Abstract:
The disclosure pertains to a method of constructing structures and the resulting structures with SEP technology but with additional building components that create very strong buildings, including the ability to withstand high winds. The disclosure includes the option of constructing vertical concrete columns and horizontal concrete beams within the joined panel walls. This results in combining structural insulated panel technology with insulated concrete form technology. The disclosure also teaches use of compression fasteners that extend through both layers of the panel skin to achieve a mechanical attachment of the panel skins and not relying totally on the adhesive bond found on the typical SIP thus creating a “true” box beam effect of the panel itself. The fasteners have large chambered heads. These fasteners can be used at the junction of abutting panels. The panels are block lap cut and the fastener extends through both block extensions.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority to and the benefit of the provisional application Ser. No. 60/901,738 filed Feb. 17, 2007 entitled “Building System Utilizing Integrated Technology with Molded Expanded Polystyrene Cores.” The text and the drawings of the provisional application Ser. No. 60/901,738 are incorporated by reference herein. 
     
    
     BACKGROUND OF INVENTION 
       [0002]    1. Field of Use 
         [0003]    The invention pertains to modular constructed building systems that employ green technology and little, if any, wood products. 
         [0004]    2. Related Technology 
         [0005]    Off site manufacturing of building components such as wood roof trusses are known. 
       SUMMARY OF DISCLOSURE 
       [0006]    The disclosure pertains to a plurality of wall panels fabricated of molded expanded polystyrene (MEPS) with an outer layer or “skin” of cement board, oriented strand board, metal or magnesium oxide. In one example the panels can be 4 feet wide by 8 feet high and 3½ inches to 11½ inches thick. Other dimensions are possible. The vertical ends of the panels may be cut to form block and tongue lap joints with the next adjoining panel. The resulting lap joint allows for increased surface area for bonding the panels together. Adhesives are used to “weld” the MEPS at the panel lap joint to create a “continuous like” structural wall. The panels are secured with compression fasteners that traverse through the thickness of both panels at the block and tongue lap joint and anchor at the outer surface. 
         [0007]    The structure can be anchored to a concrete pad. The roof structure can be made of the panel material and attached to the walls with attachment connectors. 
         [0008]    The panels may also contain preformed voids creating forms for pouring and shaping internal vertical concrete columns and horizontal concrete beams thereby combining structural insulated panel (SIP) technology with insulated concrete form (ICF) technology. 
         [0009]    The horizontal ends of the panels may also be similarly cut and shaped to form block and tongue lap joints. 
     
    
     
       SUMMARY OF DRAWINGS 
         [0010]    The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention. These drawings, together with the general description of the invention given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention. 
           [0011]      FIG. 1  illustrates an example of a SIP panel illustrated to be  4  feet wide and  8  feet long. This is a side view. Also illustrated are the chamfer heads of the compression fasteners mounted vertically every  2  feet. Also illustrated in the tongue component of the lap joint. 
           [0012]      FIGS. 2A and 2B  illustrate opposing lap joint ends of two SIP panels. 
           [0013]      FIG. 2C  illustrates the two panels joined together utilizing a compression fastener. 
           [0014]      FIG. 2D  illustrates a two piece threaded compression fastener. 
           [0015]      FIG. 3  illustrates a block lap end cut of a SIP panel with an internal column forming void or annulus. 
           [0016]      FIG. 4  illustrates an end view of the SIP panel showing the void for a concrete horizontal beam. 
           [0017]      FIG. 5  illustrates an end view of another SIP panel showing an expanded installed top portion into which a concrete horizontal beam can be formed. 
           [0018]      FIG. 6  is a detail of the end view of  FIG. 5  with vertical and horizontal reinforcing bar and compression fasteners. 
           [0019]      FIGS. 7 and 8  illustrate examples of a SIP I-beam attached to a vertical SIP panel with associated structural connectors and compression fasteners. 
           [0020]      FIGS. 9A ,  9 B and  9 C illustrate differing perspective views of connectors that can be used to connect I-beam to the SIP panel. 
