The present invention relates generally a method for structurally connecting load bearing insulated building panels. More specifically, the present invention uses a laminated spline that it is made of a magnesium oxide board and a phenolic resin layer in order to form a unique spline that is superior in strength, fire rating and greatly reduces thermal bridging at the connection joint.
Load bearing insulated building panels are composite building materials of an insulating layer of rigid polymer foam sandwiched between two layers of structural board. These structural boards can consist of material such as sheet metal, plywood, particle board, etc. while the insulating layer of rigid polymer foam is commonly expanded polystyrene foam, extruded polystyrene foam, polyisocyanurate foam, or polyurethane foam. The load bearing insulated building panels can be used within many different construction applications, such as exterior walls, interior walls, roofs, floors, and foundation systems since the structural insulated panels combine the functionality of the conventional building components, such as studs, joists, insulation, vapor barrier, and air barrier. However, a connection issue occurs within the load bearing insulated building panels when the structural boards of the load bearing insulated building panels are made from magnesium oxide boards. Builders normally face with the connection issue in between multiple load bearing insulated building panels due to the soft in nature and poor attachment pullout strength of the magnesium oxide board, making structural applications difficult without the use of combustible material splines such as wood which greatly reduces the thermal efficiency of the panel system.
It is therefore an object of the present invention to provide a method to improve the connection in between multiple load bearing insulated building panels when the load bearing insulated building panels have magnesium oxide boards as the structural skin of the panels. The unique spline that is used within the present invention is superior in strength and fire rating compare to the conventional splines and greatly reduces the thermal bridging that typically occurs at the panel joints with other common connection methods.
All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.
The present invention is a method of connecting the structural insulated building panel through connecting splines. The method of connecting the multiple structural insulated building panels are explained in relation to an arbitrary structural insulated panel 1, an adjoining structural insulated panel 2, a first spline 11, and a second spline 12.
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Since the first MgO board 3 and the phenolic resin sheet 4 are laminated to each other, the phenolic resin sheet 4 converts the brittleness of the MgO board into high impact panel so that the structural insulated panels are able to withstand high impact forces and high stress forces. In other words, the first MgO board 3 and the phenolic resin sheet 4 form a non-brittle outer layer within the structural insulated panels.
Even though the structural insulated panels use laminating as the preferred connection method, the structural insulated panels can utilize any other type of connection methods or any other type adhesive materials, such as high pressure bonding, mechanical fasteners, and adhesive, to connect the first MgO board 3, the phenolic resin sheet 4, the expanded polystyrene layer 5, and the second MgO board 6 together.
The first MgO board 3, the phenolic resin sheet 4, the expanded polystyrene layer 5, and the second MgO board 6 each comprise a first edge and a second edge. More specifically, the first edge of the first MgO board 3, the phenolic resin sheet 4, the expanded polystyrene layer 5, and the second MgO board 6 are oppositely positioned from the second edge of the first MgO board 3, the phenolic resin sheet 4, the expanded polystyrene layer 5, and the second MgO board 6.
In reference to the first configuration of the structural insulated panels, the first edge of the first MgO board 3, the phenolic resin sheet 4, the expanded polystyrene layer 5, and the second MgO board 6 are coincidentally positioned with each other so that the all of the first edges are able to create a flat surface within the structural insulated panels. Similarly, the second edge of the first MgO board 3, the phenolic resin sheet 4, the expanded polystyrene layer 5, and the second MgO board 6 are coincidentally positioned with each other so that the all of the second edges are able to create a flat surface within the structural insulated panels
In reference to the second configuration of the structural insulated panels, the first edge of the first MgO board 3, the phenolic resin sheet 4, the expanded polystyrene layer 5, and the second MgO board 6 are coincidentally positioned with each other so that the all of the first edges are able to create a flat surface within the structural insulated panels. Similar to the first configuration, the second edge of the first MgO board 3, the expanded polystyrene layer 5, and the second MgO board 6 are coincidentally positioned with each other; however, the second edge of the phenolic resin sheet 4 is extended from the second edge of the first MgO board 3, the expanded polystyrene layer 5, and the second MgO board 6 so that a seal section can be formed within the structural insulated panels. The seal section function as a moisture barrier in between the arbitrary structural insulated panel 1 and the adjoining structural insulated panel 2 to stop moisture penetration.
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The method of connecting the arbitrary structural insulated panel 1 and the adjoining structural insulated panel 2 is shown in
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If the structural insulated panel with the seal section is used within the present invention, the seal section of the arbitrary structural insulated panel 1 is inserted into the first lateral channel 7 of the adjoining structural insulated panel 2 before inserting the second half portion 16 of the first spline 11. Then the seal section of the arbitrary structural insulated panel 1 can be sealed with the first lateral channel 7 of the adjoining structural insulated panel 2. The insertion of the first spline 11 further secures the seal section of the arbitrary structural insulated panel 1 within the third lateral channel 9 of the adjoining structural. Then the seal section creates a moisture barrier in between the arbitrary structural insulated panel 1 and the adjoining structural insulated panel 2 of the building envelope system in order to minimize the thermal break in between the arbitrary structural insulated panel 1 and the adjoining structural insulated panel 2.
The plurality of fasteners is then used to connect the adjoining structural insulated panel 2 with the arbitrary structural insulated panel 1 through the first spline 11 and the second spline 12. More specifically, the plurality of fasteners is externally traversed into the first spline 11 through the first MgO board 3 and the phenolic resin sheet 4 of the arbitrary structural insulated panel 1. The plurality of fasteners is also externally traversed into the first spline 11 through the first MgO board 3 and the phenolic resin sheet 4 of the adjoining structural insulated panel 2. Then the adjoining structural insulated panel 2 and the arbitrary structural insulated panel 1 can be attached to each other through the first spline 11 from the exterior side of the structural building. Similarly, the plurality of fasteners is externally traversed into the second spline 12 through the second MgO board 6 of the arbitrary structural insulated panel 1. The plurality of fasteners is also externally traversed into the second spline 12 through the second MgO board 6 of the adjoining structural insulated panel 2 so that the adjoining structural insulated panel 2 and the arbitrary structural insulated panel 1 can be attached to each other through the second spline 12 from the interior side of the structural building. As the final step, the adjoining structural insulated panel 2 is further secured to the building floor foundation by the plurality of fasteners.
Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.
The current application claims a priority to the U.S. Provisional Patent application Ser. No. 61/773,489 filed on Mar. 6, 2013.
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Number | Date | Country | |
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61773489 | Mar 2013 | US |