Prefabricated structural building panel

• US 10,563,400 B2
• Filed: 04/21/2017
• Issued: 02/18/2020
• Est. Priority Date: 04/22/2016
• Status: Active Grant

• Current Assignee: Nickolas Graham, Rickey Graham
• Original Assignee: Nickolas Graham, Rickey Graham
• Inventors: Graham, Rickey, Graham, Nickolas
• Primary Examiner(s): Fonseca, Jessie T
• Application Number:
  US15/494,024
• Publication Number:
  US 20170306624A1
• Time in Patent Office: 1,033 Days
• CPC Class Codes: B32B 13/06 of metal
• CPC Class Codes: B32B 15/046 of foam
• CPC Class Codes: B32B 15/18 comprising iron or steel B32B15/011, B32B15/012 and B32B15/013 take precedence
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2250/04 4 layers
• CPC Class Codes: B32B 2250/05 5 or more layers
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2255/06 on metal layer
• CPC Class Codes: B32B 2255/205 Metallic coating
• CPC Class Codes: B32B 2266/02 Organic
• CPC Class Codes: B32B 2266/0214 Materials belonging to B32B27/00
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2305/022 Foam
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 3/02 characterised by features of form at particular places, e.g. in edge regions non-uniform thickness B32B3/263
• CPC Class Codes: B32B 3/06 for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: B32B 3/08 : characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 3/20 : of hollow pieces, e.g. tubes; of pieces with channels or cavities
• CPC Class Codes: B32B 3/28 : characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 5/145 : Variation across the thickness of the layer
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/32 : at least two layers being foamed and next to each other
• CPC Class Codes: E04C 2/284 : at least one of the materials being insulating
• CPC Class Codes: E04C 2/292 : composed of insulating material and sheet metal
• CPC Class Codes: E04C 2/322 : with parallel corrugations
• CPC Class Codes: E04C 2/34 : composed of two or more spaced sheet-like parts E04C2/32 takes precedence; spacers for cavity walls E04B2/44
• CPC Class Codes: E04C 2/36 : spaced apart by transversely-placed strip material, e.g. honeycomb panels honeycomb or other core members for layered products B32B
• CPC Class Codes: E04C 2/38 : with attached ribs, flanges, or the like, e.g. framed panels concerned with attaching to other panels or elements to form a structure, see the places for the relevant structure, e.g. E04B2/00
• CPC Class Codes: E04C 2/384 : with a metal frame
• CPC Class Codes: E04C 2/521 : serving for locating conduits; for ventilating, heating or cooling
• CPC Class Codes: E04C 2002/001 : Mechanical features of panels

Abstract

A load bearing building panel having a first sheet intended to provide an inner building surface, a second sheet intended to provide an outer building surface, and an insulating foam core sandwiched between them. The sheet that provides the inner building surface is corrugated to define co-planar portions separated by a plurality of channels which are dimensioned so as to be able to accommodate standard size electrical boxes and/or plumbing pipes. Advantageously, the other sheet is also corrugated to define a plurality of channels so that a plurality of panels can be stacked in a partially nesting relationship.

Claims

1. A building panel comprising:

a first sheet intended to provide an inner building surface, the first sheet being corrugated to define a plurality of generally parallel channels that extend along the length of the panel;

a second sheet arranged generally parallel to the first sheet and intended to provide an outer building surface;

the longer dimension of each of the first and second sheets defining the length of the panel, and the shorter dimension of each of the first and second sheets defining the width of the panel;

an insulating foam core sandwiched between the first and second sheets extending substantially the entire length and width of the panel, such that the foam core occupies the entirety of the space defined by the first sheet and the second sheet, including the space defined by the second sheet and the corrugations of the first sheet;

the panel also having edges defined by the surfaces of the foam core between the sheets running the length of the panel;

the first and second sheets being in spaced apart relationship for substantially the entire length and width of the panel apart from along at least one edge of the panel; and

a discreet load bearing rib separate from the first and second sheets, the rib extending along one edge of the panel and being connected to the first sheet and to the second sheet,

wherein the channels each have side walls that define intermediate ledges extending inwardly at a depth to accommodate within the respective channel an electrical box of a first size and also have a bottom at a depth to accommodate within the respective channel an electrical box of a second size, said first size being different from said second size.

2. The building panel of claim 1, wherein the rib has two fastening portions for fastening the rib to each of the first and second sheets and a transverse portion that extends between the two fastening portions.

3. The building panel of claim 2, wherein the rib is generally C-shaped.

4. The building panel of claim 1, wherein the rib is fastened to each of the first and second sheets with insulating foam sheets therebetween to provide a thermal break.

5. The building panel of claim 1, wherein the first sheet is corrugated to define co-planar portions separated by a plurality of generally parallel channels that extend along the length of the panel, the channels being dimensioned so as to be able to accommodate electrical boxes or plumbing pipes.

6. The building panel of claim 5, wherein

the depth of the intermediate ledges is about 1½

inches, and

the depth of the channel bottom is about 2 inches.

7. The building panel of claim 6, wherein the second sheet is corrugated defining a plurality of mating channels that are dimensioned and spaced to align with and receive the co-planar portions of the first sheet so that a plurality of panels can be stacked in a partially nesting relationship.

8. The building panel of claim 1, further comprising mating left and right edges such that a plurality of abutting building panels can be inserted and locked together and the building panel is dimensioned such that a pair of building panels defines a nominal width of about 4 ft.

9. The building panel of claim 8, wherein the first and second sheets have a nominal width of about 2 ft.

10. The building panel of claim 8, wherein the first and second sheets are generally rectangular.

11. The building panel of claim 8, wherein at least one of the mating left and right edges is angled such that the building panel can be inserted and locked together with another building panel to form a corner.

12. A building panel system comprising a building panel according to claim 1, and further comprising a U-shaped base member to secure a plurality of abutting building panels to a base, the U-shaped base member having a pair of base flanges extending up from a connecting web, the U-shaped base member being dimensioned to fit within the building panel at an end thereof so that the base flanges are enclosed in proximity with the interior surfaces of the first and second sheets.

13. The building panel system of claim 12, wherein the ends of the building panel are pre-cut to provide a groove to accommodate the base flanges of the U-shaped base member.

14. The building panel of claim 5, wherein the channels are dimensioned to accommodate electrical boxes having a width of from about 1½

inches to about 2½

inches, and/or plumbing pipes having a diameter of from about ⅜

inches to about 1½

inches.

15. The building panel of claim 1, wherein at least one of the channels defines a depth of about 2 inches.

16. The building panel of claim 1, wherein at least one of the channels defines a depth of about 1½

inches.