Abstract:
A system for constructing a structure, such as a wall, by assembling a plurality of interlocking panels together, is provided. Each of the panels includes a core made of an insulating material, preferably, an expanded polystyrene (EPS). Importantly, the panels include stiffeners (studs) on the outer surfaces; each spaced, preferably, about 24 inches on center (OC), to form a rigid exoskeleton. Unlike in conventional wood framing, the studs do not extend from the exterior surface to the interior surface. Instead, the studs are each structured as C-shaped supports wherein each stud is inserted into a grove pair cut into the core. Accordingly, conduction across the studs from the exterior to the interior, and vice versa, does not occur because the studs do not extend through the panels.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application is a continuation of, and claims priority to and the benefit of, U.S. Ser. No. 12/715,288 entitled “CONSTRUCTION SYSTEM USING INTERLOCKING PANELS” filed on Mar. 1, 2010. The &#39;288 application is related to and claims priority from prior provisional application U.S. Ser. No. 61/157,021 filed by Jeffrey A. Black on Mar. 3, 2009. Both of which are incorporated herein by reference for any purpose. 
     
    
     FIELD OF INVENTION 
       [0002]    The present invention relates to prefabricated building components, and, more particularly, to a construction system using interlocking panels, the panels including a polymeric insulated core and a steel exoskeleton. 
       BACKGROUND OF THE INVENTION 
       [0003]    Recent changes in the construction industry have led to an increased use by builders of prefabricated building components. Despite its many benefits, however, builders have not fully embraced prefabricated building components using alternatives to wood. For example, there has been reluctance to use components made from steel, rather than wood, in the mistaken belief that steel is more costly. However, several studies have actually shown that building a structure using steel costs about the same as using conventional wood framing. Furthermore, another reason that builders have been reluctant to use prefabricated alternatives to wood has been the lack of certification by recognized groups such as the International Code Council (ICC). 
       SUMMARY OF THE INVENTION 
       [0004]    A system for constructing a structure, such as a wall, by assembling a plurality of interlocking panels together, is provided. Each of the panels includes a core made of an insulating material, preferably, expanded polystyrene (EPS). Importantly, the panels include stiffeners (studs) on the outer surfaces; each spaced, preferably to national and international code requirements at 24-inches on center (24″ OC), to form a rigid exoskeleton. Preferably, the studs are made of galvanized steel. Unlike in conventional wood framing, the studs do not extend from the exterior surface to the interior surface. Instead, the studs are each structured as C-shaped supports wherein each stud is inserted into a grove pair cut into the core. Accordingly, conduction across the studs from the exterior to the interior, and vice versa, does not occur because the studs do not extend through the panels. 
         [0005]    Preferably, each of the panels has a top track and a bottom track, these tracks made from steel. Preferably, the bottom panels are attachable to a floor, such as a concrete floor, using suitable fasteners. Preferably, the top tracks are attachable to a ceiling using suitable fasteners. Preferably, the panels can be joined together by fitting complementary L-shaped edges together. However, any suitable mating or attachment method can be used to join adjacent panels. Accordingly, workers can build a wall, for example by connecting a series of panels together, and fastening the bottom and top tracks. Panels can be assembled to form a comer by trimming a portion of a first track to allow a second track to overlap. Preferably, the comer portion is secured to the floor with an additional fastener for extra strength. Preferably, the panels are marked with indicia to assist in assembly of the wall structure and/or identify the maker and/or seller of the wall system. 
         [0006]    A notable feature of the present invention is that each of the panels can have pre-molded (or cut) channels useable to receive utility runs, such as, for example, wires, cables, and plumbing. In one embodiment, each panel has a vertical channel and two horizontal channels along the entire width of the panel. Preferably, the horizontal channels have a depth greater than the depth of the groove pairs holding the studs, so as to prevent the studs from impeding utility runs through the horizontal channels. 
         [0007]    Another notable feature of the present invention is that for added structural support, a splice plate can be used to connect one top track to an adjacent top track. The splice plate can be made of any suitably strong and stiff material and secured to the top tracks by known methods, such as, for example, using adhesive bonding or fasteners. The dimensions of the splice plate depend on the dimensions of the top track. 
         [0008]    Another notable feature of the present invention is that the studs preferably include inwardly extending tabs to assist in securing the studs to the panel. 
         [0009]    Another notable feature of the present invention is that the components used to create each of the panels are made in accordance with ICC and ICBO code requirements. 
         [0010]    Additional components of the present invention include jam sections that can be inserted between the panels to create window openings or entrance ways such as doorways, and trim tracks that can be used to trim window areas. 
         [0011]    These and other aspects, features, and advantages of the present invention will become apparent from the following detailed description of preferred embodiments, which is to be read in connection with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  shows an example of a panel useable, in conjunction with other such panels, to construct a structure according to the construction system described herein; 
           [0013]      FIG. 2  shows an example of a bottom track; 
           [0014]      FIG. 3  shows an example of the bottom track of  FIG. 2  fastened to a concrete floor; 
           [0015]      FIG. 4  shows the panel of  FIG. 1  in greater detail; 
           [0016]      FIG. 5  shows an example of interlocking panels; 
           [0017]      FIG. 6  shows an example of a stud attachable to a panel to provide support, including inwardly extending tabs to assist in securing the studs to the panel; 
           [0018]      FIG. 7  shows a close-up detail of grooves formed in the panel core for receiving the studs; 
           [0019]      FIG. 8  shows an embodiment in which panels are secured to a bottom track by screwing leg members of the bottom track to each stud on each of front and back sides the panels with sheet metal screws; 
           [0020]      FIG. 9  shows an example of splice plates being added to the top tracks for added structural support; 
           [0021]      FIG. 10  shows an example of bottom tracks meeting at a corner; 
           [0022]      FIGS. 10 and 11  show assembly of bottom tracks and top tracks meeting at respective corners; 
           [0023]      FIG. 12  shows an example of a C-shaped end cap covering a flat side of a comer panel; 
           [0024]      FIGS. 13 and 14  show examples of jam sections being installed; 
           [0025]      FIG. 15  shows an example of a trim track being installed; and 
           [0026]      FIGS. 16 and 17  show additional views of the panel. 
       
    
    
     DETAILED DESCRIPTION 
       [0027]      FIG. 1  shows an example of a panel  1  useable, in conjunction with other such panels  1 , to construct a structure. As shown, the panel  1  includes a plurality of supports, referred to herein as studs  2 , which are made from a rigid material, such as, for example, galvanized steel. The panel  1  preferably includes a bottom track  3  and a top track  4 , as shown. As shown in  FIG. 2 , the bottom track  3  can be constructed of a C-shaped, sheet metal having leg members  5 ,  6  extending upward from a base member  7 . Preferably, the top track  4  is identical to the bottom track  3 . In a preferred embodiment, the bottom track  3  can be constructed from 16-gauge galvanized steel sheet metal However, it is to be understood that other structurally strong and relatively stiff materials can be used, depending on the desired structural specification of the completed wall. The base member  3  can be fastened to a concrete floor slab by any suitable means, such as, for example, using adhesive bonding, fasteners (e.g., expansion bolts, concrete nails, etc.) In the embodiment shown in  FIG. 3 , the track  3  is secured to a concrete floor using bolts, each bolt secured to the floor using a nut/washer combination. It is understood that the systems and methods of the present disclosure can be used to create other structures such as roofs. In certain cases, fastening of the bottom track  3  to a floor would then not be necessary. 
         [0028]      FIG. 4  shows the panel  1  in greater detail, according to a preferred embodiment. The panel  1  preferably includes a polymer foam insulating core A. In one embodiment, the insulating core A includes an expanded polystyrene (EPS). Fiber reinforcement, such as, for example, carbon fiber, can be added to the polystyrene for added structural strength. Additionally, the core A can include flame retardant components. The insulating core A can be molded in a variety of shapes and sizes and cut to a desired size, by a saw or hot-wire cutting or pre-molded to the desired specifications, for example. In one embodiment, the insulating core A can be pre-molded EPS and can have a height of about 10 feet, a width of about 4 feet, and a thickness of about 6 inches. (See  FIG. 16 ). The density of the EPS used for the insulating core A can be 1.5 pounds per cubic foot, for example. A notable and distinguishing feature of the present invention is that the components used to create each of the panels are made in accordance with International Code Council (ICC) and ICBO code requirements. 