           [0021]      FIG. 10  illustrates the positioning of an angle structural connecting plate on top of a vertical SIP panel and angle roof comprised of an I-Beam. 
           [0022]      FIG. 11  illustrates the attachment of a horizontal I beam on the top of a vertically oriented SIP panel. 
           [0023]      FIG. 12A ,  12 B and  12 C illustrate  3  views of the angled structural connector plate illustrated in  FIG. 10 . 
           [0024]      FIGS. 13  and  FIG. 14  illustrate alternative structural attachment connectors for attaching the vertical SIP panel to an angle I-beam. 
           [0025]      FIG. 15A ,  15 B and  15 C illustrate a front, side and back view respectively of one connector device. 
           [0026]      FIGS. 16 and 17  illustrate details of the lap joints joining the adjacent SIP panels for a roof structure. 
           [0027]      FIG. 18  illustrates a block and tongue lap joint reinforced by a preformed structural Z shaped member. 
           [0028]      FIG. 19  and  FIG. 20  illustrate the SIP vertical panel base attached to the floor concrete slab with a structural connector. 
           [0029]      FIG. 21  illustrates an isometric view of  3  SIP panels joined together into a wall and containing internal vertical concrete columns and horizontal beams. 
           [0030]      FIG. 22  illustrates an isometric view of the vertical edge of two panels forming a block and tongue lap joint and the placement of the compression fasteners. 
           [0031]      FIG. 23  illustrates an isometric view of a series of SIP panels joined into a wall and including the structural top and bottom base connectors joining two panels. 
           [0032]      FIG. 24  illustrates an isometric view of a block and tongue lap joint reinforced by the  2  shaped structural member illustrated in  FIG. 18  and the installation of compression fasteners with a top structural connector plate joining two panels. 
           [0033]      FIGS. 25 and 26  illustrate a top view and side view respectively of a SIP panel production line. 
           [0034]      FIGS. 27 and 28  illustrate front and side views respectively of a twin SIP laminating press. 
       
    
    
       [0035]    It will be appreciated that the foregoing drawings illustrate only one embodiment of the invention and that numerous other variations may be created within the scope of the described invention. Further, the accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention. These drawings, together with the general description of the invention given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention. 
       DETAILED DESCRIPTION OF INVENTION 
       [0036]    The building structure and method described herein incorporates structural insulated panel technology (hereinafter “SIPs”) and may include a concrete pad or foundation, wall panels that are adhesive bonded and secured together with compression fasteners, optional internal concrete beams and a roofing system attached to the wall system. The structure and the building method come in two versions, one that integrates concrete and one that does not. 
         [0037]    Utilization of the concrete column and beam technology achieves a combination of structural insulated panel technology with insulated concrete form technology. Both versions utilize structural insulated panels (hereinafter “SIPs”). In the embodiments disclosed, the concrete columns and beams are installed within the interior of the SIP panels. 
         [0038]    The panel is a structural insulated wall or roof panel  11  which has a core made of molded expanded polystyrene (hereinafter “MEPS”) of various thicknesses from 3½″ to 11½″. The outer layers  110  are cement board (CB) or oriented strand board (OSB), metal or Magnesium Oxide (MgO) board which may be pressure adhered with a Type II, Class 2 structural adhesive or similar. One embodiment of a SIP panel is illustrated in  FIG. 1 . The panel is 4 feet wide and 8 feet high. As discussed the thickness of the panel may be between 3½ inches and 11½ inches. The illustrated panel  1  is a side perspective. Also illustrated are the chamfer heads  3  of the compression fasteners as will be discussed later. The head of the compression fastener can also have square sides. The compression fittings are illustrated as placed every two feet. Other configurations are possible. The tongue  115  of the block and tongue lap joint is also shown protruding from the vertical side of the panel. 
         [0039]    The CB and MgO outer materials also have fire retardant properties. 
         [0040]    Other components of the structure system, e.g., fiberglass, may be made from an extrusion process. This can allow fabrication of components in custom shapes. 
