HIGH-STRENGTH INSULATED BUILDING PANEL WITH INTERNAL STUD MEMBERS

• US 20110047908A1
• Filed: 07/29/2010
• Published: 03/03/2011
• Est. Priority Date: 08/28/2009
• Status: Abandoned Application

• Current Assignee: Bryan Daniel Brusman, Robert Charles Brusman
• Original Assignee: Bryan Daniel Brusman, Robert Charles Brusman
• Inventors: Brusman, Robert Charles, BRUSMAN, Bryan Daniel
• Application Number:
  US12/845,887
• Publication Number:
  US 20110047908A1
• Time in Patent Office: Days
• US Class Current: 52/220.1
• CPC Class Codes: E04B 2001/386 Nailable or screwable inserts for foam panels
• CPC Class Codes: E04C 2/205 of foamed plastics, or of plastics and foamed plastics, optionally reinforced
• CPC Class Codes: E04C 2/22 reinforced E04C2/205 takes precedence
• 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 2/521 serving for locating conduits; for ventilating, heating or cooling
• CPC Class Codes: Y10T 29/49629 Panel

Abstract

The invention is directed to a building panel which has structural integrity. A plurality of stud members with opposed side surfaces and opposed end surfaces extend from a first face of the panel toward a second face. The plurality of stud members are spaced from each other and extend in a direction which is essentially parallel to each other. A rigid foam fills the volume of the panel which is not filled by the plurality of stud members. The rigid foam is bonded to at least one side surface of each of the plurality of stud members. The bonding of the rigid foam to the plurality of stud members results in a stable and strong panel which is capable of accommodating large shear loads.

Claims

1. A building panel having structural integrity, the panel comprising:

a first face and an oppositely facing second face, a pair of panel end walls and a pair of panel sidewalls extend between the first face and the second face;

a plurality of stud members having opposed side surfaces and opposed end surfaces, the plurality of stud members extend from the first face toward the second face, the plurality of stud members are spaced from each other and extend in a direction which is essentially parallel to each other;

a rigid foam, the rigid foam fills the volume of the panel which is not filled by the plurality of stud members, the rigid foam is bonded to at least one side surface of each of the plurality of stud members;

whereby the bonding of the rigid foam to the plurality of stud members results in a stable and strong panel which is capable of accommodating large shear loads.

2. The building panel as recited in claim 1, wherein the rigid foam is a closed-cell polyurethane foam which is injection molded between the stud members to provide a continuous, void-free structure for maximum insulation value at a minimum thickness of the panel.

3. The building panel as recited in claim 1, wherein the rigid foam has a variable density whereby the higher density is located at exposed, unprotected edges to confer greater resistance to damage in handling.

4. The building panel as recited in claim 1, wherein the first face has a layer of facing material which extends across the first face to increase the insulation value of the panel.

5. The building panel as recited in claim 4, wherein the facing material is a fiberglass reinforced aluminized polyester film.

6. The building panel as recited in claim 4, wherein the facing material is bonded to the rigid foam.

7. The building panel as recited in claim 1, wherein a first side wall is formed from one of the plurality of stud members and a second side wall is formed from the rigid foam.

8. The building panel as recited in claim 1, wherein the side walls are formed from respective stud members of the plurality of stud members.

9. The building panel as recited in claim 1, wherein a first row of the plurality of stud members is provided which extend from the first face, the first row of the plurality of stud members has the rigid foam provided between the first row of the plurality of stud members and the second face, whereby a thermal break is provided to prevent a thermal pathway across the width of the panel through the plurality of stud members.

10. The building panel as recited in claim 9, wherein a second row of the plurality of stud members is provided which extend from the second face, the second row of the plurality of stud members has the rigid foam provided between the second row of the plurality of stud members and the first face, the second row of the plurality of stud members is staggered from the first row of the plurality of stud members whereby a thermal break is provided to prevent a thermal pathway across the width of the panel through the plurality of stud members.

11. The building panel as recited in claim 1, wherein conduits are provided in the panel, the conduits are provided to accommodate wiring, plumbing or air flow through the panel.

12. A panel having structural integrity for use in floors, ceilings, walls or roofs of a structure, the panel comprising:

a first face and an oppositely facing second face, a pair of panel end walls and a pair of panel sidewalls extend between the first face and the second face;

a plurality of stud members having opposed side surfaces and opposed end surfaces, the plurality of stud members extend from the first face toward the second face, the plurality of stud members are spaced from each other and extend in a direction which is essentially parallel to each other;

a rigid foam, the rigid foam fills the volume of the panel which is not filled by the plurality of stud members;

a facing material extending across the first face of the panel, the facing material is bonded to the rigid foam;

whereby the bonding of the rigid foam to the plurality of stud members and to the facing material results in a stable and strong panel which is capable of accommodating large shear loads.

13. The panel as recited in claim 12, wherein the rigid foam is a closed-cell polyurethane foam which is injection molded between the stud members to provide a continuous, void-free structure for maximum insulation value at a minimum thickness of the panel.

14. The panel as recited in claim 12, wherein the rigid foam has a variable density whereby the higher density is located at exposed, unprotected edges to confer greater resistance to damage in handling.

15. The panel as recited in claim 12, wherein the facing material is a fiberglass reinforced aluminized polyester film.

16. The panel as recited in claim 12, wherein the facing material extends across the second face to increase the insulation value of the panel, the facing material is bonded to the rigid foam and to the plurality of stud members of the second face.

17. A method of manufacturing a building panel having structural integrity, the method comprising;

positioning a plurality of stud members in a mold in a direction which is essentially parallel to each other, each stud member of the plurality of stud members having opposed side surfaces and opposed end surfaces;

spacing the plurality of stud members from each;

injecting a foam into the mold to fill the volume of the mold which is not filled by the plurality of stud members;

applying increased pressure and temperature to allow the foam to cure, become rigid and bond to at least one side surface of each of the plurality of stud members;

removing the panel from the mold;

whereby the bonding of the rigid foam to the plurality of stud members results in a stable and strong panel which is capable of accommodating large shear loads.

18. The method as recited in claim 17, wherein the density of the foam injected into the mold has a variable density whereby the higher density is injected at locations which more wear will occur to confer greater resistance to damage in handling.

19. The method as recited in claim 17, wherein a facing material is positioned in the mold, the facing material extending across the width of the mold, the facing material bonding with the foam when the appropriate pressure and temperature are applied.

20. The method as recited in claim 17, wherein conduits are formed in the foam during the molding process, the conduits are provided to accommodate wiring, plumbing or air flow through the panel.

21. The method as recited in claim 17, wherein a first row of the plurality of stud members is positioned in the mold and a second row of the plurality of stud members is positioned in the mold and is staggered and offset from the first row of the plurality of stud members whereby as the foam is cured, a thermal break is provided to prevent a thermal pathway across the width of the panel through the plurality of stud members.