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CROSS REFERENCE TO RELATED APPLICATIONS 
     This present application claims the benefit of U.S. Provisional Application Ser. No. 61/648,980 filed 18 May 2012, which is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to structural panels, and more particularly, to a structural panel framing system without mechanical fastening. 
     BACKGROUND 
     Conventional construction of a building is generally performed according to well-known processes. Near the beginning of the construction project, excavation equipment prepares a foundation at a job site. Once the foundation is laid, building materials are brought to the job site, such as wood, metal, cement, and other various building materials. Once the raw materials arrive at the job site, construction workers begin the process of erecting a frame at the job site. For example, when a house is constructed, construction workers generally erect wooden framing for the house. After the frame is completed, construction workers fasten sheathing, such as plywood, that covers the outside of the frame using mechanical fasteners, such as nails or screws. After the sheathing has been fastened to the frame, the frames are raised into place to become walls. The walls later receive electrical and plumbing appliances, insulation, and drywall. 
     The conventional construction method of building walls and wall panels requires a great deal of construction work on the job site. The construction workers must assemble a wall frame, attach sheathing, alter the frame to accommodate electrical and plumbing appliances, and many other steps all at the job site. If the weather is rainy or snowy, construction workers may be unable to build the walls and framing during that time, thereby losing construction time. So, a method of preparing wall panels before construction begins at the job site accelerates the time to construct a building at the job site. 
     Some companies prepare structural panels in a factory and transport fully assembled structural panels to the construction site where the fully assembled structural panels are raised to form a wall for the building. Some of these factory prepared structural panels are insulated. 
     Conventional structural insulated panels require top and bottom panels to be integrated or incorporated into the panel. This structure requires an additional step during field installation. Typically, a bottom track must first be installed, a structural insulated wall panel inserted into the bottom track, installing the top track, and fastening the structural insulated wall panel with stud members. This requires a signification amount of time and manpower, as well as slowing down the building process when using structural insulated panels. So, a structural insulated panel that overcomes the problems discussed above is desired. 
     SUMMARY 
     The systems and methods described herein attempt to overcome the drawbacks discussed above by forming a structural insulated panel without mechanical fasteners. The structural insulated panel according to the exemplary embodiments may be formed in a factory. The structural insulated panel according to the exemplary embodiments may include pre-formed members of a frame that results in simple assembly of the frame. Also, the frame is pre-cut with pipe holes in the frame members for pipes to run through the panels and anchor holes for easy installation at the job site. 
     In one embodiment, a structural insulated panel framing system comprises: insulation sheathing receivable by a wall jig; a frame for placement atop the insulation sheathing; and spray foam for application to the frame and the insulation sheathing to fuse the frame and insulation sheathing to produce a structural insulated panel. 
     In another embodiment, a method for constructing a structural insulated panel comprises: fusing a frame and insulation sheathing using spray foam to produce a structural insulated panel, wherein the insulation sheathing is placed atop a wall jig, and wherein the frame is also placed atop the wall jig in alignment with the insulation sheathing. 
     In another embodiment, a structural insulated panel comprises: exterior insulation sheathing; a frame engaging the exterior insulation sheathing; and spray foam sprayed within cavities of the frame such that the spray foam substantially covers internal surfaces of the cavities and fuses the frame to the exterior insulation sheathing. 
     Additional features and advantages of an embodiment will be set forth in the description which follows, and in part will be apparent from the description. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the exemplary embodiments in the written description and claims hereof as well as the appended drawings. 
     It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings constitute a part of this specification and illustrate an embodiment of the invention and together with the specification, explain the invention. 
         FIG. 1  illustrates material layers comprising a structural insulated panel, according to an exemplary embodiment. 
         FIGS. 2A-2E  illustrate an exemplary structural framework for the structural insulated panel, according to an exemplary embodiment. 
         FIGS. 3A and 3B  illustrate a wall jig used to assemble the structural insulated panel, according to an exemplary embodiment. 
         FIGS. 4A and 4B  illustrate exterior insulation sheathing being placed on a wall jig, according to an exemplary embodiment. 
         FIGS. 5A and 5B  illustrate a woven fiberglass mesh being applied to the exterior insulation sheathing, according to an exemplary embodiment. 