         [0041]    The system utilizes a 3-4″ block projecting tongue fabricated on the vertical edge, and in some cases the top horizontal edge, of each panel and which butt and lap together with the similar edge of a second panel. A series of compression fasteners are placed vertically and horizontally along the butt joint forming the lap juncture. The compression fasteners attach to each panel skin, whether cement board, OSB, metal or MgO of each panel. The compression fastener therefore incorporates both skins of the SIP panels. The compression fasteners are placed horizontally at gables and 2 story walls. This strengthens the bond between the panels. 
         [0042]    In one option, concrete may be used in the structure. The panel contains a vertically oriented void that forms the various shapes of the concrete column internal to the panel. A panel is placed on the cement pad of the structure where a vertical concrete column is to be placed. The reinforcing bar (rebar) placed in the column is tied to rebar extending from the concrete pad. Compression fasteners are utilized to stabilize the sides of the form (within the panel wall) when the concrete is poured. The form for the concrete column is a void created in the interior MEPS and extends the length of the SIP panel. 
         [0043]    A horizontal beam that sits on top of the vertical column can be created by a second void in the top of the SIP panel or by use of an installed or “detachable” beam form. The rebar of the horizontal beam will be tied to the vertical rebar extending from and attached to the structure&#39;s concrete pad. (See information below). 
         [0044]    Block projecting tongue lapping is used on all vertical panel joining and at gable ends and when structure side walls have a greater height than the standard SIP wall panels 
         [0045]    Block projecting tongue lapping or lap juncture is illustrated in  FIGS. 2A through 2C . A two part compression fastener is also illustrated  1 ,  2 ,  3 . In one embodiment the MPES panel  105  is shown to be between 6 and 8 inches in thickness with an outer surface ( 7/16 inch)  110  of cement board, OSB, metal or MgO. The outer surface or skin is pressure adhered with a Type II, Class 2 structural adhesive. 
         [0046]    Waterproof construction adhesive  5  may be applied to both sides of the lap joint. A ⅛ inch air gap  130  is recommended between the joined SIP wall panels. The horizontal off set  135  of the block projecting tongue combination may be approximately 4 inches. 
         [0047]    Panel lapping of three roof panels  20 A,  20 B,  20 C is also illustrated in  FIGS. 16 . Each roof panel comprises a series of individual SIP panels joined in the block projecting tongue lapping configuration. 
         [0048]    The SIP panel  20 D,  20 E illustrated in  FIG. 17  may be various thicknesses, including the cement bonded particle board, OSB, metal or MgO layer. Also illustrated is the recommended ⅛ inch expansion joint  130  and the approximate 4 inch offset  135  of the lap joint. The placement of the adhesive  5  is also illustrated. 
         [0049]    SIP panel lapping is used on all vertical (wall) panel joining and may be used horizontally at gable ends of the structure. 
         [0050]    The system utilizes a unique compression fastener comprising a bolt that can be mounted flush to the SIP panel surface or “skin”. The compression fastener is illustrated in  FIG. 2D  comprising a bolt component  1  and a nut component  2 . The two part combination is designated  3 . 
         [0051]    The large chamfer or square sided head on both bolt and nut ends of the compression fastener and engage with the SIP panel skins facilitates compression of the SIP panel. The head and nut components are threaded and can be tightened. This is a more secure connection that staples, nails or screws. This also enhances the stability of the structure, including stability in earth movement or high wind conditions. The construction technique forms a box beam effect on the panel wall connection. 
         [0052]    Composition of fasteners can be either non-metallic, e.g., fiberglass, or metallic, e.g., stainless steel. The compression fasteners may be of any appropriate length consistent with the thickness of the SIP panel. In one embodiment, the fasteners are 7 inches to 10 inches in length. The diameter of the rod portion of the fastener may, in one embodiment, be ¼ inch. In one embodiment, the chamfer or square ends may have a 1 inch diameter. The chamfer ends may include hex slot for tightening. 