         [0029]    As shown in  FIG. 4 , the panel  1  can have two spaced apart parallel groove pairs  8 ,  9  and  10 ,  11  of a front side  12  along the entire height of the panel  1 , each one of the grove pairs  8 ,  9  and  10 ,  11  for receiving a respective stud  2 . Similarly, a rear side  13  can also include two groove pairs  14 ,  15  and  16 ,  17 , each one of the grove pairs  14 ,  15  and  16 ,  17  for receiving a respective stud  2 , as shown. Depending on the structural support desired, the panel  1  can include more or fewer of the studs  2 . Alternatively, a single channel can be used instead of the groove pairs to receive the studs  2 . The groove pairs  8 ,  9  and  10 ,  11  are preferably positioned directly opposite of the respective grooves pairs  14 ,  15  and  16 ,  17 . Material can be removed from the core A between each groove pair  8 , 9 ;  10 ,  11 ;  14 ,  15 ; and  16 ,  17  to create recessed areas  18  (also shown  FIG. 7 ) so that when the studs  2  are inserted in the respective groove pairs, each stud  2  can be flush with the front and rear sides  12 ,  13  of core A.  FIGS. 7 and 17  also show that core A can be marked with indicia  19  to assist in assembly of the wall structure and/or identify the maker and/or seller of the wall system. 
         [0030]    In an embodiment of the present invention, groove pairs are positioned on the panel  1  so that the studs  2  are spaced about 24 inches apart from each other. In prior art wall construction, insulating material is placed between studs which extend the depth of the wall. This permits conduction from one side (interior or exterior) to the opposite side (interior or exterior) of the wall. In contrast, wall structures created with the wall system of the present invention do not allow conduction of heat (and transmission of sound, vibration, etc.) through the studs since the studs do not extend from one side to the opposite side. In other words, having the studs  2  on both sides  12 ,  13 , without contacting each other, prevents conduction from the one side  12  to the other side  13  through the studs  2 . Panel  1  does not have any conductive components passing through the core A from one side  12  to the other side  13  which results in superior insulative properties. 
         [0031]    One of the front rear sides  12 ,  13 , depending on which will face the interior of the structure to be constructed, can have one or more horizontal channels  20 ,  22  and/or vertical channels  24  to receive utility runs, such as, for example, electric and plumbing. In one embodiment, shown in  FIG. 4 , panel  1  has one vertical channel  24  along the interior height of panel  1  and two horizontal channels  20 ,  22  along the entire width of the panel  1 . The channel  20  can be spaced eighteen inches from top end  26 , and channel  22  can be spaced eighteen inches from bottom end  28 . In one embodiment, the channels  20 ,  22 ,  24  can have a square cross-sectional shape, and, specifically, can be a 2.5 by 2.5 inch channel. The horizontal channels  20 ,  22  preferably are made to have a depth into the panel  1  greater than the depth of the groove pairs  8 ,  9  and  10 ,  11  extending into the panel  1  to prevent the studs  2  from impeding utility runs through the horizontal channels  20 ,  22 . The horizontal and vertical channels  20 ,  22 ,  24  and the groove pairs  8 ,  9 ,  10 ,  11 ,  14 ,  15 ,  16 ,  17  can be pre-molded with the molding of the core A or cut into the core A after formation of the core A. 
         [0032]    Preferably, each panel  1  includes a left side  30  and a right side  32  having complementary mating members  34 ,  36  such that adjacent panels  1  can interlock or mate to form a continuous wall surface.  FIG. 5  illustrates two such panels  1  that are joined together in this manner. Notably, this system of interlocking panels creates a continuous insulated barrier. In the embodiment shown in  FIGS. 4 and 5 , the mating members  34 ,  36  include complementary L-shaped ends. However, it is to be understood that other suitable interlocking or mating structures can be used. For example, a tongue-and-groove or jigsaw-type mating arrangement could instead be used. End panels  1 , such as those meeting other panels at a corner, can either be molded to not include the mating members  34 ,  36 , or a portion of core A adjacent mating members  34 ,  36  can be removed by cutting it with a saw or hot wire, for example. 
         [0033]    Referring to  FIG. 6 , according to an embodiment of the present invention, the stud  2  can be C-shaped and have legs  40 ,  42  extending from base  44 , as shown. Each leg  40 ,  42  can have an inwardly extending tab or barb  46  to assist in securing stud  2  to panel  1 . In one embodiment, the depth or thickness of core A can be about three times greater than the distance the legs  40 ,  42  extend from the base  44 . The stud  2  can be made from any number of strong, relatively stiff structural materials, such as, for example, metal, plastic or composite materials. In the embodiments shown in  FIG. 6 , the stud  2  is formed from about 18 to 20 gauge galvanized steel sheet metal having the dimensions in inches as shown. 
