Patent Publication Number: US-2016222659-A1

Title: Modular building panel with frame

Description:
PRIORITY CLAIM 
     This application is a continuation of U.S. patent application Ser. No. 13/926,426 entitled “MODULAR BUILDING PANEL WITH FRAME” filed Jun. 25, 2013 which claims priority to U.S. Provisional Application Ser. No. 61/664,567 entitled “MODULAR BUILDING PANEL WITH FRAME” filed Jun. 26, 2012, which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     1. Field 
     The present invention relates generally to systems and methods of constructing buildings. More particularly, the present disclosure relates to systems and methods of using modular building panels with framed insulating blocks. 
     2. Description of the Related Art 
     For many years, a common manner of constructing residential structures involved constructing a wood frame. One of the problems with a wood framed house is that such a house may be relatively expensive to heat in the winter and hard to cool in the summer. As the cost of energy has continued to rise, this has been a continuing concern for the homeowners and, hence, a concern for home builders. 
     Foam may be used for insulation purposes in residential buildings. Sometimes expanded foam is sprayed inside the walls or under the roofs of residential buildings to provide additional insulation. In recent years, insulating concrete forms (referred to as “ICF”) has been used in residential structures. Many different types of methods have evolved for building ICF residential buildings. 
     A problem with some foam systems is that much labor is required in the shaping, cutting or modifying the foam blocks for the particular structure. A second problem is that after cutting, shaping or modifying the foam structure, the foam structure loses much of its insulating value. Third, the insulating foam may not have good structural integrity, so concrete must be used to give the strength necessary for the structure. 
     Some insulating modular panels have been used for building. In some cases, the panels must be held in place by braces or other temporary structural members during the construction process. Supplying and implementing such temporary bracing systems adds labor and cost to the construction process. 
     Custom passages, notches or other features may be added to a foam panel when it is to be installed, for example, to run electrical cables or plumbing. In many cases, making such features may require cutting into structural members associated with the panel. For example, to make passage for a conduit in an insulating panel, it may be necessary to cut a hole or notch in a metal rail supporting the panel. Such cutting adds time and complexity to the planning and construction of the building. 
     SUMMARY 
     Embodiments of building panels, and methods and systems for making and using building panels, are described herein. In an embodiment, a building panel includes a polymeric block, one or more framing studs and one or more framing studs at least partially embedded in or to the polymeric block. The block includes a panel interior surface and a panel exterior surface. The panel interior surface of the polymeric block is offset from at least one of the one or more framing studs. The panel interior surface of the polymeric block includes one or more slots that can receive framing studs. 
     In an embodiment, a building panel includes one or more polymeric blocks, one or more framing studs at least partially embedded in or to at least one of the one or more polymeric blocks, and one or more surface-mounted framing studs mounted on at least one exterior surface of the polymeric block. The orientation of at least one of the surface-mounted framing studs is different from than orientation of at least one of the one or more embedded framing studs. 
     In an embodiment, a method of making a building panel including positioning at least a portion of one or more frame members in a loose polymer material. A solid block is formed from the loose polymer material. At least a portion of the frames is embedded in the solid block. 
     In an embodiment, a building includes two or more building panels coupled to one another. The building panels may include a polymeric block and one or more framing studs at least partially embedded in or to the polymeric block. The panel interior surface of the polymeric block is offset from the framing studs. 
     In an embodiment, a method of constructing a building includes providing two or more building panels having a frame and polymeric block. The polymeric block of the building panes includes a framed portion and an offset portion. The panels are positioned such that the offset portion extends toward the interior of the building. The building panels are connected to one another. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates one embodiment of one embodiment of a building panel. 
         FIG. 2  illustrates an exploded view of one embodiment of a building panel. 
         FIG. 3  illustrates an interior view of a building panel. 
         FIG. 4  illustrates one embodiment of a connection between building panels. 
         FIG. 5  is a schematic top view illustrating one embodiment of a tongue and groove connection between building panels. 
         FIG. 6  illustrates a stock block from which multiple building panels can be produced. 
         FIG. 7  illustrates building panels after separation of a stock block. 
         FIG. 8  illustrates one embodiment of a block from which building panels may be produced. 
         FIG. 9  illustrates one embodiment of an assembly for producing a set of building panels. 
         FIG. 10  illustrates one embodiment of frame members at a connection between two building panels. 
         FIG. 11  illustrates one embodiment of a junction between two building panels at a corner of a building. 
         FIG. 12  illustrates one embodiment of a building constructed from building panels having a framed polymeric block construction. 
         FIG. 13A  illustrates one embodiment of a trough footing and a building panel that can be mounted on the trough footing. 
         FIG. 13B  illustrates one embodiment of a building panel installed in a trough. 
         FIG. 14  is a side view illustrating one embodiment of a building panel with an exterior footing. 
         FIG. 15  is a top view illustrating a wall that includes an insulating portion between a building panel frame and interior wallboard. 
         FIG. 16  is a schematic top view illustrating one embodiment of a building panel. 
         FIG. 17  illustrates a detail view of a portion of a building panel. 
         FIG. 18  illustrates one embodiment of a building panel base coupled to slab having a standard edge. 
         FIG. 19  illustrates one embodiment of a building panel base coupled to slab having a brick ledge. 
         FIG. 20  illustrates one embodiment of a building panel base coupled to slab having a brick ledge by way of a threaded fastener. 
         FIG. 21  illustrates a base of a building panel coupled to a slab. 
         FIG. 22  is a partially exploded view illustrating one embodiment of a building panel installed on a slab with a form at its edge. 
         FIG. 23  illustrates one embodiment of a portion a frame member that can be reinforced with an elongated member between spaced elements of the frame member. 
         FIG. 24  illustrates one embodiment of a building panel with a framed doorway. 
         FIG. 25  illustrates an embodiment of panel that includes horizontal slots on the interior face of the panel. 
         FIG. 26  illustrates one embodiment of a panel including a dovetail slot. 
         FIG. 27  is a top view illustrating one embodiment of a panel with staggered studs on opposing sides of a panel. 
     
    
    
     While the invention is described herein by way of example for several embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments or drawings described. It should be understood, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims. The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including, but not limited to. 
     DETAILED DESCRIPTION OF EMBODIMENTS 
     As used herein, a “polymeric material” means a material that is made at least primarily of one or more polymers. As used herein, a “polymer” means a naturally occurring or synthetic compound consisting of large molecules made up of a linked series of repeated simple monomers. Examples of polymers include polyolefins (such as polyethylene and polypropylene), polyurethanes, polyvinylchloride, polyesters, poly ethylene vinyl alcohol, polyvinyl alcohol, polycaprolactone, polylactic acid and foamed starch. A polymeric material may be expanded foam, such as expanded polystyrene. In some embodiments, a polymeric material is fire retardant. 
     As used herein, “polymeric block” means a block that is at least primarily made of a polymeric material. 
     As used herein, to be “embedded” in or to another element or elements means at least partially contained within, or at least partially surrounded by, the element or elements. As one example, a framing stud is embedded in a polymeric block if the framing stud is inserted, pressed, or dropped into a pre-cut slot or channel in the block. As another example, a framing stud may be embedded by expanding a loose foam material around the framing stud. In certain embodiments, there may be clearance between the surfaces (for example, a gap between the surfaces of a framing stud and the adjacent surfaces of a polymeric block). 
     As used herein, “frame member” means a member that can be coupled with one or more other members to form a frame. 
     As used herein, “framing stud”, or “stud”, means a primarily vertical member that can bear a downward load. 
     As used herein, a “c-shaped” cross section refers to a cross section that is generally in the form of a C. As used herein, a “u-shaped” cross section refers to a cross section that is generally in the form of a U. A c-shaped member or a u-shaped member may include variations such as bumps, bulges, ridges, corrugations, lips, rounded corners, sharp corners, tapers. 
       FIG. 1  illustrates one embodiment of a building panel. Building panels may be used, for example, as elements of a wall, floor, ceiling, or roof of a building. Building panel  100  includes block  102  and frame  104 . Frame  104  includes main studs  106 , top cross rail  108 , and bottom cross rail  110 . Block  102  includes main body  112  and offset  114 . Building panel  100  is installed on slab  116 . Building panel  100  may be coupled to adjacent building panel  101 . Main studs  106  may extend in a vertical direction through block  102 . 
     Offset  114  may extend from the framed portion of block  102  toward the interior portion of a building relative to frame  104 . In  FIG. 1 , the thickness of the offset is shown as dimension  115 . In one embodiment, frame members are about 3 and ⅝ inches up to about 7 and ⅝ inches in thickness, and the thickness of offset  114  is about 4 and ⅜ inches up to about 8 and ⅜ inches. 
     Interior surface studs  120  are mounted on the interior surface of offset  114 . In the embodiment illustrated in  FIG. 1 , interior surface studs  120  are installed such that both interior surface studs  120  and main studs  106  run vertically and are parallel to each other. With respect to the cross section of the studs, however, interior surface studs  120  may be installed in a different orientation than main studs  106 . In this case, interior surface studs  120  are installed such that the cross section of interior surface studs  120  is perpendicular to the cross section of main studs  106 . In certain embodiments, different studs may run in different directions that one another. For example, one or more of studs in the frame of a building panel may be embedded in the building panel at a slant and others of studs in the frame of the building panel may run vertically. As another example, the surface-mounted studs for a building panel may be installed at a slant, and the studs in the frame of the building panel may run vertically. 
     In the embodiment shown in  FIG. 1 , the surface-mounted studs are at an orientation that is perpendicular to that of the main studs. A building panel may, nevertheless, in various embodiments include studs that are installed in other relative orientations to one another. For example, a stud in a building panel may be installed in an orientation that is 45 degrees relative to another stud in the building panel. 
     Block  102  may be made of a polymeric material. In some embodiments, block  102  is made of expanded polystyrene foam. Block  102  may be of an insulating material. In some embodiments, the density of a block is between about 1.5 and about 2.0 pounds per cubic foot. 
     In some embodiments, a block of a building panel includes passages or openings. For example, as shown in  FIG. 1 , block  102  includes cylindrical passages  118  and passages  121 . Cylindrical passages  118  and passages  121  may be used for running conduit, electrical wires, plumbing, or other elements. A block for a building panel may also include openings for doors or windows. In some embodiments, a block includes notches, channels, or other features for receiving, connecting, or meshing with other building elements. In some embodiments, passages are provided at spaced intervals along the length of a panel. For example, a vertical chase may be provided in the offset portion of building panel  100  at 8 inch intervals along the length of the panel. 
     Frame members such as main studs  106 , top cross rail  108 , bottom cross rail  110 , may be made of a metal, such as steel or aluminum. In one embodiment, main studs  106 , top cross rail  108 , bottom cross rail  110  are made of 24 gauge galvanized steel. 
     Main studs  106 , top cross rail  108 , and bottom cross rail  110  may combine to form frame  104 . Top cross rail  108  may couple with main studs  106  at the top of block  102 . Bottom cross rail  108  may couple with main studs  106  at the top of block  102 . In one embodiment, top cross rail  108  and bottom cross rail  110  are coupled to the main studs by way threaded fasteners, such as bolts or machine screws. In certain embodiments, the cross rails for the panel may be connected to the main studs by way of rivets  117 . 
     A building panel may be of any suitable dimensions. A building panel may be, for example, between 8 feet and 18 feet tall. In one embodiment, a building panel is about 9 feet tall. In another embodiment, a building panel is about 50 inches tall. Two or more panels may be stacked on one another. As shown in  FIG. 1 , the bottom portion of a building panel may have a notch corresponding to a step on the slab on which the panel is to be installed. 
     In some embodiments, different building panels may be produced with different offset thicknesses. In some embodiments, different building panels may have different densities from one another. In certain embodiments, an offset portion of a panel (for example, offset from a frame), has a different density than other portions of the panel. 
     In the embodiment illustrated in  FIG. 1 , the offset portion of block  110  is offset in an interior direction. A panel block may, nevertheless, in various embodiments include an offset in other directions. For example, a panel block may include an offset in an exterior direction. 
     In some embodiments, passages in a block for a panel are provided in a portion of the panel that is offset from frame members of the panel. For example, passages may be provided in offset  114  of building panel  100 . In some cases, pipes, wiring, conduits or other elements may be routed in the passages without drilling or cutting in frame members for a panel. 
       FIG. 2  illustrates an exploded view of the building panel shown in  FIG. 1 . Main studs  106  may reside in main slots  123 . Main studs  106  may be at least partially embedded in block  102 . In some embodiments, main studs  106  are in place when block  102  is molded into a solid block. For example, main studs  106  may be held in position in loose polymeric material, such as beads or pellets, from which block  102  is made (for example, by way of a fixture). 
     Interior surface studs  120  may be installed in interior surface slots  126  in the offset portion of block  102 . In some embodiments, each of studs  120  is inserted from the top (for example, through the top surface of offset  114 ). In some embodiments, cross members of frame, such as top cross rail  108 , bottom cross rail  110 , or both, may be positioned in a block when the block is molded. In certain embodiments, all of the frame members of a panel are in place during molding of a block. 
       FIG. 3  illustrates an interior view of a building panel. Interior surface studs  120  are installed on interior surface  130  of block  102  in slots  126  in the interior offset portion of block  102 . In some embodiments, interior surface studs are press-fit into interior surface slots  126 . Interior surface studs  120  may be used for attaching additional building elements or decorative elements to building panels  100 . 
     Interior surface studs  120  may run the full height of the offset portion. In some embodiments, two or more sections of studs are stacked within a particular slot. In this manner, relatively short lengths of studs (for example, scrap generated during construction of the building) can be used for the surface-mounted studs. 
     Block  102  includes junction box cavity  124 . Junction box cavity  124  may be adjacent to a pair of slots  126  for interior surface studs  120 . A junction box may be positioned in junction box cavity  124  and attached to interior surface studs  120 . 
       FIG. 4  illustrates one embodiment of a connection between building panels. Building panels  100   a  and  100   b  are connected with panel connector  140 . Panel connector  140  bridges the top of frames  104  of building panels  100   a  and  100   b . Panel connector  140  may connect building panels  100   a  and  100   b  at junction  144 . 
     Pins  142  may pass through holes in panel connector  140  and engage in corresponding holes or sockets in frames  104 , blocks  102 , or both. In some embodiments, pins  142  temporarily hold building panels  100   a  and  100   b  together until a more permanent connection is established between the panels. For example, pins  142  may temporarily hold building panels  100   a  and  100   b  in place until building panels  100   a  and  100   b  are coupled to one another by way of an adhesive, or by way of threaded fasteners securing panel connector  140  to building panels  100   a  and  100   b . Pins  142  may be made of any suitable material. In one embodiment, pins  142  are made of a polymer. 
     In some embodiments, passages may be provided between internal passages in a panel and the surfaces of the panel. For example, in  FIG. 4 , passage  145  may be drilled to create access between passage  118  and the exterior face of panel  100   a . In some embodiments, surface studs and studs of a frame (for example, main studs  106 ) are generally aligned with one another along the length of a panel, such that any obstruction of passages (such as passage  145 ) is minimized. 
     In some embodiments, a tongue and groove connection is provided between adjacent building panels. Each building panel may have a tongue element on one side of the panel and a complementary groove element on the other side of the building panel. In this arrangement, an unlimited number of building panels may be connected, one after another.  FIG. 5  is a schematic top view illustrating one embodiment of a tongue and groove connection between building panels. Building panel  100   a  includes tongue  156 . Building panel  100   b  includes groove  158 . In certain embodiments, a tongue and groove connection is provided between building panels that are located one above another. 
     In some embodiments, pins are used to align adjacent panels. For example, pins may be inserted in one or more of holes  125  in the side of panel  100  in  FIG. 3  and a corresponding hole in the adjacent building panel. 
     In some embodiments, multiple building panels are produced from a solid block made in one molding process. Each of the building panels may be produced by slicing the building panel from a solid larger solid block.  FIG. 6  illustrates a stock block from which multiple building panels can be produced. Frames  160  may be placed in a mold in a parallel spaced relationship to one another. In some embodiments, frames  160  include studs and cross rails, such as those described above relative to  FIGS. 1 and 2 . Fixture elements  162  may maintain frames  160  in the desired spacing from one another during a molding process. Loose polymeric material, such as polymeric beads or pellets, may be introduced into the mold around and within frames  160 . In some embodiments, the loose polymeric material includes pre-foamed polystyrene beads. The polymeric material may be heated to fuse the media. The block may be allowed to cool to form stock block  164 . At this point, the frame elements are fixed in place in the stock block. Fixture elements  162  may be removed. 
     After stock block  164  is formed, it may be removed from the mold and positioned at a cutting station. The cutting station may include a hot wire cutting system with one or more hot wires. The hot wire system may be used to slice stock block  164  at planes  166  to create multiple block segments. Each of the segments may form a building panel  168 . Each building panel  168  may include one of frames  160  and a block  170 . The hot wire system may be used to perform additional shaping and cutting, such as adding notches, cavities, passages, or windows to the panel. 
       FIG. 7  illustrates building panels  168  after separation of a stock block. As illustrated in  FIG. 7 , each panel  168  may include offsets  172  and  174  in either direction from the frame. In one embodiment, a building panel includes a frame section 3 and ⅝ inches thick, with an offset in one direction of 3 and ⅝ inches and an offset in the other direction of 5 and ⅜ inches. In one embodiment, a building panel includes a frame section 3 and ⅝ inches thick, with an offset in one direction of 4 and ⅜ inches and no offset (offset of zero) in the other direction. In one embodiment, a building panel includes a frame section 3 and ⅝ inches thick, with an offset in one direction of 8 and ⅜ inches and no offset (offset of zero) in the other direction. 
     In an embodiment, a block for producing building panels includes a solid polymeric block and two or more building panel frames coupled to the solid polymeric block. The solid polymeric block may be sliced into portions (for example, segmented) to produce two or more building panels. Each of the building panels so produced may include one of the building panel frames. In some embodiments, the frames are included in the block in an array such that the block can be sliced in two more different directions to slice off rows or columns of building panels from the block. In some embodiments, the block is produced using the procedures described above relative to  FIGS. 6 and 7 . 
     In some embodiments, panels are aligned to promote flow of the polymeric material during formation of the solid block. In one embodiment, a cradle is used to align elements during formation. Holes may be provide in steel to improve flow, for example, to allow the polymeric material to reach spaces in or around doors and windows. 
     Steam may be used to heat the loose polymeric material. In one embodiment, the oven is heated to a temperature of about 212 degrees F. to about 220 degrees F. In one embodiment, the oven is heated to a temperature of about 200 degrees F. to about 250 degrees F. In certain embodiments, the polymeric material is heat molded. For example, the polymeric material is molded to expand against metal elements, such as frame elements. In certain embodiments, a vacuum is pulled such that the polymeric material is vacuum packed. 
     In some embodiments, a polymer material is selected to reduce moisture retention. In one embodiment, a block is formed from a closed cell polystyrene. The block may be allowed to cure. In one process, the block is allowed to cure for about 3 days. 
       FIG. 8  illustrates one embodiment of a block from which building panels may be produced. Block  176  includes frames  178  and solid polymeric block  180 . Each of frame  178  is partially included within block  180 . Frames  178  are arranged in rows and columns in block  180 . Within each row, frames  178  may be arranged in an end-to-end arrangement (As used herein, “end-to-end” does not require that the ends of adjacent items are in contact with one another.) For example, in  FIG. 8 , frame  178   a  is arranged in an end-to-end arrangement with frame  178   b . Frame arranged end to end may be coupled to one another by a connector member, such as connecting member  186 . Rows may be is a spaced relationship with one another by spacing rails  184 . 
     Although in the embodiment shown in  FIG. 8 , the frames are arranged in 3 by 2 arrangement for illustrative purposes, any number of frames may in various embodiments be placed in array in, for example, any number of row and columns. In certain embodiments, adjacent rows or columns of frames may be staggered from one another. 
     In an embodiment, an assembly for producing building panels includes two or more building panel frames and one or more fixture members coupled to the building panel frames. The fixture members may maintain building panel frames in a fixed spatial relationship to one another while a solid polymeric block formed from loose polymeric materials in, near, or around the frames. 
       FIG. 9  illustrates one embodiment of an assembly for producing a set of building panels. The assembly may be used, for example, to produce a block from which panels can be sliced such as the block shown in  FIG. 8 . Assembly  192  includes frames  178  arranged in an array. Frames  178  may be connected to one another by way of fixture members. In  FIG. 9 , rows of frames  178  are held in a spaced relationship from one another by way of angles  184 . Adjoining frames  178  within a given rows are coupled by way of connecting members  186 . Angles  184  and connecting members  186  may be made of metal. 
     Frame members and fixture members in an assembly may include holes that allow polymeric material, steam, air, or other materials to pass through. For example, in the embodiment shown in  FIG. 9 , frames  178  include holes  190 . Holes  190  may allow or promote loose polymeric material reach spaces within frames  178 . Holes  190  may also allow or promote hot air, steam or other things used in creating solid polymeric block  180  to reach locations as part of the solid block formation process. 
     In some embodiments, a building panel frame member includes an element for coupling to adjacent frame members.  FIG. 10  illustrates one embodiment of frame members at a connection between two building panels (in  FIG. 10 , polymeric blocks are omitted for illustrative purposes.) Building panel  200  includes frame  202 . Frame  202  includes studs  204  and bottom rail  206 . Bottom rail  206  includes coupler channels  208 . Coupler channels  208  extend laterally from either end of building panel  200 . 
     Building panel  210  includes frame  212 . Frame  212  includes studs  214  and bottom rail  216 . Building panel  210  may be positioned next to building panel  200  such that bottom rail  216  is received in coupler channel  208 . In some embodiments, building panel  210  is secured in coupler channel  208  by way of, for example, a pin or a bolt. 
     Although in the embodiment shown in  FIG. 10 , building panel  200  includes coupler channels at both ends of the panel, a building panel may, in various embodiments, include a coupler elements at only one end, or include no coupler elements. In certain embodiments, each building panel in a row of building panels includes a coupler channel at only one end, and one end of each successive panel is received in a coupler channel of the building panel next to it. 
     In some embodiments, offsets of building panels are arranged to at least partially overlap one another at a junction between two building panels.  FIG. 11  illustrates one embodiment of a junction between two building panels at a corner of a building. Building panel  220   a  includes block  222   a  and frame  224   a . Block  222   a  includes offset  226   a . Building panel  220   b  includes block  222   b  and frame  224   b . Block  222   b  includes offset  226   b . Offsets  226   a  and  226   b  are notched relative to the ends of building panels  220   a  and  220   b  such that the end of offset  226   a  meets the interior side of block  222   b  and the end of offset  226   b  meets the interior side of offset  226   a.    
       FIG. 12  illustrates one embodiment of a building constructed from building panels having a framed polymeric block construction. Building  240  includes various types of building panels  242 . Building panels  242  include, for example, wall panels  244 , door panel  246 , and window panel  248 . Any or all of wall panels  244 , door panel  246 , and window panel  248  may include a polymeric block with a frame. Building panels  242  may be similar in construction to those described above relative to  FIGS. 1 and 2 . Any or all of wall panels  244 , door panel  246 , and window panel  248  may include block offsets from the frame of the panel. In some embodiments, one or more of the building panels for a building are cut to size and shape. Cutting of the panels may be performed on-site (for example, during construction of the building) or off-site. 
     Various types of siding or other exterior elements may be attached to, or placed in front of, the exterior surfaces of building panels  242 . Various types of finishing elements or materials, such as drywall, may be attached to, or placed in front of, the interior surfaces of building panels  242 . 
     In some embodiments, a building is assembled by placing two or more building panels on a surface to form a row. Building panels may be connected by any of the various approaches described above. In some embodiments, each panel is free standing when placed on the slab or other supporting element or structure. As such, in some embodiments, a building is constructed without bracing elements to hold the building panels in place during construction. 
     In some embodiments, one or more building panels are installed on a footing. The footing may account for geometric variances or features of a slab or foundation. For example, a footing may compensate for curvature or a slope in a slab on which the building panel is to be mounted. In certain embodiments, a trough footing is used to level  FIG. 13A  illustrates one embodiment of a trough footing and a building panel that can be mounted on the trough footing. In  FIG. 13A , the trough footing and building panel are shown separated from one another for illustrative purposes. 
     Trough footing  280  includes base  282 , flanges  284 , channel  286 , and apertures  288 . Base  282  includes bottom  290 . Bottom surface  290  of base  282  may be non-parallel to top surface  292 . Building panel  294  may seat in channel  286  of trough footing  280 . Building panel  294  may be similar in construction to that described above relative to  FIG. 1 . 
     The size of a trough footing (for example, thickness) or shape of a trough footing (for example, curvature or slope in bottom surface  290 ) may compensate for deviations in the surface of a slab on which the building panels are to be mounted (for example, curvature in the top surface of a slab). In certain embodiments, a trough footing includes steps or ridges. The trough footing may be positioned on a slab such that a building panel is horizontal when installed on the slab. 
     In one embodiment, trough footing  280  is made of galvanized steel. Apertures  288  may allow any liquid to drain from channel  286 . For example, apertures  288  may allow condensation that drips into channel  286  to drain out the bottom of base  282 . 
     In some embodiments, a sealant is used between elements of a building panel, or between a building panel and adjoining elements of a building.  FIG. 13B  illustrates one embodiment of a building panel installed in a trough. Sealant  296  may inhibit liquids from entering in the space between trough footing  280  and building panel  294 . In one embodiment, sealant is sprayed on at the seams where building panel  294  and flanges  284  meet. 
     In some embodiments, a footing is installed at or near the base of a building panel on the interior or exterior side of the panel.  FIG. 14  is a side view illustrating one embodiment of a building panel with an exterior footing. Footing  302  is installed on an the exterior side of block  300 . Block  300  may be a polymeric foam. Footing  302  may be a galvanized steel angle. Footing  302  includes holes  304 . Sealant  306  may be applied at the junction between footing  302  and block  300 . Sealant  306  may inhibit condensation or other liquids from accumulating on footing  302 . 
     In some embodiments, an insulating portion of a polymeric block in a building panel provides thermal insulation between frame members of the building panel and interior or exterior elements attached to the panel.  FIG. 15  is a top view illustrating a wall that includes an insulating portion between a building panel frame and interior wallboard mounted to the building panel. In  FIG. 15 , offset  114  of block  102  may serve as an insulating portion between wallboard  310  and frame  104 . The insulating portion may increase an R-factor of the wall. 
       FIG. 16  is a schematic top view illustrating one embodiment of a building panel. Building panel  320  includes polymeric block  322  and frame  324 . Vapor barrier layer  325  is coupled to the exterior surface of polymeric block  322 . Polymeric block  322  includes passages  326 . Passages  326  may be, for example, through holes passing from the top to the bottom of polymeric block  322 . In some embodiments, exterior elements such as stucco or hardi board may be applied to the vapor barrier layer. In one embodiment, the vapor barrier layer is at least ½ inches thick. 
     Surfaces studs  328  are included in slots in the polymeric block  328 . Surface studs may be spaced across the interior surface of polymeric block  322 . In this embodiment, surface studs are provided in the interior offset portion of polymeric block  322 . Studs may nevertheless be, in various embodiments, provided in other locations than the offset. For example, studs may be mounted on the exterior surface of polymeric block  322 . In some embodiments, exterior elements may be coupled vapor barrier layer  325 . 
       FIG. 17  illustrates a detail view of a portion of the building panel shown in  FIG. 16 . Stud  328  includes tails  330 . Tails  330  may inhibit separation or movement of surface studs  328  in polymeric block  322 . In some embodiments, an adhesive is provided between a stud and the polymeric block in which it is installed. 
     In some embodiments, electrical lines or plumbing lines are pre-installed in building panels. Building panels may be pre-installed before delivery of the panels to the site. For example, referring to  FIG. 17 , cable bundle  340  may be installed in passage  326   
     In some embodiments, windows, doors, or other apertures may be created in a building panel prior to delivery to a building site. Creating openings or apertures may reduce the time to a construct the building. 
     In an embodiment, a building panel includes a polymeric block, a frame coupled to the polymeric block, and a base member coupled to the polymeric block, the frame, or both. The base member couples with a slab. 
     In an embodiment, a method of constructing a building includes placing two or more building panels including polymeric blocks on a slab. The base of the building panels may be fastened to the slab. 
     In an embodiment, a building includes a slab and two or more building panels. Each of the building panels may include a polymeric block and a base. The bases of the building panels are fastened to the slab. 
       FIG. 18  illustrates one embodiment of a building panel base coupled to slab having a standard edge. Building panel  360  is installed on slab  362 . Building panel  360  includes polymeric block  364  and base  366 . Base  366  may be attached to slab  362 . In some embodiments, a slab is floated or chipped off to prepare the slab for installation of the panels. 
       FIG. 19  illustrates one embodiment of a building panel base coupled to slab having a brick ledge. Building panel  370  is installed on slab  372 . Building panel  370  includes polymeric block  374  and base  376 . Base  376  may be attached to slab  372 . In certain embodiments, an 18-20 gauge sheet is provided. The sheet metal may span over voids in the slab. 
       FIG. 20  illustrates one embodiment of a building panel base coupled to slab having a brick ledge by way of a threaded fastener. Building panel  380  is installed on slab  382 . Building panel  380  includes polymeric block  384  and base  386 . Base  386  may be attached to slab  382  by way of fastener assembly  388 . When building panel  380  is installed on slab  382 , the threaded portion of fastener assembly  388  that extends above base  388  may be accommodated in bore  385  in polymeric block  384 . In certain embodiments, holes are punched out for j-bolts/washers. 
       FIG. 21  illustrates a base of a building panel coupled to a slab. The base may be provided, for example, on a polymeric foam panel with a frame, such as described herein. In  FIG. 21 , element of the building panel other than the base have been omitted for illustrative purposes. System  390  includes a base  394  of a building panel coupled to slab  392 . In this example, base  394  is coupled to slab  392  by way of j-bolt  396 . J-bolt  396  may be, for example, a ½ inch flat-head j-bolt. J-bolts may pass through corresponding clearance holes in base  394 . In some embodiments, j-bolt fasteners are installed during slab pour. In certain embodiments, an adhesive may be used in addition to, or instead of, metal fasteners. Nut  397  may be threaded onto j-bolt  396  to attach base  394  to slab  392 . Fender washers/may be provided under nut  397 . In certain embodiments, a track weld washer is provided on j-bolt fasteners. 
     A base for a building panel may be made of any suitable material. In some embodiments, base  394  is a strip or angle of sheet metal. In certain embodiments, a base of a panel may be a strip of wood (for example, a 2 by 4). 
     In some embodiments, a base for a building panel is mounted on a form during construction of a building.  FIG. 22  is a partially exploded view illustrating one embodiment of a building panel installed on a slab with a form at its edge. Building panel  400  may be installed on slab  402 . Building panel  400  includes block  404  and base  406 . In some embodiments, building panel  400  includes one or more frame members. For illustrative purposes, block  404  and base  406  are shown separated from one another. During installation, however, block  404  and base  406  may be coupled to one another, for example, by an adhesive, screws, rivets, or other method. Building panel  400  may be installed in notch  416  of slab  406  so that base  406  may be secured using threaded fasteners  412 . Nuts and washers may be removed and reinstalled to hold down base  406 . In some embodiments, adhesive is provided between a surface of a slab and panel. For example, adhesive may be provided in area  419  of slab  402  and bond with the bottom of the interior offset portion of block  404 . 