         FIGS. 6A-6D  illustrate framing being positioned on the wall jig and fastened to the wall jig, according to an exemplary embodiment. 
         FIGS. 7A-7D  illustrate holes and grommets in the structural framework for electrical or plumbing appliances that extend through the structural insulated panel, according to an exemplary embodiment. 
         FIGS. 8A and 8B  illustrate spray foam being applied to the structural insulated panel, according to an exemplary embodiment. 
         FIG. 9  illustrates a flow chart for assembling the structural insulated panel, according to an exemplary embodiment. 
         FIGS. 10A-10D  illustrate connection plates and splice covers for enabling panel-to-panel connections between structural insulated panels, according to exemplary embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to the preferred embodiments, examples of which are illustrated in the accompanying drawings. 
     The embodiments described above are intended to be exemplary. One skilled in the art recognizes that numerous alternative components and embodiments may be substituted for the particular examples described herein and still fall within the scope of the invention. 
     Referring to  FIG. 1 ,  FIG. 1  illustrates the material layers comprising the structural insulated panel  100 . The structural insulated panel  100  includes a structural framework  102 , an exterior insulation sheathing  104 , an armor mesh  106 , and closed cell spray foam  108 . 
     The structural framework  102  may comprise metal studs or any other framing materials, such as wood framing. The structural framework  102  may comprise any automatic framing system, but preferably, the structural framework  102  comprises cold-formed steel framing, such as the Nuconsteel® Nuframe 3.5″ wide steel framing. Also, any size steel frame may comprise the structural framework  102 . The structural framework  102  may include steel frames of any steel gauge. For example, the structural framework  102  may have 20 gauge studs at 20 inches on center. The gauge and distance between studs may vary depending on design choices. The structural framework  102  may be riveted, screwed, or crimped, depending on the steel stud manufacturers recommendation. The structural framework  102  includes studs, members  202 D 3 , braces  202 D 2 , blockings  202 D 1 , and any other pieces necessary to construct the structural framework  102 . The structural framework  102  may be formed and assembled before assembling the structural insulated panel  100 , which is described in greater detail below in reference to  FIG. 2 . 
     The exterior insulation sheathing  104  may be, but is not limited to, expanded polystyrene (EPS). The exterior insulation sheathing  104  may also comprise extruded polystyrene (XPS) or any other rigid sheathing. For example, if EPS sheathing is used, the EPS sheathing may have a thickness of 1 inch, and a minimum density of 2 pounds per cubic foot. The exterior insulation sheathing  104  may come in a standard size of 4 feet by 16 feet, but the exterior insulation sheathing  104  may be cut according to a specification for the panel. The exterior insulation sheathing  104  may also be cut for openings, such as doors or windows, or irregularities, such as if the panel  100  is not rectangular in shape. 
     The armor mesh  106  may comprise a woven fiber glass mesh material that is applied to the external insulation sheathing  104  or embedded into the closed cell spray foam  108 . Preferably, the woven fiber glass material comprising the armor mesh  106  has a weight of 4.5 ounces per yard, but other weights may be used to form the armor mesh  106 . The armor mesh  106  may include other thicknesses, weights, or materials so long as the closed cell spray foam  108  is able to circumvent or penetrate the armor mesh  106  and glue together the exterior insulation sheathing  104 , the structural framework  102 , and the armor mesh  106 . 
     The closed cell spray foam  108  may generally be sprayed onto the other material layers to a thickness of 1 inch. The closed cell spray foam  108  may have any thickness, but the closed cell spray foam  108  may have at least one inch thickness. The closed cell spray foam  108  may have a density of 2 pounds per cubic foot. The closed cell spray foam  108  may have another density, but the closed cell spray foam  108  has a density of at least 1.8 pounds per cubic foot. The density of the closed cell spray foam  108  may be chosen based on a desired impact resistance and r-value for thermal resistance. 
     In some embodiments, the structural insulated panel  100  further comprises open cell spray foam  110 . The open cell spray foam  110  may have a density of 0.5 pounds per cubic foot. The open cell spray foam  110  may have a thickness that depends on the width of the structural framework  102 . For example, if the structural framework  102  is 3.5″ in depth, the open cell spray foam  110  may have a maximum thickness of 2.5″. The density of the open cell spray foam  110  may also be chosen based on a desired impact resistance and r-value. 
