Abstract:
A building system using drywall for interior and exterior wall panels is discussed. A building system using drywall for roof and floor panels is discussed. A building system using drywall which simplifies on site fabrication and construction is discussed. A building system which reduces or eliminates wood in many embodiments is described. Building systems which substantially reduce costs are described.

Description:
BACKGROUND 
       [0001]    Residential building has remained essentially unchanged for the last 300 years, with wood, wood byproducts and to a lesser extent masonry products providing the structure materials for the building. 
         [0002]    Panelized building is not new, but has typically utilized wood and wood byproducts and utilized factory fabrication. The cost of shipping and no savings in materials has resulted in minimal to no economy to the end user. 
         [0003]    There is a need for alternate materials to replace wood. Environmental concerns and increased regulation have made wood and consequently wood byproducts rise dramatically in cost. 
         [0004]    Another need is for a complete system. Typically a panelized building is only panelized in it&#39;s walls and roofs and floors are a variation of wall panels. Timbrook patented a primitive drywall panel system approximately 14 years ago (U.S. Pat. No. 5,493,839 Feb. 27, 1996). It relied on complex equipment to fabricate the panels and was not conforming to requirements to obtain building permits. 
         [0005]    There remains a need for a panelized system that imparts a substantial economy. 
         [0006]    There remains a need for alternative materials to replace or substantially reduce the use of wood and wood byproducts in the construction process. 
         [0007]    There remains a need for a complete panelized building system. 
         [0008]    There remains a need for a panelized building system where the majority of components can be fabricated on site. 
       BRIEF SUMMARY OF INVENTION 
       [0009]    This invention encompasses a total system with roof, floor, interior and utility panels and an exterior panel that includes integral framing for windows and doors. In addition, the exterior panel includes bi-directional studs for increased strength not only vertically but horizontally. 
         [0010]    Finally, the panels are easily assembled on site resulting in a reduction of wood and wood bi-products of 91-95% and resultant savings of 35-45% on the entire building. 
         [0011]    This invention simplifies fabrication, erection and complies with building code requirements. 
         [0012]    The increased cost of wood and environmental concerns have made the decreased use of wood a priority for consumers, builders and governmental authorities. 
         [0013]    As discussed above, there is a need to reduce or eliminate the need for wood in residential construction as well as commercial, institutional and industrial construction. There is a need for on site fabrication to reduce transportation costs and to reduce labor costs in construction. 
         [0014]    This invention will allow for fabrication of panels of between 4 and 18 feet in height and of 4 and 20 feet in width and incorporate window and door frames utilizing drywall as it&#39;s primary component. 
         [0015]    A preferred embodiment of this invention is directed to on site fabrication of the panels. 
         [0016]    One embodiment is a building panel comprised of a first drywall sheet, a second drywall sheet, at least a plurality of drywall studs attached between the first drywall sheet and the second drywall sheet and where the studs separate the drywall sheets by at least 3 inches wherein the drywall studs attached between the first and second drywall sheets comprise drywall studs at least in part adhesively attached to the first and second drywall sheets. 
         [0017]    One embodiment is a building panel comprised of first drywall sheets, a second drywall sheet, at least 3 studs separating first drywall sheet and the second drywall sheet and at least one drywall stud is substantially parallel with the other two drywall studs and wherein at least 3 drywall studs are attached to the first and second drywall sheet. 
         [0018]    One embodiment is a building panel comprised of first drywall sheets, second drywall sheet, at least 1 drywall stud forms an angle of at least 40 degrees to the other 2 drywall studs. 
         [0019]    One embodiment is a building panel comprised of first drywall sheets, a second drywall sheet, at least 1 drywall stud forms an angle of at least 80 degrees to the other 2 drywall studs, 
         [0020]    One embodiment is a building panel comprised of first drywall sheets, a second drywall sheet, a plurality of drywall studs attached between the first drywall sheet and the second drywall sheet, a bottom plate between the first and second drywall sheets and attached to the first and second drywall sheets, a corner stud extending between the first drywall sheet and the second drywall sheet and attached to the first and second drywall sheets. 
     
