Building panel

• US 4,984,406 A
• Filed: 07/17/1989
• Issued: 01/15/1991
• Est. Priority Date: 01/14/1988
• Status: Expired due to Term

• Current Assignee: Peter Friesen
• Original Assignee: Peter Friesen
• Inventors: Friesen, Peter
• Primary Examiner(s): Safavi, Michael
• Application Number:
  US07/297,465
• Time in Patent Office: 547 Days
• Field of Search: 52/593, 52/594, 52/595, 52/588, 52/589, 52/591, 52/309.8, 52/309.9, 52/406, 52/309.2, 52/309.16, 52/529, 52/530, 52/284, 52/583, 52/92
• US Class Current: 52/588.1
• CPC Class Codes: E04B 1/12 the elements consisting of other material
• CPC Class Codes: E04B 2/72 Non-load-bearing walls of elements of relatively thin form with respect to the thickness of the wallE04B2/56, E04B2/74, E04B2/88 take precedence; with joint fillings acting as framework or pillars E04B2/68; elements E04C2/00
• CPC Class Codes: E04H 5/10 Buildings forming part of cooling plants

Abstract

A building system includes a plurality of building panels which are connected together to form a wall structure and are then connected to roof panels to form a roof structure. Each of the panels is formed by rotational molding to form a hollow body. The hollow body can be filled with a foamed insulation material. Side edges of the hollow body include either a projection or a correspondingly shaped recess which has a web and a bulbous part of increased width on the outer end of the web so that the panels can be connected only by longitudinal sliding movement. Metal plates are embedded in the top and bottom surfaces for connection to metal plates in the roof panels and to a footing respectively. A rib on the front surface of the panel has a width of the order of one third of the width of the panel and extend from the front surface of the panel substantially equal to the thickness of the panel so as to provide sufficient longitudinal strength in the panel that the weight of the roof can be supported wholly upon the panels. Corner, window and door panels are provided to complete the system.

Claims

1. A building system comprising a plurality of building panels, each building panel comprising a panel body integrally molded by rotational molding from a synthetic plastics material, said panel body having an outer wall substantially wholly enveloping a hollow interior of the panel body and defining a top surface, two side surfaces, a front surface and a rear surface, the panels each having a height sufficient to extend from a floor level to a roof level of a building, the front surface of at least some of the panels including a longitudinal vertical rib projecting outwardly from the front surface to provide structural strength for the panel so that vertical strength of a wall of a building can be provided solely by the panels, each panel having connecting means on the side surfaces thereof for connection to an adjacent side surface of an adjacent panel wherein the rear surface has a plurality of parallel ribs of less height than said rib on the front surface to allow the attachment of a facing material on the rear surface of the panel body.

2. A building panel comprising a panel body integrally molded from a synthetic plastic material, said panel body having an outer wall substantially wholly enveloping a hollow interior and defining a top surface, a bottom surface, two side surfaces, a front surface and a rear surface, one of said two side surfaces having a recess extending longitudinally of said one side the other of said sides having a projecting portion extending longitudinally of said other side, the recess and projecting portion being correspondingly shaped so that the projecting portion of one panel can only be interconnected with the recess of a next adjacent identical panel by sliding movement in a longitudinal direction of said one panel along a next adjacent panel, the panel body being formed by rotational molding to form a substantially fully closed body with a thickness of the outer wall which is substantially constant and thin relative to the dimensions of the panel body, the front surface including a rib longitudinally of the surface with the rib projecting outwardly from the front surface so as to provide longitudinal structural strength for the panel body and to provide bending resistance for the front surface.

3. The invention according to claim 2 wherein the panel body has a hole molded in an outer surface thereof for the injection into the hollow interior of a foaming material so that the hollow interior can be filled with an insulating foam material.

4. The invention according to claim 2 wherein the rib is arranged centrally of the surface and has a transverse width of the order of 1/4 to 1/3 of the width of the panel body.

5. The invention according to claim 2 wherein a height of the rib from the front surface is tapered at the upper and lower ends of the rib so as to converge toward the front surface at the top and bottom of the panel body.

6. The invention according to claim 2 wherein the rear surface has a plurality of ribs of very much less height than said rib on the front surface to allow the attachment of a facing material on the rear surface of the panel body.

7. The invention according to claim 2 wherein the projecting portion and recess are continuous along the sides and are commonly shaped defining a web and a curved bulbous part attached to the web.

8. The invention according to claim 2 wherein at least one of the top and bottom surfaces has a metal plate molded into the surface for fastening to an adjacent structure.

9. A building system comprising a plurality of building panels, each building panel comprising a panel body integrally molded by rotational molding from a synthetic plastics material, said panel body having an outer wall substantially wholly enveloping a hollow interior of the panel body and defining a top surface, two side surfaces, a front surface and a rear surface, the panels each having a height sufficient to extend from a floor level to a roof level of a building, the front surface of at least some of the panels including a longitudinal vertical rib projecting outwardly from the front surface to provide structural strength for the panel so that vertical strength of a wall of a building can be provided solely by the panels, each panel having connecting means on the side surfaces thereof for connection to an adjacent side surface of an adjacent panel wherein, one of said side surfaces has a recess extending longitudinally of said one side and the other of the sides having a projecting portion extending longitudinally of said other side, the recess and projecting portion being correspondingly shaped so that the projecting portion of one panel can only be interconnected with the recess of a next adjacent panel by longitudinal sliding movement of said one panel along said next adjacent panel.

10. The invention according to claim 9 wherein the panel body is formed by rotational molding to form a substantially fully closed body with a thickness of the outer wall which is substantially constant and thin relative to the dimensions of the panel body.

11. The invention according to claim 9 wherein the rib is arranged centrally of the surface and has a transverse width of the order of 1/4 to 1/3 of the width of the panel body.

12. The invention according to claim 9 wherein a height of the rib from the front surface is tapered at the upper and lower ends of the rib so as to converge toward the front surface at the top and bottom of the panel body.

13. The invention according to claim 9 wherein the projecting portion and recess are continuous along the sides and are commonly shaped in cross-section to define a web and a curved bulbous part attached to the web.

14. The invention according to claim 9 wherein at least one of the top and bottom surfaces has a metal plate molded into the surface for fastening to an adjacent structure.

15. The invention according to claim 9 including a plurality of corner panels each having a body defining connecting means along side edges thereof and defining a corner such that the side edges are arranged at an angle to one another.

16. The invention according to claim 9 including a plurality of roof panels, each roof panel comprising a panel body integrally molded from a synthetic plastics material, said panel body having an outer wall substantially wholly enveloping an interior thereof, each roof panel defining side surfaces for connecting to an adjacent side surface of an adjacent roof panel, one of the side surfaces including a recess extending longitudinally of said one side and the other of said sides having a projecting portion extending longitudinally of said other side, the recess and projecting portion being correspondingly shaped so that the projecting portion of one panel can be interconnected with the recess of a next adjacent panel only by sliding movement in a longitudinal direction of said one panel along the next adjacent panel, the recesses and projecting portions including at least one surface which extends upwardly from an upper surface of the panel to prevent moisture wicking through the interconnection between said one panel and said next adjacent panel.

17. The invention according to claim 16 wherein at least some of the roof panels include coupling means on an under surface thereof adjacent an end surface thereof for connecting the roof panel to a top surface of a wall panel.