemblies42,44,46are adjoined end-to-end and situated on the foundation40. The foam layer is visible in all three panel assemblies42,44,46on the exterior faces of the first panel17between the first studs13, and on the exterior face of the second panel57between the second studs53. Although not explicit inFIG. 13, it is readily understood that the foam layer also coats the exterior face of the third panel77between the third studs73.

FIG. 13Ais an enlarged vertical sectional view of a portion, designated generally at “A” inFIG. 13, of a construction unit according to a substantially completed method of the present disclosure.FIG. 13Ais similar toFIG. 2, but offers additional detail regarding advantageous features of the method and system of the invention. TheFIG. 13Aconfiguration typifies the connections between wall panel assemblies (e.g., panel assemblies42,46ofFIG. 13) and associated roof panel assemblies (e.g., panel assembly44ofFIG. 13) throughout a construction unit according to the present disclosure. Perceived instead as a horizontal sectional view,FIG. 13Aalso suffices to illustrate generally the configuration at the connections between adjacent vertically oriented wall panel assemblies (i.e. at a wall corner stanchion where two wall panel assemblies44are adjoined) in this construction unit.

FIG. 13Ashows a first stud13, with a couple of its first standoffs16attached to its interior side. The exterior face of the first panel17is attached to the first standoffs16to space the panel17apart from, but about parallel to, the first stud13. Spaces22are between the interior side of the first stud13and the exterior face of the first panel17.FIG. 13Aalso indicates a second stud53resting atop the top end of the first stud13(e.g., with top plate there between). The exterior face of the second panel57is attached to the second standoffs (not seen inFIG. 13A) to space the second panel57apart from, but about parallel to, the second stud53. A space thus also is between the interior side of the second stud53and the exterior face of the second panel57.

The top edge of the first panel17is closely adjacent to and preferably abuts an edge of the second panel57at the first juncture90. The foam layer30is applied substantially continuously to the exterior faces of panels17,57, so to fill the spaces defined between the panels and the studs13,53. Significantly and as shown inFIGS. 13A and 13B, the foam layer30also wraps around the exterior side of the juncture90where the panels abut, thereby provided a seamless seal where the panels come together. So doing at all junctures between adjoining panels provides a sealing envelope which substantially encases the exterior faces of all the panel assemblies of the construction unit to supply benefits of the invention.FIG. 13B, for example, illustrates that the foam layer30is seamless and continuous as it covers both a vertical first panel and a horizontal second panel as it envelopes the junction of the panels. A third panel assembly adjoining the first two seen inFIG. 13Blikewise is enveloped seamlessly and continuously by the same application of the foam layer30.

The foundation40seen inFIG. 13is seen in the enlarged view ofFIG. 13C. In an embodiment of the invention, the foundation includes a vertical stem wall92having an exterior face. In this alternative embodiment, the foam layer30is applied substantially continuously to coat and cover not only the exterior face of a first panel on the studs13, but also the top of a toe or sole plate93and the face94of the stem wall as well, thereby to seal and encapsulate the connection between the first panel assembly (e.g., panel assembly42) and the foundation of the construction unit structure.

Whereas the figures and description have illustrated and described the concept and preferred embodiment of the present invention, it should be apparent to those skilled in the art that various changes may be made in the form of the invention without affecting the scope thereof. The detailed description above is not intended to limit the broad features or principles of the invention, or the scope of patent monopoly to be granted. Thus although the invention has been described in detail with particular reference to these preferred embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents.