Modular building panel and method for constructing the same

• US 6,099,768 A
• Filed: 04/21/1999
• Issued: 08/08/2000
• Est. Priority Date: 05/22/1998
• Status: Expired due to Fees

• Current Assignee: Groupe Canam Incorporated / Canam Group Incorporated
• Original Assignee: Canam Manac Group, Inc. (Canam Group Incorporated)
• Inventors: Strickland, Michael R., Theodore, Charles A. J.
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): A, PHI DIEU TRAN
• Application Number:
  US09/295,911
• Time in Patent Office: 475 Days
• Field of Search: 29/897.32, 52/745.19, 52/742.13, 52/309.11, 52/309.7, 52/309.9, 264/46.4, 264/46.7, 264/46.5, 264/511
• US Class Current: 264/46.4
• CPC Class Codes: E04C 2/06 reinforced
• CPC Class Codes: E04C 2/384 with a metal frame

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.

Claims

1. A method for constructing a modular building panel comprising the steps of:

providing a backer board for applying an exterior finish thereto;

providing a structural metal framework having an outer perimeter and comprising a plurality of interconnected structural metal frame members wherein a plurality of interstitial bays are formed between said structural metal frame members;

suspending the structural metal framework apart from the backer board by over-hanging clamps at a predetermined gauged distance so that the backer board is fully isolated from the structural metal framework; and

applying an insulating foam in liquid form over substantially an entire area defined between the backer board and the framework and within an area defined by the interstitial bays located between the structural metal frame members, which substantially fills the bays to adhesively join the backer board and the framework to each other when the foam layer subsequently cures into a solid form, whereby a desired spacing is maintained between the backer board and the framework and wherein the predetermined gauged spacing distance and an insulating property of the foam cause a dewpoint condensation condition resulting from interior building temperature mixing with a cold outside air condition to occur remote from the frame members in a direction toward the backer board, wherein the backer board comprises a plurality of interconnected backer board sections adhered end to end, which form a backer board assemblage having a substantially flat exterior surface and having an outer perimeter, wherein the backer board sections are adhered end to end by an adhering structure, wherein the adhering structure comprises a plurality of biscuits, which maintain alignment between the confronting edges of the backer board sections, wherein the dimensions of the outer perimeter of the backer board assemblage substantially comport with the dimensions of the outer perimeter of the metal framework and wherein the backer board assemblage is assembled prior to applying the insulating foam; and

providing a supporting structure for supporting the backer board assemblage, wherein the supporting structure is inclined at an angle A with respect to a ground surface such that the backer board is suspended at an incline.

2. The method as set forth in claim 1 wherein the backer board is secured to the inclined backing surface of the supporting structure by spike or screws.

3. The method as set forth in claim 1 wherein the backer board is secured to the inclined backing surface of the supporting structure by a vacuum.

4. A method for constructing a modular building panel comprising the steps of:

providing a backer board for applying an exterior finish thereto;

providing a structural metal framework having an outer perimeter and comprising a plurality of interconnected structural metal frame members wherein a plurality of interstitial bays are formed between said structural metal frame members;

suspending the structural metal framework apart from the backer board by over-hanging clamps at a predetermined gauged distance so that the backer board is fully isolated from the structural metal framework; and

applying an insulating foam in liquid form over substantially an entire area defined between the backer board and the framework and within an area defined by the interstitial bays located between the structural metal frame members, which substantially fills the bays to adhesively join the backer board and the framework to each other when the foam layer subsequently cures into a solid form, whereby a desired spacing is maintained between the backer board and the framework and wherein the predetermined gauged spacing distance and an insulating property of the foam cause a dewpoint condensation condition resulting from interior building temperature mixing with a cold outside air condition to occur remote from the frame members in a direction toward the backer board, wherein the backer board comprises a plurality of interconnected backer board sections adhered end to end, which form a backer board assemblage having a substantially flat exterior surface and having an outer perimeter, wherein the backer board sections are adhered end to end by an adhering structure, wherein the adhering structure comprises a plurality of biscuits, which maintain alignment between the confronting edges of the backer board sections, wherein the dimensions of the outer perimeter of the backer board assemblage substantially comport with the dimensions of the outer perimeter of the metal framework, wherein the backer board assemblage is assembled prior to applying the insulating foam and wherein the supporting structure further comprises a bottom stop and a backing surface.

5. The method as set forth in claim 4 wherein, in lieu of suspending the framework by overhanging clamps, the framework is positioned relative to the inclined backer board, prior to applying the insulating foam liquid, by temporarily adhering a plurality of insulating spacers to the inclined backer board and adhering the framework to the plurality of insulating spacers.