Static structures (e.g. – buildings) – Machine or implement
Patent
1994-09-22
1997-06-24
Canfield, Robert
Static structures (e.g., buildings)
Machine or implement
524041, 5278314, 527981, 528001, 5278411, 5278711, 52284, 522933, E04C 234, E04B 200
Patent
active
056408242
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
This invention relates generally to construction materials, and specifically to modular building panels for use in buildings as walls, floors or roofs. The modular building panels disclosed herein can be used as or on either the exterior or the interior walls of buildings including roofs and floors. The panels of the present invention are particularly well suited for use for protection from fire, and from penetration of ballistic projectiles.
BACKGROUND OF THE INVENTION
At the present time, all states in the United States have a building code requirement that on certain commercial buildings, the exterior walls and roof must be constructed with noncombustible materials. When exposed to fire (1,700 degrees Fahrenheit (.degree.F.)), materials used are to be noncombustible and not give off toxic fumes. In order to meet the requirement, the exterior of these buildings have been constructed with some or all of the following materials: concrete, brick, block, steel, and fire rated drywall. Blocks and/or steel studs make up the main body of these exterior walls, with brick veneer, stucco, or other finishing material applied to the exterior surface. Although the above named materials are noncombustible, nonmelting, and do not give off toxic fumes when exposed to fire, they are extremely poor insulators against the heat and cold. For instance, hollow concrete blocks (light aggregate) have the resistance (R) values as follows: 4-inch (4") block--R-1.11; 8-inch (8") block--R-1.72, and 12-inch (12") block--R-1.89. Even though the steel stud wall can be filled with thermal insulation, the steel stud itself will be a thermal conductor between the exterior and the interior of the building. Consequently, for these buildings to be habitable, these walls will require an additional thermal insulated wall or ceiling to protect the interior of the building from the heat of summer and the cold of the winter. When the concrete, brick, block, steel and fire rated drywall materials are used in exterior walls and roof area, they presently must all be built on site with expensive materials and field labor, thus maintaining high cost and adding time to the construction financing.
Further, the use of concrete blocks requires appropriate concrete footings and supports for the wall and foundation and attention to the weight of the materials, for example, the weight of hollow concrete blocks (light aggregate) must be considered in providing footings. A 4" block weighs 21 pounds per square foot, an 8" block weighs 38 pounds per square foot, and a 12" block weighs 55 pounds per square foot. This significant difference in square footage weight means the modular building panel requires less weight to be borne by the concrete footings and wall (foundation). The extra supports and footings add to the cost of the block walls.
Thus, a problem in the art is the construction of affordable buildings that meet code requirements. In addition to block and/or steel stud construction, the person of ordinary skill in the construction industry has attempted to solve the problem of providing affordable buildings in other ways. Some commercial buildings have been produced with a single metal skin. These buildings meet fire codes but have very high heating and cooling costs because there is little or no insulation. Other commercial buildings utilize steel framing, to which is applied 4" or 6" fiberglass insulation along with a metalized vinyl facing sheet, to the framing walls and roof. An exterior steel rib panel is applied using self drilling/self tapping stitching screws which drill a hole through the steel rib panel, through the insulation and fasten into the framing. Because of this procedure, every stitching screw that is fastened into the framing becomes a thermal conductor of cold and heat to the framing. In cold weather and with the interior heated, these cold areas on the framing will cause moisture and frost to form, damaging the insulation. Over a period of years, the moisture will cause the exterior steel rib panel to rust fro
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Garrison William M.
Johnson Ronald K.
Canfield Robert
Welch Teresa J.
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