         [0053]    The system described herein permits the installation of vertically oriented concrete columns within constructed SIP panels. See  FIG. 3 . In one embodiment, the molded expanded polystyrene  105  can be molded or cut to create the form or annulus for the concrete. The shape of the concrete column is formed using pre-formed voids or annulus within the SIP panels. Also illustrated in  FIG. 3  are the double layers of outer skin  110  (first skin on one side of the panel and a second skin on the opposite side of the panel). The compression fastener  3  spanning across the form is also illustrated. These compression fasteners are utilized to stabilize and secure the sides of the form when the concrete is poured. These compression fasteners may be placed vertically every 2 feet although other configurations may be selected. 
         [0054]    A rectangular or other shaped void  140  is placed vertically in a wall panel for the purpose of pouring a structural concrete column. The void extends the entire length of the SIP panel. If a horizontal concrete beam is to be installed, the concrete column will not extend to the top of the panel. The form or void may be 5¼ inches by 13½ inches in a panel that is 7¼ inch wide. The rectangular shape is shown as an example only and is not a limitation. 
         [0055]    Recall that compression fasteners and adhesive will be applied at each lap joint. The compression fasteners may be placed vertically every two feet. The series of joined wall panels, having fasteners traversing through the thickness of the lapped panels and the large chamfered ends engage the outer surface of each skin of the joined panels to pull them together which thereby becomes rigid and unified. 
         [0056]    In addition to the building of vertical concrete columns, horizontal concrete beams may be constructed across the top of some or all panels. Two options are illustrated. 
         [0057]      FIG. 4  illustrates the top section of a vertically oriented SIP panel comprised of the interior molded expanded polystyrene  105  and exterior skins  110 . The panel includes a void  145  creating a form used for the purpose of pouring a horizontal concrete beam. In one example, the form  145  may be 13½ inch deep. It is intended that the concrete be reinforced with rebar and that this rebar be tied into the rebar of adjacent vertical columns. 
         [0058]    In the second variation,  FIG. 5 , a “U” shaped molded expanded polystyrene (MEPS)  105  form or void  145  that snugly fits over the top  215  of a SIP wall panel for the purpose of pouring a horizontal concrete bond beam. The detachable beam  125  form is clad with facings,  110  e.g., cement board, OSB, metal or MgO that project downward past the base  150  of the MEPS to create a securing mechanism for setting the beam form on a wall panel  220 . 
         [0059]    To assist securing the detachable beam form, compression fasteners  3  are utilized to stabilize and secure the sides of the form  145  when concrete is poured as illustrated in  FIG. 6 . Also illustrated in  FIG. 6  are the compression fasteners  3  extending through both layers of skin  110 . Also shown is the horizontal rebar extending through the top beam  150  and the vertical rebar  155  extending through the vertical concrete column. 
         [0060]    Note that the form fits over the top of the SIP wall panel  215 . This can be a method for raising the wall height as well as increasing the wall strength and wind resistance. 
         [0061]    The use of concrete columns and beam can allow the construction of multi-story structures. Appropriate engineering of the column, beam and wall thickness dimensions would be required. 
         [0062]      FIGS. 7 and 8  illustrate two examples of a structural connector plate  320 ,  321 . The plate extends across the top  215  of the SIP panel. It contains holes for tying the connector plate to the panel using at least one compression fastener  3 . The top of the panel also includes a cut out  316  for access to a bolt  310  extending through the horizontal roof I-beam  305  that includes a U shaped collar  311  for holding the beam to the connector. 
         [0063]      FIGS. 9A ,  9 B and  9 C illustrate alternate side views of the structural connector  320 .  FIG. 9C  illustrates a cross section of a roof system I-beam and a U shaped collar holding the I-beam to the wall. 
         [0064]      FIG. 10  illustrates a structural connector plate  325  attached to the top of a horizontal concrete beam constructed as described above in conjunction with  FIGS. 5 and 6 . The connecting plate is sloped or wedge shaped. Illustrated is the concrete  312  within the form  145 , the MEP  105  and skin  110  creating the form and the top  215  of the SIP panel. Also illustrated is a sloped roof structure illustrated here to include an I-beam  305 . 