    
     
       BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
         [0021]      FIG. 1  is an artist&#39;s drawing of a preferred embodiment of the exterior wall section of this invention from a top view perspective.
       Reference Numeral  10  shows the interior sheet of drywall composition.   Reference Numeral  11  shows the vertical studs of drywall composition.   Reference Numeral  12  shows the connection plate of drywall composition.   Reference Numeral  13  shows the core sheet of drywall composition.   Reference Numeral  14  shows the horizontal stud of drywall composition.   Reference Numeral  15 . shows the exterior sheet of drywall composition.   Reference Numeral  16  shows an example of adhesive joint utilizing an elastomeric adhesive.   Reference Numeral  17  shows an example of a cavity created to accept the male edge of the adjacent panel when assembled.       
 
           [0030]      FIG. 2  is an artist&#39;s drawing of a preferred embodiment of the exterior wall section of this invention from a side view perspective.
       Reference Numeral  10  shows the interior sheet of drywall composition.   Reference Numeral  11  shows the vertical stud of drywall composition.   Reference Numeral  12  shows connection plates of drywall composition.   Reference Numeral  13  shows the core sheet of drywall composition.   Reference Numeral  15  shows the horizontal studs of drywall composition.   Reference Numeral  16  shows an example of adhesive joint utilizing an elastomeric adhesive.   Reference Numeral  17  shows a cavity required to accommodate the top plate.   Reference Numeral  18  shows a cavity required to accommodate the bottom plate.       
 
           [0039]      FIG. 3  is an artist&#39;s drawing of a preferred embodiment of an interior wall section of this invention from a top view perspective.
       Reference Numeral  30  shows the interior sheets of drywall composition.   Reference Numeral  32  shows the vertical studs of drywall composition.   Reference Numeral  33  shows an example of adhesive joint utilizing an elastomeric adhesive.   Reference Numeral  36  shows the cavity required to join adjacent interior panels together utilizing I connector (figure twelve shown herein).       
 
           [0044]      FIG. 4  is an artist&#39;s drawing of a preferred embodiment of an interior wall section of this invention from a side view perspective.
       Reference Numeral  30  shows the interior sheets of drywall composition.   Reference Numeral  32  shows the vertical stud of drywall composition.   Reference Numeral  33  shows an example of adhesive joint utilizing an elastomeric adhesive.   Reference Numeral  34  shows a cavity required to accommodate the top plate.   Reference Numeral  35  shows a cavity required to accommodate the bottom plate.       
 
           [0050]      FIG. 5  is an artist&#39;s drawing of a preferred embodiment of a floor section of this invention from a top view perspective.
       Reference Numeral  50  shows the under sheet of drywall composition.   Reference Numeral  51  shows the top sheet of cellulitic composition.   Reference Numeral  52  shows the joists of drywall composition.   Reference Numeral  53  shows an example of adhesive joint utilizing an elastomeric adhesive.   Reference Numeral  54  shows the cavity required to join adjacent floor panels together utilizing Box connector (figure eleven shown herein).   Reference Numeral  55  shows the cavity required to join adjacent floor panels together utilizing I connector (figure twelve shown herein).       
 
           [0057]      FIG. 6  is an artist&#39;s drawing of a preferred embodiment of a floor section of this invention from a side view perspective.
       Reference Numeral  50  shows the under sheet of drywall composition.   Reference Numeral  51  shows the top sheet of cellulitic composition.   Reference Numeral  52  shows the joists of drywall composition.   Reference Numeral  53  shows an example of adhesive joint utilizing an elastomeric adhesive.       
 
           [0062]      FIG. 7  is an artist&#39;s drawing of a preferred embodiment of a corner support section of this invention from a top view perspective.
       Reference Numeral  71  shows structural members of cellulitic, metal, plastic or composite composition.   Reference Numeral  72  shows base plate of cellulitic, metal, plastic or composite composition.   Reference Numeral  73  shows exterior sheets of drywall composition.   Reference Numeral  74  shows connection plates of drywall composition.   Reference Numeral  75  shows one example of an adhesive joint utilizing elastomeric adhesive.   Reference Numeral  76  Shows interior sheets of drywall composition. Reference Numeral  77  shows a core sheet of drywall composition.       
 
           [0069]      FIG. 8  is an artist&#39;s drawing of a preferred embodiment of a corner support section of this invention from a side view perspective.
       Reference Numeral  72  shows base plate of cellulitic, metal, plastic or composite composition.   Reference Numeral  73  shows exterior sheets of drywall composition.   Reference Numeral  74  shows connection plates of drywall composition.   Reference Numeral  75  shows one example of an adhesive joint utilizing elastomeric adhesive.   Reference Numeral  77  shows a core sheet of drywall composition.   Reference Numeral  81  shows mechanical fasteners used to secure exterior sheet to underlying structural members.       
 
           [0076]      FIG. 9  is an artist&#39;s drawing of a preferred embodiment of a corner support section of this invention from an alternate side view perspective.
       Reference Numeral  72  shows base plate of cellulitic, metal, plastic or composite composition.   Reference Numeral  73  shows exterior sheets of drywall composition.   Reference Numeral  81  shows mechanical fasteners used to secure exterior sheet to underlying structural members.       
 
           [0080]      FIG. 10  is an artist&#39;s drawing of a preferred embodiment of a roof section of this invention from a side view perspective.
       Reference Numeral  100  shows the roof deck of drywall or cellulitic composition.   Reference Numeral  101  shows the undersheet of drywall composition.   Reference Numeral  102  shows one embodiment of roof studs of drywall composition.   Reference Numeral  103  shows the cavity required to join adjacent roof panels together utilizing I connector (figure twelve shown herein).   Reference Numeral  104  shows the cavity required to join adjacent interior panels together utilizing Box connector (figure eleven shown herein).   Reference Numeral  105  shows one example of an adhesive joint utilizing elastomeric adhesive.       
 
           [0087]      FIG. 11  is an artist&#39;s drawing of a preferred embodiment of a box connector section of this invention from a side view perspective.
       Reference Numeral  111  shows a top sheet of drywall or cellulitic composition.   Reference Numeral  112  shows studs of drywall composition.   Reference Numeral  113  shows an example of an adhesive joint utilizing elastomeric adhesive.   Reference Numeral  115  shows of a bottom sheet of drywall or cellulitic composition.       
 
           [0092]      FIG. 12  is an artist&#39;s drawing of a preferred embodiment of an I connector section of this invention from a side view perspective.
       Reference Numeral  120  shows a top sheet of drywall or cellulitic composition.   Reference Numeral  121  shows a stud of drywall composition.   Reference Numeral  122  shows a bottom sheet of drywall or cellulitic composition.   Reference Numeral  123  shows one example of an adhesive joint utilizing elastomeric adhesive.       
 
           [0097]      FIG. 13  is an artist&#39;s drawing of a preferred embodiment of a utility section of this invention from a rear view perspective.
       Reference Numeral  131  shows a top cap of cellulitic composition.   Reference Numeral  132  shows the face sheet of drywall composition.   Reference Numeral  133 . shows crossmembers of drywall composition.   Reference Numeral  134 . shows vertical studs of drywall composition.   Reference Numeral  135  shows one example of an adhesive joint utilizing elastomeric adhesive.       
 
