PANELS, SYSTEMS AND METHODS FOR INSULATED BUILDING WALLS

Abstract

A system for constructing an insulated building wall, includes a plurality of building panels, wherein a first level of building panels are installed below a frost line and the panels are installed adjacent and attached to other panels. The panels each have an insulated core attached between an interior sheathing and an exterior sheathing. The insulated core may be expanded polystyrene including graphite and may contain one or more steel studs. Each of the panels may be rectangular having two female edges and two male edges, wherein a male edge and a female edges of adjacent panels are for cooperatively attaching using fasteners. The walls may also have a top plate and a bottom plate, and may have strapping and cladding attached to the exterior sheathing.

Description

FIELD OF THE DISCLOSURE

The present disclosure relates generally to panels, systems and methods for constructing building walls, and in particular, to panels, systems and methods for constructing walls of insulated panels.

BACKGROUND

A building envelope generally provides separation between the interior environment and the exterior environment for a building structure, and may include all of the components relating to this separation including a roof, a foundation, exterior walls, windows, and doors. As climate can vary greatly between the interior environment and the exterior environment, a more effective building envelope can result in significant cost and energy savings. This may be especially evident depending on geographical location and the current season, where conditions including temperature, humidity, and other weather conditions may require greater isolation between the indoor and the outdoor environments.

The interior or indoor temperature of a building is generally kept at room temperature, which may be around twenty to twenty two degrees Celsius (20-22° C.). When the exterior or outside temperature is above room temperature, such as is the case in hotter geographical climates and/or during summer seasons, active cooling may be required. Active cooling may involve the use of heat exchangers or forced air mechanical units (such as air conditioners). When the outside temperature is below room temperature, such as in the case in cooler geographical climates and/or during winter seasons, active heating may be required. Active heating may involve the use of heating units that generally burn or combust wood, gas, and/or the like or use electricity to provide heat. In both the case of active cooling and active heating, additional resources are required with associated environmental and monetary costs.

Heat is transferred between the interior environment and the exterior environment through the building envelope. To minimize heat transfer through the building envelope, the building envelope includes insulating elements to minimize thermal conduction. Further, it is important to minimize the presence and size of thermal bridges in the building envelope, which are portions thereof which have a high thermal conductivity, as they may result in a disproportionate amount of thermal conduction relative to area or size. Preferably, the building envelope would provide a complete thermal break absent any thermal bridges. However, building elements such as doors and windows may introduce areas of reduced insulation and/or thermal bridges. Further, construction components, such as screws, bolts, nuts, and/or the like used to connect elements of the building envelope are commonly made of highly thermal conductive materials, such as steel.

Walls and ceilings/roofs are generally insulated to minimize thermal conductions. In some applications, such insulation may be provided by cladding affixed to the exterior of the building. In addition, the floor and/or foundation of a building may requires insulation to prevent being a thermal bridge and/or a source of high thermal conduction. The requirement to provide such insulation introduces increased construction complexity and associated costs.

SUMMARY

Embodiments of systems and methods disclosed herein provide panels, systems and methods for constructing an insulated building wall of a plurality of panels. Installation of a first level of the insulated building wall below a frost line may obviate the need to insulate the floor and/or foundation of a building. Each panel may comprise an insulated core attached between an interior sheathing and an exterior sheathing. The insulated core may be expanded polystyrene including graphite and may contain one or more internal steel studs. Each of the panels may be rectangular having two female edges and two male edges, wherein a male edge and a female edges of adjacent panels are for cooperatively attaching using fasteners. The walls may also have a top plate and a bottom plate, and may have strapping and cladding attached to the exterior sheathing. The use of prefabricated, modular panels provide a quick means to construct an insulated wall while providing storage and transportation advantages.

In some embodiments of the present disclosure, an insulated building panel for forming a portion of a building envelope of a building, the panel comprises: an insulated core; an interior sheathing attached to a first side of the insulated core, the interior sheathing for being installed facing an interior of the building; and an exterior sheathing attached to a second side of the insulated core, the exterior sheathing for being installed facing an exterior of the building, wherein the first side is opposite the second side, and wherein the insulated core is for providing a thermal break between the interior sheathing and the exterior sheathing.

