Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application No. 61/976,326 filed Apr. 7, 2014; and U.S. Provisional Patent Application No. 62/099,337 filed Jan. 2, 2015, the disclosures of which are hereby incorporated herein in their entirety by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention is directed to a panel system for building structures and in particular insulated panels for reducing energy consumption in buildings. 
       BACKGROUND OF THE INVENTION 
       [0003]    The immediate problem of climate change effects on future generations make low carbon solutions today an imperative. In the United States approximately 40% of greenhouse gas (GHG) pollutants are associated with our buildings, with 93% of these GHGs being created through the lifetime operations of the building through energy use intensity. With such a large percentage of GHG created through our buildings combined with the fact that it is not atypical for a building to have life expectancy of 100 years or more it follows that the creation of net zero low energy buildings is a necessity now. We have the knowledge and experience to create buildings today that use 70% less energy than current code requires, prior to any site generation being added. The problem today is that in the absence of the legislative will to mandate this change, market rate solutions are the only viable way to deliver these buildings today. The inventions described here represent this market-rate solution. 
         [0004]    Previous attempts at making such market rate solutions have suffered from several problems including: 
         [0005]    lacking affordability; 
         [0006]    boutique status because the products are too foreign for most builders and consumers to adopt in a wide manner; 
         [0007]    lack of a comprehensive systematized methodology of design, testing and performance; 
         [0008]    lack of a simple strategy that mitigates thermal bridges, creates an air tight envelope; and uses high performance transparent components; 
         [0009]    lack of building physics support of low energy strategies; and simplicity of design, installation and use. 
       SUMMARY OF THE INVENTION 
       [0010]    This disclosure describes prefabricated exterior panels, slab foundation systems and an integrated simple design procedure for use in low-energy use buildings, methods for joining the panels to form airtight seams, and methods and apparatus for manufacturing the panels. The assembled panels present airtight seals and also eliminate thermal bridging. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is a diagrammatic view of a variety of panels forming a modular wall panel system. 
           [0012]      FIG. 2  is a front perspective view of a continuous panel of the modular wall panel system. 
           [0013]      FIG. 3  is a rear perspective view of the continuous panel shown in  FIG. 2   
           [0014]      FIG. 4  is a front perspective view of a window panel of the modular wall panel system having a window mounted in an opening through the panel. 
           [0015]      FIG. 5  is a rear perspective view of the window panel as shown in  FIG. 4 . 
           [0016]      FIG. 6  is an enlarged scale and fragmentary cross-sectional view of the window panel and window taken along line  6 - 6  of  FIG. 4 . 
           [0017]      FIG. 7  is a front perspective view of an outer corner panel of the modular wall panel system. 
           [0018]      FIG. 8  is a rear perspective view of the outer corner panel as shown in  FIG. 7 . 
           [0019]      FIG. 9  is a front perspective view of an inner corner panel of the modular wall panel system. 
           [0020]      FIG. 10  is a rear perspective view of the inner corner panel as shown in  FIG. 9 . 
           [0021]      FIG. 11  is a perspective view of an L-shaped clip for connecting a window or door frame to a window or door panel. 
           [0022]      FIG. 12  is a left side elevation view of the clip shown in  FIG. 11 . 
           [0023]      FIG. 13  is a rear elevational view of the clip as shown in  FIG. 11 . 
           [0024]      FIG. 14  is a bottom view of the clip as shown in  FIG. 11 . 
           [0025]      FIG. 15  is a cross-sectional view similar to  FIG. 6 , showing the clip connected to a frame of a window. 
           [0026]      FIG. 16  is an enlarged and fragmentary exploded perspective view showing a joint between two panels of the modular wall panel system. 
           [0027]      FIG. 17  is an enlarged and fragmentary perspective view showing a joint between two panels of the modular wall panel system. 
           [0028]      FIG. 18  is a view similar to  FIG. 16  showing a butt joint between two panels. 
           [0029]      FIG. 19  is a schematic cross-sectional view showing a panel mounted on a slab formed using a J-shaped insulating from. 
