Abstract:
A juncture system for structural insulated panels includes magnesium oxide moldings and/or components made of cementitious materials that are shaped to join structural insulated panels (SIPs) with inorganic faces. The various components employ “standard” shapes to make for a minimum of parts and made of materials for adequate strength. For example, connecting shapes are made of magnesium oxide reinforced with the fiberglass. Thickness of the shapes approximate the same thickness as the outside face used on the magnesium oxide SIP, thus simplifying construction.

Description:
[0001]    This application claims benefit under 35 U.S.C. §119(e) of a provisional application Ser. No. 61/057,236, filed May 30, 2008, entitled MAGNESIUM OXIDE SIP PANEL JUNCTURES, the entire contents of which are incorporated herein in their entirety. 
     
    
     BACKGROUND 
       [0002]    The present invention relates to building structures incorporating magnesium oxide structural insulated panels and junctures for same. 
         [0003]    Magnesium oxide and (non-wood) cementitious faced structural insulated panels (SIPs) are in demand in areas where termites and rot are common. However, the current approach to making these panels with plastic foam core is to use dimensional lumber (sometimes treated) for junctures, plates and blocking. A problem is that the use of wood in a product that is rot and termite resistant like magnesium oxide or fiber reinforced cement does not make sense and defeats the purpose, since wood is basically not a rot and termite resistant material that is going to last as long as magnesium oxide and cement. Yet this practice continues. 
       SUMMARY OF THE PRESENT INVENTION 
       [0004]    In one aspect of the present invention, a juncture system for joining structural insulated panels includes a plurality of connecting junctures including molded reinforced cementitious material shapes configured to connect adjacently-positioned ones of the structural insulated panels. 
         [0005]    In another aspect of the present invention, a building construction includes a plurality of structural insulated panels arranged adjacently to form joints, and a plurality of connecting junctures including molded shapes made of cementitious material and connecting adjacently-positioned ones of the structural insulated panels at the joints. 
         [0006]    The present invention includes the use of magnesium oxide for components of the juncture system, the material being well adapted to join structural insulated panels (i.e., “SIP panels”) with inorganic faces. Also, a minimum of “standard” shapes are used to make for a minimum of parts in the system. 
         [0007]    In one form, connecting shapes are made of magnesium oxide reinforced with the fiberglass, with the material strength allowing a thickness of the shapes to approximately the same thickness as the outside face used on the magnesium oxide SIP. It is contemplated that other cementitious materials may be substituted for the magnesium oxide shapes, though it is noted that some of these shapes may have flanges that are much thinner than the outer sheet on the SIP panels, thus potentially complicating construction and assembly. 
         [0008]    These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0009]      FIGS. 1 and 2  show an SIP panel with facing components made of magnesium oxide and fiberglass reinforcement. 
           [0010]      FIGS. 3-9  show versions of various junctures including connecting shape joining adjacent SIP panels like  FIG. 1 . 
           [0011]      FIGS. 10A-10J , and  FIG. 11  show various connectors for junctures. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0012]    The present concept includes the use of magnesium oxide (or other cementitious material) and fiberglass reinforcement for the juncture system that joins the SIP panels with inorganic faces. “Standard” shapes are used to make for a minimum of parts. Connecting shapes (also called “connecting junctures”) are made of magnesium oxide that is reinforced with the fiberglass for optimal strength, with a thickness of the shape being approximately the same thickness as the outside face used on the magnesium oxide SIP. It is contemplated that other cementitious materials may be substituted for the magnesium oxide shapes except the shapes may have thinner flanges, which can complicate construction. It is also contemplated that the reinforcement can be materials other than fiberglass, including metal, virgin plastic, plastic composite, recycled plastic, and/or recycled carpet. 
         [0013]    Typical thickness for the magnesium oxide panel and connecting shape might be 8 mm (or 0.314 inches) and if the shape were to be of material much stronger, it would probably be less thick such as about 18 gauge (or 0.048 inches) thick. 
         [0014]    The shapes provided will be a series of different shapes and sizes, such as:
       I&#39;S              CHANNELS              ANGLES              Z&#39;S              WEDGES                  
 
