Prefabricated building panel

• US 10,676,928 B2
• Filed: 02/27/2019
• Issued: 06/09/2020
• Est. Priority Date: 02/04/2015
• Status: Active Grant

• Current Assignee: Easi-Set Worldwide
• Original Assignee: Easi-Set Worldwide
• Inventors: Smith, Rodney I.
• Primary Examiner(s): Maestri, Patrick J
• Assistant Examiner(s): Sadlon, Joseph J.
• Application Number:
  US16/287,538
• Publication Number:
  US 20190194942A1
• Time in Patent Office: 468 Days
• Field of Search: 428223, 52414
• CPC Class Codes: E04C 2/049 completely or partially of insulating material, e.g. cellular concrete or foamed plaster
• 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 2002/3488 spaced apart by frame like structures

Abstract

Prefabricated building panels combine new and unexpected element dimensions and materials with the effect of reducing overall weight and depth while simultaneously improving panel performance such as thermal insulation. As compared to former panels, prefabricated building panels according to exemplary embodiments of the invention generally include thinner concrete slabs, wider separations between concrete and support framing, and new material choices for anchors connecting slabs with framing. Exemplary panels are compliant with energy codes such as the latest ASHRAE and IECC.

Claims

1. A method for constructing exterior faç

ades of buildings to comply with different climate zones thermal insulation requirements, comprising the steps of

assembling a plurality of prefabricated building panels, wherein the prefabricated building panels each comprise

a concrete slab having a thickness equal to or less than 2 inches,

framing including a plurality of studs or beams permanently secured to the concrete slab with a spacing of 0.5 to 3.0 inches between the concrete slab and the framing,

a continuous insulation which fills the spacing between the concrete slab and the framing, and

a total insulation thickness equal to or greater than the spacing,

wherein each of the plurality of prefabricated building panels have identical properties in terms of concrete slab, framing, and continuous insulation, including total insulation thickness, and

wherein a spacing between a concrete slab and a framing of some panels of the plurality of prefabricated building panels is adjusted to be larger than a spacing between a concrete slab and a framing of other panels of the plurality of prefabricated building panels to satisfy more stringent envelope thermal insulation performance criteria.

2. The method of claim 1, wherein the framing is secured to the concrete slab by a plurality of stainless steel anchors.

3. The method of claim 1, further comprising bolting or welding the assembled prefabricated building panels to building frames.

4. The method of claim 1, wherein the spacing for said some of the plurality of prefabricated building panels is at least 2 inches, and the spacing for said other panels is 1.5 inches.

5. The method of claim 1, wherein the total insulation extends into a cavity between the webs of adjacent studs or beams of the framing.

6. The method of claim 1, wherein the thickness of the concrete slab is between 1.5 and 2 inches.

7. The method of claim 1, wherein said plurality of beams or studs are spaced apart at intervals of more than 2 feet and up to 4 feet.

8. The method of claim 1, wherein said width of each of said plurality of studs or beams is 4 to 6 inches.

9. The method of claim 1, wherein said plurality of studs or beams include C-shaped studs or beams.

10. A method for constructing exterior faç

ades of buildings to comply with different climate zones thermal insulation requirements, comprising the steps of

assembling a plurality of prefabricated building panels, wherein the prefabricated building panels each comprise

a concrete slab having a thickness equal to or less than 2 inches,

framing including a plurality of studs or beams permanently secured to the concrete slab with a spacing of 0.5 to 3.0 inches between the concrete slab and the framing,

a continuous insulation which fills the spacing between the concrete slab and the framing, and

a total insulation thickness equal to or greater than the spacing in compliance with predetermined energy code climate zones requirements,

wherein each of the plurality of prefabricated building panels have identical properties in terms of concrete slab, framing, and continuous insulation, including total insulation thickness, selected and combined to achieve a specific thermal performance contained in the predetermined energy code climate zones requirements, and

wherein a spacing between a concrete slab and a framing of some of the plurality of prefabricated building panels is adjusted larger than a spacing between a concrete slab and a framing of other panels of the plurality of prefabricated building panels to satisfy more stringent thermal insulation performance criteria contained in the predetermined energy code climate zones requirements.

11. The method of claim 10, wherein the framing is anchored to the concrete slab by a plurality of stainless steel anchors.

12. The method of claim 10, further comprising bolting or welding the assembled prefabricated building panels to building frames.

13. The method of claim 10, wherein the spacing for said some of the plurality of prefabricated building panels is at least 2 inches, and the spacing for said other panels is 1.5 inches.

14. The method of claim 10, wherein the continuous insulation extends between the webs of adjacent studs or beams of the framing.

15. The method of claim 10, wherein the thickness of the concrete slab is between 1.5 and 2 inches.

16. The method of claim 10, wherein said plurality of beams or studs are spaced apart at intervals of more than 2 feet and up to 4 feet.

17. The method of claim 10, wherein said width of each of said plurality of studs or beams is 4 to 6 inches.

18. The method of claim 10, wherein said plurality of studs or beams include C-shaped studs or beams.

19. A method for constructing exteriors of buildings to comply with different climate zones envelope thermal insulation requirements by adjusting a thermal break spacing, comprising the steps of

assembling a plurality of prefabricated building panels, wherein the prefabricated building panels each comprise

a concrete slab,

framing including a plurality of studs or beams permanently secured to the concrete slab with a thermal break spacing of 0.5 to 3.0 inches between the concrete slab and the framing,

a continuous insulation which fills the thermal break spacing between the concrete slab and the framing, and

a total insulation thickness equal to or greater than the thermal break spacing,

wherein each of the plurality of prefabricated building panels have identical properties in terms of concrete slab, framing, and continuous insulation, and

wherein a thermal break spacing between a concrete slab and a framing of some panels of the plurality of prefabricated building panels is adjusted to be larger than a thermal break spacing between a concrete slab and a framing of other panels of the plurality of prefabricated building panels to satisfy more stringent envelope thermal insulation performance criteria.