           [0103]      FIG. 14  is an artist&#39;s drawing of a preferred embodiment of a utility section of this invention from a side view perspective.
       Reference Numeral  131  shows a top cap of cellulitic composition.   Reference Numeral  132  shows the face sheet of drywall composition.   Reference Numeral  133 . shows crossmembers of drywall composition.   Reference Numeral  134 . shows vertical studs of drywall composition.   Reference Numeral  135  shows one example of an adhesive joint utilizing elastomeric adhesive.   Reference Numeral  136  shows a cavity created to accommodate a bottom plate.   Reference Numeral accommodate a top plate.  137  shows a cavity created to       
 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0111]    The panelized building system is a departure from traditional building methods including panelized systems currently available. One embodiment of this system comprises 5 separate panels constructed primarily of drywall sheets to construct a building. 
         [0112]    One embodiment of a drywall sheet comprises a sheet having gypsum between layers of paper. Another embodiment of a drywall sheet comprises a sheet having fly ash between layers of paper. Additionally, 2 separate connectors are utilized to provide structural integrity and increase strength.
       1. Floor Panel: A panel of between 4 and 12 feet long and 4 and 8 feet wide, constructed of drywall for it&#39;s core. The core is secured to the under layer comprised of drywall and top layer comprises of drywall or cellulitic material with an elastomeric adhesive and secured to the foundation with a mechanical fastener anchored in the foundation and extending through the base plate of cellulitic composition.   2. Exterior Wall Panel: A panel of between 4 and 18 feet in height and 4 and 12 feet in width constructed of drywall for it&#39;s core and interior and exterior layers as well as the connection plates. The component pieces are an interior layer and exterior layer of the same size, a core layer of the same width as the interior and exterior layers and 6 inches to 24 inches less in height than the interior and exterior layers, vertical studs between 1 and 24 inches wide and the same height as the core layer and the same thickness as the core layer (installed parallel to each other between 1 and 24 inches apart at an angle of 10 degrees to 170 degrees to the bottom of the core layer) installed on centers of between 1 and 24 inches, horizontal studs substantially the same length as the width of the core layer (installed parallel to each other between 1 and 24 inches apart at an angle of 10 degrees to 170 degrees to the side of the core layer) installed on centers of 1 to 24 inches. The horizontal studs are installed between the core layer and the exterior layer and the vertical studs are installed between the core layer and the interior layer. The core layer is installed at the center between the horizontal and vertical studs and is offset between 1 inch and 24 inches to the side and is centered heightwise between the interior and exterior layers leaving space for the top and bottom plates. The vertical studs are not to be installed parallel to the horizontal studs. Finally, the connection plates are installed between the interior layer and the core layer extending between the last vertical stud and the end of the core layer at between 1 inch and 36 inch centers. The entire panel is secured utilizing an elastomeric adhesive.   3. Interior Wall Panel: A panel of between 4 feet and 18 feet in height and 4 and 12 feet in width constructed of drywall for it&#39;s core and interior walls.   The component pieces are two interior layers and a core of vertical studs. The vertical studs will be between 1 inch and 24 inches wide and be of varying length to accommodate top and bottom plates. The vertical studs will be installed at 10 degrees to 170 degrees to the bottom of the interior layers. The entire panel will be secured utilizing an elastomeric adhesive.   4. Roof Panel: A panel consisting of between 4 feet and 12 feet in height and 4 and 18 feet in width constructed of drywall for it&#39;s core and underside and an exterior roof deck side of either drywall or cellulitic material (to accommodate finish roofing preference). The component pieces are an interior underside, a core of vertical studs and an exterior roof deck. The vertical studs will be between 1 inch and 24 inches wide and be of varying length depending on orientation to the underside and exterior roof deck. The vertical studs will be installed at 10 degrees to 170 degrees to the bottom of the interior layers. The entire panel will be secured utilizing an elastomeric adhesive.   5. Utility Panel: A panel of between 1 feet and 18 feet in height and 4 and 12 feet in width constructed of drywall for it&#39;s core and interior walls. The component pieces are an interior layer and a core of vertical studs. The vertical studs will be between 1 inch and 24 inches wide and be of varying length to accommodate top and bottom plates. The vertical studs will be installed at 0 degrees to 89 degrees to the bottom of the interior layer. The vertical studs will be connected in the utility cavity by cross pieces of gypsum or fly ash board construction of widths between 1 inch and 36 inches. The cap can be made of drywall or cellulitic material and attached with mechanical fasteners to allow access to utilities concealed in the utility cavity. The entire panel except for cap installation will be secured utilizing an elastomeric adhesive.   6. Box Connector: A connector of between 1 and 12 feet in length with a width and height designed to fit snugly into the panels they are connecting. Connector will consist of a top and bottom layer the width of the space between 2 studs and the height of the distance between the under layer and the top layer less the thickness of material comprising the under layer and the top layer, placed at opposite ends of the width of the top and bottom layers of the connector. The panel will slide between the vertical studs of 2 floor or roof panels and be secured by an elastomeric adhesive. This will join 2 or more panels into one structurally integrated unit. The box connector can be made of drywall or cellulitic material or combination of those materials and secured using elastomeric adhesive.   7. I Connector: A connector of between 1 and 12 feet in length with a width and height designed to fit snugly between the panels they are connecting. Connector will consist of a top and bottom layer the width of the space between the end studs of 2 adjacent panels (floor, roof or interior wall panels) and one stud the height of the distance between the under layer and the top layer less the thickness of material comprising the under layer and the top layer and be centered widthwise to the top and bottom layer. The panel will slide between the vertical studs of 2 floor, roof or interior panels and be secured by an elastomeric adhesive. This will join 2 or more panels into one structurally integrated unit. The I connector can be made of drywall or cellulitic material or combination of those materials and secured using elastomeric adhesive.   8. Corner Support Section. A corner support column between 4 and 18 feet in height and 1 foot and 4 feet in width and 1 foot and 4 feet in length. Corner support column will consist of a bottom plate and top plate of cellulitic, metal, plastic or composite construction. A column of cellulitic, metal, plastic or composite construction is attached between top and bottom plates at least partially with mechanical fasteners and exterior sheets of drywall composition and interior sheets of drywall composition. Interior and exterior sheets will be secured to column and top and bottom plates at least partially with mechanical fasteners. Drywall studs and connection plates will fit between interior and exterior sheets and be attached using an elatomeric adhesive.   Figure one is an artist&#39;s drawing of a preferred embodiment of an exterior panel. Reference numerals  10 ,  11 ,  13  and  15  impart vertical strength to the wall while reference numerals  10 ,  13 ,  14 , and  15  impart strength to resist side impact and high wind. Reference numerals  12 ,  13  and  14  form a male edge designed to join multiple panels together to form a contiguous wall. Reference numeral  19  is a cavity designed to receive the male edge previously referred to in this paragraph in order to form a contiguous wall. Reference numeral  16  shows an example of a an elastomeric adhesive joint.     FIG. 2  is an artist&#39;s drawing of a preferred embodiment of the exterior wall section of this invention from a side view perspective. Reference numerals  17  and  18  are cavities designed to accommodate a top and bottom plate respectively.     FIG. 3  is an artist&#39;s drawing of a preferred embodiment of an interior wall section of this invention from a top view perspective. The panel is designed primarily for vertical strength in order to support floors and/or roof structures above. Reference numeral  36  shows a cavity designed to allow multiple panels to be joined together utilizing an I connector as shown in  FIG. 12  contained herein. Reference Numeral  33  shows an example of adhesive joint utilizing an elastomeric adhesive.     FIG. 4  is an artist&#39;s drawing of a preferred embodiment of an interior wall section of this invention from a side view perspective. Reference numerals  34  and  35  are cavities designed to accommodate a top and bottom plate respectively.     FIG. 5  is an artist&#39;s drawing of a preferred embodiment of a floor section of this invention from a top view perspective. Reference number  50  shows a top sheet of cellulitic composition as this is required by all building codes. Joists and undersheet are of drywall composition as depicted in reference numerals  52  and  50  respectively. Reference numeral  54  shows a cavity created to accommodate a box connector as shown in  FIG. 11  herein. Reference numeral  55  shows the cavity required to join adjacent floor panels together utilizing I connector shown in  FIG. 12  herein.     FIG. 6  is an artist&#39;s drawing of a preferred embodiment of a floor section of this invention from a side view perspective.     FIG. 7  is an artist&#39;s drawing of a preferred embodiment of a corner support section of this invention from a top view perspective. The corner support section is designed to give an anchoring device and provide vertical and horizontal strength to the exterior walls of a structure. Reference numeral  71  refers to the structural members. This assembly is joined to the bottom and top plates at least in part by mechanical fasteners and can be of cellulitic, metal, plastic or composite composition. Reference numeral  72  refers to a base plate of celluiltic, metal, plastic or composite composition. Reference numerals  73 ,  76 ,  77 , and  74  refer to a male end designed to mate with the female edge of the exterior wall panel.     FIG. 8  is an artist&#39;s drawing of a preferred embodiment of a corner support section of this invention from a side view perspective. Reference numeral  81  refers to mechanical fasteners used at least in part to secure exterior sheet to underlying structural members.     FIG. 9  is an artist&#39;s drawing of a preferred embodiment of a corner support section of this invention from an alternate side view perspective. Reference Numeral  72  refers to a base plate of cellulitic, metal, plastic or composite composition. Reference Numeral  73  refers to exterior sheets of drywall composition. Reference Numeral  81  refers to mechanical fasteners used to secure exterior sheet to underlying structural members.     FIG. 10  is an artist&#39;s drawing of a preferred embodiment of a roof section of this invention from a side view perspective. Reference numeral  100  shows the roof deck of drywall or cellulitic composition. Reference numeral  101  refers to the undersheet of drywall composition. Reference numeral  102  refers to roof studs of drywall composition. Reference numeral  103  refers to the cavity required to join adjacent roof panels together utilizing I connector (figure twelve shown herein). Reference numeral  104  refers to the cavity required to join adjacent interior panels together utilizing Box connector (figure eleven shown herein).     FIG. 11  is an artist&#39;s drawing of a preferred embodiment of a box connector section of this invention from a side view perspective. Reference numeral  111  shows a top sheet of drywall or cellulitic composition. Reference numeral  112  shows studs of drywall composition. Reference numeral  113  shows an example of an adhesive joint utilizing elastomeric adhesive. Reference Numeral  115  shows of a bottom sheet of drywall or cellulitic composition. Reference numerals  111 ,  112 ,  113  and  115  as a unit allow floor and roof panels to be joined together in a structurally sound manner to increase the span of the floor or roof.     FIG. 12  is an artist&#39;s drawing of a preferred embodiment of an I connector section of this invention from a side view perspective. Reference numeral  120  refers to a top sheet of drywall or cellulitic composition. Reference numeral  121  refers to a stud of drywall composition. Reference numeral  122  refers to a bottom sheet of drywall or cellulitic composition.     FIG. 13  is an artist&#39;s drawing of a preferred embodiment of a utility section of this invention from a rear view perspective. Reference numeral  131  refers to a top cap of cellulitic composition. Reference numeral  132  refers to the face sheet of drywall composition. Reference numeral  133  refers to crossmembers of drywall composition. Reference numeral  134  refers to vertical studs of drywall composition.     FIG. 14  is an artist&#39;s drawing of a preferred embodiment of a utility section of this invention from a side view perspective. Reference numeral  135  shows one example of an adhesive joint utilizing elastomeric adhesive. Reference numeral  136  refers to a cavity created to accommodate a bottom plate. Reference numeral  137  refers to a cavity created to accommodate a top plate.