         [0020]    Shapes for typical SIP construction are rectangular, while organic faces are a variety of different materials. 
         [0021]    A first issue in determining how to make an acceptable SIP panel is to determine the appropriate thickness. The thickness is determined by strength requirements of the structure and fire code. For structure, a 12 mm thick magnesium oxide panel is stronger than a 7/16″ OSB (oriented strand board), and 7/16″ OSB is stronger than stick construction (i.e. building constructions using 2×4 and 2×6 wood studs and boards). It is appropriate to use thinner gauge to avoid “overkill” and the associated “wasted extra cost.” Generally, 6, 8, or 10 mm magnesium oxide panel will work if they both have the same amount of fiberglass as in the 12 mm magnesium oxide panels. 
         [0022]    Junctures and materials are particularly important for meeting fire codes. Specifically, part of the fire test, especially in the use of SIP panels, is what type of junctures and materials are appropriate and produce optimal results. Customers who want magnesium oxide board SIPs probably do not want dimensional lumber for junctures for the reasons noted above in the background discussion. The present components “re-invent” the junctures of “stick-like” constructions with rot and insect resistant materials. Exemplary components include molded magnesium oxide shapes having a same thickness and reinforcement as at the panel faces. Alternatively, they can be made of cementitious material and/or with other reinforced material, preferably at a thickness of at least about 18 gauge. 
         [0023]      FIGS. 1 and 2  show an SIP panel  20  with foam interior core  21  and facing components  22  made of magnesium oxide and fiberglass reinforcement. The core  21  includes grooves  23  along edges, the grooves  23  being under edges of the reinforced magnesium oxide facing components  22 . 
         [0024]      FIGS. 3-9  show versions of various junctures including connecting shape joining adjacent SIP panels like  FIG. 1 , where the connecting shapes include a flange(s) fitting into the grooves  23  to add strength and fire resistance to the juncture. Specifically,  FIG. 3  illustrates spline connector shapes  25  that fit into coplanar grooves  23  of in-line adjacent SIP panels  20 . Screws or fasteners  26  are used to secure the juncture. Field-applied expanded foam  27  is used to fill any void between cores  21 , and field-applied mastic  28  is used to fill any void between the spline connecting shape  25  and facing components  22 .  FIG. 4  shows a U-shaped connecting shape  30  fitted into grooves  23  in an end of a SIP panel  20 . The assembly is abutted against sealant  31  on a flat upper surface  32  of a foundation  33 . An anchoring bolt  34  extends from the foundation  33  up through the connecting shape  30 . Notably, the U-shaped connecting shape  30  is first bolted to the foundation  33 ; and sealant  31  and mastic  28  applied, and then the SIP panel  20  is placed. 
         [0025]      FIG. 5  shows a corner formed by SIP panels  20 , with a U-shaped connecting shape  30  in each SIP panel  20 , and with a corner angle connecting shape  40  used to secure the juncture. Various screws  26  and  41  are used, along with a long screw  42  that extends through one of the SIP panels  20  and into the U-shaped connecting shape  30  on the other SIP panel  20 . 
         [0026]      FIG. 6  shows a roof SIP panel  20  jointed to a vertical wall SIP panel  20 . The wall SIP panel  20  includes a U-shaped connecting shape  30  and top-mounted wedge shaped connecting shape  45 . Side-facing beads of mastic  28  join the U-shaped connecting shape  30  to the wall SIP panel  20 , and top-facing beads of mastic  28  join the wedge-shaped connecting shape  45  to the U-shaped connecting shape  30  along with an angled short screw  46 . A long screw  47  extends at an angle through the roof SIP panel  20  into the wedge-shaped connecting shape  45  and to the U-shaped connecting shape  30 . 
         [0027]      FIG. 7  show coplanar wall SIP panels  20  spaced apart for receiving a floor joist  50 , and  FIG. 8  shows the wall SIP panels  20  with the floor joist  50  in place. Specifically, the wall SIP panels  20  each include a U-shaped connecting shape  30 , with mastic  28  and screws  26  and  41  for retention. The bottom wall SIP panel  20  includes a top plate  51  on which an end of the joist  50  sets. Angled screws or nails  52  extend through a portion of the joist  50 , the top plate  51 , and into the U-shaped connecting shape  30 . An outer cap board  53  coves an outer end of the floor joist  50 , and an outer face component  54  is attached to an outer surface of the cap board  53 . A Z-shaped connecting shape  55  includes a center flange resting on a top of the floor joist  50 , and outer down flange  56  forming a drip surface for the joint, and an inner up flange  57  for setting an inside position of the upper wall SIP panel  20 . Sub-floor panels  58  are secured to a top of the floor joists  50 . A screw  41  attaches the top U-shaped connecting shape  30  to a top of the top U-shaped connecting shape  30  prior to attachment of the top wall SIP panel  20 .  FIG. 9  shows a similar arrangement of top and bottom wall SIP panels  20 , each having a U-shaped connecting shape  30  but also each including a Z-shaped connecting shape  55 . An intermediate wall SIP panel (not shown in  FIG. 9 ) would be positioned in the gap between the two illustrated SIP panels  20 . 
         [0028]      FIG. 10  shows various connectors for junctures. In particular, there are shown a spline connector shape  25 , wedge connector shape  45 , and two different width U-shaped connecting shapes  30  and  30 ′. The illustrated connecting shapes also include an offset in-line connector shape  60  (for connecting wall SIP panels  20  positioned in parallel but offset longitudinally), two different corner connecting shapes  40  and  40 ′, and two different Z-shaped connecting shapes  55  and  55 ′. The edge detail of a SIP panel  20  includes grooves  23  forming a groove width of about 1″ by 2 5/16 inch deep. It is contemplated that most circumstances can be handled by a juncture system that includes five shapes, as are illustrated in  FIG. 11 . These shapes include “I” shapes, C channel shapes, “L” shapes, “Z” shapes, and wedge shapes. 
         [0029]    It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.