Static structures (e.g. – buildings) – With synthetic resinous component – Foam
Reexamination Certificate
2000-07-11
2002-04-02
Stephan, Beth A. (Department: 3635)
Static structures (e.g., buildings)
With synthetic resinous component
Foam
C052S794100, C052S309120, C052S309130, C052S800120, C052S781300, C052S404400, C052S407300, C052S270000, C052S309700, C052S309800
Reexamination Certificate
active
06363674
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to premanufactured structural building panels for the construction of insulated exterior walls. More particularly, the present invention relates to a system of insulated premanufactured structural building panels that can be arranged in a side-by-side fashion to form one or more exterior walls of a building.
BACKGROUND OF THE INVENTION
The floors of conventional commercial and residential buildings are commonly framed using a plurality of horizontally extending structural support beams which are supported on multiple load bearing columns or wood studs. The walls are constructed using uniformly spaced metal or wood studs that extend vertically between the floors of the building.
The roof system of a conventional commercial building includes uniformly spaced joists spanning the length between pairs of parallel support beams. A metal deck is placed on top of the uniformly spaced joists. Panels of insulation board are then layered on top of the deck. The exterior covering of the roof can be formed using a polymer sheeting placed on top of both the deck and the insulation board and secured with ballast or an adhesive.
The roof system of a conventional residential building includes uniformly spaced joists spanning the length between pairs of parallel support beams. Plywood may be placed on top of the uniformly spaced joists. Metal or wood trusses are then erected above the joists to form the framing for the roof. Exterior plywood sheathing is applied on top of the trusses and an exterior covering, such as a roofing felt and either asphalt or wood shingles, is then secured to the exterior surface of the sheathing.
The exposed underside of a conventional commercial or residential roof system is generally not a smooth surface, but instead reveals the exposed joists and deck. Additional materials, such as gypsum coreboard or fiberglass ceiling tiles, in conjunction with a metal grid, can be utilized to form the finished ceiling. In either case, an air space will generally remain between the ceiling and the exposed roof structure. Such ceiling and roof systems can have less than desirable insulation properties and thus additional insulation is often installed. Additionally, conventional ceiling and roof systems have limited sound attenuation and fire retardant properties.
The exterior facade of the building, which may include brick, concrete, stone, metal or wood, is formed adjacent to the studs. Conventional batt insulation is placed between the studs and the interior is then covered with gypsum coreboard to form a smooth surface for finishing. The batt insulation in the wall has a tendency to sag, which can also result in decreased insulation properties and limited sound attenuation, in addition to having limited fire retardant properties.
Accordingly, the construction of conventional sidewalls, ceiling walls and roof systems requires a variety of materials, some of which are quite heavy. The installation of these materials can also be complex and require varying degrees of precision. Thus, installation of these materials is often labor intensive, which can result in higher costs being associated with the construction of these types of buildings.
In seeking better materials for constructing the walls of a building, several forms of premanufactured building panels have been suggested. One such example of a building panel is disclosed in U.S. Pat. No. 5,265,389 to Mazzone, et al. which discloses an exterior curtain wall panel. The panel has a pair of opposed end caps consisting of channels of light gauge galvanized steel and a foam core of expanded polystyrene with a thickness greater than the width of the channels. The structural strength for the panel is provided by multiple open box type tubes extending vertically along the height of the panel and located within the foam core. However, the panel does not provide fire retardation. In addition, the upper and lower channels are exposed to external conditions and the patent discloses that the channels are thus preferably made from rust resistant galvanized steel, which can be expensive if used in all applications.
Another example of a building panel is disclosed in U.S. Pat. No. 5,524,400 to Schmechel which discloses a sidewall assembly for a building. The sidewall assembly includes a plurality of expanded polystyrene panels. Each panel has side and end surfaces which define grooves therein. Each panel has a pair of opposed U-shaped side supports which interface with a corresponding groove extending along one of the longitudinally extending laterally displaced sides of the panel. Adjacent panels are secured together by a pair of opposed U-shaped end supports which interface with corresponding grooves extending along the laterally extending longitudinally displaced ends of the panels and which are secured to the side supports by suitable fasteners. Adjacent panels may also be secured together by joining the abutting side supports with suitable fasteners. However, as with the Mazzone patent, the sidewall assembly disclosed in the Schmechel patent does not provide for fire retardation. In the event of a fire, the expanded polystyrene panels of the sidewall assembly will melt thus removing the internal reinforcement of the U-shaped side and end supports which is necessary to prevent displacement of the supports. In the case of horizontal roof and ceiling panels, which are not disclosed in Schmechel, strength is especially important.
Thus, there is a need for improved building materials for use in the construction of exterior walls, such as sidewalls, ceiling walls and roof systems of buildings. Such materials must be capable of being efficiently installed to reduce labor costs while at the same time providing adequate insulation properties, sound attenuation, fire retardation and structural strength. These materials should also be protected from the weather.
SUMMARY OF THE INVENTION
The present invention provides a premanufactured structural building panel system whereby the structural panels can be constructed inexpensively and efficiently off-site for subsequent installation at the construction site. The individual structural panels are made of a pair of C-shaped structural channels partially encompassing a foam insulation member. The structural panels are connected to each other in a side-by-side fashion to form an exterior wall, including a roof, of a building.
In one embodiment, the premanufactured structural building panels include a pair of structural channels extending longitudinally in parallel directions. Each of the channels is of a generally C-shaped cross section which is defined by a web portion having a laterally outer surface and by first and second flanges connected at opposite ends of the web portion. Where the building panels are used to form a roof and ceiling wall, a plurality of retaining members can be extended between the second flanges of the channels to provide additional structural strength. Each of the channels faces the other such that the flanges extend from the respective web portion in a direction towards the opposing channel.
Advantageously, a fire retarding board extends between the web portions of the channels such that it is adjacent to the first flanges of the channels. The fire retarding board has a surface facing the interior of the building and an opposite exteriorly facing surface.
The structural channels also include third flanges extending from the web portions of each of the channels. The third flanges are located between the first and second flanges and each third flange extends from the respective web portion in a direction towards the other channel. The third flanges are secured to the exteriorly facing surface of the fire retarding board.
A foam insulation member extends between the web portions of the channels. The insulation member has an interiorly facing surface adjacent the exteriorly facing surface of the fire retarding board and an opposite exteriorly facing surface. The insulation member also has a pair of opposite lateral sides, each
Alston and Bird LLP
Dorsey Dennis L.
Stephan Beth A.
LandOfFree
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