         [0065]    The structural connector is tied to the concrete bean by a bolt  311  vertically oriented within the concrete  312 . A U shaped collar  313  extends from the structural fastener over the I-beam. The mechanism may include a flat plate bolted  310  over the I-beam. 
         [0066]      FIGS. 12A ,  12 B, and  12 C illustrates three views of the structural connector  325 . 
         [0067]      FIG. 11  illustrates a flat roof system fastened over a horizontal concrete beam  312  placed on top of a SIP panel  215 . The form  145  comprises the MEPS  105  creating the concrete form and the outer skins  110 . The roof system is illustrated to include an I-beam  305  attached to the concrete beam with a bolt or similar attachment  310  embedded in the concrete. 
         [0068]      FIG. 13  also illustrates another embodiment of a sloped roof system attached to the top  215  of the SIP wall panel. The illustrated roof system includes an I-beam  305 . The structural connector  326  is dimensioned to fit between the molded expanded polystyrene (MEP)  105  and the two layers of outer skin  110 . The structural connector includes holes for accommodating one or more compression fasteners  3  proximate to the top of the SIP wall panel. The structural fastener is also sloped compatible with the roof system. The I-beam can be held by a U shaped collar  313  spanning over the I-beam. It may also be held by a bolt traversing the I-beam. A wedge shaped block of MEPS may be inserted into the void  331  of the sloped structural fastener. 
         [0069]      FIG. 14  illustrates a similar system with the structural connector  327  dimensioned to fit over the two skin layers  110 .  FIG. 15A ,  15 B, and  15 C illustrate  3  views (front, side and back respectively) of the structural connector  326 . The remaining components have been identified by the numbering sequence of  FIG. 13   FIG. 16  illustrates SIP panels lapped together and used for a roofing system. The lap joints are unified into a single piece using adhesive and compression fasteners. Recall compression fasteners may be installed a various intervals depending upon the load factor. This load factor may be wind associated with storms. The roof can be constructed for high wind resistance by the placement of compression fasteners, structural connector at the top and bottom of the walls and connected to horizontal beams and fastener connecting the wall to the concrete slab. 
         [0070]      FIG. 17  illustrates another detail of the lap joining method. The SIP panel may be of various thicknesses. Illustrated is the compression fastener  3 . The adhesive  5  is also illustrated. The offset for the lap structure is approximately 4 inches. The recommended expansion gap  130  of ⅛ inch is also illustrated. 
         [0071]      FIG. 18  illustrates another embodiment of a lap joint wherein a “Z” shaped component  8  is inserted between the two lapped panels  18 - 1  and  18 - 2 . The component may be fiberglass. This strengthens the bond between the joined panels. This component  8  is also shown in  FIG. 24 . 
         [0072]      FIG. 19  illustrates the preparation of the bottom  219  of the SIP wall panel and bottom plate  220  fabricated from MgO or similar water impervious material (See  FIG. 20 ). Illustrated is the molded expanded polystyrene  105  and the outer skin  110  of cement board, oriented strand board, metal or magnesium oxide. The void  224  manufactured for placement of the structural connector (not shown) to be installed between the MEP and outer skin is also shown. 
         [0073]      FIG. 20  illustrates the SIP board bottom assembled on a concrete pad  175  and held in place with a bolt  170  embedded within the concrete. The structural connector  225  is installed on top of the bottom plate  220  and held with a compression fastener  3  and adhesives  5 . 
         [0074]      FIG. 21  is an isometric drawing of a SIP wall comprised of multiple SIP panels  11 . Illustrated is the structural base connector  225  as part of the system that unifies or solidifies the multiple panels into a single structural wall. Also illustrated is the anchor bolt  170  fastened to the MgO base plate  220 . Also illustrated are the multiple compression fasteners placed vertically at each lap joint. The  FIG. 21  shows by phantom lines the placement of vertical cement columns  141  and containing rebar. Also shown is the horizontal beam  312  also containing rebar  150 . Illustrated is the MEP  105  and outer skin  110 . A portion of the roof system is illustrated, particularly its connection to the wall. A threaded rod  313  is placed in the horizontal concrete beam with a hub nut  311  that holds down the roof. The structural connector is not, however, shown. See  FIGS. 7 ,  8 ,  10 ,  11 . 