     In some embodiments, the outer rim  413  of base  406  comes to rest on forms  414 . In certain embodiments, base  406  may be secured to the upper one of forms  414 , for example, by way of screws in passed through holes  415  and threaded into holes  417  of forms  414 . Forms  414  may be unfastened from base  406  and removed from slab  402 . In some embodiments, rim  413  is a breakaway piece, and can be snapped off from the remaining portion of base  406 . 
     In an embodiment, a building panel includes a solid polymeric block having an aperture, and a frame coupled in the aperture. Reinforcing elements are coupled to the frame along at least one side of the aperture. The reinforcing elements may inhibit deformation of the frame in the aperture. 
     In an embodiment, a method of making a building panel includes providing a frame for an aperture. At least one side of the frame is reinforced with reinforcing elements. Loose polymeric material is provided adjacent to the frame. A solid polymeric block is formed from the loose polymer material such that the frame the frame defines an aperture in the solid block. The reinforcing elements may inhibit deformation of the frame in the aperture. 
       FIG. 23  illustrates one embodiment of a portion a frame member that can be reinforced with an elongated member between spaced elements of the frame member. Frame system  420  includes frame member  424  and reinforcing element  428 . Reinforcing element may be, for example, a flat head screw. 
       FIG. 24  illustrates one embodiment of a building panel with a framed doorway. Building panel  440  includes polymeric block  442  and frame  444 . Frame  444  defines aperture  443 . Frame  444  includes inside frame  446  and outside frame  448 . Nogs  450  and  452  may span from inside frame  446  to outside frame  448 . Nogs  450  and  452  may reinforce frame  444  and inhibit distortion of frame  444 . Distortion may occur, for example, due to swell caused by engagement of the frame with polymeric foam. In some embodiments, some of the reinforcing elements are standard with the frame, and others are added to the frame. For example, nogs  450  may be standard, while nog  452  is added for additional stiffening of the frame. In one embodiment, 4 screws are provided per door in a building panel, and 8 screws are provided per window in a building panel. In one embodiment, one nog is added to each side of a door. In one embodiment, two nogs are added to each side of a door. 
     In some embodiments, a panel includes slots for carrying conduit, cables, plumbing, or other elements. The horizontal slots may intersect vertical slots in the panel.  FIG. 25  illustrates an embodiment of panel that includes horizontal slots on the interior face of the panel. Panel  500  includes block  502 , horizontal slot  504 , and vertical slot  506 . Horizontal slot  504  and vertical slot  506  may intersect with one another. 
     In some embodiments, slots for running conduits, plumbing, wires, or other elements have a dovetail cross section. For example, horizontal slot  504 , vertical slot  506 , or both may have dove-tail cross section  508 , as shown in  FIG. 26 . 
     In some embodiments, vertical studs on opposing sides of a panel are offset from one another. In one embodiment, vertical studs on opposing sides of a panel are staggered with respect to one another.  FIG. 27  is a top view illustrating one embodiment of a panel with staggered studs on opposing sides of a panel. Panel  520  includes block  522 , interior studs  524 , exterior studs  526 , and passages  528 . Interior studs  524  are offset with respect to exterior studs  526 . 
     In certain embodiments, air cavities are provided in a panel. For example, block  502  includes pockets  530 . Air cavities may be sized and shaped to provide thermal isolation, acoustic isolation, or both, between the interior and the exterior of the panel. 
     In some embodiments, one or both sides of a panel includes cross bracing. The ends of each of the cross bracing members by couple to junctions at the  4  corners of the panel. The crossing members may be attached to one or more additional vertical studs (for example, at the intersection of the cross members with one another. In certain embodiments, a building panel is a shear panel. 
     In certain embodiments, a panel includes 2⅝ inch studs. In one embodiment, a panel is about 5½ inches. Examples of other thicknesses for a panel include about 2⅜ inches, or 3½ inches. 
     In some embodiments described above, the cross section of a stud or other structural member is in the form of a hat section (for example, in  FIG. 27 ). A stud or other structural member of a panel may nevertheless have any other suitable cross section. For example, a stud may have a c-shaped cross-section, a u-shaped cross-section, an arcuate cross section, a corrugated cross section, or vee-shaped cross section. 
     Further modifications and alternative embodiments of various aspects of the invention may be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. Methods may be implemented manually, in software, in hardware, or a combination thereof. The order of any method may be changed, and various elements may be added, reordered, combined, omitted, modified, etc. Changes may be made in the elements described herein without departing from the spirit and scope of the invention as described in the following claims.