Some embodiments of the present disclosure relate to a panel, wherein the insulated core is comprised of expanded polystyrene (EPS).

Some embodiments of the present disclosure relate to a panel, wherein the EPS comprises graphite.

Some embodiments of the present disclosure relate to a panel, wherein the insulated core comprises one or more internal studs.

Some embodiments of the present disclosure relate to a panel, wherein the one or more internal studs are comprised of steel.

Some embodiments of the present disclosure relate to a panel, wherein the interior sheathing and the exterior sheathing are each comprised of one or more of cement board, gypsum, and plywood.

Some embodiments of the present disclosure relate to a panel, wherein the panel is rectangular and comprises two female edges and two male edges, wherein each female edge is opposite a male edge, wherein each male edge is for cooperatively attaching to a female edge of another panel, and wherein each female edge is for cooperatively attaching to a male edge of another panel.

In some embodiments of the present disclosure, a system for constructing an insulated building wall, the system comprises: a plurality of building panels, each panel comprising an insulated core attached between an interior sheathing and an exterior sheathing, wherein a first level of building panels are for installation below a frost line, and wherein each panel is for installation adjacent to and attaching to one or more other building panels to form the building wall.

Some embodiments of the present disclosure relate to a system, wherein each of the insulated cores are comprised of EPS.

Some embodiments of the present disclosure relate to a system, wherein the EPS comprises graphite.

Some embodiments of the present disclosure relate to a system, wherein each of the insulated core comprises one or more internal studs.

Some embodiments of the present disclosure relate to a system, wherein each of the interior sheathings and the exterior sheathings are each comprised of one or more of cement board, gypsum, and plywood.

Some embodiments of the present disclosure relate to a system, wherein each panel is rectangular and comprises two female edges and two male edges, wherein each female edge is opposite a male edge, wherein each male edge is for cooperatively attaching to a female edge of another panel, and wherein each female edge is for cooperatively attaching to a male edge of another panel.

Some embodiments of the present disclosure relate to a system, wherein adjacent panels are attached at cooperatively attached female or male edges using fasteners.

Some embodiments of the present disclosure relate to a system, the system further comprises strapping attached to the exterior sheathing of the panels, and cladding is attached to the strapping.

Some embodiments of the present disclosure relate to a system, the system further comprises: a top plate installed along a top edge of the insulated building wall; and a bottom plate installed along a bottom edge of the insulated building wall.

In some embodiments of the present disclosure, a method for constructing an insulated building wall, the method comprises: installing a first level of insulated building panels below a frost line; and attaching one or more additional levels of insulated building panels above the first level.

Some embodiments of the present disclosure relate to a method further comprising installing a bottom plate, and wherein installing the first level comprises installing the first level on the bottom plate.

Some embodiments of the present disclosure relate to a method further comprising installing a top plate along a top edge of the insulated building wall.

Some embodiments of the present disclosure relate to a method further comprising attaching strapping to an exterior side of the wall, and attaching cladding to the strapping.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the disclosure, reference is made to the following description and accompanying drawings, in which:

FIG. 1A is a side view of an embodiment as disclosed herein of an insulated wall panel;

FIG. 1B is a front view of an embodiment of the insulated wall panel of FIG. 1A;

FIG. 1C is a detail view of a male edge and a female edge of the panel of FIG. 1A;

FIG. 2 is a front view of an embodiment of an insulated building wall comprising the panels of FIG. 1A;

FIG. 3 is a perspective view of an embodiment of an insulated building wall;

FIG. 4A is an illustration of a step of attaching a bottom plate to a stem wall of a foundation for the wall of FIG. 3;

FIG. 4B is an illustration of a step of fastening panels of the wall of FIG. 4A;

FIG. 4C is an illustration of a step of attaching a top plate to the wall of FIG. 4B;

FIG. 4D is an illustration of a step of attaching strapping to an exterior sheathing of the wall of FIG. 4C;

FIG. 4E is an illustration of a step of attaching metal cladding to strapping of the wall of FIG. 4D;

FIG. 4F is an illustration of a step of attaching parapet bracing to the top plate of the of the wall of FIG. 4E;

FIG. 4G is an illustration of a step of attaching adjoining parapet bracing of the wall of FIG. 4F;

FIG. 4H is an illustration of a step of attaching a parapet panel to parable bracing of the wall of FIG. 4G;

FIG. 4I is an illustration of a step of attaching roof strapping to exterior sheathing of the wall of FIG. 4H;

FIG. 4J is an illustration of a step of attaching a Q-Deck™ to the roof of the wall of FIG. 4I;

FIG. 4K is an illustration of a step of attaching roof panels to Q-Deck™ of the wall of FIG. 4J;

FIG. 4L is an illustration of a step of attaching metal roof cladding to the roof panels of the wall of FIG. 4K;

FIG. 5A is a perspective view of a roof supported by a column;

FIG. 5B is an alternative perspective view of a roof supported by a column; and

FIG. 6 is a flowchart illustrating the steps of a method of building an insulated wall.

DETAILED DESCRIPTION

Unless otherwise defined, all technical and scientific terms used herein generally have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. Exemplary terms are defined below for ease in understanding the subject matter of the present disclosure.

The term “a” or “an” refers to one or more of that entity; for example, “a terminal” refers to one or more terminals or at least one terminal. As such, the terms “a” (or “an”), “one or more” and “at least one” are used interchangeably herein. In addition, reference to an element or feature by the indefinite article “a” or “an” does not exclude the possibility that more than one of the elements or features are present, unless the context clearly requires that there is one and only one of the elements. Furthermore, reference to a feature in the plurality (e.g., panels), unless clearly intended, does not mean that the systems or methods disclosed herein must comprise a plurality.

The expression “and/or” refers to and encompasses any and all possible combinations of one or more of the associated listed items (e.g. one or the other, or both), as well as the lack of combinations when interrupted in the alternative (or).

In some embodiments disclosed herein, panels described are fabricated in a facility located away from a building construction site. The panels may be sized in a manner suitable for economical transportation to the building construction site, whereupon the panels may be installed to form insulated building walls. In some embodiments disclosed herein, the panels are carbon neutral as a result of using cement that is oxygen (O₂) negative, while curing.

Referring to FIG. 1A to FIG. 1B, in some embodiments disclosed herein, an insulated building panel 100 comprises an insulated core 102, an interior sheathing 104, and an exterior sheathing 106. The insulated core 102 is generally attached between or sandwiched between the interior sheathing 104 and the exterior sheathing 106. The interior sheathing 104 is attached to a first side 108 of the insulated core 102 and the exterior sheathing 106 is attached to a second side 110 of the insulated core 102, wherein the first side 108 and the second side 110 are on opposing sides of the insulated core 102.

The insulated core 102 may be comprised of any suitable building material having the required rigidity and insulating properties. In some embodiments disclosed herein, the insulated core 102 is comprised of expanded polystyrene (EPS). The EPS may be a grey EPS variation comprising graphite, which provides additional thermal properties than standard, white EPS variations. The insulated core 102 generally provides a thermal break between the interior sheathing 104, which is indoor interfacing, and the exterior sheathing 106, which is outdoor interfacing.

In some embodiments disclosed herein, the insulated core 102 may comprise an embedded supporting structure, such as one or more internal studs 112A, 112B. The internal studs 112A, 112B may have any suitable configuration or orientation, and may be formed of any suitable material such as steel, wood, and/or the like. The internal studs 112A, 112B may run parallel or they may intersect. The internal studs 112A, 112B may be located proximate edges of the insulated core 102 or any other position so that fasteners can be directly attached thereto providing additional strength and support for the panels 100.

The interior sheathing 104 may be comprised of any suitable material for use as an interior wall, such as cement board, gypsum, plywood, and/or the like. Similarly, the exterior sheathing 106 may be comprised of any suitable material for use as an exterior wall. As a result of being exterior interfacing, the exterior sheathing 106 may be required to be more weather resistant, such as cement board, outdoor gypsum, plywood, and/or the like. The exterior sheathing 106 may be treated for weatherproofing and/or have additional coverings attached thereto. The interior sheathing 104 and the exterior sheathing 106 may be comprised of a building material having a planar shape constructed in sheets, and are cut or formed to generally conform to the shape of the insulated core 102.

The panels 100 may be of any suitable shape. Referring to FIG. 1B, in some embodiments disclosed herein, a panel 100 is generally rectangular, wherein two edges are male and two edges are female. Referring to FIG. 1B and FIG. 1C, the panel 100 comprises a first male edge 120A, a second male edge 120B, a first female edge 120C, and a second female edge 120D. The first male edge 120A is configured to cooperatively attach to the first female edge 120C or the second female edge 120D of another panel. Similarly, the second male edge 120B is also configured to cooperatively attach to the first female edge 120C or the second female edge 120D of another panel. The first male edge 120A is generally arranged on the panel 100 opposite the first female edge 120C while the second male edge 120B is generally arranged on the panel 100 opposite the second female edge 120D. As shown in FIG. 1C, the first male edge 120A and the second male edge 120B comprise a protrusion 122A, 122B for insertion into a groove 124A, 124B. Adjacent panels 100 may be attached using one or more fasteners 126, which may be attached in an overlapping portion of the protrusion 122A, 122B and the groove 124A, 124B. A fastener may be a screw, a bolt, a nail, a rivet, and/or the like. The panels 100 have may pre-drilled holes or markings to indicate desired fastener 126 locations. As described above, these pre-drilled holes or markings may be used to ensure that the fasteners 126 are attached to any internal studs 112A, 112B present in the insulted core 102 for further structural integrity.

Referring to FIG. 2, in some embodiments disclosed herein, a system for constructing an insulated building wall comprises a plurality of insulated building panels 100. The panels 100 are cooperatively attached to adjacent panels 100 to form a wall 130. The wall 130 extends below the ground level 140 and past a frost line 142 or freezing depth. The frost line 142 is commonly understood to be the depth below the ground level 140 in soil that is expected to freeze. The frost line 142 of a particular geographical location is based upon historical information and may depend on climactic conditions prevalent in an area, heat transfer properties of the soil in the area, adjacent materials, and any nearby heat sources. Identifying the location of the frost line 142 is important for the construction of building as frost heaving caused by the formation and melting of frost above the frost line may cause damage to buildings by moving components of the building, such as the foundation.

The wall 130 comprises a first level 101 of panels 100 installed past the frost line 142 to prevent shifting of the wall due to frost heaving. Further, soil temperature below the frost line 142 is generally stable. By extending the wall 130 below the frost line 142, which is comprised of insulated wall panels 100, the soil within the perimeter of the wall 130 remains insulated from the surrounding area between the ground level 140 and the frost line 142, which may freeze. The floor level 132 of the building, which may be interfaced or proximate the ground level 140 is correspondingly insulated. In the event that frost extends past the frost line 142, in order for frost to reach the floor level 132, frost would need to extend past the frost line 142, around the wall 130, and back upwards towards the floor level 132. Upon the rare occurrence that frost extends past the frost line 142, seasonally warmer weather would generally obviate the concern of frost reaching around the wall 130 and to the floor level 132. A building constructed of walls 130 constructed in this manner would provide an envelope or shell, wherein interior interfacing elements of the walls 130 are thermally isolated from the exterior elements of the walls 130.

Referring to FIG. 3A, in some embodiments disclosed herein, a wall 130 comprised of interconnected panels 100 is installed upon a foundation 132. The foundation 132 may comprise a concrete slab 134, a concrete stem wall 136, and a concrete strip 138, which may each comprise rebar 140 to provide reinforcement thereof. The wall 130 may be constructed to any suitable dimensions using the requisite number of interconnected panels 100. In some embodiments disclosed herein, strapping 142 may be attached to the exterior sheathing 106 and metal cladding 144 may be attached to the strapping 142. The wall 130 may also comprise building wrap, fire resistant assemblies, and additional insulation. In some embodiments disclosed herein, the wall 130 may also comprise a bottom plate 148 attached to the wall 130 along a bottom edge, and a top plate 150 attached to the wall 130 along a top edge. A roof 160 may be installed atop the wall 130.

FIG. 4A to FIG. 4L illustrate steps of an exemplary installation of a wall 130. Referring to FIG. 4A, a bottom plate 148 is attached to a stem wall 136 of the foundation 132 using suitable fasteners. Suitable fasteners may include wedge anchors spaced apart at specified distances or locations on the bottom plate 148 or stem wall 136. For example, the fasteners may be spaced approximately forty-eight inches apart. Referring to FIG. 4B, panels 100 assembled above the bottom plate 148 are fastened to one another using suitable fasteners proximate mated male edges 120A, 120B and female edges 120C, 120D. In this instance, suitable fasteners may be cement board self-drilling screws. The panels 100 may be also be pre-drilled or marked for indicating desired locations of fasteners. Referring to FIG. 4C, a top plate 150 is fastened to the wall 130 using suitable fasteners. In this case, suitable fasteners may be cement board self-drilling screws. In some embodiments disclosed herein, two rows of fasteners may be used approximately twelve inches apart.

Referring to FIG. 4D, strapping 142 are attached to exterior sheathing 106 of the panels 100. The strapping 142 may be attached to the exterior sheathing 106 using fasteners, wherein the fasteners may be screws. It may be desirable for the fasteners to be attached to internal studs 112A, 112B of the panels. In some embodiments disclosed herein, the pieces of strapping 142 may be arranged parallel to one another and may run horizontally. The strapping 142 may be comprised of wood, steel, or any other suitable material. Alternatively, sheets of material may be used in place of strapping 142 or strapping may be omitted altogether. Referring to FIG. 4E, metal cladding 144 may be attached to the strapping 142 using suitable fasteners. The fasteners may be hex head sheet metal roof screws. Alternatively, metal cladding 144 may be directly attached to the exterior sheathing 106 including through internal studs 112A, 112B.

A roof 160 structure may be attached to the wall 130. Referring to FIG. 4F, parapet bracing 162 is attached to the top plate 150 using suitable fasteners. In this case, suitable fasteners may be hex washer self-drilling screws. Referring to FIG. 4G, parapet bracing 162 are attached to adjoining parapet bracing 162 with parapet bracing cross-members 164 using suitable fasteners. The fasteners may be screws spaced approximately twenty-four inches apart. Referring to FIG. 4H, a parapet panel 166 may be attached to the parapet bracing 162 using suitable fasteners. The fasteners used may be light-duty drill point fasteners. In some embodiments disclosed herein, the parapet panels 166 may be substantially similar to the panels 100. Referring to FIG. 4I, parapet strapping 168 are attached to exterior sheathing of the parapet panels 166 using suitable fasteners such as screws. Again, it may be desirable for the fasteners to be attached to internal studs of the parapet panels. In some embodiments disclosed herein, the pieces of parapet strapping 168 may be arranged parallel to one another and may run horizontally. Referring to FIG. 4I, metal parapet cladding 170 may be attached to the parapet strapping 168 using suitable fasteners. The fasteners may be hex head sheet metal roof screws. Referring to FIG. 4J, a Q-Deck™ 171 may be attached to the top of the parapet bracing 162 using suitable fasteners. In this case, the fasteners may be hex washer self-drilling fasteners that are spaced apart approximately every twelve inches.

Referring to FIG. 4K, roof panels 172 are attached to top of the Q-Deck™ 171 using suitable fasteners, which may be light-duty drill point fasteners. In some embodiments disclosed herein, the roof panels 172 may be substantially similar to the panels 100. Referring to FIG. 4L, metal roof cladding 174 may be attached to the roof panels 172 using suitable fasteners. The fasteners may be hex head sheet metal roof screws. FIGS. 5A and 5B illustrate some embodiments disclosed herein, wherein the roof 160 is further supported by a column 180 attached between the roof 160 and the foundation 132.

FIG. 6 is a flowchart showing the steps of a method 600, according to some embodiments of the present disclosure. The method 600 begins with installing building panels below a frost line (step 602). At step 604, one or more additional levels of insulated building panels are installed above the first level. Optionally, at step 606, a bottom plate is installed, and wherein installing the first level comprises installing the first level on the bottom plate. Optionally, at step 608, a top plate is installed along a top edge of the wall. Optionally, at step 610, strapping is attached to an exterior side of the wall, and cladding is attached to the strapping.

Although a few embodiments have been shown and described with reference to the accompanying drawings, it will be appreciated by those skilled in the art that various changes and modifications can be made to those skilled in the art that various changes and modifications can be made to these embodiments without changing or departing from their scope, intent, or functionality as defined by the appended claims. The terms and expressions used in the preceding specification have been used herein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof.

Claims

1. An insulated building panel for forming a portion of a building envelope of a building, the panel comprising: an insulated core;an interior sheathing attached to a first side of the insulated core, the interior sheathing for being installed facing an interior of the building; andan exterior sheathing attached to a second side of the insulated core, the exterior sheathing for being installed facing an exterior of the building,wherein the first side is opposite the second side, andwherein the insulated core is for providing a thermal break between the interior sheathing and the exterior sheathing.

2. The panel of claim 1, wherein the insulated core is comprised of expanded polystyrene (EPS).

3. The panel of claim 2, wherein the EPS comprises graphite.

4. The panel of claim 1, wherein the insulated core comprises one or more internal studs.

5. The panel of claim 4, wherein the one or more internal studs are comprised of steel.

6. The panel of claim 1, wherein the interior sheathing and the exterior sheathing are each comprised of one or more of cement board, gypsum, and plywood.

7. The panel of claim 1, wherein the panel is rectangular comprising two female edges and two male edges, wherein each female edge is opposite a male edge,wherein each male edge is for cooperatively attaching to a female edge of another panel, andwherein each female edge is for cooperatively attaching to a male edge of another panel.

8. A system for constructing an insulated building wall, the system comprising: a plurality of building panels, each panel comprising an insulated core attached between an interior sheathing and an exterior sheathing, wherein a first level of building panels are for installation below a frost line, andwherein each panel is for installation adjacent to and attaching to one or more other building panels to form the insulated building wall.

9. The system of claim 8, wherein each of the insulated cores are comprised of EPS.

10. The system of claim 9, wherein the EPS comprises graphite.

11. The system of claim 8, wherein each of the insulated core comprises one or more internal studs.

12. The system of claim 8, wherein each of the interior sheathings and the exterior sheathings are each comprised of one or more of cement board, gypsum, and plywood.

13. The system of claim 8, wherein each panel is rectangular and comprises two female edges and two male edges, wherein each female edge is opposite a male edge,wherein each male edge is for cooperatively attaching to a female edge of another panel, andwherein each female edge is for cooperatively attaching to a male edge of another panel.

14. The system of claim 13, wherein adjacent panels are attached at cooperatively attached female or male edges using fasteners.

15. The system of claim 8, further comprising strapping attached to the exterior sheathing of the panels, and cladding is attached to the strapping.

16. The system of claim 8, further comprising: a top plate installed along a top edge of the insulated building wall; anda bottom plate installed along a bottom edge of the insulated building wall.

17. A method for constructing an insulated building wall, the method comprising: installing a first level of insulated building panels below a frost line; andattaching one or more additional levels of insulated building panels above the first level.

18. The method of claim 17, further comprising installing a bottom plate, and wherein installing the first level comprises installing the first level on the bottom plate.

19. The method of claim 17, further comprising installing a top plate along a top edge of the insulated building wall.

20. The method of claim 17, further comprising attaching strapping to an exterior side of the wall, and attaching cladding to the strapping.