US20060179782A1

US20060179782A1 - Composite construction building panel

Info

Publication number: US20060179782A1
Application number: US11/349,816
Authority: US
Inventors: James Cox
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-02-08
Filing date: 2006-02-07
Publication date: 2006-08-17

Abstract

The present invention relates to the Composite Construction Building Panel now present in the prior art, it provides an improved Composite Construction Building Panel. The present invention allows for the Composite Construction Building Panel to be mounted on varying configurations, ranging from vertical, horizontal or overhead securely without requiring any elaborate construction processes. The present invention allows for the Composite Construction Building Panel to be manufactured using simple, relatively inexpensive process equipment that is already available. The present invention allows for the Composite Construction Building Panel to be a complete structural component with the insulating factors for thermal and sound, plus an exterior finished surface that will protect the foam panels and the interior of the building from the elements and also complete the aesthetically pleasing exterior surface so that no other surface need be installed to the exterior of the building. The present invention allows for the Composite Construction Building Panel to allow for windows, doors or any other thru-way to be installed easily and without excessive impact to the cost or labor.

Description

BACKGROUND

1. Description of the Prior Art
Current methods used to construct buildings, notably commercial buildings but, not limited to, is to construct a wall or roof by installing the outer planer surface of a suitable material that will support and protect the interior of the building, it's occupants, and the property contained within, onto a multitude of vertical columns spaced evenly, creating a substantially rectangular, three dimensional shape. A subsequent interior layer of insulating material may then be applied to the interior of the building adjacent to the exterior planer surface facilitating a thermal and sound barrier. Alternately, the walls or roof sections may be pre-fabricated in substantially rectangular sections and then installed onto the building frame work effectively enclosing the interior of the building as noted in Lanahan Aug. 31, 1999 U.S. Pat. No. # 5,943,775. Lanahan's design requires an elaborate pre-process that would impede the manufacture to only the most basic sizes and shapes, thus raising the manufacturing costs to an unacceptable level. Lanahan Jan. 2, 2001, which is a re-issue of Lanahan Aug. 31, 1999 U.S. Pat. No. # 5,943,775. This reissue also requires extensive and elaborate pre-processing, as well as, elaborate and expensive process equipment.
2. Objects and Advantages
Accordingly, several objects and advantages of this invention are:

- a) To provide a Composite Construction Building Panel
- b) To provide a Composite Construction Building Panel that is inexpensive.
- c) To provide a Composite Construction Building Panel that can be installed on different types of surfaces.
- d) To provide a Composite Construction Building Panel that can be installed quickly and easily.
- e) To provide a Composite Construction Building Panel that can be manufactured from readily available materials.
- f) To provide a Composite Construction Building Panel that can be mass produced using current manufacturing procedures.
- g) To provide a Composite Construction Building Panel that can be produced using currently available process equipment.
- h) To provide a Composite Construction Building Panel that can be custom produced in varying sizes and shapes without increasing the manufacturing costs significantly.
- i) To provide a Composite Construction Building Panel that has an integral exterior finish.
- j) To provide a Composite Construction Building Panel that can be pre-assembled off site.
- k) To provide a Composite Construction Building Panel that can be pre-assembled on site.
- l) To provide a Composite Construction Building Panel that can be transported easily.
- m) To provide a Composite Construction Building Panel that doesn't require great skill to manufacture.
- n) To provide a Composite Construction Building Panel that doesn't require great skill to assemble into a structure.
- o) To provide a Composite Construction Building Panel that meets the highest energy savings requirements.
- p) To provide a Composite Construction Building Panel that does not contribute to the depletion of material resources.
- q) To provide a Composite Construction Building Panel that uses more than 50% recycled materials in the manufacturing process.
- r) To provide a Composite Construction Building Panel that can qualify for an energy star rating.
- s) To provide a Composite Construction Building Panel that can get a green building classification.
- t) To provide a Composite Construction Building Panel that has a class fire rating.
- u) To provide a Composite Construction Building Panel that has an insect and vermin repellent.
- v) To provide a Composite Construction Building Panel that will not feed or support the growth of mold.
- w) To provide a Composite Construction Building Panel that is water impervious.
- x) To provide a Composite Construction Building Panel that is completely recyclable.

