Patent Publication Number: US-10323413-B1

Title: Building panel structure and method of manufacturing thereof

Description:
RELATED APPLICATIONS 
     This application claims priority from provisional application 62/503,467 filed on May 9, 2017 and is a continuation in part of U.S. patent application Ser. No. 15/485,520 filed on Apr. 12, 2017. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a prefabricated building panel that provides high insulation value and rigidity. The building panel of the present invention may be made in a wide range of sizes and is configured for positioning and transportation on flatbed trucks. The building panel is suitable for any size building including commercial, institutional, residential and industrial. 
     BACKGROUND OF THE INVENTION 
     Current art building panels are typically manufactured in three layers: a concrete layer that faces to the outside of the building, a concrete layer that faces to the inside of the building and an insulation layer in between. Typical insulating materials that are used in these panels include polyisocyanurate or polystyrene loosely sandwiched between the two concrete layers. Typical R values for this type of a panel range between about 4/inch to about 8/inch. 
     The structures made of two layers of concrete and loose foam insulation generally have high compression strength, but lack tensile and shear strength. This makes the panels susceptible to delamination from shearing forces such as due to high winds. Concrete also has a tendency to crack or shatter from the impact of blunt force. 
     Heating or cooling losses resulting from the use of low insulation values of typical panels used in all buildings can be significant. It would be, therefore, be desirable to use building panels in all construction that have high insulation value in the range of about 30/inch to about 40/inch and even higher, yet have high compressive strength, tensile strength, shearing strength and bending rigidity to withstand high winds, withstand the high vertical loads exerted by roofs and floors, and maintain integrity while being hoisted, loaded onto trucks and transported. 
     SUMMARY OF THE PRESENT INVENTION 
     In one aspect of the present invention, a reinforcing assembly for a wall panel structure contains an upper channel containing a) a first plate, b) a first vertical member attached to a first longitudinal side of the first plate, the b) being downwardly disposed, and c) a second vertical member attached to a second longitudinal side of the first plate, the c) being downwardly disposed; a lower channel containing d) a second plate, e) a first vertical member attached to a first longitudinal side of the second plate, the e) being upwardly disposed, and f) a second vertical member attached to a second longitudinal side of the second plate, the f) being upwardly disposed; a first plurality of studs, the each stud of the first plurality of studs being attached to an area of the upper channel at one end and attached to an area of the lower channel at another end; and a second plurality of studs, the each stud of the second plurality of studs being attached at one end to c), the each stud of the second plurality of studs being attached at another end to f). 
     In another aspect of the present invention, a layered panel comprises: a first layer having a first surface disposed at the front side of the panel and a second opposing surface being disposed on an inside of the panel, the first layer also comprising a top surface and a bottom surface; a second layer having a first surface in contact with the second surface of the first layer and a second opposing surface being disposed on an inside of the panel, the second layer also comprising a top surface and a bottom surface; a third layer having a first surface disposed at the rear side of the panel, a second opposing surface being disposed on an inside of the panel, the second surface of the third later being in contact with the second opposing surface of the second layer; an upper channel containing a) a first plate, b) a first vertical member attached to a first longitudinal side of the first plate, the b) being downwardly disposed, and c) a second vertical member attached to a second longitudinal side of the first plate, the c) being downwardly disposed, b) being embedded in the first layer, c) being embedded in the second layer, the first plate overlaying a portion of the top surface of the first layer and a portion of the top surface of the second layer; and a lower channel containing a d) second plate, e) a first vertical member attached to a first longitudinal side of the second plate, e) being upwardly disposed, and f) a second vertical member attached to a second longitudinal side of the second plate, f) being upwardly disposed, e) being embedded in the first layer, f) being embedded in the second layer, the second plate overlaying a portion of the bottom surface of the first layer and a portion of the bottom surface of the second layer. 
     In yet another aspect of the present invention, a process for manufacturing a layered panel of comprises: providing an open-top container having a bottom, a first side wall and an opposing second side wall; providing a reinforcing assembly; pouring wet concrete into the bottom of the container such as to form a layer of concrete of predetermined thickness; placing the reinforcing assembly inside the container in a manner such that the first plate is disposed against the first side wall of the container, such that the second plate is disposed against the second side wall of the container, such that the first vertical member attached to a first longitudinal side of the first plate is disposed at a midpoint of the concrete layer thickness inside the concrete and the second vertical member attached to a second longitudinal side of the first plate is disposed at a midpoint of the concrete layer thickness inside the concrete; setting the wet concrete layer such that the concrete fully hardens; placing the third layer in suspension above the container; placing the second layer inside the container, the second layer interfacing with the first layer such that the second plurality of studs, the second vertical member attached to the second longitudinal side of the first plate and second vertical member attached to the second longitudinal side of the second plate are disposed inside the second layer; and placing the third layer over the second layer, the third layer interfacing with the second layer. 
     These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a perspective side view of a building panel according to a first embodiment of the present invention; 
         FIG. 2A  is a cross sectional perspective side view of the building panel according to a second embodiment of the present invention; 
         FIG. 2B  is a cross sectional perspective side view of the building panel according to a third embodiment of the present invention; 
         FIG. 3A  is a different illustration of  FIG. 2A ; 
         FIG. 3B  is a different illustration of  FIG. 2B ; 
         FIG. 4A  is a top view of a building panel according to a first embodiment of the present invention; 
         FIG. 4B  is a top view of a building panel according to a second and a third embodiment of the present invention; 
         FIG. 5  represents a front and rear view of a building panel according to a first, second and third embodiment of the present invention; 
         FIG. 6  depicts a side view of a building panel according to a first, a second and a third embodiment of the present invention; 
         FIG. 7  is a top view of a component of the building panel according a first, a second and a third embodiment of the present invention; 
         FIG. 8A  is an illustration of the manufacturing process setup for the building panel of the second embodiment; 
         FIG. 8B  is a portrayal of the manufacturing process setup for the building panel of the third embodiment; 
         FIG. 9A  portrays the building panel of the second embodiment at the completion of the manufacturing process in a cross sectional side view; 
         FIG. 9B  illustrates the building panel of the third embodiment at the completion of the manufacturing process in a cross sectional side view; 
         FIG. 10  portrays a variation of the second the panel structure embodiment of the present invention in a perspective cross sectional side view; and 
         FIG. 11  is a close-up view of a component of  FIG. 10 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention. 
     It is the object of the present invention to provide for a composite panel structure generally used in construction that has a high R value, high compression strength, high tensile strength and high bending stiffness. 
       FIGS. 1-11  describe three embodiments of the composite panel structure of the present invention. The first embodiment  10  is represented by  FIGS. 1, and 4A and 5-7 . The second embodiment  20 A is described in  FIGS. 2A, 2B, 4B, 5-7 and 10 . The third embodiment  20 B is shown by  FIGS. 2B, 3B, 4B and 5-7 . The first embodiment relates to standard building panel structures, while the second and the third embodiments represent reinforcement structures. 
       FIGS. 8A and 9A  illustrate the process of manufacturing  30 A of the second embodiment composite panel  20 A, while  FIGS. 8B and 9B  show the process of manufacturing  30 B of the third embodiment panel  20 B of the present invention. 
     In  FIG. 1  representing the first embodiment of the panel, the composite panel  10  contains a layer made of concrete  12 , an insulation layer  11 , and a corrugated layer  13 . The shape of the concrete layer is generally rectangular with the top surface being substantially parallel with the bottom that is disposed on the ground and the sides being vertical in relation to the ground. Likewise, the shape of the insulation layer is generally rectangular with the top surface being substantially parallel with the bottom that is disposed on the ground and the sides being vertical in relation to the ground. 
     The concrete is made of a specific formulation that maximizes the compression strength of the structures. The composition may contain silicon oxide, aluminum oxide, iron oxide, calcium oxide, magnesium oxide and sulfur trioxide in varying proportions. However, other component materials for the concrete also fall within the scope of the present invention. 
     The insulating material is, preferably, polyurethane; however, other insulating materials also fall within the scope of the present invention. 
     The corrugated sheet layer  13  is preferably made of steel. A range of different thicknesses is suitable for the corrugated sheet. An exemplary corrugated panel configuration and dimensions are shown in  FIG. 7 ; however, other panel configurations and dimensions also fall within the scope of the present invention. 
     The second embodiment of the present invention combines the first embodiment panel with a reinforcing assembly that is integrated with the panel. The reinforcing assembly has an upper channel that contains a first plate  21 A that has two vertical members,  22 A and  23 A attached to the first plate  21 A at their long sides in the width direction. As shown by  FIGS. 2A and 3A , the first plate  21 A interfaces with a portion of the top surface of the concrete layer and a portion of the top surface of the insulating layer. The first vertical member  22 A is downwardly disposed in relation to the first plate  21 A and is embedded in the concrete while the second vertical member  23 A is downwardly disposed in relation to the first plate  21 A and is embedded in the insulating layer. The reinforcing assembly also has a lower channel that contains a second plate  21 B that has two vertical members,  22 B and  23 B attached to the second plate  21 B at their long sides in the width direction. The second plate  21 B covers a portion of the bottom surface of the concrete layer and a portion of the bottom surface of the insulating layer. The first vertical member  22 B attached to the second plate  21 B is upwardly disposed in relation to the second plate and is embedded in the concrete layer while the second vertical member  23 B is upwardly disposed in relation to the second plate  21 B and is embedded in the insulating layer. 
     The channels are made of steel; however, other materials of construction also fall within the scope of the present invention. 
     A plurality of studs  24  are attached to and connect vertical members  22 A,  22 B,  23 A and  23 B. As shown in  FIGS. 2A and 3A  representing the second embodiment of the layered panel, three studs  24 A are attached to vertical member  22 A at one end and to vertical member  22 B at the other end. Studs  24 A are all embedded in the concrete layer  12 . Another three studs  24 B are attached to vertical member  23 A at one end and to vertical member  23 B at the other end. These studs are all embedded in the insulation layer  11 . In an embodiment of the present invention, the studs are spaced 24″ apart in the center and 12″ from each end of the insulation layer  11  and concrete layer  12  of the panel  20 . However, other spacing distances fall within the scope of the present invention. The studs are about 1″ to about 2″ wide and preferably made of steel; however, other materials of construction also fall within the scope of the present invention. The channel and stud structure reinforce the panel  20 , but because they are not exposed to the outer side of the panel or the inside of the panel, they do not contribute to heat or cooling conduction and losses to the outside. 
