Building panel and utilization thereof

• US 4,157,638 A
• Filed: 10/03/1977
• Issued: 06/12/1979
• Est. Priority Date: 10/03/1977
• Status: Expired due to Term

• Current Assignee: The Thermo-Core Building Systems Incorporated
• Original Assignee: The Thermo-Core Building Systems Incorporated
• Inventors: Della-Donna, Alphonse
• Primary Examiner(s): Murtagh, John E.
• Application Number:
  US05/839,037
• Time in Patent Office: 617 Days
• Field of Search: 52/419, 52/420, 52/592, 52/71, 52/265, 52/264, 52/309.9, 52/518, 52/619, 52/173, 52/71, 52/309.4, 52/309.7, 428/121, 428/322, 428/314, 428/318, 428/321
• US Class Current: 52/309.9
• CPC Class Codes: B32B 2266/0228 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof
• CPC Class Codes: B32B 27/10 of paper or cardboard
• CPC Class Codes: B32B 29/007 next to a foam layer
• CPC Class Codes: E04B 1/16 Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material E04B1/32 - E04B1/36 take precedence
• CPC Class Codes: E04C 2/243 one at least of the material being insulating

Abstract

A building structure and a method of constructing a wall utilizing the building structure, for the construction of concrete buildings in a simplified manner. Each building structure unit includes a pair of exterior panels of cardboard sandwiching an insulating foam panel, or sandwiching two foam panels which in turn sandwich another cardboard panel. The various panels are glued together, and tabs extend from the exterior panels along the bottom of the structure, and along one side of the structure. A number of the structures are stood in place so that they extend vertically, with the tab portions along their bottoms attached to the building base, and the structures all arranged side by side in interlocking engagement to provide a continuous self-supporting wall structure providing a horizontally impenetrable barrier. Reticulated metal reinforcing material is attached to each opposed exterior face of the wall structure, and cementitious material is sprayed onto each exterior face to form a wall with no cementitious material extending between the exterior faces.

Claims

1. A building structure intermediate construction comprising

a pair of exterior substantially quadrate panels, each panel formed of stiff lightweight relatively inexpensive cellulosic material,

an interior substantially quadrate panel, formed of insulating material having a generally foam structure, of generally the same width and length as each said exterior panel,

means for attaching said interior panel between said exterior panels,

said exterior panels having tab portions along a first edge thereof extending past the termination of said interior panel,

at least one of said exterior panels having a tab portion along a second edge thereof extending past the termination of said interior panel, said second edge being a generally perpendicular edge of said exterior quadrate panel to said first edge,

an interior substantially quadrate panel of stiff lightweight relatively inexpensive cellulosic material,

a second substantially quadrate panel formed of insulating material having a generally foam structure, said interior panel of stiff cellulosic material being disposed between said interior foam structured panels, and said interior panels being sandwiched between said exterior panels, and

means for attaching said interior foam structured panels to said interior stiff panel, and to said exterior panels.

2. A building structure comprising

a pair of exterior substantially quadrate panels, each panel formed of stiff lightweight relatively inexpensive cellulosic material,

an interior substantially quadrate panel, formed of insulating material having a generally foam structure, of generally the same width and length as each said exterior panel,

means for attaching said interior panel between said exterior panels,

each said exterior panel having bendable tab portions along all four edges thereof extending past the termination of said interior panel, and

a groove extending along at least each of two of the edges of said interior quadrate panel for receipt of bent-over tab portions of said exterior panel therein each said groove being constructed so that the tab portions received thereby can be readily removed therefrom.

3. A building structure intermediate nonload bearing construction comprising

a pair of exterior substantially quadrate panels, each panel formed of stiff lightweight relatively inexpensive cellulosic material,

an interior substantially quadrate panel, formed of insulating material having a generally foam structure, of generally the same width and length as each said exterior panel,

means for attaching said interior panel between said exterior panels,

4. said exterior panels having bendable tab portions along a first edge thereof extending past the termination of said interior panel, and the exterior and interior panels being flush along the edge thereof opposite said first edge,

all four edges of each of said quadrate exterior panels having tab portions therealong extending past the termination of said interior panel, and

a groove extending along at least each of two of the edges of said interior quadrate panel for receipt of bent-over tab portions of said exterior panel therein.

6. A structure as recited in claim 4 wherein said interior stiff panel has a length and width slightly less than the length and width of said interior foam structured panels, so that a groove is provided between the interior foam structured panels along at least two edges thereof, said grooves having sufficient thickness for receipt of bent-over tab portions of said exterior panels therein.

5. A building structure intermediate nonload bearing construction comprising

a pair of exterior substantially quadrate panels, each panel formed of stiff lightweight relatively inexpensive cellulosic material,

an interior substantially quadrate panel, formed of insulating material having a generally foam structure, of generally the same width and length as each said exterior panel,

means for attaching said interior panel between said exterior panels,

said exterior panels having bendable tab portions along a first edge thereof extending past the termination of said interior panel, and the exterior and interior panels being flush along the edge thereof opposite said first edge,

at least one of said exterior panels having a tab portion along a second edge thereof extending past the termination of said interior panel, said second edge being a generally perpendicular edge of said exterior quadrate panel to said first edge,

an interior substantially quadrate panel of stiff lightweight relatively inexpensive material, and a second substantially quadrate panel formed of insulating material having a generally foam structure, said interior panel of stiff material being disposed between said interior foam structured panels, and said interior panels being sandwiched between said exterior panels, and

means for attaching said interior foam structured panels to said interior stiff panel, and to said exterior panels.

7. A structure as recited in claim 5 wherein each of said quadrate exterior panels has tab portions along each of the four edges thereof extending past the termination of said interior panels, and wherein grooves are provided between the interior foam structures panels along at least three edges thereof.

8. A building structure intermediate nonload bearing construction comprising

a pair of exterior substantially quadrate panels, each panel formed of stiff lightweight relatively inexpensive cellulosic material,

an interior substantially quadrate panel, formed of insulating material having a generally foam structure, of generally the same width and length as each said exterior panel,

means for attaching said interior panel between said exterior panels,

said exterior panels having bendable tab portions along a first edge thereof extending past the termination of said interior panel, and the exterior and interior panels being plush along the edge thereof opposite said first edge,

at least one of said exterior panels having a tab portion along a second edge thereof extending past the termination of said interior panel, said second edge being a generally perpendicular edge of said exterior quadrate panel to said first edge, and

an adhesive with a release paper covering disposed on the interior face of the tab portion along each exterior panel second edge.

9. A building structure intermediate nonload bearing construction comprising

a pair of exterior substantially quadrate panels, each panel formed of stiff lightweight relatively inexpensive cellulosic material,

an interior substantially quadrate panel, formed of insulating material having a generally foam structure, of generally the same width and length as each said exterior panel,

means for attaching said interior panel between said exterior panels,

said exterior panels having bendable tab portions along a first edge thereof extending past the termination of said interior panel, and the exterior and interior panels being flush along the edge thereof opposite said first edge,

at least one of said exterior panels having a tab portion along a second edge thereof extending past the termination of said interior panel, said second edge being a generally perpendicular edge of said exterior quadrate panel to said first edge, and

wherein said generally foam structured insulating material is selected from the group consisting of polystyrene foam and polyurethane foam.