SUMMARY OF INVENTION

The present invention relates to the Composite Construction Building Panel now present in the prior art, it provides an improved Composite Construction Building Panel. The present invention allows for the Composite Construction Building Panel to be mounted securely on any uneven or odd shaped surface, ranging from vertical, horizontal or overhead. The present invention allows for the Composite Construction Building Panel to be manufactured using simple, relatively inexpensive process equipment that is already available. The present invention allows for the Composite Construction Building Panel to be a complete structural component including an exterior finished surface that will protect the foam panels from the elements and also complete the aesthetically pleasing exterior surface so that no other surface need be installed to the exterior of the building.

DRAWING FIGURES

FIG. 1 shows a perspective view of the Composite Construction Building Panel.
FIG. 2 shows a perspective view of the partially assembled building using Composite Construction Building Panels.
FIG. 3 shows a perspective cutaway depiction of the Composite Construction Building Panel.
FIG. 4 shows an exploded perspective view of the Composite Construction Building Panel.
FIG. 5 shows a perspective view of the exterior finish bonded to the Composite Construction Building Panel Expanded Polystyrene Foam Block/structural member.
FIG. 6 shows a perspective view of the Composite Construction Thruway Building Panel.

REFERENCE NUMERALS IN DRAWINGS

2 Composite Construction Building Panel
4 Composite Construction Roof Panel
6 Composite Construction Floor Panel
8 Composite Construction Thruway Building Panel
10 Finish cut Expanded Polystyrene Foam Block
12A Top thin metal structural member
12B Bottom thin metal structural member
14A Right side thin metal structural stud member
14B Left side thin metal structural stud member
16A Right/center thin metal structural stud member
16B Left/center thin metal structural stud member
18A Left side thin metal structural stud polymerous cellular foam
18B Center thin metal structural stud polymerous cellular foam
18C Right side thin metal structural stud polymerous cellular foam
20A Upper thin metal structural stud polymerous cellular foam
20B Lower thin metal structural stud polymerous cellular foam
22A Right side upper thin metal structural stud member polymerous cellular foam
22B Right side lower thin metal structural stud member polymerous cellular foam
24A Left side upper thin metal structural stud member polymerous cellular foam
24B Left side lower thin metal structural stud member polymerous cellular foam
26 Panel/structural member substrate
28 Exterior surface coating
30 Thruway opening header
32 Thruway door opening support stud