     In some embodiments, the structural insulated panel  100  further comprises a drywall board  112 . The drywall board  112  may comprise gypsum and may be coated with any common interior finish, such as paint or wall paper. For example, the drywall board  112  may have a thickness of ½ inch. 
     In some embodiments, the structural insulated panel  100  may further comprise an exterior insulation finishing system (EIFS) or stucco base coat  114  and finishing coat  116 , such as BASF® Synergy™ Alpha basecoat and BASF® Synergy™ finish coat, if the structural insulated panel  100  includes EIFS or stucco. If the structural insulated panel  100  includes the base coat  114 , an open weave glass fiber reinforcement mesh  115  may embed the base coat  114 . The finish coat  116  may include textured or colored material, or the finish coat  116  may be 100% acrylic. 
     The base coat  114  and the finishing coat  116  are one example of an exterior surface that may be applied to the structural insulated panel  100 , but many other exterior finishes may be applied to the structural insulated panel  100 , such as cement siding, metal siding, PVC siding, paint, or any other exterior finish. 
     Referring to  FIGS. 2A-2E ,  FIGS. 2A-2E  illustrate exemplary structural frameworks  202 B-E and structural framework components. As shown in  FIG. 2A , a plurality of framing components  230  may be formed using a roll former. The roll former may include galvanized steel coils that assist in forming the framing components  230 . A software application may be used to design the structural framework  202 , and the software created design may be printed out using the roll former. The software application allows a designer to not only control the sizes, thickness, gauge, and distance between studs, but the software application also allows a designer to design for abnormalities into the structural framework  202 , such as holes  232  where electrical wiring, may extend through the structural insulated panel. 
     The roll former may create studs, blocks, beams, posts, bracings, strappings, or any other type of framing component  230  for inclusion in the structural frameworks  202 B-E. The framing components  230  are cut, punched, notched and pre-drilled to receive rivets or screws for assembly. When all the framing components  230  have been formed, the framing components  230  are assembled with a pop-riveter or an electric screw gun based on the type of fasteners chosen to assemble the structural framework  202 . The structural frameworks  202  may be fabricated to any length or height.  FIGS. 2B-2E  show a plurality of different structural frameworks  202 B-E. As shown in  FIGS. 2B-2E , the shape and structure of the structural frameworks  202 B-E may vary according to design specifications. For example, the structural framework  202 D in  FIG. 2D  is cut for a window  234 , and the structural framework  202 E in  FIG. 2E  is cut for a doorway  236 . When forming the frame components  230 , each frame component  230  may be pre-labeled with an alpha-numeric label. The labels on the frame components  230  may match labels from the software application, and the labels may assist in assembling the structural framework  202 . 
       FIGS. 3A and 3B  illustrate an exemplary wall jig  340  that may be used to assist in assembling the structural insulated panel.  FIG. 3A  illustrates a front view of the wall jig  340 , and  FIG. 3B  illustrates a side view of the wall jig  340 . As shown in  FIGS. 3A and 3B , the wall jig  340  includes a flat back panel  342  and a ledge  344 . Components of the structural insulated panel may be placed on the ledge  344  and laid against the flat back panel  342 . The flat back panel  342  may be angled so that components of the structural insulated panel may be leaned against the flat back panel  342  during panel assembly. The flat back panel  342  and the ledge  344  may each extend substantially perpendicularly to each other. The wall jig  340  may be relatively tall, such as over 18 feet tall so that the wall jig  340  is taller than any structural insulated panel being assembled using the wall jig  340 . The flat back panel  342  may be surrounded by a metal locking bar  346 . The metal locking bar  346  may receive tie bars, and the tie bars secure the panel components against the wall jig  340 , which is described in greater detail with reference to  FIGS. 6A-6B . The wall jig  340  may further include a clamping mechanism used to secure horizontal tie bars to the ledge  344 . 
