Modular insulated building panels

• US 9,580,906 B1
• Filed: 10/19/2015
• Issued: 02/28/2017
• Est. Priority Date: 10/19/2015
• Status: Active Grant

• Current Assignee: Blokaloks, LLC
• Original Assignee: Blokaloks, LLC
• Inventors: Spencer, Stan
• Primary Examiner(s): Nguyen, Chi Q
• Application Number:
  US14/887,029
• Time in Patent Office: 498 Days
• Field of Search: 525/72, 525/902, 522/237, 522/86, 527/450.3, 527/481.1, 527/411, 405/285
• US Class Current: 1/1
• CPC Class Codes: E04B 2/08 by interlocking of projections or inserts with indentations, e.g. of tongues, grooves, dovetails
• CPC Class Codes: E04B 2/18 by interlocking of projections or inserts with indentations, e.g. of tongues, grooves, dovetails
• CPC Class Codes: E04B 2002/0206 of rectangular shape
• CPC Class Codes: E04B 2002/0208 of trapezoidal shape
• CPC Class Codes: E04B 2002/021 of triangular shape
• CPC Class Codes: E04B 2002/0215 with separate protrusions
• CPC Class Codes: E04B 2002/0217 of prismatic shape
• CPC Class Codes: E04B 2002/023 with rabbets, e.g. stepped
• CPC Class Codes: E04B 2002/0232 Undercut connections, e.g. using undercut tongues and grooves
• CPC Class Codes: E04B 2002/0234 Angular dovetails
• CPC Class Codes: E04C 1/40 built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
• CPC Class Codes: E04C 2/041 composed of a number of smaller elements, e.g. bricks, also combined with a slab of hardenable material
• CPC Class Codes: E04C 2/38 with attached ribs, flanges, or the like, e.g. framed panels concerned with attaching to other panels or elements to form a structure, see the places for the relevant structure, e.g. E04B2/00
• CPC Class Codes: E04C 2/46 specially adapted for making walls E04C2/52, E04C2/54 take precedence; structure of slab-shaped elements E04B1/02; walls of elements of relatively thin form E04B2/72

Abstract

A building panel includes an insulating member having a first surface and a second, opposing surface, and a first sheathing member secured to the first surface of the insulating member and including a coupling portion. The coupling portion has a recessed portion, a first extension portion adjacent the recessed portion, and a second extension portion on the opposite side of the recessed portion from the first extension portion. A sum of a width dimension of the first extension portion and a width dimension of the second extension portion is substantially equal to a width dimension of the recessed portion, and at least one side surface of the insulating member is substantially coplanar with a respective side surface of the first sheathing member.

Claims

1. A building panel, comprising:

an insulating member having a first surface and a second, opposing surface;

a first sheathing member secured to the first surface of the insulating member and including a coupling portion, the coupling portion having a recessed portion, a first extension portion adjacent the recessed portion, and a second extension portion on the opposite side of the recessed portion from the first extension portion;

wherein a sum of a width dimension of the first extension portion and a width dimension of the second extension portion is substantially equal to a width dimension of the recessed portion;

wherein at least one side surface of the insulating member is substantially coplanar with a respective side surface of the first sheathing member; and

wherein at least a portion of the recessed portion is coplanar with an exterior surface of the first sheathing member.

2. The building panel of claim 1, wherein the recessed portion further comprises radiused corners.

3. The building panel of claim 2, wherein respective inner side surfaces of the first and second extension portions are angled with respect to a lower surface of the recessed portion.

4. The building panel of claim 1, wherein the coupling portion is a first coupling portion, and the first sheathing member further comprises a second coupling portion opposite the first coupling portion.

5. The building panel of claim 4, further comprising a second sheathing member secured to the second surface of the insulating member opposite the first sheathing member, the second sheathing member comprising first and second coupling portions including respective first and second extension portions and recessed portions defined therebetween.

6. The building panel of claim 1, wherein a respective surface of the insulating member is located beyond a horizontal surface of the first sheathing member defining the recessed portion.

7. The building panel of claim 1, wherein the respective width dimensions of the first and second extension portions are substantially equal.

8. The building panel of claim 1, wherein the respective width dimensions of the first and second extension portions are unequal.

9. The building panel of claim 1, wherein the first sheathing member comprises wood, metal, stone, ceramic, fiber-reinforced polymer composite, fiber-reinforced cementitious material, or any combination thereof.

10. The building panel of claim 1, wherein the insulating member comprises expanded or extruded polystyrene, polyurethane, fiberglass, pumice, mineral wool, polymer-based honeycomb materials, straw, or any combination thereof.

11. The building panel of claim 1, wherein the insulating member defines a substantially airtight evacuated vacuum chamber.

12. The building panel of claim 1, wherein the first sheathing member is secured to the insulating member by adhesive, fasteners, or any combination thereof.

13. A structure including the building panel of claim 1.

14. A method of making a building panel, comprising:

coupling a first sheathing member to a first side surface of an insulating member, the first sheathing member including a coupling portion having a recessed portion, a first extension portion adjacent the recessed portion, and a second extension portion on the opposite side of the recessed portion from the first extension portion, a sum of a width dimension of the first extension portion and a width dimension of the second extension portion being substantially equal to a width dimension of the recessed portion, wherein at least a portion of the recessed portion is coplanar with an exterior surface of the first sheathing member;

coupling a second sheathing member to a second side surface of the insulating member opposite the first side surface such that the insulating member is disposed between the first and second sheathing members and at least one side surface of the insulating member is substantially coplanar with respective side surfaces of the first and second sheathing members, the second sheathing member including a coupling portion having a recessed portion, a first extension portion adjacent the recessed portion, and a second extension portion on the opposite side of the recessed portion from the first extension portion, a sum of a width dimension of the first extension portion and a width dimension of the second extension portion being substantially equal to a width dimension of the recessed portion.

15. The method of claim 14, wherein coupling the second sheathing member further comprises coupling the second sheathing member such that a respective surface of the insulating member extends beyond respective horizontal surfaces of the recessed portions of the first and second sheathing members.

16. The method of claim 14, wherein coupling the first and second sheathing members further comprises coupling the first and second sheathing members to the insulating member with adhesive, fasteners, or any combination thereof.

17. The method of claim 14, wherein coupling the first and second sheathing members further comprises injecting liquid insulation between the sheathing members to form the insulating member.

18. The method of claim 14, wherein the sheathing members comprise wood, metal, stone, ceramic, fiber-reinforced polymer composite, fiber-reinforced cementitious material, or any combination thereof.

19. The method of claim 14, wherein the insulating member comprises expanded or extruded polystyrene, polyurethane, fiberglass, pumice, mineral wool, polymer-based honeycomb materials, straw, or any combination thereof.

20. A method of making a structure, comprising:

situating a first building panel side by side with a second building panel, the first and second building panels comprising respective insulating members with respective first and second sheathing members coupled to first and second surfaces of the insulating members, the first and second sheathing members comprising respective upper and lower coupling portions located on opposite sides of the sheathing members from one another, the upper and lower coupling portions including respective first and second extension portions and recessed portions defined therebetween, a sum of the respective width dimensions of the first and second extension portions of each respective coupling portion being substantially equal to width dimensions of the respective recessed portions of the first and second sheathing members, at least one side surface of the respective insulating members being substantially coplanar with respective side surfaces of the first and second sheathing members coupled thereto, wherein at least a portion of each respective coupling portion is coplanar with an exterior surface of the respective sheathing member; and

situating a third building panel on top of the first and second building panels such that respective lower coupling portions of first and second sheathing members of the third building panel engage the upper coupling portions of the first and second sheathing members of the first and second building panels.