           [0030]      FIG. 20  is a diagrammatic view of a jig used to form and secure together components of an outer corner panel of the modular wall panel system which is positioned within a press. 
           [0031]      FIG. 21  is an exploded diagrammatic view of the jig as shown in  FIG. 20  used to form and secure together components of an outer corner panel which is positioned within a press 
           [0032]      FIG. 22  is a diagrammatic view of a jig used to form and secure together components of an inner corner panel of the modular wall panel system which is positioned within a press. 
           [0033]      FIG. 23  is a diagrammatic view of the jig as shown in  FIG. 22  used to form and secure together components of an inner corner panel which is positioned within a press. 
           [0034]      FIG. 24  is a diagrammatic view of a continuous building panel positioned within a press. 
           [0035]      FIG. 25  is a diagrammatic view of a screen computer screen showing the creation of a floor plan in process using graphical representations of the continuous, window, door and corner panels of the wall panel system. 
           [0036]      FIG. 26  is a diagrammatic view similar to  FIG. 25  showing the floor plan completed. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0037]    As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
         [0038]    Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, the words “upwardly,” “downwardly,” “rightwardly,” and “leftwardly” will refer to directions in the drawings to which reference is made. The words “inwardly” and “outwardly” will refer to directions toward and away from respectively, the geometric center of the embodiment being described and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof and words of a similar import. 
         [0039]    Referring to the drawings in more detail, a modular, insulated wall panel system  1  is shown which can be used in the construction of buildings including habitable structures. The wall panel system  1  includes a plurality of types of panels of varying widths and configuration which can be assembled together by a builder to construct a wide variety of straight walled buildings. The panel system  1  includes a set of continuous panels  4  of a standard height and varying widths, including for example, widths of one, two, three, four, six and eight feet wide. 
         [0040]    The panel system also includes a set of door panels  5  and window panels  6 . Door panels  5  include openings  7  in which a door  8  may be hung and window panels  6  include an opening  9  in which windows  10  may be installed. Doors  8  and windows  10  are preferably centered from side to side in the panel  5  or  6  in which they are installed. Doors  8  may be installed in door panels  5  four feet or greater in width including six and eight feet. Single windows  10  may be installed in window panels  6  four feet or greater in width including six or eight feet. Double windows  10  may be installed in window panels  6  six foot or greater in width including eight feet. The door panels  5  and window panels  6  may also be referred to as discontinuous panels in that they do not present a continuous exterior surface but have openings formed therein to receive doors  8  and windows  10 . It is to be understood that the width of the panels  4 ,  5  and  6  can be varied to accommodate regional or jurisdictional preferences related to stud spacing or metric versus English measurements. 
         [0041]    The panel system  1  also includes a plurality of corner panels  11  for use in forming corners of the building including outside corner panels  11   a  and inside corner panels  11   b . The outside corner panels  11   a  are used to construct outside corners of a building where two walls come together to form an external angle, as in a corner one can walk around. The inside corner panels  11   b  are used to construct inside corners of a building where two walls form an internal angle. 
         [0042]    Door panels  5 , window panels  6  and corner panels  11  also are preferably constructed to a standard height. The standard height of panels  4 ,  5 ,  6  and  11  may be, for example, eight or nine feet or taller depending on the intended use. 
         [0043]    The construction of each of each of the panels  5 ,  7  and  11  is similar and exemplary embodiments are shown in  FIGS. 2 through 10 .  FIG. 6  is a fragmentary cross sectional view of a window panel  6  with a window  10  supported in the opening  9  formed therein. Window panel  6  includes a structural frame  15  preferably formed using conventional framing members  16  which may be formed of wood, steel or other suitable construction materials including composite or engineered framing members. Framing members  16  of standard dimensions, including 2×4 or 2×6 are preferably used depending on regional preferences or factors such as the preferred depth of insulation to be installed between the framing members  16 . 
         [0044]    The structural frames  15  are preferably constructed using conventional stick and frame construction techniques and practices for forming walls for buildings and in a preferred embodiment are constructed as rectangular frames. Each structural frame  15  preferably includes a top plate  17 , a sill or bottom plate  18  and a plurality of studs  19  extending between the top plate  17  and bottom plate  18 . The number of studs  19  will depend on the width of the panel  4 ,  5 ,  6  or  11  and studs  19  may be spaced using a conventional spacing of sixteen inches from each other&#39;s center or with a spacing of twelve or twenty four inches. Conventional framing techniques are also preferably used for forming window sills  20  and  21  and for framing openings  7  and  9  for doors  8  for windows  10 . The structural frames  15  may be secured together using conventional fasteners such as nails or screws or other fastener means including brackets with integrated spikes to connect two or more adjacent frame members together. 
         [0045]    In one embodiment, an inner sheathing  25  is secured to and across the exterior surface of the structural frame  15  using fasteners such as nails or screw or other acceptable means such as adhesives. The sheathing  25  preferably extends the entire height of the frame  15 . Holes are cut or otherwise formed in the sheathing  25  to match any openings formed in the structural frame  15  for windows  10  or doors  9 . The inner sheathing  25  may be formed from oriented strand board or plywood or other engineered wood sheathing or other suitable sheathing material. Sheathing  25  may be formed from multiple sheets of material including a water impermeable layer applied as a sheet which is adhered to bonded to or mechanically fastened to an exterior surface of the engineered wood or as a liquid or spreadable type coating. The sealed sheathing  25  forms an airtight barrier. It is also to be understood that a layer of inner sheathing  25  formed from engineered wood or the like and without a waterproof layer applied to an exterior surface thereof may be attached to the frame  15 . 
         [0046]    A layer of insulation  28  is secured to an exterior surface of the inner sheathing  25  using a compatible adhesive or other acceptable means such as fasteners. However, in a preferred embodiment, the layer of insulation  28  is secured to an exterior surface of the inner sheathing with an adhesive and without the use of any fasteners such as nails or screws extending through the insulation which would form a thermal bridge therethrough. It is also foreseen that the insulation  28  could be secured directly to the structural frame  15  without inclusion of the inner sheathing  25  Holes are cut or otherwise formed in the layer of insulation  28  corresponding to any openings  7  and  9  formed in the structural frame  15  for windows  10  or doors  8 . The insulation is preferably formed as rigid panels and may be a rigid foam type insulation including polystyrene or polyurethane foams. The rigid panels may also be formed from materials including mineral wool insulation, wood fiber, wheat straw, mycillium or foam glass or other insulating materials that are now known or later developed. 
         [0047]    An exterior sheathing  31  is secured to and across the exterior surface of the insulating layer  28  using a compatible adhesive or other acceptable means including the use of fasteners. In a preferred embodiment, the exterior sheathing  31  is connected to the layer of insulation  28  using an adhesive and without the use of fasteners extending through the insulating layer  28  which would form a thermal bridge therethrough. The exterior sheathing  31  is preferably formed from a material into which nails can be driven such as oriented strand board or plywood. The insulating layer  28  and exterior sheathing  31  preferably are the same width as the structural frame  15  and may be sized the same height as the structural frame  15  or shorter with portions of the frame  15  and interior sheathing  25  extending above and/or below the insulating layer  28  and exterior sheathing  31 . Exterior siding (not shown) or additional layers may then be secured to the exterior sheathing  31  using fasteners such as nails or screws. The exterior sheathing  31  may also be formed from a plurality of sheets of material including a water impermeable layer applied as a sheet which is adhered to, bonded to or mechanically fastened to an exterior surface of the engineered wood or as a liquid or spreadable type coating. The water impermeable layer may be applied to the exterior sheathing  31  in a factory in which the panels  4 ,  5 ,  6  and  11  are assembled or in the field. 
         [0048]    As shown in  FIG. 6 , windows  10  may be secured in the openings  9  of window panels  6  using a plurality of fastening angle clips  35 . Referring to  FIGS. 12-15 , each clip  35  includes first and second legs  37  extending in perpendicular relationship and with respective pairs of fastener holes  38  and  39  formed in each leg  36  and  37 . Centers of the fastener holes  38  in the first leg  36  of each clip  35  are aligned on an axis extending parallel to a corner  40  formed between the first and second legs  36  and  37 . Centers of the fastener holes  39  in the second leg  37  of each clip  35  are aligned on an axis extending transverse to the corner  40 . It is also foreseen that centers of the fastener holes  38  in first leg  36  may extend in spaced relation across the width of the first leg  36  but not with the centers aligned in parallel relation to the corner  40 . Similarly, the centers of the fastener holes  39  in the second leg may extend in spaced relation lengthwise relative to the second leg  37  without extending in alignment on an axis extending transverse to the corner  40 . 
         [0049]    The first leg  36  of each angle clip  35  is secured to an exterior surface of mounting structure of the window  10  using nails or screws (not shown) driven through fastener holes  38 . The second leg  37  of each clip  35  projects radially outward from the window  10  and may be secured to the inner sheathing  25  around the opening  9  formed therein and secured in place using fasteners driven through fastener holes  39  formed in the second leg  37 . The opening  9  is sized slightly larger than the window  10  so that a gap of approximately ½ inch or larger is formed between the first leg  36  of each clip and an inner surface of the portion of the inner sheathing  25  extending around the opening  9 . The insulating layer  28  with a mating opening formed therein, may then be attached to the exterior surface of the inner sheathing  25  with a small gap, typically between ¼ to ¾ of an inch, formed between the first leg  36  and insulating layer  28  along the bottom of the window  10 . In an exemplary embodiment, the first leg is 1 and 31/32 inches long and the second leg is 31/32 inches long with both legs formed from ⅛ inch thick sheet metal. Clips  35  may be formed of a variety of widths including 31/32 inches wide. 
         [0050]    A variety of sealants or sealing members may be applied or positioned in the gaps formed between the frame of the window  10  and the portion of the window panel  6  surrounding the opening  9 . As shown in  FIG. 6 , a strip of expandable foam  41  and a layer of sealant  42  are shown positioned between the periphery of the window  10  and an inner edge of the frame  15  and inner sheathing  25  around the opening  9 . A trim piece (not show) may be installed across the sill to cover the exterior gap between the bottom of widow  10  and the inner edge of the insulating layer  28  and exterior sheathing  31 . 
         [0051]    Frames for doors  8  may be secured in an opening  7  of a door panel  5  using angle clips  35  in a manner similar to that described with respect to securing windows  10  in an opening  9  in a window panel  6 . 
         [0052]    Panels  4 ,  5 ,  6  and  11  are adapted to be secured to a floor or sub floor by nailing or screwing the bottom plate  18  to the floor or a sill connected to the foundation. Additional stories and a roof may be added to the structure formed by panels  4 ,  5 ,  6 , and  11  using conventional framing and flooring techniques. 
         [0053]    Adjacent panels  4 ,  5 ,  6  and  11  may be connected together by a variety of means. As shown in  FIGS. 16 and 17 , the inner sheathing  25  of each panel  4 ,  5 ,  6  and  11  may be sized narrower than the structural frame  15 , insulation layer  28  and exterior sheathing  31  so that a groove or channel  45  extends vertically along each side of the panels  4 ,  5 ,  6  and  11 . A spline  47 , twice as wide as the grooves  45 , may then be positioned in aligned grooves  45  of adjacent panels  4 ,  5 ,  6  or  11  for joining the panels  4 ,  5 ,  6  or  11  together. A sealant (not shown) may be applied in the grooves  45  to prevent air or water penetration around the joint. Abutting studs  19  of adjacent panels  4 ,  5 ,  6  or  11  may be secured together using wood screws driven horizontally therethrough. Alternatively, and as shown in  FIG. 18 , panels  4 ,  5 ,  6  and  11  may be formed without the channels  45  and simply butted together with a layer of expandable foam tape  48 , or other sealant, applied between adjacent studs  19  of the panels  4 ,  5 ,  6  or  11  with wood screws driven through the abutting studs  19  to secure the panels  4 ,  5 ,  6  or  11  together. 
         [0054]      FIG. 19  shows a J-shaped, insulating foundation form or J-form  51  used in forming a slab foundation  52  and to provide an insulating layer between the slab  52  and the ground. J-form  51  may be formed from a foam material. J-form  51  is preferably used in combination with planar insulating panels  53  to form a layer of insulation underneath the entire foundation  52 . The J-forms  51  are positioned to form the outer periphery of the foundation and form a slab  52  with a thicker peripheral edge. The planar insulating panels  53  extend between the J-forms  51  and have a uniform thickness which may be approximately four inches or thicker. 
         [0055]    The J-form  51  includes an exterior wall  55 , a bottom  57  and an inner wall or lip  59 . Exterior wall  55  projects upward from the bottom  57  along an exterior edge thereof and is rectangular in cross-section. The thickness of the exterior wall  55  preferably matches the thickness of insulating layer  28  and exterior sheathing  31  of the panels  4 ,  5 ,  6  and  11 . The inner lip  59  extends upward from the bottom  57  along an inner edge thereof and in spaced relation from the exterior wall  55 . Inner lip  59  slopes upward and away from the exterior wall  55  and in the embodiment shown is triangular in cross-section Inner lip  59  is shorter than exterior wall  55  and a trough  61  is formed between the exterior wall  55  and the inner lip  59 . An air barrier  63  formed from a sheet of polymeric material such as polyethylene is adhered to the inner and upper surface of the J-form  51 . 
         [0056]    J-forms  51  and planar insulating panels  53  are preferably laid in place on top of a layer of compacted stone  64  shaped so that the upper surface of the planar insulating panels  53  extend horizontally and generally flush with an upper edge of the inner lip  59  of the J-forms  51 . In the embodiment shown, a shoulder  65  projects outward from lip  59  a distance below the upper edge of the lip  59  corresponding to the thickness of a planar insulating panel  53 . The shoulder  65  supports the edges of the insulating panel  53  against sagging as the compacted stone layer  64  settles. Shoulder  65  may be formed from a strip  66  of foam material inserted in a groove  67  formed in and extending the length of the J-form  51 . 
         [0057]    When all of the J-forms  51  and planar insulating panels  53  are positioned in place, concrete is poured into the J-forms  51  and over the planar insulating panels  53  to fill the trough  61  and extend above the upper surface of the insulating panels  53  a uniform depth which may be approximately four inches or greater. Additional forms (not shown) may be positioned on top of the J-forms so that the concrete may be poured to a depth extending above the top of the J-forms  53 . Once the concrete has set and cured, pressure treated lumber may be anchored to the foundation  52  around the periphery thereof to form a sill  68 . Bottom panels  18  of panels  4 ,  5 ,  6  and  11  may be then be secured to the sills  68  with the insulating layer  28  and exterior sheathing  31  extending over the exterior wall  55  of the J-form  51 . An insulating strip  69 , which may be formed from expandable foam or liquid sealant, is preferably positioned and secured in the gap between an upper surface of the exterior wall  55  of J-form  51  and a lower edge of the insulating layer  28  and exterior sheathing  31 . 
         [0058]    It is to be understood that the wall panel system  1  can be used with a wide variety of foundations and is not limited to use with flat slab type foundation formed using the J-form  51 . The panels  4 ,  5 ,  6  and  11  may be connected to a sill  68  anchored to a foundation wall. In addition, the panels  4 ,  5 ,  6  and  11  may be anchored or secured to the sub-floor of different levels of a building. 
         [0059]      FIGS. 20-23  are diagrammatic views showing corner panel jigs  80   a  and  80   b  for assembling the outer and inner corner panels  11   a  and  11   b  respectively. Each jig  80   a  and  80   b  includes a jig cradle  81   a  and  81   b  and a jig cap  82   a  and  82   b . The jigs  80   a  and  80   b  can be used with a standard hydraulic press  83  to press the components together and allow the adhesive securing the insulation layer  28  to the interior sheathing  25  and the exterior sheathing  31  to the insulating layer  28  to set or cure under pressure, bonding the insulation layer  28  to the interior sheathing  25  and exterior sheathing  31 . 
         [0060]    Referring to  FIGS. 21 and 22 , jig cradle  81   a  includes first and second cradle walls  85   a  and  86   a  which are formed to extend perpendicular to each other and slope downward and inward relative to each other to form a trough. First and second panels of exterior sheathing  89   a  and  90   a , sized to form adjacent sides of an outside corner  11   a , are positioned against the first and second cradle walls  85   a  and  86   a . First and second panels of insulation  91   a  and  92   a  are sized to fit on top of the exterior sheathing panels  89   a  and  90   a  respectively. A layer of adhesive is applied to an upper surface of the first and second panels of exterior sheathing  89   a  and  90   a  in cradle  81   a  or on a bottom surface of first and second panels of insulation  91   a  and  92   a  or both, prior to positioning insulation panels  91   a  and  92   a  on top of exterior sheathing panels  89   a  and  90   a  respectively. 
         [0061]    First and second frame sections  93   a  and  94   a  are constructed from framing members and first and second panels of interior sheathing  95   a  and  96   a  are fastened thereto. A layer of adhesive is applied to the bottom or exterior surface of the interior sheathing panels  95   a  and  96   a  or to the upper surface of the insulation panels  91   a  and  92   a  or both prior to positioning frame sections  93   a  and  94   a  with attached sheathing  95   a  and  96   a  on top of insulation panels  91   a  and  92   a  respectively. Jig cap  82   a  is then positioned on top of the frame sections  93   a  and  94   a . Jig cap  82   a  includes first and second cap walls  97   a  and  98   a  which extend perpendicular to each other and slope downward and inward toward each other to form a downward projecting v-shaped structure. 
         [0062]    The jig cradle  81   a  and jig cap  82   a  with exterior sheathing panels  89   a  and  90   a , insulation panels  91   a  and  92   a , frame sections  93   a  and  94   a  with attached interior sheathing panels  95   a  and  96   a  positioned therebetween are positioned between upper and lower platens  101  and  102  and pressed together while the adhesive between layers at least partially cures. As seen in  FIG. 21 , the second panel of exterior sheathing  90   a  is sized wider than the second insulation panel  92   a  to cover an end of the first insulation panel  91   a  which overlaps with second insulation panel  92   a . Similarly the second panel of interior sheathing  96   a  is sized wider than the second frame section  94   a  so that the wider portion of interior sheathing second panel  96   a  covers an end of the first frame section  93   a  which overlaps with the second frame section  94   a . First insulation panel  91   a  is also wider than second insulation panel  92   a  and first frame section  93   a  is wider than second frame section  94   a.    
         [0063]    Referring to  FIGS. 22 and 23 , jig cradle  81   b  is also constructed with first and second cradle walls  85   b  and  86   b  extending perpendicular to each other but sloping downward and outward to form a peaked structure against which first and second panels of exterior sheathing  89   b  and  90   b  may be laid in forming a laminated inside corner panel  11   b . First and second insulation panels  91   b  and  92   b  are positioned on top of the exterior sheathing panels  89   b  and  90   b  with a layer of adhesive therebetween and first and second frame sections  93   b  and  94   b  with interior sheathing panels  95   b  and  96   b  fastened thereto are positioned on top of the insulation panels  91   b  and  92   b  with a layer of adhesive therebetween. Jig cap  82   b  having outwardly and downwardly sloped, perpendicular first and second cap walls  97   b  and  98   b  is then positioned over frame sections  93   b  and  94   b . The jig cradle  81   b  and jig cap  82   b  with exterior sheathing panels  89   b  and  90   b , insulation panels  91   b  and  92   b , frame sections  93   b  and  94   b  with attached interior sheathing panels  95   b  and  96   b  positioned therebetween are positioned between upper and lower platens  101  and  102  and pressed together while the adhesive between layers at least partially cures. In them embodiment shown, insulation panel  92   b  is longer than and overlaps with an end of insulation panel  91   b  and frame section  93   b  with attached interior sheathing panel  95   b  is longer than and overlaps with frame section  94   b  and attached interior sheathing panel  96   b.    
         [0064]      FIG. 24  is a diagrammatic view of a continuous panel assembly  4  compressed between platens  101  and  102 . The continuous panel assembly  4  includes frame  15 , inner sheathing  25 , insulation layer  28  and exterior sheathing  31 . In one embodiment, the inner sheathing  25  is fastened to frame  15  prior to positioning between the platens  101  and  102 . A layer of adhesive is applied between the inner sheathing  25  and the insulation layer  28  and another layer of adhesive is applied between the insulation layer is constructed prior to positioning between platens  101  and  102 . It is to be understood that a wide variety of presses could be used in forming the panels including panels  4 ,  5 ,  6  and  11 . 
         [0065]    It is foreseen that a wide variety of adhesives could be used for adhering the insulation layer  28  to the inner sheathing  25  and exterior sheathing  31 . Examples of adhesives may include polyurethane, silicone, silyl terminated polyether and silyl terminated polyurethane. The panel system  1  is particularly well adapted for use in modular construction of the exterior walls of buildings. A computer design program is preferably utilized to aid an architect or designer in selecting the panels  4 ,  5 ,  6  and  11  to be assembled together to construct a proposed design or plan. Referring to  FIGS. 22 and 23 , the design program preferably allows the designer to drag and drop graphical representations  91  of each panel from a toolbox  92  or the like into position on a grid or work area  93  on a computer screen or display  94 . The program may allow the architect or designer to initially create a floor plan in a traditional drawing format or import a previously drawn floor plan into the program and then drag and drop in representations  91  of panels  4 ,  5 ,  6  and  11  necessary to assemble the design. The program allows the designer to revise the design if necessary based upon limitations as to the size and type of existing panels and positioning of windows  10  and doors  9 . The toolbox  92  also preferably includes labels  95  for each of the graphical representations  91  providing information corresponding to the dimensions of the panel or other information such as whether the corner panel  11  is an outside corner panel  11   a  or inside corner panel  11   b . The program can also be used to select and specify the foundation forms, such as J-forms  51 , to be utilized. 
         [0066]      FIG. 22  represents a screen shot of a computer screen  94  on which a designer is selecting panels  4 ,  5 ,  6  and  7  to create the exterior walls of a floor plan. The designer initially drew the outline of the floor plan and then placed representations  91  of outside and inside corner panels  11   a  and  11   b  in the corners of the floor plan. The designer has also added representations of a couple of window panels  6  and a door panel  5  along one side of the floor plan and has added some of the interior detail.  FIG. 23  shows the completed floor plan with graphical representations  91  for all of the exterior wall panels  4 ,  5 ,  6  and  11  added to the work area to complete the exterior walls. The designer has also filled in additional detail for the floor plan. 
         [0067]    In one embodiment of the wall panel system  1  and method of using, the exterior walls will often be designed in even foot increments facilitating use panels  4 ,  5 ,  6  and  11  formed in even increments of two, four and eight feet. In such panels  4 ,  5 ,  6  and  11 , the frames  15  are preferably formed with studs  19  spaced apart in two foot increments. The addition of the insulating layer  28  and exterior sheathing  31  to the frame  15  results in a panel that is generally stronger than a panel formed from a frame  15  and interior sheathing  25  formed with studs  19  on sixteen inch spacing. The one foot panels  4  may be used where necessary and are particularly well adapted for use around door or window panels  5  and  6  to center the panels relative to a wall if necessary. 
         [0068]    The program is adapted to inventory the panels incorporated into the design based upon the labels  95  associated with each graphical representation  91 . Once the inventory of panels  4 ,  5 ,  6  and  11  required to build the proposed design has been prepared using the program, the panels  4 ,  5 ,  6  and  11  can be ordered from a supplier to be delivered to the construction site for assembly. The supplier may be the manufacturer or wholesale or retail outlets. 
         [0069]    It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown. As used in the claims, identification of an element with an indefinite article “a” or “an” or the phrase “at least one” is intended to cover any device assembly including one or more of the elements at issue. Similarly, references to first and second elements is not intended to limit the claims to such assemblies including only two of the elements, but rather is intended to cover two or more of the elements at issue. Only where limiting language such as “a single” or “only one” with reference to an element, is the language intended to be limited to one of the elements specified, or any other similarly limited number of elements.

Technology Category: 3