Static structures (e.g. – buildings) – Module or panel having discrete edgewise or face-to-face... – Having integral key
Reexamination Certificate
1999-04-12
2001-07-10
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
Module or panel having discrete edgewise or face-to-face...
Having integral key
C052S281000, C052S586200, C052S794100, C052S309110, C052S309700, C052S295000, C052S293300
Reexamination Certificate
active
06256960
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to structures which are assembled from modular components, pre-manufactured at a plant and subsequently assembled into a complete home or building at a remote site. More specifically, the invention pertains to a building system using a plurality of structural insulated panels which are assembled together quickly and easily using a special connector system requiring no special tools or skills.
2. Description of the Prior Art
There are many conventional construction techniques currently in use in the small building and housing industries. These techniques include wood frame construction, masonry frame construction, and light-gauge steel construction. Each of these construction techniques has its own advantages and disadvantages, taking into consideration various factors such as cost, energy efficiency, durability, aesthetics, difficulty of assembly, and reliance upon special tools or components which may be necessary for assembly.
Wood frame construction is currently the most commonly used system for residential construction. Although wood as a construction material remains relatively inexpensive, there is growing concern over the quality and quantity of the world's dwindling wood supply. These concerns are particularly acute in countries where native forests have been depleted, and reforestation is not practiced. In terms of difficulty in assembly, wood frame construction requires a basic knowledge of the structural characteristics and capabilities of a variety of wood products and pieces. The carpenter must also have adequate skills and experience to employ the appropriate framing techniques for the structural project at hand. Further, the connection system for the wood components relies upon mechanical fasteners. These fasteners must be selected and assembled through the application of professional skills.
Masonry frame construction is still used in many parts of the world, particularly in third-world countries. Masonry construction can be inexpensive if the raw materials are available locally and the components are manufactured close to the building site. Nevertheless, proper assembly of masonry blocks is labor intensive, time consuming, and requires a fairly high level of skill and experience. After the blocks have been assembled, a suitable roof system must still be constructed and structurally integrated with the upper layer of wall blocks. The point of connection between the walls and the roof is critical, as high winds may cause a catastrophic separation of the two, if the connection is defective or weak. Masonry construction is also subject to damage or complete failure as the result of earthquakes, prevalent in many areas where such construction is commonly undertaken.
A third prior art construction technique which has become more popular in recent years for both commercial and residential structures, is light-gauge steel construction. One advantage of such steel construction is that is does not directly, at least, have a negative impact on the world's forests. Also, steel construction is relatively light weight, and pest-proof However, a disadvantage is that steel construction is structurally similar to wood frame construction, and requires an even higher level of construction knowledge and on-site training. The connection system for steel structural and panel components is based entirely upon mechanical fasteners. The assembly of components with such fasteners must be done properly, through the application of learned skills and the use of necessary tools.
More recently, yet another building technique, using Structural Insulated Panels (“SIPS”), has emerged. In a standard SIPS system, a pre-manufactured panel replaces the framing, sheathing, and insulation used in prior art construction. Typically, a SIP includes either polystyrene foam or polyurethane foam as material for its core. This rigid and dense foam spans the entire thickness of each panel, and provides a desirably high R-factor. Consequently, structures made from SIPS are generally stronger, more energy efficient, and offer a higher and more consistent level of quality than structures employing wood frame construction. However, the fastening system used in the standard SIPS system is similar to that used in wood frame construction. Even though assembly of the standard SIPS system requires a lower degree of construction knowledge than that necessary for wood-stick framing, it still requires basic carpentry skills and the use of heavy equipment to move and locate the large panels which are usually employed.
SUMMARY OF THE INVENTION
The present invention employs a plurality of Structural Insulated Panels having a relatively small size, compared to prior art designs. These smaller SIPS can easily be moved, arranged, and secured into place, without the use of heavy equipment or other special tools.
The SIPS wall panels are generally constructed from a foam core, sandwiched between inner and outer parallel skins of finished sheet material. At the time the foam core is molded, each SIPS is structurally integrated with a steel stud, located along a first vertical edge of the panel and partially protruding therefrom. The steel stud is generally U-shaped, in cross-section, having an open side extending from the top to the bottom of the panel. Each panel also includes a second vertical edge, along which the outer face of the foam core is slightly recessed. The combination of the recessed foam and the outer edges of the skins provides a channel extending from the top to the bottom of the panel.
A lower metal track, secured to a cement or block foundation through the use of spaced anchor or “J” bolts, defines the perimeter wall of the structure to be built. Nuts are provided over some of the anchor bolts, while threaded rod couplers are provided over others. The location of the anchor bolts with the threaded couplers corresponds to the location of a respective vertical connector rod. These threaded connector rods comprise the heart of the special connection system which secures the panels and a modular roof system together.
The lower edges of adjacent panels are first aligned with the track, and then lowered into the track. A first vertical edge, containing the stud, and the second vertical edge containing the channel, are slid together with the vertical connector rod extending therebetween. Adjacent edges of the skins for each panel are spaced approximately {fraction (3/16)}″ apart, while overlapping and substantially covering inner and outer edges of the stud. Self-drilling screws are screwed through the skin and extending side portions of the lower track, then into the steel connecting stud to secure the panels in place.
An upper metal track overlies the upper edges of the panels, and overlaps the joints therebetween. The upper track is generally coextensive with the lower metal track, and may include portions having an inclined upper surface to correspond to the desired pitch of the roof system. The upper track includes apertures through which the upper ends of the connector rods pass. Nuts are screwed and tightened over the connector rods, vertically compressing the panels while securing them to the foundation.
A modular roof system may also be used with the SIPS wall panel construction, just described. Modular roof panels, similar to the modular wall panels, include a foam core sandwiched between a corrugated metal outer skin and a generally planar inner skin. The roof panels are preferably long enough to extend in one continuous piece from a ridge beam assembly over and past the upper track of the wall panels to form an overhang around the building.
A metal stud extends along one edge of each roof panel, between the outer skin and the inner skin. The outer skin extends laterally past the metal stud, to form a specially configured overlapping portion. The configuration of this overlapping portion conforms to a corresponding structure on an adjacent panel. The lower side of the stud extends past the lateral termin
Babcock Frank J.
Scuka Jeffrey R.
Smith Reginald D.
Boutin, Dentino, Gibson, Di Giusto, Hodell & Wes
Dorsey Dennis L.
Friedman Carl D.
West R. Michael
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