Static structures (e.g. – buildings) – Composite prefabricated panel including adjunctive means – Sandwich or hollow with sheet-like facing members
Reexamination Certificate
1999-03-01
2001-04-03
Kent, Christopher T. (Department: 3635)
Static structures (e.g., buildings)
Composite prefabricated panel including adjunctive means
Sandwich or hollow with sheet-like facing members
C052S268000, C052S270000, C052S407300, C052S586100, C052S309110
Reexamination Certificate
active
06209284
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 which is particularly adapted for use in 2× stick construction.
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. Manufacturing the panels involves 4-5 times the amount of time cutting and sizing the panels in the shop than required in laminating the panels. This increased in-shop preparation of the panels also requires additional in-house designers. 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 4½″ thickness and requires special door and window jamb sizes. Current structural insulated panels are thus incompatible with the conventional 2× structural member system of construction in general use today. 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 in structures built with 2× stick construction.
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 core sheet and an inner facing of a high strength, structural paper attached to a second opposed surface of the core sheet and which is particularly adapted for use in and is compatible with conventional stick construction using 2× dimensional structural lumber.
Yet another object of the present invention is to provide a high strength planar structural insulated panel which can be incorporated in walls, ceilings, etc., constructed of 2× dimensional lumber without modifying or adding to the lumber structure.
A further object of the present invention is to provide a lightweight, high strength structural insulated panel having an inner insulating 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 panel coupling arrangement for use in 2× stick construction comprising a 2× structural member of lumber and having a given thickness and a given width; a first asymmetric structural insulated panel having an 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, wherein the insulating core has a width equal to the width of the 2× structural member and includes a notched out edge portion forming an edge extension of the rigid outer facing having a thickness equal to the thickness of the 2× structural member; and means for attaching a first surface of the 2× structural member to the edge extension of the rigid outer facing and a third surface of the 2× structural member to the insulating core of the structural insulated panel, wherein the sheet of plastic impregnated paper on the panel is aligned with a third surface of the 2× structural member, and wherein the first and third surfaces are in opposed relation on the 2× structural member.
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Emrich & -Dithmar
Kent Christopher T.
Thissell Jennifer I.
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