MODULAR, CUSTOMIZABLE, PREFABRICATED BUILDING ENVELOPE SYSTEM

Abstract

An object of the present invention is to provide a modular, customizable, prefabricated building envelope system. In accordance with an aspect of the present invention, there is provided a high-performance building envelope system comprising an external wall comprising connected expanded polystyrene (EPS) wall panels having generally squared C-shape light gauge steel profile framing members inserted into both sides of the EPS panel, and a roof assembly comprising connected expanded polystyrene (EPS) roof panels having parallel or coplanar, light gauge galvanized steel framing squared C-shaped framing members embedded on the upper surface and parallel or co-planar, light gauge galvanized I or H-shaped steel framing members embedded in the lower surface.

Description

FIELD OF THE INVENTION

This invention pertains generally to a building envelope system and, more particularly to a modular, customizable, prefabricated building envelope system.

BACKGROUND OF THE INVENTION

The building envelope or building enclosure includes the elements of the outer shell of a building and is critical for structural integrity of the building and environmental control including moisture control, temperature control and air flow. The performance of the building envelope impacts the environmental performance of the building.

Building envelope systems are known in the art and are limited in their ability to be readily customized while maintaining the structural integrity and moisture and thermal control necessary.

This background information is provided for the purpose of making known information believed by the applicant to be of possible relevance to the present invention. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present invention.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a modular, customizable, prefabricated building envelope system. In accordance with an aspect of the present invention, there is provided a high-performance building envelope system comprising an external wall comprising connected expanded polystyrene (EPS) wall panels having generally squared C-shape light gauge steel profile framing members inserted into both sides of the EPS panel, and a roof assembly comprising connected expanded polystyrene (EPS) roof panels having parallel or co-planar, light gauge galvanized steel framing squared C-shaped framing members embedded on the upper surface and parallel or co-planar, light gauge galvanized I or H-shaped steel framing members embedded in the lower surface.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the invention will become more apparent in the following detailed description in which reference is made to the appended drawings.

FIG. 1 illustrates (A) an isometric view of a single-story building having the building envelope system of one embodiment of the invention. (B) illustrates an isometric view of a cross section of building illustrated in (A).

FIG. 2 illustrates various wall panels in accordance with the invention detailing light gauge steel framing members and expanded polystyrene (EPS). (A) illustrates a cross-sectional view of a standard wall panel (200) in accordance with the invention detailing light gauge steel framing (210) members embedded in expanded polystyrene (EPS) panel (220) and optional resilient channels (225) attached to the framing members to improve sound proofing. The panel is shown with attached gypsum wallboard (230), optional air channel (235), strapping (240) and cladding (245). (B) is an isometric view of the panel illustrated in (A). (C) illustrates a cross-sectional view of an alternative wall panel (300) in accordance with the invention detailing light gauge steel framing members (210) embedded in expanded polystyrene (EPS) panel (220). (D) and (E) illustrates various views of an electrical chase wall panel (350) in accordance with one embodiment of the invention detailing light gauge steel framing members (210) embedded in expanded polystyrene (EPS) panel (220) with horizontally oriented wire chases (355) having electrical protection brackets (360).

FIG. 3 illustrates alternative wall panels in accordance with the invention configured to withstand increased horizontal shear stress. (A) illustrates a wall panel having inclined and crossed strapping (255). (B) illustrates a wall panel having metal sheeting (260).

FIG. 4 illustrates various views of a fire wall panel in accordance with an alternative embodiment of the invention detailing light gauge steel framing members (210, 410) and expanded polystyrene (EPS) panel (220). Also shown are rail (250) and strapping (450) used to form an airgap between EPS panel, gaps in EPS panel and second panel.

FIG. 5 illustrates (A) a wall panel with door opening; (B) a close up view of the top of the door detailing the door lintel and (C) the door lintel.

FIG. 6 illustrates an alternative wall panel with door opening.

FIG. 7 illustrates a wall panel with window opening.

FIG. 8 illustrates an alternative wall panel with window opening.

FIG. 9 illustrates joining of two wall panels.

FIG. 10 illustrates floor and wall connection detailing wall panels (200) with framing members, notched floor panels with C-shaped and I-shaped framing members (610, 615), C-track (660) configured for connection to wall framing members and floor panels, rail (630) and metal plates (620).

FIG. 11 illustrates raised or second story floor and wall connection detailing the joists (670), C-track (660), wall panels (200), rail (630) connections to joists (670), insulated flooring (661) and subflooring (662). Also shown is where insulation stops (662) and EPS block (667)

FIG. 12 illustrates raised or second story floor and wall connection detailing the CFS joist system and notched wall panels, rail (630) connections between joists (670) with web stiffners (1215), panel framing members, track section for CFS joist system (1205) and exterior stud caps (120) connecting the first story and second story wall panels framing elements. The wall panels shown have exterior strapping (1210).

FIG. 13 illustrates connection to CFS Joist System with rails connected to the joists and sill plate. The wall panels shown have exterior strapping (1210).

FIG. 14 illustrates a wall panel in accordance with one embodiment of the invention detailing connection to a Legalet slab (1410) (A) using L shaped rails (630) and (B) with optional EPS block (1420) and drip edge (1415).

FIG. 15 illustrates a floor assembly in accordance with one embodiment of the invention.

FIG. 16 illustrates various connection of a floor assembly of the invention to insulated concrete form (ICF) foundations. (A) illustrates connection to ICF (1600) with drip edge (1605) and lumber ledger (1615). A C-shaped framing member (1610) in the floor is secured to the lumber ledge (1615) by appropriate brackets and flat plates (1610) which can be extended to connect to wall assembly. (B) illustrates connection to ICF using appropriate anchors (1630), lumber ledge, appropriate brackets and flat plates which can be extended to connect to wall assembly.

FIG. 17 illustrates a roof assembly in accordance with one embodiment of the invention.

FIG. 18 illustrates various views of a wall panel roof interface in accordance with one embodiment of the invention.

FIG. 19 illustrates various views of a wall panel roof interface in accordance with one embodiment of the invention detailing the clip-on eave.

FIG. 20 illustrates various views of an alternative eave framing.

FIG. 21 illustrates isometric views of portions of various light gauge steel framing member including various sized including “C”-shaped, I-beam or “H”-shaped framing members. Also shown are corner members.

DETAILED DESCRIPTION OF THE INVENTION

Overview

The invention provides a building envelope system, panels and connections for preparing a building envelope. The components of the building envelope system are designed to facilitate customization by providing a variety of standard components that can be used to provide a customized building envelopes including single or multi-story buildings that can be configured to meet a wide range of structural and design requirements The building envelope system includes components for the building floor, exterior walls, and roof. Optionally, the system includes components for interior building components including interior walls.

Optionally, the building envelope system can be used in multi-story buildings.

The building envelope system may be connected to supporting structures including steel supporting structures known in the art and/or concrete structures.

The building envelopment of the invention is configurable for connection to various foundation types including poured foundations and insulated concrete form (ICF) foundations and to cold-formed steel floor (CSF) and net-zero-ready (NZR) joist system.

The building envelope optionally further includes additional weather barriers and/or membranes.

The system includes EPS (Expanded Polystyrene) panels with light gauge galvanized steel framing members having various profiles including “c”-shaped, “u-shaped” and I-beam or “H”-shaped. The size and shape of the framing members can be adjusted based on design parameters. Optionally, framing members are bent into the required profile shape from flat stock or manufactured by other means known in the art. I-beam or “H”-shaped framing members are optional formed by affixing two “c”-shaped members together by adhesive, screws or welding.

The flexibility in framing member type, size, number and position in the EPS (Expanded Polystyrene) increases customization options based on structural requirements, performance considerations and design requirements. The system also includes various connection systems that connect the wall to the floor, wall to foundation and the wall to the roof.

Also included are add-on design elements including clip-on eaves.

The system is designed to standardize its customization ability. The system provides a net zero design (site, client and build) process, scalable manufacturing (fabrication and assembly) process, shipping (panel weight and size) process, and rapid construction (installation and finishing) process.

Structural capacity of the assemblies can be increased by modifying profile shape, profile orientation/web depth, gauge and type of steel, and frequency (o/c—“on center” framing) and location of placement in the wall.

The system includes EPS (Expanded Polystyrene) panels with light gauge galvanized steel framing members having various profiles including “C”-shaped, “U-shaped” and I-beam or “H”-shaped, or other shapes to facilitate connection to other elements.

Thermal performance of the assemblies can be adjusted by modifying EPS thickness (R/U value rating), EPS bead (i.e., BASF Neopor vs Styropor) (R/U value rating), EPS type (moisture and permeability rating), and blend of insulating materials (secondary performance such as sound or fire requirements).

Wall Assemblies

The insulated wall assemblies have inherent thermal breaks and thus have reduced or no thermal bridging. Wall thickness can be varied based on client's needs or design requirements.

The system is configured to provide various wall shapes including straight, pre-built corners (of any angle), and curved walls (of any radius) without compromising thermal performance.

The system is configured to provide walls that are compatible with various floor assemblies including floor assemblies made with the system components; concrete slab on grade; Legalett Geo slab; ICF foundations; concrete/wood foundations; and platform-built wood/steel floors.

The building shown in FIG. 1 includes a building envelope system, shown generally at (100), in accordance with the teachings of the present invention. The building envelope system (100) includes exterior walls comprising connected wall panels forming the exterior walls of the building, roof comprising connected roof panels with optional clip-on eave and optional floor comprising connected floor panels. Alternatively, traditional floor assemblies can be used.

Referring to FIG. 2, each wall panel comprises EPS (Expanded Polystyrene) panel (220) with vertically oriented, substantially parallel or co-planar, light gauge galvanized steel framing members (210) in two rows. The frequency of on-center framing (o/c) is optionally variable.

In some embodiments, the light gauge galvanized steel framing members are generally a squared C-shape (210) and are inserted into both sides of the EPS panel (220) such that framing members on one side of the panel generally have a corresponding framing member that it is substantially aligned with it. The framing members may be oriented within the EPS such that the opening of the C-shape is to the interior of the panel, opening of the C-shape is to the edge panel or corresponding pairs of framing members having one member open to the interior and one open to the edge.

Orientation of the framing members within the EPS panel is dependent on building requirements including strength and thermodynamic properties. Generally, orientations where the opening of the C-shape is to the interior of the panel increases the R rating of the panel. R rating of the panel is further increased by increasing the width of the EPS panel.

Orientation of the framing member such that the one arm of the C-shape is to the edge of the panel increases strength of the panel and are optionally for use in taller walls. Size of the framing members including size, thickness and arm length are dependent on design and structural requirements. Optionally screws holes are provided in the framing members.

Optionally, the resilient channels (225) are attached horizontally to the framing members to improve sound proofing of the constructed structure.

Optionally, gypsum wallboard (230) or the like can be attached to one or both sides of wall panels of the invention.

In some embodiments, wall panels are configured to facilitate wiring of the building and include electrical chase(s) (355) in the EPS panel. Appropriate electrical brackets (360) are provided in the electrical chase(s) (360).

Optionally, L-shaped rails are affixed to the bottom and top edges of the panels. The top surface of the L-shaped rails may include adhesive to facilitate attachment of the walls panels to concrete structures.

Referring to FIG. 3, the wall panels may be configured to withstand increased horizontal shear stress. In some embodiments, as shown in FIG. 3(A), the shear wall panel includes rails (250) at the top and bottom edge of the panels and, on one side of the panel, crossing straps (255), at a 45° incline to horizontal extending from the top corner to the opposite bottom corner of the panel attached at each framing member (210), to the bottom and top rails at the corners and to each other at the center of the panel. Optionally, shear resistance may be doubled by strapping both sides of the panel. In alternative embodiments, as shown in FIG. 3(B), the shear wall panel includes steel sheeting (260) on one or both sides of the panel, preferably steel sheeting joints are overset from panel joints. The steel sheeting is attached to the framing members.

In some embodiments, the wall comprises modified wall panels. Referring to FIG. 4, the generally squared C-shape light gauge galvanized steel framing members (210) are inserted into one sides of the EPS panel (220) and modified framing members (410) or generally squared C-shape framing members are inserted partially into and perpendicular to the panel such that the framing member is rotated about 90° and only one arm of the “C” is in the EPS panel. In such embodiments, the unembedded arms of the perpendicular framing members are connected with rails and/or strapping. In some embodiments, the perpendicular framing members is off set from the C-shaped framing members. Optionally, the partially inserted framing members are linked by a strapping member (450). In some embodiments, the perpendicular framing members are inserted into cutouts (420) in the EPS panel and optionally glued in place.

In some embodiments, the perpendicular framing member is sized to provide an air gap between the EPS panel and gypsum wallboard. Optionally, the perpendicular framing member is sized to provide an air gap of sufficient size to receive the required depth of mineral/rock wool insulation for fire protection.

In some embodiments, the wall panels include door or window openings. Door and window openings' size and shape are dependent on design requirements with the wall panels readily amendable to accept off-the-shelf or custom shapes and sizes. Referring to FIG. 5, in some embodiments, the wall panel with door open includes standard framing members (210), a top rail (250) and lintel (510) across the whole span and attached to each frame member. The lintel (510) is attached at either end to king studs (520) which are provided on either side of the opening. The lintel is therefore provided with tails for attachment to the king studs. Referring to FIG. 6, in some embodiments, the wall panel is provided with a roughed in door opening. Extra EPS is provided at the sides and top of the opening to allow for adjustment of opening size.

Referring to FIG. 7 in some embodiments, the wall panel with window open includes standard framing members (210), rails (250) at top and bottom of panel and upper and lower window rails (710, 720). The window rails are attached to each framing member across the width of the opening and may be extended past the width of the window on each side. The upper and lower window rail tails may be shortened or elongated as required for different seismic requirements. The rail can stop on the first stud or extended up to 3 studs past the window opening). Rails may be provided on both sides of the panel. Referring to FIG. 8, in some embodiments, the wall panel is provided with a roughed in window opening. Extra EPS is provided at the sides, top and bottom of the opening to allow for adjustment of opening size.

Optionally, wall panels are constructed by inserting the framing members into EPS panels. Alternatively, EPS panels can be prepared with metal framing members already embedded.

Individual wall panels are connected to form the walls. The dimension and number of individual wall panels are based on design requirements. Optionally, wall panels can be curved. Corners of the walls are optionally preformed or can be assembled from two individual wall panels and a corner framing member. The angle of individual corners can be customized based on design specifications, for example, including 90° internal corner angle and 135° internal corner angle. In some embodiments, one wall intersecting at the corner is start and the second intersecting wall is curved.

Referring to FIG. 9, wall panels are joined at by adhesive, optionally NP1 adhesive or other adhesive known in the art. Optionally, each panel includes a cut out at the seam that is filled with spray foam. Optionally, upper and lower rails (250) that cross the seams are provided.

In some embodiments, wall height can be increased by either using taller EPS panels or by joining multiple panels together vertically. In such embodiments, longer framing elements may be used or a framing element may be effectively lengthened by nesting a second, appropriately sized framing element into the channel of a first frame element, telescoping it to the appropriate length and securing the appropriate length.

In some embodiments, a combination of the wall assemblies described above is provided to optimize both thermal and structural performance.

The system further includes panel joints including standard, standard with vertical chase, Passive House ready with channel for double sided gum tape.

The system can be configured for exterior walls or interior walls and used in retrofits.

Other embodiments include those for mid-rise buildings with concrete platforms and mid-rise buildings with concrete platforms with thermally broke platforms.

Wall panels are connected to both the assembly floor and roof.

Wall/Floor Connections

Wall panels are connectable to various floor assemblies including floor assemblies made with the system components; concrete slab on grade; Legalett Geo slab; ICF foundations; concrete/wood foundations; and platform-built wood/steel floors and as illustrated in FIG. 10-14.

In multistory builds, connection to floors include connection to higher story floors.

Connection of wall panels to can be via C-tracks, rails, metal straps and other means known in the art.

FIG. 10 illustrates a ground floor/wall connections between wall and flooring assemblies of the invention. A notch is cut out of the EPS of the floor panel (600) and a C-track member is attached thereto. The C-track (660) is attached to the exterior oriented framing elements of wall by steel strips (620). The wall panels (200) are further connected on the interior surface to floor C-framing members by an L-shaped rail (630).

FIG. 11 illustrates second story floor and wall connections where a notch is cut out of the EPS panel of the floor and a C-track is attached thereto. The C-track (660) is attached to the upper story and lower framing elements of the wall by steel strips (620), the C-shape and I-shaped framing elements (610, 615) of the floor are also attached to the framing elements of the upper and lower walls by L-shaped rails (630) on the interior surface. Alternatively, as shown in (B), the second story floor and wall is connected using a C-track (660) and rails to connect the wall panels (200) to the floor. The floor is notched for insertion of the C-track. The C-track (660) is attached to the floor joist (670) or framing member and the upper story and lower story framing elements of the wall panels by L-shaped rail (630).

In alternative embodiments, the sub flooring of the second story is connected to the upper and lower walls by L-shaped rails or other appropriate connections. In still further embodiments, a C-track is connected to the walls framing elements and the floor connected there to.

Referring to FIG. 12, in some embodiments, the second story floor is supported by a cold formed steel (CFS) joist system. The framing members of the interior facing surface of the lower story wall are shortened and a notch (1200) is cut out of the EPS panel (220) to allow for attachment of the track section (1205) of the CFS joist system. The framing elements of the lower and upper story are aligned with the joists (670) and attached to the joist by L-shaped rails (630). The exterior surface framing elements (210) are connected using exterior stud caps (1210). Exterior strapping is also shown (1220) and optional web stiffeners (1215) are shown.

Referring to FIG. 13, in some embodiments, the floor is supported by a cold formed steel (CFS) joist system and is attached to a concrete foundation (1310) with optional wood sill plate (1315). The framing members of the interior facing surface are shortened and a notch (1200) is cut out of the EPS panel (220) to allow for attachment of the track section of the CFS joist system. The framing elements of the lower and upper story are aligned with the joists (670) and attached to the joist by L-shaped rails (630). The exterior surface framing elements (210) are connected using exterior stud caps (1210). Exterior strapping is also shown (1220) and optional web stiffeners (1215) are shown. The shown foundation is brick ledge compatible

Floor Assemblies

The system is configured to provide floor assemblies. Referring to FIG. 15, each floor panel comprises EPS (Expanded Polystyrene) panel (1520) with parallel or co-planar, light gauge galvanized steel framing squared C-shaped framing members (1510) embedded on the upper surface and parallel or co-planar, light gauge galvanized steel I- or H-shaped framing members (1515) embedded in the lower surface. Panel thickness is selected based on design and structural requirements.

The C-shaped framing members are oriented within the EPS such that the opening of the C-shape is to the interior of the panel. The I-shaped or H-shaped framing members are oriented such that the flanges are substantially parallel or co-planar with the surface of the panel. Size of the framing members including arm and flange size or thickness and webbing depth and size and thickness are dependent on design and structural requirements.

Optionally screws holes are provided in the framing members.

Panels that are at the floor edge may be optionally notched at the end that is secured to the wall. Optionally, the notched section includes additional framing members or supports.

Multiple panels may be joined together as described above.

Subflooring (1525) may be attached to the top surface and be secured to the C-shaped framing members to which flooring (1530) may be attached.

Rodent barrier (1535) including for example FRP or similar may be installed on the lower surface of the panel.

FIG. 16 illustrates various connection of a floor assembly to insulated concrete form (ICF) foundations (1600) in accordance with one embodiment of the invention. (A) illustrates connection to ICF with drip edge (1605) and lumber ledger (1615). A C-shaped framing member (1610) is in the floor and is secured to the lumber ledge by appropriate brackets and flat plates (1620) which can be extended to connect to wall assembly. (B) illustrates connection to ICF using appropriate anchors (1630), lumber ledge, appropriate brackets and flat plates which can be extended to connect to wall assembly.

Roof Assemblies

The system is configured to provide roof assemblies. Referring to FIG. 17, each roof panel comprises EPS (Expanded Polystyrene) panel with parallel or co-planar, light gauge galvanized steel framing squared C-shaped framing members embedded on the upper surface and parallel or co-planar, light gauge galvanized I or H-shaped steel framing members embedded in the lower surface. Panel thickness is selected based on design and structural requirements. Openings in the panels may be provided for roof vents and chimneys.

The C-shaped framing members are oriented within the EPS such that the opening of the C-shape is to the interior of the panel. The I-shaped or H-shaped framing members are oriented such that the flanges are substantially parallel or co-planar with the surface of the panel. Size of the framing members including arm and flange size or thickness and webbing depth and size and thickness are dependent on design and structural requirements.

Optionally screws holes are provided in the framing members. Multiple panels may be joined together as described above.

Decking (1710) or strapping (1715) may be attached to the top surface and be secured to the C-shaped framing members to which roofing may be attached. Optionally, the C-shaped framing members are only partially inserted into the EPS panel to provide convention channels (1730). The top surface of the roof may be finished with means known in the art including shingles (1740) and steel roofing (1740). The bottom surface is optional finished with strapping and gypsum board (1735).

Weather proofing may be used as appropriate.

In some embodiments, referring to FIG. 18, the edges of panels that intersect with the walls are notched such that part of the roof is sunk into the outside wall.

Optionally, the tops of the walls are angled to match the angle of the roof. Alternatively, lumber pieces may be provided to fill in the angles.

In embodiments, where the roof has a ridge, panels which meet are angled to form a flush junction.

Brackets and metal straps attach the roof to the walls and roofing sections to other roofing sections. Ridge caps (as shown in FIG. 1(B)) and fascia may be provided.

To facilitate installation of wiring an air gap may be provided between the roof and the wall.

Referring to FIG. 19, optionally, clip-on eaves may be provided and secured using brackets and optionally adhesive.

Alternately, referring to FIG. 20, an eave may be provided by extending the framing elements past the edge of the EPS panel and attaching a front plate (2010).

Method of Manufacture:

In one embodiment, EPS panels are formed by hotwire machine cutting blocks to the appropriate size. Channels to insert the steel into, all slopes, angles and electrical chases are cut into the EPS panel prior to assembly. Framing elements and connections including brackets are formed from flat stock steel by shearing the steel and bending it into the required profile shape. Steel framing members are cut to length. Panels are assembled by inserted framing members into the EPS panel at the prescribed precut locations.

Kits

In some embodiments, kits including wall assembly, roof assembly and optionally floor, door and windows are provided.

At the installation site, the foundation is prepared, and the floor is installed. Exterior walls and supporting structural elements are installed. Any subsequent floors and roof, electrical and plumbing are installed. Interior and exterior are finished to design specifications.

Although the invention has been described with reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art without departing from the spirit and scope of the invention. All such modifications as would be apparent to one skilled in the art are intended to be included within the scope of the following claims.

Claims

1. A building envelope system comprising: a. an external wall comprising connected expanded polystyrene (EPS) wall panels having generally squared C-shape light gauge steel profile framing members inserted into both sides of the EPS panel, andb. a roof assembly comprising connected expanded polystyrene (EPS) roof panels having parallel or co-planar, light gauge galvanized steel framing squared C-shaped framing members embedded on the upper surface and parallel or co-planar, light gauge galvanized I or H-shaped steel framing members embedded in the lower surface.

2. The system of claim 1, wherein one or more wall panels comprise a door or a window opening.

3. The system of claim 1, wherein the wall panels are configured to withstand increased horizontal shear stress.

4. The system of claim 3, wherein each wall panels wall includes crossing straps on one or both sides.

5. The system of claim 3, wherein each wall panels wall includes metal sheeting.

6. The system of claim 1, wherein the C-shape light gauge galvanized steel framing members are rotated and partially inserted into one sides of the wall panel, thereby providing an air gap when gypsum wallboard is installed.

7. The system of claim 6, wherein the air gap is sized to receive the required depth of mineral/rock wool insulation for fire protection.

8. The system of claim 1, comprising a floor assembly.

9. The system of claim 8, wherein the floor assembly comprises connected expanded polystyrene (EPS) floor panels having parallel or co-planar, light gauge galvanized steel framing squared C-shaped framing members embedded on the upper surface and parallel or co-planar, light gauge galvanized I or H-shaped steel framing members embedded in the lower surface.

10. A building comprising the building envelope of claim 1 or 8.