       FIGS. 4A-B  illustrates two sections of the exterior insulation sheathing  404  being laid against the wall jig  440 . As shown in  FIG. 4A , a section of exterior insulation sheathing  404  is being laid against the wall jig  440 , and in  FIG. 4B , two sections of exterior insulation sheathing  404  rest against the wall jig  440 . 
     After placing the exterior insulation sheathing  404  on the wall jig  440 , the armor mesh is applied to the exterior insulation sheathing  404 . Referring to  FIGS. 5A and 5B , the armor mesh  506  is attached to the exterior insulation sheathing  504 . The armor mesh  506  may be temporarily attached to the exterior insulation sheathing  504  using mechanical fasteners, such as nail tacks, glue, spray foam, or another adhesive. In some embodiments, the armor mesh  506  comes as a roll, and the roll has a width, such as 48 inches. The armor mesh  406  may be cut and applied to the exterior insulation sheathing  504 . When applying the armor mesh  506 , the armor mesh  506  should overlap at least 3 inches at joints between two strips of armor mesh  506 . The armor mesh  506  reinforces the strength of the exterior insulation sheathing  504 . For example, in areas where hurricane force winds occur regularly, the reinforcement provided by the armor mesh  506  helps the structural insulated panel withstand such high winds and strong forces. 
     After placing the exterior insulation sheathing  504  on the wall jig and placing the armor mesh  506  on the exterior insulation sheathing  504 , the exterior insulation sheathing  504  and the armor mesh  506  may be cut to match the design specifications. For example, the exterior insulation sheathing  504  and the armor mesh  506  may be cut for doors and windows. As a result of cutting the exterior insulation sheathing  504  and the armor mesh  506 , the exterior insulation sheathing  504  and armor mesh  506  should match the structure of the assembled structural framing. 
     Referring now to  FIGS. 6A-6D , after the exterior insulation sheathing  604  and the armor mesh  606  have been cut according to the design of the panel, the wall jig  640  receives the structural framework  602 , as shown in  FIG. 6A . As shown in  FIG. 6A , the cut exterior insulation sheathing  604  matches the assembled structural framework  602  in form, and the structural framework  602  is placed on the wall jig  640  such that the form of the structural framework  602  and the cut exterior insulation sheathing  604  align. 
     Subsequently, the structural framework  602  and the exterior insulation sheathing  604  are not attached with the use of mechanical fastenings, such as nails or screws. Instead, as shown in  FIG. 6B , vertical tie bars  650  are clamped into the wall jig  640  to secure the structural framework  602  to the exterior insulation sheathing  604  and prevent any movement of the structural framework  602  or the exterior insulation sheathing  604  on the wall jig  640 .  FIG. 6C  illustrates two vertical tie bars  650  securely fixing the structural framework  602  to the wall jig  640 . 
     In addition to the vertical tie bars  650 , a horizontal spacer bar  652  may be placed on the ledge  644  of the wall jig  640  against the bottom of the structural framework  602 , which is illustrated in  FIG. 6D . The horizontal spacer bar  652  secures a bottom member of the structural framework  602  to the wall jig  640 . A locking mechanism  654  locks the horizontal spacer bar  652  against the structural framework  602 . 
     The horizontal spacer bar  652  and the vertical tie bars  650  securely clamp the structural framework  602  and the exterior insulation sheathing  604 , including the adhered armor mesh  606 , to the wall jig  640  while a spray foam is applied. The application of the spray foam is described in greater detail with reference to  FIGS. 8A and 8B . Once the structural framework  602 , the exterior insulation sheathing  604 , and the armor mesh  606  are locked into place on the wall jig  640 , the spray foam may be applied to fuse together the structural framework  602 , the exterior insulation sheathing  604 , and the armor mesh  606 . After fusing the structural framework  602 , the exterior insulation sheathing  604 , and the armor mesh  606  using the spray foam, the tie bars  650  and the horizontal space bar  652  are removed and are not included in the structural insulated panel. 
     Some structural insulated panels include appliances for plumbing or electrical wiring. As described above, the structural framework  602  was designed and cut according to a design that was mindful of such electrical or plumbing appliances. For example, the structural insulated panel may include pipes where plumbing fluid or electrical wires may extend through the panel.  FIGS. 7A-7D  illustrate such electrical or plumbing appliances installed into a panel. 