         [0075]      FIG. 22  is a detail from  21  and illustrates the inter-joining lap joints of SIP wall panels. Each SIP panel contains a block lap juncture or lap joint. Panel  11  fits with the second panel  11  A. The lap joint block  115  of each joint fits adjacent to the next adjoining panel. The joint is structurally unified by a series of compression fasteners  3 A,  3 B,  3 C. Adhesives may also be used (not shown). The void  140  for the concrete form is illustrated along with the MEP  105  from which the void is formed. Also shown is a fascia board  325  with drip ledge. 
         [0076]      FIG. 23  is another isometric view of the SIP wall construction. Illustrated are the top structural connecting plates  320 . These components can span each juncture between two SIP panels. Also illustrated are the bottom structural base connections  225  in  FIGS. 20 and 21 . These components can also span each juncture of two SIP panels. These top and bottom components, combined with the compression fasteners vertically oriented along each juncture and tying together of lap joints, the structural Z component  8  at each juncture, and further combined with adhesives at the juncture, form a structurally unified wall. The concrete pad  175  and bolt  170  traversing through the MgO plate  115   
         [0077]      FIG. 24  illustrates a detail of the lap juncture of two panels. Illustrated is the top structural fastening plate  320  that spans the panel juncture. The plate is held in place by two compression fasteners  3 A,  3 B,  3 C. Also inserted between the lap blocks  115  is the Z component  8 . 
         [0078]    It will be appreciated that the same manufacturing techniques are used in creating the wind resistant roof system. The result is a structurally unified roof system strongly connected to the wall system (optionally containing concrete columns and beams). The complete structure is well adapted to area subject to earth movement and to storm prone areas where wind damage is experienced. The manufacturing system also permits rapid construction of structures. Since components are factory manufacture, costs are minimized. 
         [0079]      FIG. 25  is an overhead view of the manufacturing equipment layout for fabricating SIP panels. The process begins with in feed of mold expanded polystyrene (MEP)  426  to a gravity roller conveyor and then to an adhesive spreader  424  and water mister  423 . The skins are next fed  422  to the exterior of the panels to a pit mounted scissors lift with roller deck  420 . Included is an overhead truss vacuum lift  427 . Transfer carts on trolley rails  412  carry the combined panel (MEP panel with adhesive attached “skin” e.g., CB, MgO, etc.) to a press  400 . Also shown is the area  410  in which additional presses can be added to increase production (due to the time required for the adhesive to cure under pressure of the press). With more presses, more panels can be curing simultaneously. The equipment configuration forms a T-formation with the heated presses forming the top of the “T”. 
         [0080]      FIG. 26  provides a side view of the manufacturing layout. The same item numbers are used for the counter part equipment. 
         [0081]      FIG. 27  is a front view of the press unit  400  used to bond the skin to the MEPS component. The press may be termed a “T-press”  406  since one vertical structure is used for two presses. The press includes steel wide flange beams  401  and a base plate bolted to the slab floor  402 . Included are two hold down rods  403 .  FIG. 29  illustrates the presses  400  and hold down rods. The presses are operated by hydraulic cylinders  404  attached to a structural box channel  405 . Other type or designed cold presses can be substituted for the “T-press” as long as they meet the standard and production requirements. 
         [0082]      FIG. 28  is a side view of the T-press assembly. 
         [0083]    In addition, this specification is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the manner of carrying out the invention. It is to be understood that the forms of the invention herein shown and described are to be taken as the presently preferred embodiments. As already stated, various changes may be made in the shape, size and arrangement of components or adjustments made in the steps of the method without departing from the scope of this invention. For example, equivalent elements may be substituted for those illustrated and described herein and certain features of the invention maybe utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. 
         [0084]    While specific embodiments have been illustrated and described, numerous modifications are possible without departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying claims.