Self supportive panel system

• US 9,689,165 B2
• Filed: 10/28/2015
• Issued: 06/27/2017
• Est. Priority Date: 03/31/2003
• Status: Active Grant

• Current Assignee: PN II Incorporated (Pultegroup Incorporated)
• Original Assignee: PN II Incorporated (Pultegroup Incorporated)
• Inventors: Peterson, James K., Broad, Robert P., Wrass, Lawrence J.
• Primary Examiner(s): Chapman, Jeanette E
• Application Number:
  US14/924,867
• Publication Number:
  US 20160047127A1
• Time in Patent Office: 608 Days
• CPC Class Codes: E04B 7/22 the slabs having insulating properties, e.g. laminated with layers of insulating material
• CPC Class Codes: E04C 2/365 by honeycomb structures
• CPC Class Codes: E04C 2/384 with a metal frame
• CPC Class Codes: E04C 2/386 with a frame of unreconstituted or laminated wood
• CPC Class Codes: E04C 2/388 with a frame of other materials, e.g. fibres, plastics
• CPC Class Codes: E04D 1/28 Roofing elements comprising two or more layers, e.g. for insulation
• CPC Class Codes: E04D 1/36 Devices for sealing the spaces or joints between roof-covering elements sealing joints not restricted to roof-covering elements E04B1/68; channels at the intersection of roof surfaces E04D13/0445
• CPC Class Codes: E04D 11/005 Supports for elevated load-supporting roof coverings
• CPC Class Codes: E04D 13/17 Ventilation of roof coverings not otherwise provided for ventilation of rooms or spaces F24F
• CPC Class Codes: E04D 3/32 of plastics, fibrous materials, or asbestos cement
• CPC Class Codes: E04D 3/351 at least one of the layers being composed of insulating material, e.g. fibre or foam material
• CPC Class Codes: E04D 3/357 comprising hollow cavities
• CPC Class Codes: Y10T 428/236 Honeycomb type cells extend perpendicularly to nonthickness layer
• CPC Class Codes: Y10T 428/239 Complete cover or casing
• CPC Class Codes: Y10T 428/24149 Honeycomb-like
• CPC Class Codes: Y10T 428/24157 Filled honeycomb cells [e.g., solid substance in cavities, etc.]
• CPC Class Codes: Y10T 428/24165 Hexagonally shaped cavities
• CPC Class Codes: Y10T 428/24777 Edge feature
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]
• CPC Class Codes: Y10T 442/3423 Plural metallic films or foils or sheets
• CPC Class Codes: Y10T 442/3854 : Woven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/3943 : Plural paper or wood pulp layers

Abstract

A self supporting panel system used to fabricate ceilings, floors, walls, or roofs. The panel system is assembled from a plurality of panels, each having a core that is sandwiched between opposing plate members. In a preferred embodiment, the core of each panel includes a unifying material to enhance the load bearing capacity of the panel.

Claims

1. A self-supportive insulated structure for a house comprising:

a first insulated structural roof panel, including opposing spaced apart load bearing plates and a structure for maintaining the plates of the first structural roof panel in spaced apart relation,

a second insulated structural roof panel, including opposing spaced apart load bearing plates, and a structure for maintaining the plates of the second structural roof panel in spaced apart relation,

wherein the first and second structural roof panels are joined together and in direct contact with one another along respectively associated adjacent edges for defining an attic space that is free of a truss structure for supporting the first and second structural roof panels,

wherein at least the first and second structural roof panels include a honeycomb insert within the structures for maintaining the plates of the first and second structural roof panels in spaced apart relation,

wherein a plastic foam is dispersed onto the honeycomb insert;

wherein a system for heating and cooling the house located in the attic space; and

wherein at least one of the load bearing plates of the first and second structural roof panels is metal.

2. The structure of claim 1, wherein a third, cross-tie panel is connected between the first and second structural roof panels by way of a wedge member.

3. The structure of claim 1, wherein the honeycomb insert defines a plurality of tubes.

4. The structure of claim 2, wherein the honeycomb insert defines a plurality of tubes.

6. The structure of claim 1, wherein all of the load bearing plates are metal.

7. The structure of claim 6, wherein the honeycomb insert defines a plurality of tubes.

8. The structure of claim 1, wherein the load bearing plates have a flat exterior surface.

16. The structure of claim 1, wherein a third cross-tie member defines a floor.

17. The structure of claim 3, wherein the plurality of tubes contain the plastic foam.

18. The structure of claim 7, wherein the plurality of tubes contain the plastic foam.

19. The structure of claim 17, wherein the plurality of tubes is formed by joining a plurality of peripheral edges of each individual tube.

20. The structure of claim 18, wherein the plurality of tubes is formed by joining a plurality of peripheral edges of each individual tube.

5. A self-supportive insulated structure for a house comprising:

a first insulated roof panel, including opposing spaced apart metal load bearing plates and a support structure for maintaining the plates of the first roof panel in spaced apart relation,

a second insulated roof panel, including opposing spaced apart load bearing plates and a support structure for maintaining the plates of the second roof panel in spaced apart relation,

a third, horizontally extending cross-tie panel, including opposing spaced apart load bearing plates and a support structure for maintaining the plates of the third cross-tie panel in spaced apart relation,

a first wedge;

a second wedge; and

a third wedge;

wherein the first and second panels are inclined relative to the third panel, and are joined together along respectively associated adjacent edges, with the first wedge disposed therebetween, for defining an attic space that is free of a truss structure for supporting the roof panels,

wherein said third, cross-tie panel is connected between said first and second roof panels, the second wedge being disposed along one edge of the cross-tie panel between the first roof panel and the cross-tie panel, and the third wedge being disposed along another edge of the cross-tie panel between the second roof panel and the cross-tie panel;

wherein one of the load bearing plates of the cross-tie panel defines a floor for the attic space; and

wherein at least the first and second roof panels include a honeycomb insert within the structures for maintaining the plates of the first and second structural roof panels in a spaced apart relation; and

wherein a plastic foam is dispersed onto the honeycomb insert.

9. The structure of claim 5, wherein the attic space has a heating and cooling system for the house located therein.

10. The structure of claim 5, wherein the honeycomb insert defines a plurality of tubes.

11. The structure of claim 9, wherein the honeycomb insert defines a plurality of tubes.

12. The structure of claim 5, wherein all of the load bearing plates are metal.

13. The structure of claim 12, wherein the honeycomb insert defines a plurality of tubes.

14. The structure of claim 5, wherein the load bearing plates have a flat exterior surface.

15. The structure of claim 13, wherein the load bearing plates have a flat exterior surface.