DETAILED DESCRIPTION

Description—FIG. 1
the following detailed description is directed to the presently contemplated mode of carrying out the invention. This description is not intended to be limitative, but be made solely for the purpose of illustrating the general principles of the invention. The various features and advantages of the present invention may be more readily understood with reference to the following detailed description, taken in conjunction with the accompanying drawings, like numbers refer to the same feature or part thereof.
The preferred embodiment of the Composite Construction Building Panel of the present invention is illustrated in FIG. 1, a perspective view of the Composite Construction Building Panel 2. Finish cut Expanded Polystyrene Foam Block 10 receives the Top thin metal structural member 12A into the recessed provisions on the planer surface of the 2 Finish cut Expanded Polystyrene Foam Block 10. Finish cut Expanded Polystyrene Foam Block 10 receives the Bottom thin metal structural member 12B into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10. Finish cut Expanded Polystyrene Foam Block 10 receives the Right side thin metal structural stud member 14A into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10. Finish cut Expanded Polystyrene Foam Block 10 receives the Left side thin metal structural stud member 14B into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10. Finish cut Expanded Polystyrene Foam Block 10 receives the Right/center thin metal structural stud member 16A into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10. Finish cut Expanded Polystyrene Foam Block 10 receives the Left/center thin metal structural stud member 16B into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10. Finish cut Expanded Polystyrene Foam Block 10 receives the Left side thin metal structural stud polymerous cellular foam 18A into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10 next to the inside planer surface of the Top thin metal structural member 12A. Finish cut Expanded Polystyrene Foam Block 10 receives the Center thin metal structural stud polymerous cellular foam 18B into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10 next to the inside planer surface of the Top thin metal structural member 12A. Finish cut Expanded Polystyrene Foam Block 10 receives the Right side thin metal structural stud polymerous cellular foam 18C into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10 next to the inside planer surface of the Top thin metal structural member 12A. This forms the basic structure of the Composite Construction Building Panel 2.
FIGS. 1-4—Additional Embodiments
FIG. 2—The preferred embodiment of the Composite Construction Building Panel 2 of the present invention is illustrated in FIG. 2, a perspective view of the Composite Construction Building Panel 2 configured in a partially assembled building comprised of seven Composite Construction Building Panels 2 forming three walls of the building. Placed on top of the three walls consisting of multiple Composite Construction Building Panels 2 are two Composite Construction Roof Panels 4 forming a peaked roof over the building.
FIG. 3—The Composite Construction Building Panel 2 of the present invention is illustrated in FIG. 3. a perspective cutaway view of the Composite Construction Building Panel 2. The Top thin metal structural member 12A is cut away revealing the right side of the upper Right side upper thin metal structural stud member polymerous cellular foam 22A the right side lower thin metal structural stud member polymerous cellular foam 22B which is also cutaway. The Left/center thin metal structural stud member 16B is cut away revealing the Lower thin metal structural stud polymerous cellular foam 20B and the left side lower thin metal structural stud member polymerous cellular foam 24B. The Right/center thin metal structural stud member 16A and the Left/center thin metal structural stud member 16B are captured between the Bottom thin metal structural member 12B and the Top thin metal structural member 12A.
FIG. 4—The Composite Construction Building Panel 2 of the present invention is illustrated in FIG. 4. a perspective exploded view of the Composite Construction Building Panel 2 showing the relative position of the Left/center thin metal structural stud member 16B and the Lower thin metal structural stud polymerous cellular foam 20B to the finish cut Expanded Polystyrene Foam Block 10. It also shows the relative position of the Top thin metal structural member 12A and the Right side lower thin metal structural stud member polymerous cellular foam 22B and the right side upper thin metal structural stud member polymerous cellular foam 22A to the finish cut Expanded Polystyrene Foam Block 10. The depiction also shows the relationship of the Bottom thin metal structural member 12B and the left side lower thin metal structural stud member polymerous cellular foam 24B and the left side upper thin metal structural stud member polymerous cellular foam 24A to the finish cut Expanded Polystyrene Foam Block 10. Showing the relative position of the Right/center thin metal structural stud member 16A and the Upper thin metal structural stud polymerous cellular foam 20A to the finish cut Expanded Polystyrene Foam Block 10.
FIG. 5—The exterior composite panel of the present invention is illustrated in FIG. 5. a perspective view of the exterior composite panel showing the exterior surface coating 28 bonded to the panel/structural member substrate 26
FIG. 6—The composite construction thruway panel of the present invention is illustrated in FIG. 6 a perspective view of the composite construction thruway panel 8 showing the thruway opening header 30 connected perpendicular to thruway door opening support stud 32 creating a substantially rectangular opening.