         [0034]    To create a wall structure, one or more bottom tracks  3  can be secured to a floor, the number of bottom tracks  3  depending on the length to be spanned by the wall structure. After studs  2  have been inserted in the groove pairs of the core A, a panel  1  can be mounted in the bottom track  3 , and fastened thereto using adhesives or fasteners. Bottom and top tracks  3 ,  4  can receive one or more panels  1  depending on the respective size of the panels  1  and tracks  3 ,  4 . In the embodiment shown in  FIG. 8 , panel  1  is secured to bottom track  3  by screwing leg members  5 ,  6  of bottom track to each stud  2  on each of front and back sides  12 ,  13  with sheet metal screws. Another panel  1  having studs  2  inserted therein can be mounted in bottom track  3  and the two panels  1  can be brought together that mating member  36  of one panel  1  interlocks or mates with mating members  34  of another panel  1  and secured with screws as previously discussed. This process can continue until the desired length of the wall structure is formed. 
         [0035]    The top track  4  can be secured to the panels  1  in a similar fashion, such as by screwing the leg members  5 ,  6  of the top track  4  to each stud  2  on each of the front and back sides  12 ,  13 , with sheet metal screws, for example. Referring to  FIG. 8 , for added structural support, a splice plate  48  can be used to connect one top track  4  to an adjacent top track  4 , as shown. The splice plate  48  can be made of any suitably strong and stiff material and secured to the top tracks  4  by known methods, such as, for example, using adhesive bonding or fasteners. The dimensions of the splice plate depend on the dimensions of the top track  4 . In the embodiment shown in  FIG. 9 , the splice plate  48  is a 4-by-8 inch, 16-gauge steel sheet metal, and is secured to the top track  4  with sheet metal screws. 
         [0036]      FIGS. 10 and 11  show assembly of bottom tracks  3  meeting at a comer and top tracks  4  meeting at a corner, respectively. To improve structural strength of the wall structure, bottom and top tracks  3 ,  4  can be overlapped by trimming a portion of an end of tracks  3 ,  4 , as shown more clearly in  FIG. 10 . As also shown in  FIG. 10 , the overlapped bottom tracks  3  can be secured together and to the floor with bolt or screw passing through both tracks  3 . 
         [0037]    As shown in  FIG. 12 , a C-shaped end cap  50  can cover a flat side  52  of comer panel  1 A and be secured to a bottom track  3  and a top track  4  (not shown). The end cap  52  can be constructed of any strong stiff material. In a preferred embodiment, the end cap  52  is made of 20-gauge galvanized steel sheet metal. Alternatively, side  13  of panel  1  can be trimmed to size instead of utilizing the separate comer panel  1 A. 
         [0038]      FIG. 13  shows a jamb section  54  that is identical to the panel  1  except for the dimensions of the core A and the dimensions and placement of the studs  2 . Also, in this embodiment, the jamb section  54  has flat sides  56 ,  58  but could be made to include mating members, such as the mating members  34 ,  36 , to permit interlocking, described above with respect to the interlocking of the panels  1 . One or more jamb sections  54  can be inserted between the panels  1  to create window openings or entrance ways such as doorways. For example, as shown in  FIG. 14 , the jamb section  54  is secured to the panels  1  with an L-shaped header  60  having perpendicular disposed members  62 ,  62 . The headers  60  can be constructed of any strong and stiff material. In one embodiment, the headers  60  are made of 16-gauge steel sheet metal and secured to panels  1  and studs  2  with sheet metal screws or other known fastening methods. 
         [0039]    Referring to  FIG. 15 , a trim track  66  can be used to trim window areas. The trim track  66  can have a base plate  68  sized to the window opening and strips  70 ,  72  extending perpendicularly from a base plate  68 . The strips  70 ,  72  can extend beyond the length of the base plate  68  to permit securing of the trim track  66  to panel  1  with screws, or any other suitable fastening method. According to an embodiment of the present invention, the trim track  66  is made of 20-gauge steel sheet metal and has the dimensions shown. 
         [0040]    The wall system once assembled can be finished on the internal and external surfaces with suitable covering materials along with paint or using other finishing methods. In one embodiment, the inside surface of the wall system can be finished with dry wall attached thereto with any suitable means. Such means can include fasteners such as bolts or screws and/or adhesives. The outer surface likewise can be finished with dry wall, concrete sheets, stucco or other covering material, for example. 
         [0041]    Multiple wall systems can be combined to form structures such as a habitable building capable of bearing significant loads and be structurally sound for its intended purpose. 
         [0042]    While this invention has been described in conjunction with the various exemplary embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention.