Static structures (e.g. – buildings) – With synthetic resinous component – Foam
Reexamination Certificate
1998-11-18
2001-03-27
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
With synthetic resinous component
Foam
C052S220100, C052S309900, C052S586100, C052S794100
Reexamination Certificate
active
06205729
ABSTRACT:
FIELD OF THE INVENTION
This invention relates generally to structural insulated panels for use in building construction and is particularly directed to a structural insulated panel having an inner plastic foam core with a rigid outer facing on one surface thereof and plastic impregnated paper on a second opposed surface of the foam core. In one embodiment, spaced nailers are disposed in contact with the plastic impregnated paper to facilitate attaching the panel to a support member and to increase the panel's compressive strength.
BACKGROUND OF THE INVENTION
Lumber stick construction which employs 2× dimensional structural lumber members and nails is how most houses are constructed. This handcrafted stick built approach is slow and manpower intensive requiring many hours of field work, requires a large supply of a limited natural resource, typically incorporates many thermal bridges in combination with gaps in insulation and thus is not particularly energy efficient, and affords a limited number of structural shapes. An alternative approach employs steel studs. This approach also suffers from limitations in that the steel studs are difficult to work with and are good thermal conductors of heat through walls and roofs.
Another approach gaining increasing acceptance involves the use of Structural Insulated Panels (SIPs). SIP construction typically employs two rigid faces on either side of a light insulating foam core. High strength bonding of the outer facings to the inner core forms a structural I-beam in the form of flat panels which are typically joined together by lumber and nails. The outer, opposed panel faces are generally formed from conventional building materials such as gypsum or cementous composites, plywood, oriented strand board (OSB), drywall, or other rigid construction boards from ¼″ to ¾″ thick. Several factors have impeded wide-spread acceptance of SIPs in building construction. For example, the use of SIPs requires a great deal of pre-planning for efficient field erection because these panels are not easily field-cut without the use of special tools. In addition, these panels are generally heavy, weighing much more than conventional wallboard panels, and frequently require the use of special handling equipment such as cranes. Because SIPs are difficult to modify in the field, more precise planning and building techniques are required than the stick built approach of simply working out of a wood pile of 2× dimensional structural lumber members. Finally, current double-faced structural insulated panels are typically 5″ thick when installed with drywall. This is wider than typical stick framing of 4-½″ thickness and requires special door and window jamb sizes. For these reasons, contractors have not accepted SIPs as a basic structural member in building construction on a widespread scale.
The present invention addresses the aforementioned limitations of the prior art by providing a lightweight, high strength, insulated panel which is easily fabricated, modified and installed.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a lightweight structural insulated panel which is easier to manufacture and adapt for a specific installation in the field than currently available structural insulated panels.
It is another object of the present invention to provide a structural insulated panel capable of withstanding large transverse, axial and racking loads having an outer rigid facing attached to one surface of an inner insulating foam core sheet and an inner facing of a high strength, structural paper attached to a second opposed surface of the foam core sheet.
Yet another object of the present invention is to provide tensile strength in a planar structural insulated panel having a plastic foam core to withstand high transverse loads using a high strength plastic-impregnated paper and high compression strength by means of spaced wood, oriented strand board, composite gypsum, cement or metal strips attached to the inner or outer surface of the sheet of paper.
A further object of the present invention is to provide a lightweight, high strength structural insulated panel having an inner plastic foam core and a single outer rigid facing for use in a wall, ceiling, floor or roof of a building which is easily adapted in the field for and installed in a particular installation.
This invention contemplates a structural insulated panel arrangement comprising a generally flat insulating core; a rigid outer facing attached to a first surface of the insulating core; and a high strength sheet of plastic impregnated paper attached to a second opposed surface of the insulating core for increasing the tensile strength of the panel.
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Emrich & -Dithmar
Friedman Carl D.
Wilkens Kevin
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