OPERATION OF INVENTION

The preferred embodiment of the Composite Construction Building Panel of the present invention is illustrated in FIG. 1, a perspective view of the Composite Construction Building Panel 2. Finish cut Expanded Polystyrene Foam Block 10 receives the Top thin metal structural member 12A Top C-track structural member into the recessed provisions on the planer surface of the 2 Finish cut Expanded Polystyrene Foam Block 10. Finish cut Expanded Polystyrene Foam Block 10 receives the Bottom thin metal structural member 12B into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10. Finish cut Expanded Polystyrene Foam Block 10 receives the Right side thin metal structural stud member 14A into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10. Finish cut Expanded Polystyrene Foam Block 10 receives the Left side thin metal structural stud member 14B into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10. Finish cut Expanded Polystyrene Foam Block 10 receives the Right/center thin metal structural stud member 16A into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10. Finish cut Expanded Polystyrene Foam Block 10 receives the Left/center thin metal structural stud member 16B into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10. Finish cut Expanded Polystyrene Foam Block 10 receives the Left side thin metal structural stud polymerous cellular foam 18A into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10 next to the inside planer surface of the Top thin metal structural member 12A. Finish cut Expanded Polystyrene Foam Block 10 receives the Center thin metal structural stud polymerous cellular foam 18B into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10 next to the inside planer surface of the Top thin metal structural member 12A. Finish cut Expanded Polystyrene Foam Block 10 receives the Right side thin metal structural stud polymerous cellular foam 18C into the recessed provisions on the planer surface of the Finish cut Expanded Polystyrene Foam Block 10 next to the inside planer surface of the Top thin metal structural member 12A. This forms the basic structure of the Composite Construction Building Panel 2.

CONCLUSIONS, RAMIFICATIONS AND SCOPE

Accordingly, the reader will see that the Composite Construction Building Panel of this invention can be used conveniently, inexpensively and can be set up quickly.
It can be made of different materials.
It can be made using different dimensions, such as, making it taller, shorter, wider, narrower, lighter, heavier, or in whatever configurations not stated.
It allows for an easy and quick setup requiring only basic construction skills.
Although the description above contains much specificity, these should not be construed as limiting the scope of the invention, but as merely providing illustrations of some of the presently preferred embodiments of this invention. For example, Composite Construction Building Panel can be used on single story, substantially rectangular in shape buildings to multi storied buildings having multi-angled shapes and varied dimensions. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.

Claims

1. An improved composite building panel comprising in combination:

a polymerous cellular core with substantially parallel front and back faces; and

a thin metal structural member with one planar surface having two perpendicular planar surfaces forming a substantially rectangular structural member; and

said polymerous cellular core having substantially rectangular notches removed from the perimeter to accommodate said thin metal structural members; and

said polymerous cellular core having substantially rectangular notches removed from the planar surface in a vertical orientation spaced across the planar surface for structural support of said polymerous cellular core to accommodate said thin metal structural channels; and

said polymerous cellular core having said thin metal structural members abutting the horizontal said upper and lower notch planar surfaces of said polymerous cellular core bonded to said polymerous cellular core with a chemical bonding agent; and

said thin metal structural members abutted vertically to said planner surface of said vertical notches in said polymerous cellular core with said chemical bonding agent; and

said vertically placed thin metal structural members abutted to the vertical edges of said vertical planar surface of said vertical notches cut in said polymerous cellular core attaching to said upper and lower thin metal structural members and

said vertically placed thin metal structural members having a thermal break created from the said chemical bonding agent; and

said thermal break created from said chemical bonding agent created around the said thin metal structural members, incasing the said horizontal upper and lower perimeter edges of said polymerous cellular core; and

said vertical and horizontal notches have an polymerous cellular foam placed into voids that when cured interconnects said thin metal channels to said polymerous cellular core.

2. The composite building panel of claim 1 is further defined by the planar surface of the said polymerous cellular core that will be in orientation to the outside of the structure or the weather side will have a seal coating of a polyurea and polyurethane blend applied to said planar surface facilitating a water proof barrier between the said polymerous cellular core and said weather side of the said polymerous cellular core.

3. The composite building panel of claim 2 is further defined by a second application of a blend of polyurea and polyurethane to said first coating of said blend of polyurea and polyurethane on said outer planer surface of the said polymerous cellular core to create stucco appearing outer substrate.

4. The composite building panel of claim 2 is further defined by the assembly of a multitude of said composite building panels creating a building perimeter.

5. The composite building panel of claim 2 is further defined by the assembly of a multitude of said composite building panels of said claim 2 creating a roof structure for said building perimeter.

6. The composite building panel of claim 1 is further defined by the assembly of a multitude of said composite building panels of claim 1 creating a floor structure for said building perimeter.

7. The composite building panel of claim 1 is further defined by the placement of thru-ways for windows and doorways prior to constructing said building perimeter.