     Referring to  FIG. 7A , the structural framework  702  has pre-cut holes  732  that accommodate electrical or plumbing appliances. The holes  732  were cut when forming the structural framework  702  components. Referring to  FIG. 7B , the holes  732  may be installed with grommets  762 , if necessary. A rigid pipe  764 C may extend through the holes  732  and grommets  762 , as shown in  FIG. 7C . For example, electrical wires may extend through the rigid pipe  764 C so that an electrician may easily wire a building erected using the structural insulated panels according to the exemplary embodiments described herein.  FIG. 7C  illustrates a rigid pipe  764 C extending horizontally, and  FIG. 7D  illustrates a rigid pipe  764 D extending vertically. The rigid pipe  764 C or  764 D may extend in any direction so long as the structural framework  702  has been pre-cut in preparation for the installation and extending direction of the rigid pipe  764 C or  764 D. 
     The rigid pipe  764 C or  764 D may be coated with a release agent that prevents spray foam from adhering to the surface of the rigid pipe  764 C or  764 D. The release agent may be lithium grease, polish wax, vegetable oil, other oils, or any other release agent that prevents the adhesion of spray foam. Other components in the structural insulated panel may need to be coated with the release agent other than the rigid pipe  764 C or  764 D, depending on the structure of the structural insulated panel. After the application of the spray foam, the rigid pipe  764 C or  764 D and any other components coated with the release agent my be cleaned of any spray foam clinging to the rigid pipe  764 C or  764 D before completing assembly of the structural insulated panel. 
     Referring to  FIGS. 8A-8B , the closed cell spray foam  808  is applied within stud cavities  870 . The spray foam may be sprayed on using a spray foam reactor. The spray foam reactor may heat a two component spray foam comprising icynene and spray polymer to approximately 130 degrees Fahrenheit at 1500 pounds per square inch (psi) of pressure. Other low temperature and low pressure spray foam systems may be substituted for the spray foam reactor described above, such as, for example, TVM® Foam, Tiger Foam™, Froth Pack™ foam. 
     The spray foam reactor connects to a spray foam gun  872  that is supplied with up to 160 psi of pressurized air, and the spray foam gun applies spray foam  808  within the stud cavities  870  on top of the exterior insulation sheathing  804 , the armor mesh  806 , and the structural framework  802 . As shown in  FIG. 8B , the spray foam  808  may substantially cover the studs of the structural framework  802  as well as substantially cover surfaces within the cavities  870 . The applied spray foam  808  may substantially coat the exterior insulation sheathing  804 , the armor mesh  806 , and the structural framework  802  to any thickness, but generally the thickness of the spray foam  808  is approximately 1 inch thick. 
     By using spray foam to fuse the components of the structural insulation panel rather than mechanical fasteners, the panel may be constructed very quickly. Also, the closed cell spray foam provides thermal insulation properties that help keep the structure cool or warm depending on the season. 
     The open cell spray foam may fill the remaining cavities  870 , but this process of applying the open cell spray foam may occur at the job site after electrical, mechanical, and plumbing systems have been installed in the panel. Open cell spray foam may fill the cavities  870 , or other insulation may fill the cavities  870 . The open cell spray foam may provide further insulation. So, the insulation of the panel may be provided by either the closed cell spray foam or the open cell spray foam. 
