Patent Application
20210071420
The present invention relates to an interchangeable structural module and more particularly to a structural building panel.
The interior of a structure may be subdivided into a number of smaller rooms or areas for example where an office may be formed in a commercial setting or a room for a residential house may be formed in a residential setting. In addition, exterior walls, roofs and floors need to be provided. If these rooms or areas have to be individually studded and covered with plasterboard, a large number of man-hours may be required in order to complete this task.
It would be desirable to have a module that could be easily assembled and easily joined to other modules in order to quickly and inexpensively provide a building that is suitable to be occupied and can meet local safety standards.
An interchangeable structure module to provide a structural building panel may include a structural panel having a front surface being opposed to a back surface and having side surfaces to connect the front surface and the back surface and having a top surface and a bottom surface to connect the front surface and the back surface; and a structural stud to engage the structural panel; wherein the structural stud is U-shaped.
The structural panel may include a back surface channel.
The back surface channel may include an adhesive
The side surface may include a side surface channel.
The back surface may include a structural stud.
The invention may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which, like reference numerals identify like elements, and in which:
The back surface 102 may include a back surface channel 120 which may extend the entire longitudinal length of the back surface 102. The back surface channel 120 may connect to a second (or more) interchangeable structural module 100 see
The back surface channel 120 on the back surface 102 is a chemical welding access grove. The back surface channel 120 is used when the module 100 is used in building; a first structural building panel 114 is positioned with the back surface 120 of a first module 100 being positioned to the front of another second module 100. When the structural panel 114 is installed on site, a spray foam sealant is applied from an insert of the spray foam applicator (Gun) between the back of the first module 100 and the front of a second module 100, and the spray foam sealant placed into the grove 120 allows the foam sealant to expand until the whole opening (grove) is filled, and in effect welding the first and second modules 100 together.
The interchangeable structural module 114 may be installed on site and is connected to another module. In general the modules are assembled together in the factory or a similar type setting and secured together with a top and bottom track attachment which is generally a “U” shaped track, and affixed to the structural studs with self drilling screws that affix the tracks to the structural studs. Alternately, the modules can be shipped to the site un-assembled, erected on site into the bottom track, have the top track attached and the spray foam sealant is inserted between the modules to produce a structural wall. When used as a module in a roof or floor system the modules are sent to the site individually then erected on site to produce the floors and roofs as needed.
The front surface 104 of the interchangeable structure module 100 has a structural stud 112 which may be formed from steel attached, bonded and chemically welded to the structural panel 114 which may be a foam insert
The structural stud 112 can be modified to any usable size and strength as needed.
For instance, if the interchangeable structural module 100 is used in manufacturing an interior wall, the stud 112 may be 26, 20 or 18 gauge as needed. The width of the stud 112 is variable from 2½″ up to a 6″ stud or larger for load bearing walls. The foam insert with the structural panel 114 corresponds with the width of the structural stud 112 as needed.
If the interchangeable structural module 100 is used for an exterior wall panel, the structural stud 112 may be used to ensure structural integrity as needed. The structural stud 112 can be 20 or 18 gauge in general; 16, 14 and 12 gauge can also be used as needed. The width of the structural stud 112 can be generally from 4″ up to 12″ or larger as needed.
If the interchangeable structural module 100 is used as a roof panel, the structural stud 112 (joist in this configuration) can be between 6″ to 14″ or larger inches or any size in between. The gauge for this configuration can also be between 20 and or larger to 16 gauge as needed. The thickness of the foam insert matches the width of the structural stud (joist) 112. The length and depth of the interchangeable structural module 100 is determined by a structural engineer. In other words, the interchangeable structural module 100 could be anywhere from a 12″ deep module 100 that is say 12 feet long to a module 100 that is up to 24″ deep and thirty feet long or longer. Depending on the load structural capabilities, the structural stud 112 (joist) can be virtually any width, length and gauge as needed.
If the interchangeable structural module 100 is being used as a floor joist, the same criteria as the roof modules 100 can be used.
The horizontal grove (side surface channel 122) is an electrical access channel that is cut into the foam insert. This grove can be used for installing electrical wiring, such as category 5 wiring, telephonic wiring and optic wiring as needed. The height and depth of the groove is determined as needed but is generally a 2″×2″ channel
The structural steel stud 112 also has an opening 126 that aligns with the electrical groove (side surface channel 122). The opening has an electrical insulated adapter (not shown) inserted into the opening on the stud to allow for the electrical wiring, cable etc. to be used.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed.
