Patent CA-2655466-A1 (CA)
Inventor: BLACK JEFFREY A
IPC: E04C2/292
Filed: 2009-03-03
Abstract: The Hybrid SIP Wall System Panel combines the strength and performance of cold-formed steel framing with the superior insulation properties of expanded polystyrene (EPS).  All steel used in the Hybrid SIP Wall System Panel is galvanized to industry standards to prevent rust.   Why this innovation?   Builders today are faced with more challenges than ever before: *Energy efficient- Heating and cooling bills can be reduced drastically. *Comfort- Structures are less "Drafty" and provide enhanced sound insulation. *Lower Insurance premiums. *Potential increased return on investment for property owners. *Environmentally friendly, made from recycled materials. *Peace of mind, knowing that they built their structure with a sustainable building solution. This innovative technology virtually eliminates the transfer of temperature from one side to the other side. Creating a thermal gap throughout the entire wall or structure.  The result is a thermally efficient, high-performance building technology that is stronger than brick or conventional wood, lightweight, energy efficient and economical. With the development of the Hybrid SIP wall system, Jeffrey Black has created a cost- effective, energy-efficient and structurally superior building alternative to conventional wood framing, insulation and sheathing.(we replace all three of these processes, inspections and waste in one simple step).Panels come in almost any size shape or design. They are shipped in 4'- 10' sections wideby however tall your walls are. Thickness of walls come in anywhere from a 2" up to 12"or greater if so desired. (a 4'x 8'x 6" thick panel only weights approximately 40 lbs.) A prefabricated, pre-engineered expandable polystyrene solid core and steel reinforced exoskeleton wall panel for building construction. Comprising a rectangular, tetragonal body of expandable polystyrene foam having two opposing primary structural studs securely bounded on its interior and exterior embodiment and on its end by two parallel end caps at least two light gauge metal studs in the exterior primary wall surface body, and two light gauge metal studs in the interior primary wall surface body, each stud having a c-shape body with a very specialized face, leg and hem design. The width of the wall panel between the two primary wall surfaces being three times greater than the leg of the studs, the expandable polystyrene foam extending into the central cavity of the stud to secure the stud to the body, The hem return inside the wall of each stud strengthens the entire embodiment of the structure and compliments the physical properties of both elements. Together forming a portion of the same primary wall surface of the interior body, also one stud is positioned at the opposing side on the exterior wall. The distance between each of the studs, from the center to center of the studs is 24" O.C. being a standard building construction center-to-center distance for studs, the rectangular tetragonal body of Expandable Polystyrene foam having a tongue portion at each of its two parallel end walls, the tongue portion having a width equal to the width of the studs and adapted to be and receive each wall by and securing the opening of the building construction track to form a structural wall.   The present invention generally relates to building commercial or residential load bearing exterior wall systems. In particular, the present invention relates to a solid EPS core wall panel with a steel exoskeleton infused into the foam panels for residential or commercial walls.  Pre-manufactured and engineered in a factory. that exhibit improved strength, carbon footprint, and 100% recyclable with less weight, simplistic design and installation, and highest efficiency characteristics available. The present invention is directed to polystyrene solid core & metal exoskeleton (Structural) wall panels. In particular, lightweight, thermal efficient and sound insulating, sustainable unsurpassed energy saving wall system.. The panels, optionally, often and preferably, also constitute structural supporting members.   Design Standards: *American Iron and Steel Institute (A.I.S.I.) "North AmericanSpecification for the Design of Cold-Formed Steel Structural Members," 2001 with 2004 amendments. *American Welding Society (A.W.S.) D.1.3, 1998 "Structural Welding Code-Sheet Steel."  *American Society for Testing and Materials (A.S.T.M.)