     One negative of the structure of the second embodiment is that embedding studs  24 A in the concrete layer may create cracks and weak areas in the concrete if the thickness of the concrete layer is in the range of 2″. Cracking the concrete is less likely if the thickness of the concrete layer is higher, e.g., 4 inches. In the third embodiment of the present invention, studs  24 A are attached to a midpoint of the bottom surface of the first plate at one end, and to a midpoint of the upper surface of the second plate at their other end. With this configuration, the studs  24 A are not embedded in the concrete, but are disposed at the interface between the concrete layer and the insulating layer. This placement of the studs may be used if the thickness of the concrete layer is around 2″. 
     In a variation of the second embodiment, the bottom portions of vertical members  22 A and  22 B embedded in the concrete layer are sheared and bent to the sides. This is shown in  FIGS. 10 and 11 . The shear bent extensions  25 A and  25 B of the vertical members alternate from side to side and provide additional resistance to the panel against shear forces. 
     The panel composite is manufactured in a way that the polyurethane layer strongly adheres to the concrete layer on one side and to the corrugated layer on the other side. The structure of this panel solves the problem of building a high R value into the panel while also providing structural integrity to the panel such as resistance to shearing and buckling as a result of the impact of high winds or other lateral forces. To achieve the strong adherence of the insulation layer to the concrete and corrugated layers, the insulation layer is formed in situ by reacting the components for forming the polyurethane insulation in the space between the concrete and the corrugated layers. 
     Exemplary dimensions for the panel composite and its components are as follows:
         The height (H) of the composite panel depends on the building specifications and may range from 1′ to 50′.   The thickness of the concrete layer: 2″ and ranging from 2″ to 6″.   The thickness of the insulation layer: 4.75″ with a range of 2″ to 10″   The highest thickness of the corrugated steel: gauge 26 to 2×gauge 22.   The thickness of the composite panel (T): 8″ with a range of between 5.5″ and 18″.   The width (W) of the panel is 6′ with a range of 6′ to 12′.       

     The manufacturing process for the first embodiment of the composite panel is as follows: 
     1. The concrete is poured into the bottom of an open top enclosure sufficiently large to contain the full panel. 
     2. After the concrete is set, the corrugated layer is suspended above the enclosure by hoist in a way as to allow for the proper space between the concrete and the corrugated layer. 
     3. A heavy lid is placed onto the enclosure to contain the pressure that would result from the reaction to form the polyurethane insulation layer. 
     4. The liquid ingredients that react to produce the solid polyurethane layer are injected into the enclosure. The reaction is typically accomplished by mixing a diisocyanate with a polyol at about 80° F. The reaction takes place in the space between the concrete and corrugated sheet. 
     5. Once fully formed, the solid polyurethane bonds to both the concrete and corrugated layers. 
     The steps for manufacturing the panel of the second embodiment are as follows: 
     1. An open top container that has dimensions to accommodate the panel is provided such that the front of the concrete layer lays on the bottom of the container, one side wall of the container faces the top of the panel while the other side wall of the container faces the bottom of the panel structure. 
     2. Wet concrete is poured into the container in the dimensions of the concrete layer. 
     3. While the concrete is still wet, the second embodiment reinforcing assembly is inserted in the wet concrete such that studs  24 A are embedded inside the concrete layer at about a mid-point of the concrete thickness. Likewise, vertical members  22 A and  22 B are also embedded in the concrete at about a mid-point of the concrete thickness. 
     4. The concrete is allowed to harden. 
     5. The corrugated layer is suspended above the enclosure by hoist in a way as to allow for the proper space between the concrete and the corrugated layer. 
     6. A heavy lid is placed onto the enclosure to contain the pressure that would result from the reaction to form the polyurethane insulation layer. 
     The polyurethane insulation layer may be formed in two ways as follows: 
     A. As with the process for making the first embodiment panel, the reactants needed to form the polyurethane layer are injected into the space between the concrete and corrugated layer and are reacted. This forms a solid polyurethane layer wedged between the concrete and corrugated layer such that the solid polyurethane is bonded to both the concrete and corrugated layers. Injection of the reactants maybe injected through openings in the side walls of the container. This produces an intensely exothermic reaction such that the resulting heat and pressure must be contained. 
     B. With a second process, the reactants for forming the insulation layer are introduced through the open top of the container. After the reactants are introduced into the container, the lid is placed over the top opening to create the closed environment needed for the reaction to take place. 
     The process for manufacturing the panel of the third embodiment is similar to the process of manufacturing the second embodiment panel except that the reinforcing assembly of the third embodiment is used, resulting in studs  24 A being disposed at the interface between the concrete and insulation layers. However, vertical members  22 A and  22 B are embedded in the concrete at about a mid-point of the concrete thickness. 
     It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention.