Structural insulated panels with metal edges

• US 5,497,589 A
• Filed: 07/12/1994
• Issued: 03/12/1996
• Est. Priority Date: 07/12/1994
• Status: Expired due to Fees

• Current Assignee: William H. Porter
• Original Assignee: William H. Porter
• Inventors: Porter, William H.
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): Kent, Christopher Todd
• Application Number:
  US08/273,981
• Time in Patent Office: 609 Days
• Field of Search: 52/309.2, 52/309.7, 52/309.9, 52/592.1, 52/784.15, 52/787.1, 52/794.1, 52/797.1, 52/800.1, 52/801.1
• US Class Current: 52/309.7
• CPC Class Codes: E04C 2/296 composed of insulating material and non-metallic or unspecified sheet-material E04C2/288 takes precedence
• CPC Class Codes: E04C 2/384 with a metal frame

Abstract

A generally flat structural panel includes a center foam core and opposed outer facings, or sheets, with a metal insert disposed about and attached to the edges of the core and at least one of the outer facings. The metal edge insert provides high strength for the insulated foam panel, eliminates the need for structural members such as studs which act as thermal conductors, and facilitates coupling between adjacent panels, ceilings and floors using various connection arrangements. The structural insulated panels also form the basis of a modular construction system that allows for the use of standard size inside and outside panels of the same size which form a grid in which the outside panels always enclose an area that is a multiple of the module. In one embodiment, a lateral surface of the foam core is provided with a linear array of recesses, or grooves, and a facing is attached to that surface in the field to permit electrical wire routing in the recesses, as required, at the construction site. In another embodiment, metal strips attached to the surface of the core and adapted for secure attachment to a facing such as of drywall provide a space between the foam core and drywall sheet for wire routing.

Claims

1. An insulated structural panel comprising:

a generally flat insulating core having a peripheral edge portion;

first and second outer facings disposed on opposed lateral surfaces of said insulating core each having edge portions, wherein said peripheral edge portion of said insulating core extends beyond adjacent edge portions of said first and second outer facings;

first and second thin metal strips disposed over and attached to said peripheral edge portion of said insulating core forming a tongue structure, wherein each of said panels further includes a respective recessed groove on an opposed peripheral edge portion thereof, wherein each recessed groove is adapted to receive the tongue structure of an adjacent panel; and

coupling means for securely connecting at least one of said metal strips and said peripheral edge portion of said insulating core to a second insulated structural panel.

2. The structural panel of claim 1 further comprising third and fourth thin metal strips attached to the recessed groove of each of said panels and adapted to receive said coupling means.

3. An insulated structural panel comprising:

a generally planar insulating core having a peripheral edge portion;

first and second outer facings disposed on opposed lateral surfaces of said insulating core, wherein each of said outer facings includes a respective peripheral edge portion and wherein a peripheral edge portion of said insulating core extends beyond adjacent edge portions of said outer facings along a first edge thereof to form a tongue-like structure and wherein peripheral edge portions of said outer facings extend beyond an adjacent edge portion of said insulating core along a second, opposed edge thereof to form a groove in an edge of said structural panel;

a first thin metal strip disposed intermediate and affixed to said insulating core and one of said outer facings along first adjacent edges thereof;

a second thin metal strip disposed intermediate and affixed to said insulating core and said one of said outer facings along second, opposed edges thereof; and

coupling means for securely connecting said structural panel to a second identical structural panel when the tongue-like structure of one of said panels is inserted in the groove of the other panel, wherein said coupling means engages said first metal strip in one panel and said second metal strip in the other panel.

4. The structural panel of claim 3 further comprising third and fourth thin metal strips each affixed to said insulating core and one of said outer facings and respectively disposed along the first and second edges thereof, wherein said third and fourth metal strips respectively form a portion of said tongue-structure and said groove of the structural panel.

5. The structural panel of claim 4 wherein said coupling means further engages the third metal strip of said one panel and the fourth metal strip of said other panel.

6. The structural panel of claim 5 wherein each of said first and third metal strips includes a respective inwardly angled distal edge to facilitate insertion of the tongue-like structure of said one panel into the groove of said other panel.

7. The structural panel of claim 3 wherein said coupling means includes threaded coupling pins or an adhesive.

8. The structural panel of claim 7 wherein said adhesive is epoxy cement or glue.

9. The structural panel of claim 3 wherein said insulating core is foam.

10. The structural panel of claim 3 further comprising an adhesive for affixing said first and second metal strips to said outer facings and said insulating core.

11. The structural panel of claim 4 further comprising an adhesive for affixing the metal strips to said outer facings and said insulating core.

12. The structural panel of claim 3 wherein said outer facings are comprised of gypsum or cement.

13. The structural panel of claim 3 wherein said metal strips are aluminum or galvanized steel having an epoxy paint outer coating.