     Referring now to  FIG. 9 , a method  900  for creating a structural insulated panel is illustrated. Beginning in step  902 , a software application is used to design the structural insulated panel. The software application allows a user to set the dimensions of the panel; account for any windows, doorways, or other irregularities; and specify the location of any holes for wiring or plumbing appliances. After the software application designs the panel, the software application creates a print map describing how to form all of the members, blocks, and braces that comprise the structural framework. Using the map created by the software application, all structural framework components are formed in step  904  using, for example, a roll former. After forming all the components of the structural framework, the structural framework may be assembled using the formed framework components in step  906 . Concurrently, previously, or subsequently to the forming and assembling of the structural framework, the exterior insulation sheathing may be laid on the wall jig in step  908 . Subsequently, the armor mesh may be applied to the exterior insulation sheathing in step  910 . If necessary, the exterior insulation sheathing and the armor mesh may need to be cut to accommodate doorways or windows or other design features, and this cutting may be performed after the application of the armor mesh. After the exterior insulation sheathing, the armor mesh, and the structural framework are fully formed and prepared, the structural framing may be placed on the wall jig in alignment with the exterior insulation sheathing in step  912 . The structural framework may be secured against the exterior insulation sheathing using vertical tie bars, horizontal spacing bars, and locking mechanisms in step  914 . After locking and securing the components to the wall jig, rigid pipes may be inserted through pre-cut holes for electrical or plumbing appliances. Finally, in step  916 , a spray foam may be applied to the exterior insulation sheathing, the armor mesh, and the structural framework to fuse these components together without the use of mechanical fasteners. The applied spray foam in step  916  may be closed cell or open cell spray foam, or a combination of both. The spray foam may be applied to a thickness of one inch or more depending on a chosen r-value. Optionally, an open cell spray foam may further fill the cavities of the panel, and this optional step may be performed in a factory or at a job site. For example, the closed cell spray foam may be applied to a thickness of 1 inch, and the open cell spray foam may be applied to a thickness of 2.5 inches to fill the cavities of the panel. 
     During installation at the job site, all panels have structural members built in, so additional bottom and top tracks are not necessary to install the panel at the job site. The bottom track of the structural insulated panel of the exemplary embodiments has pre-punched anchor holes so that no additional drilling is necessary to fasten the wall to the foundation cement slab at the job site. Also, all studs line up with a truss layout designed before constructing the structural insulated panel of the exemplary embodiments. So, a top track is also unnecessary. 
     The structural insulated panel of the exemplary embodiments may further have panel-to-panel connections with top track splice covers and connection plates. As shown in  FIG. 10A , a top track splice  1080  may be a C-channel that is at least 8 inches long. The top track splice  1080  bridges over the top track of two adjacent panels  1000 ,  1001 . The top track splice  1080  fastens to both adjacent structural insulated panels  1000 ,  1001  using at least 4 screws. Exterior screws may be drilled through the exterior insulation sheathing. 
     Another panel-to-panel connection is illustrated in  FIG. 10B . As shown in  FIG. 10B , a connection plate  1082  may further connect adjacent panels  1000 ,  1001 . For example, 3″×3″ connection plates  1082  may be spread evenly over the height of the panel, and each connection plate  1082  is screwed into the frame of each panel. For example, the connection plate  1082  has four holes for fasteners, and two fasteners are fastened to each panel  1000 ,  1001 . The connection plates may be placed inside or outside of the building. 
       FIG. 10C  illustrates an L-shaped connection plate  1084  for a two perpendicular panels  1000 ,  1001 . The L-shaped connection plate  1084  connects two adjacent and perpendicular panels  1000 ,  1001 . Like the connection plate  1082  in  FIG. 10B , the L-shaped connection plate  1084  fastens twice to each panel  1000 ,  1001 . The L-shaped connection plate  1084  may be used at corners. 
       FIG. 10D  illustrates a T-shaped connection plate  1086 . At the intersection of three panels  1000 ,  1001 ,  1001 P, the T-shaped connection plate  1086  fastens to each of the three panels  1000 ,  1001 ,  1001 P. For example, two fasteners may fasten the T-shaped connection plate  1086  to each panel  1000 ,  1001 ,  1001 P. 
     While three connection plates have been illustrated in  FIGS. 10B-D , other connection plate shapes and configurations may be necessary depending on the architecture of the building. 
     As described above, the structural insulation panels require simple and fast assembly of wall panels. The wall panel may be brought to the job site as a completed panel, and the pre-cut holes of the top and bottom tracks of the wall allow construction workers to quickly fasten walls to slabs, foundations, floors, ceiling, and other wall panels. 
     The embodiments described above are intended to be exemplary. One skilled in the art recognizes that numerous alternative components and embodiments that may be substituted for the particular examples described herein and still fall within the scope of the invention.

Summary:
Systems and methods are disclosed herein to a structural insulated panel framing system comprising: insulation sheathing receivable by a wall jig; a frame for placement atop the insulation sheathing; and spray foam for application to the frame and the insulation sheathing to fuse the frame and insulation sheathing to produce a structural insulated panel.