Static structures (e.g. – buildings) – Module or panel having discrete edgewise or face-to-face... – Having integral key
Reexamination Certificate
1999-08-09
2001-08-28
Stodola, Daniel P. (Department: 3634)
Static structures (e.g., buildings)
Module or panel having discrete edgewise or face-to-face...
Having integral key
C052S309900
Reexamination Certificate
active
06279287
ABSTRACT:
TECHNICAL FIELD
The present invention is directed to a prefabricated building panel which is adapted for assembly as a modular unit into a structural wall or the like, and more particularly, an insulating building panel having edge constructions which provide enhanced wall integrity and simplified panel manufacture.
BACKGROUND OF THE INVENTION
The use of prefabricated insulating building and wall panels having metal front or back side surfaces or skins in building construction is well known. U.S. Pat. No. 5,181,353 to Herrington, Jr. discloses the assembly of conventional prefabricated building panels having a thermally insulating foam core sandwiched between two side sheet panels into a building structure. To assemble the building structure, tongued edge connectors are fitted into grooved panel edges which are devoid of the foam core, to join the edges of adjacent panels. A difficulty with the building panels shown in Herrington, Jr. exists, however, in that when the panel sides are formed from metal, no thermal break exists between the outer panel side, the connector and the inner panel side. The Herrington, Jr. panel system is therefore poorly suited for use in residential or commercial building applications as it permits heat loss by thermal conduction through the panel sides and connector.
One attempt to provide a structural panel which when assembled, provides a thermal break between the inner and outer panel side surfaces is disclosed in U.S. Pat. No. 5,373,678 to Hesser. Hesser teaches a panel having a foam core and metal side skins. Each panel edge includes a forwardly projecting metal tongue which is offset from the panel center towards one panel side, and a recessed metal groove spaced towards the opposing side. The groove is formed so as to be adapted to receive the forwardly projecting tongue of an abutting panel positioned edge to edge therewith. To provide a thermal break between the outer and inner sides of the panel, the tongue and groove of each edge are spaced from each other by an exposed angularly extending face of the foam core. The edge portion of the Hesser panel further includes a separate reinforcing member which is bent around the groove to provide the panel edge with enhanced rigidity. Assembly of a wall is achieved by positioning the panels in an edge-to-edge configuration and driving two separate rows of screws through each mated panel edge, wherein each row of screws is offset from the other.
The panel of Hesser suffers a disadvantage in that the addition of the reinforcing member to the panel construction complicates the panel manufacture, and increases the overall cost of the panel. As well, to manufacture the Hesser panel, the insulating foam core must be injected between the panels, and following curing, cut to the exposed angular face extending precisely from an innermost end of the tongue to an outermost edge of the edge groove. In cutting the injected foam along each edge of the panel, it is necessary that the foam face be formed at the exact angle so as not to interfere with the interlocking of the panel tongues into the grooves of the adjacent panel, when two panels are placed edge to edge. The process step of cutting the core after the foam injection between the panel sides further results in manufacturing inefficiencies, increasing the finished panel costs.
Because the tongue and groove of the Hesser panels are laterally offset from each other, to assemble each edge of the panels securely, it is essential that rows of screws be driven through the panels at least two laterally staggered locations. This increases both the cost and time involved in the panel erection. As well, because the screws used to secure each side portion of adjacent panels together may be laterally staggered along opposite sides of the panels, rotational forces on the panels may cause the panels to twist relative to each other between the rows of fasteners. The twisting in turn may disadvantageously result in the shearing of the tongues, or the delamination of the metal panel sides or skins from the insulating core.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a building system which includes a number of modular prefabricated building panels which may be coupled together to form a building wall, roof, foundation or other building structure, and wherein the edges of two adjacent panels are secured together by screws, nails, clips or other fasteners along a single longitudinal portion of the panels.
Another object of the invention is to provide an improved prefabricated building panel having a thermally insulating core, metal inner and outer sides, and an edge configuration which permits simplified manufacture of the building panel.
Another object of the invention is to provide a modular building panel which is adapted for assembly with other like panels to form a wall, roof, foundation or other building structure by positioning two or more panels in abutting edge-to-edge relationship.
A further object of the invention is to provide a prefabricated building panel having an insulating foam core sandwiched between spaced apart inner and outer planar metal sides, whereby the panel is formed having an overall planar configuration and has edge portions which are symmetrical about the mid-plane of the panel.
Another object of the invention is to provide a building panel which includes two opposing edge surfaces, one of which includes a pair of projecting members and the other which includes a pair of complementary sized grooves, whereby the projecting members of one panel edge are adapted for insertion into the grooves formed in an abutting edge portion of an adjacent like panel, and which when secured in an abutting edge-to-edge configuration provide a thermal break between the outer and inner sides of the coupled panels.
A further object of the invention is to provide a building panel having a rigid thermally insulating core which is encased by inner and outer sides or skins, and at least two edge surfaces, wherein the edge surfaces are formed in part by bending metal sheets used to form the sides along longitudinal edges to form a first edge surface having at least two channels separated by a projecting tongue, and a second edge surface having two corresponding projections configured for mated insertion within the channels.
Another object of the invention is to provide a prefabricated building panel characterized by an edge surface having a pair of longitudinally extending square groove-like channels which are spaced from each other by an electrically insulating and/or thermally non-conductive tongue or strip made from rubber, plastic, high density polyethylene or other thermally non-conductive material.
A further object of the invention is to provide a prefabricated building panel having a thermally insulating core sandwiched between a pair of spaced co-planar metal side panels, and wherein each side panel consists of a single planar sheet of metal which is integrally formed with a projection at a first longitudinal edge portion and a complementary shaped groove at another opposing longitudinal edge portion, and wherein the projection and groove each have a double wall construction.
Another object of the invention is to provide a structural wall assembly which includes a plurality of prefabricated building panels coupled in an edge-to-edge relationship, wherein the edge surfaces of each panel are connected with an abutting edge surface of adjacent panels by inserting fasteners through interlocking portions of the panels.
A further object of the invention is to provide an improved method for manufacturing a prefabricated building panel having metal inner and outer sides and a thermally insulating rigid core consisting of a closed cell foamed polystyrene, urethane and/or polyethylene.
To achieve at least some of the foregoing objects, the present invention provides a prefabricated building panel which may be assembled as a module to other like panels in an abutting edge-to-edge configuration to form a structural wall, buildin
King and Schickli PLLC
Shoshone Station LLC
Stodola Daniel P.
Thompson Hugh B.
LandOfFree
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