Modular building panel and method for constructing the same
First Claim
1. A modular building panel comprising:
- a framework comprising a plurality of interconnected horizontal and vertical metal structural members;
a backer board having an inner surface facing an interior of a building and an outer surface for applying an exterior finish thereto, the backer board being spaced apart from the framework by a predetermined spacing distance, wherein an inner surface of the backer board faces facing edges of the structural members and in which adjacent sides of the structural members extend away from the facing edges and away from the backer board in an inward direction; and
an insulating foam layer, having a composition that cures upon application thereof from a liquid form into a solid form, extending over substantially an entire area defined between the framework and the backer board and adhesively joining the backer board to the structural members, and the foam layer extending away from the backer board in an inward direction and also adhesively joining at least part of the adjacent sides of the structural members to anchor the foam to the framework, and the foam layer locating the backer board at the predetermined spacing distance from the framework, wherein the backer board and the framework are joined by means of the foam layer and wherein the backer board and the framework are substantially free of contact therebetween so that the backer board is substantially fully thermally insulated relative to the framework, and wherein the foam layer has thickness and insulating performance constructed and arranged to place a condensation dewpoint, resulting from a mixing of an interior building temperature with a cold climate condition to which the outer surface of the backer board is exposed, remote from the framework in a direction toward the outer surface.
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Accused Products
Abstract
A modular building panel and a method for constructing the same provides a framework composed of structural members, typically formed of metal, and a backer board typically formed of a cementacious composite for receiving an exterior wall coating surface. The backer board and the framework are separated from, and insulated from, each other by a layer of foam that is applied in liquid form and that expands and cures into a solid form. Substantially no fasteners extend between the backer board and the metal framework to reduce conduction of heat therebetween. The foam serves as an adhesive to hold the backer board rigidly in place at a predetermined spacing from the framework and to anchor the backer board to the structural members. The structural members can comprise U-shaped and C-shaped channel beams for further rigidity and enhanced anchoring. Upon assembly, the backer board and the framework are overlaid upon each other, typically using spacers of a predetermined spacing thickness. Spacers can be formed from pieces of foam having adhesive or double-sided tape to maintain them in alignment with the framework and backer board. Liquid foam is applied from the interior side of the framework and expands toward the interior side of the framework.
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Citations
18 Claims
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1. A modular building panel comprising:
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a framework comprising a plurality of interconnected horizontal and vertical metal structural members; a backer board having an inner surface facing an interior of a building and an outer surface for applying an exterior finish thereto, the backer board being spaced apart from the framework by a predetermined spacing distance, wherein an inner surface of the backer board faces facing edges of the structural members and in which adjacent sides of the structural members extend away from the facing edges and away from the backer board in an inward direction; and an insulating foam layer, having a composition that cures upon application thereof from a liquid form into a solid form, extending over substantially an entire area defined between the framework and the backer board and adhesively joining the backer board to the structural members, and the foam layer extending away from the backer board in an inward direction and also adhesively joining at least part of the adjacent sides of the structural members to anchor the foam to the framework, and the foam layer locating the backer board at the predetermined spacing distance from the framework, wherein the backer board and the framework are joined by means of the foam layer and wherein the backer board and the framework are substantially free of contact therebetween so that the backer board is substantially fully thermally insulated relative to the framework, and wherein the foam layer has thickness and insulating performance constructed and arranged to place a condensation dewpoint, resulting from a mixing of an interior building temperature with a cold climate condition to which the outer surface of the backer board is exposed, remote from the framework in a direction toward the outer surface. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A modular panel system for buildings including panels arranged to be joined side by side to form a wall each of the panels comprising:
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a framework including a plurality of interconnected horizontal and vertical structural metal frame members, the structural metal frame members each including an outer edge, an inner edge and a side extending between the outer edge and the inner edge, bays being defined adjacent structural metal frame members; an exterior covering sheet material located in a facing relationship relative to the outer edge of each of the structural metal frame members, positioned remote from each outer edge at a predetermined spacing distance from each outer edge so that the exterior covering sheet material is fully isolated from the structural metal frame members, the exterior covering sheet material being constructed and arranged for exposure to an outside cold climate condition, wherein a degree of the cold climate condition causes a condensation dewpoint in each of the panels in response to mixing thereof with an interior building temperature; an insulating foam that cures from a liquid to a solid state upon application thereof, the foam extending between the each outer edge and a confronting face of the exterior covering sheet material and filling gaps defined therebetween with respect to the predetermined spacing distance and adhesively joining each of the structural metal frame members to the confronting face of the exterior covering sheet material and at least partially extending into the bays and along and in adhesive engagement with at least part of the sides of the structural metal frame members wherein the insulating properties of the foam and the predetermined spacing distance are arranged to locate the dewpoint remote from each outer edge in a direction toward the confronting face; and an interior covering located along the inner edge of each of the structural metal frame members. - View Dependent Claims (13, 14, 15, 16, 17, 18)
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Specification