Patent Application
20050247013
1. Field of the Invention
The present invention relates generally to wall and roof panels for use in the construction of buildings and to methods and processes for manufacturing wall and roof panels and methods for assembling such wall and roof panels to form building structures. More particularly, the present invention concerns reinforced wall and roof panels having structural members embedded in a polymer/Portland cement matrix for structural integrity and fire resistance and a method for their manufacture at a manufacturing site and a method for their assembly at a construction site to form a building structure.
2. Description of the Prior Art
A number of different types of prefabricated building panels have been developed and patented since the early 1930's as indicated by U.S. Pat. No. 2,114,388 of Killion, thus enabling wall structures to be installed in buildings and enabling wall and roof structures, which may be manufactured or fabricated off site, to be transported to a building site and assembled to form a building structure. For the most part, prefabricated or pre-manufactured building panels have been manufactured by assembling a variety of different mechanical components
It is a primary feature of the present invention to provide a novel building panel for a building structure that includes a structural framework, preferably composed of steel and may also include panels of wire mesh for enhanced structural integrity and resistance to bending.
It is another feature of the present invention to provide a novel panel for building construction having structural components that are encapsulated in a polyurethane or other polymer composition, the polymer composition being composed of two-parts that are mixed and poured or injected into a mold containing the structural components.
It is also a feature of the present invention to provide a novel manufacturing process for building panels wherein a two-part polymer mixture, including a quantity of cement for flame spread resistance, is poured into a mold containing structural components and after hardening of the two-part polymer mixture, is removed from the mold in substantially complete condition for use in the construction of a building.
It is an additional feature of the present invention to provide a novel pre-manufactured building panel which is provided with an exterior or interior finish material or both as desired and which may be used, essentially as it emerges from the mold, for the construction of interior walls, exterior walls, roof panels and the like, without requiring any degree of interior or exterior finishing treatment.
It is another feature of the present invention to provide a novel roof panel for building construction wherein corrugated roofing metal, roofing metal of other desired configuration or non-metal roofing materials are placed within a mold along with other desired structural components of the panel and a two-part mixture of polyurethane and Portland cement are mixed and poured or injected into the mold so that the finished roofing panel from the mold has a weather resisting metal or non-metal skin as it emerges from the mold and is substantially ready for assembly with other building panels to form a building structure.
It is also a feature of the present invention to provide a novel manufacturing process for building panels wherein a press is provided to restrain panels of the mold so that during curing of the two-part polyurethane and Portland cement mixture the panels of the mold will be prevented from being forced outwardly by the tendency of the mixture to expand during curing, and ensuring that the finished building panel will have a precisely controlled configuration and dimension and further ensuring that the building panels can be readily fitted together to form a desired building structure.
It is an even further feature of the present invention to provide novel pre-fabricated panels that incorporate assembly hardware which is also embedded within the two-part polyurethane and Portland cement panel structure as the result of the panel molding process, thereby enabling the pre-manufactured reinforced building panels to be efficiently and accurately interconnected by relatively unskilled labor during building construction.
It is also a feature of the present invention to provide novel method for pre-manufacturing building panels, such as wall panels and roofing panels wherein structural components, optional wiring and plumbing components and a weather resistant panel are placed within a mold and the mold is placed within a press or restraining fixture and the mold is filled with a two-part polyurethane and Portland cement composition and the mold is restrained by the press or restraining fixture to ensure against deformation of the panel during hardening of the polyurethane and Portland cement composition.
Briefly, the pre-manufactured building panel system of the present invention uses an encapsulated wire mesh for durability. In addition, the pre-manufactured building panel is a pre-finished panel requiring no additional exterior finishes if desired. The pre-manufactured building panel system of the present invention utilizes an encapsulated metal framing member molded within the urethane body of the panel structure. An exterior or interior finishing substrate is located within the mold so as to become an integral component of the panel during the panel molding process. If the panel is intended as a roofing panel, the exterior finishing substrate may compose a metal sheet which may conveniently take the form of corrugated metal, sheet and rib metal or may take the form of a polymer roofing material or any other suitable type of roofing material.
To form the building panels of the present invention a polymer/Portland cement mixture is poured or injected into a mold in which is positioned reinforcing materials and installation hardware components and the exterior and interior substrate panels for the particular panel that is being molded. The polymer or urethane/Portland cement mixture is not of lightweight nature, as is typically the case with pre-manufactured building panels that are available at the present time, but rather with a 10# density urethane that is further mixed with a Portland cement for further characteristics of “flame spread” protection.
The mold is provided with one or more mold doors or closures that are opened to permit extraction of the finished panel. Immediately upon being filed with the polymer/Portland cement mixture or prior to filling of the mold, the mold is placed within a press or containment fixture which prevents dimensional expansion of the finished panel even under circumstances where the mixture expands during the preliminary curing or hardening process. After having become cured to the point that the polymer/Portland cement mixture has hardened, the dimensionally stable panel is removed from the mold and is transported to a site for completion of its curing process. Thus, the present invention represents a significant departure from conventional building panel systems which employ a light-weight urethane structure or employ a urethane encapsulating a core of lightweight polymer foam or other light-weight materials. The present invention also represents a significant departure from pre-manufactured building panels having external and internal finishing panels that are bonded or cemented to the typically cast or molded panel structures, for the reason that the external and internal finishing material are integral with the panel structure as it emerges from the mold. No additional panel finished surface treatment is required to make the panels ready for construction and no post construction panel treatment is required.
Steel reinforced polyurethane panels are manufactured, according to the principles of the present invention, from raw or resin state chemicals and Portland cement which together constitute a molding medium. Polyurethane chemicals are made up of two components, Part A and Part B. After a mold has been prepared with the necessary interior elements in place, along with any necessary release agents, primer and wax, the chemicals are first mixed separately with 25% Portland cement mix for improved hardness and reduced flammability. Then the Parts A and B of the molding medium are mixed together manually or with pneumatic head and injected or poured into the already prepared mold. Kraft paper or other suitable panel barrier material is then placed on the uncured, essentially liquid molding medium filling the mold. The mold lid is then placed over the mold and the mold is rolled into a press to secure the mold against deformation by any mold medium pressure that may occur during initial curing or rising of the molding medium. The mold lid confines the molding medium to the mold cavity and ensures maintenance of a desired cured molded body density within the poured panel. The molding medium begins to set during a period of from less than a minute to about two minutes after the parts A and B have been mixed. After approximately 20 minutes, the molding medium will have become hardened to the point that it can be removed from the mold. The mold is then removed from the press and opened and the finished, but not completely cured panel structure, is removed from the mold by lifting and handling equipment, such as a lift or crane mechanism. The mold is then prepared for molding of the next like panel structure. After approximately 48 hours from the time the partially cured panel or part has been removed from the mold, the panel is then primed and prepared for the final finish. For example, the panel may be provided with a surface covering of decorative and/or weather resistant material and the finished panel is then prepared for shipping.
Structural attachments for panel removal from the mold as well as for handling the finished panel are placed into the mold prior to pouring of the molding medium into the mold to form the reinforced panel structure. This allows for a safe and permanent attachment, not only for handling in the manufacturing area but also, and especially for, the panel installation process.
The structural requirements to accommodate both shear and wind load, are achieved by placing 2½ by 20 or 18 gauge metal studs directly into the interior of the panel and at predetermined locations within the mold. These studs are typically spaced at 16 inches on-center thus following pre-established framing criteria for building structures. The studs extend the entire length of the panel and provide the necessary screw attachment points for easy anchoring at the top and bottom tracks or channels.
Design support items such as electrical boxes, telephone junction boxes, electrical and plumbing conduits are preferably placed into the mold prior to pouring or injection of the molding medium. If desired, however, these building service components may be installed in assembly with the finished panel structure at the building site. This feature can be accomplished by cutting a vertical groove in a desired panel with a router for conduit or wire access and by attaching the electrical box directly to the framing member of the panel.
Prior to the introduction of a molding medium into the mold, a ½ by 8″ anchor-bolt is installed into the top of a stud member for eventual attachment of a roof truss member to the wall panels of the building structure. The roof truss is secured to the metal stud via a J-bolt passing through the truss and secured on top by a washer and corresponding nut. It should be noted that the finished wall and roof panels are not sheet laminated, as is the current practice, but rather emerge from the mold with all components, including exterior surface preparation, weather resistant materials and the like being integral components of the panel structure.
The finished reinforced wall panels are secured to a foundation slab or subsurface by a corresponding lower track that is fixed in place by bolt and pneumatic attachments. The track structure has upstanding spaced flanges and is secured to the vertical stud members by screwing each flange of the metal track to the studs on each side as is typically required for metal stud application. A similar upper track is positioned at the top of the assembled wall panels and is joined by screws which extend through the track flanges and into the metal studs of the wall panel structure.
The wall panels have tongue and groove connections and each joint between panels is secured by a double-stick neoprene gasket which establishes positive sealing between adjacent panels at the tongue and groove joints. The joints are then caulked with an acceptable and corresponding calking compound on the inside and outside of each vertical panel joint.
Prior to installation of a wall panel, the bottom track is installed on top of a flashing that protect the interior finishes from any moisture infiltration if any moisture migrates through the joints. The bottom track or plate is secured through the flashing by bolt application and pneumatic pin attachment procedures for concrete and by bolt and screw attachment if the subfloor is a wood member or plywood substrate.
From the standpoint of specific finish and performance, the panels can be pre-finished per the end user selections from an array of designs and colors with an exterior grade paint or elastomeric coating. Additional textures, i.e., shell stone texture, simulated stone, brick or any other item that requires the surface to have “relief” more than just flat can be achieved in the mold. These textures are poured into the mold prior to any finish panel manufacturing. These “pre-finished applications” allow for very low installation durations and lend to quick occupancies of the building structures.
The inherent characteristics of the polyurethane lends to heating and cooling efficiencies determinable upon final completion and determination of the total cubic feet and layout of space. Also, finish elements such as windows and doors can be pre-installed in door and window panels as received from the panel manufacturer or factory and can be shipped for quick panel installation and erection.
The pre-manufactured, reinforced roof panels are made up with sheet metal roofing, such as corrugated sheet metal, on the top side and bottom side or reinforced sheet wiring on the bottom side. Both the metal roofing sheets and the wire mesh panels are placed into the mold prior to introduction of the molding medium and are thus integral components of the reinforced roof panels. The roof panels can be used with the corrugated metal finish on the outside and perform as shingles or with the corrugation facing downwardly and a selected finish shingle placed over the roof panel and secured thorough the panel to the sheet metal below with necessary screw attachment. The roof panels are a minimum of 2″ thick and have male and female tongue and groove joint attachments similar to that of the vertical wall panels. Lap joints are secured to each other by conventional methods of screwing overlapping sheet joints with screws and washers.
Overall, this designed steel reinforced polyurethane panel system lends to a very quick and clean installation, erection and occupancy for any builder or end user. With the optimum performing characteristics of insulating, sound resistance, non moisture absorbing, low flame spread and non-wood characteristics, the steel reinforced polyurethane panel system provides optimum performance in all areas of installation and operation.
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the preferred embodiment thereof which is illustrated in the appended drawings, which drawings are incorporated as a part hereof.
It is to be noted however, that the appended drawings illustrate only a typical embodiment of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
In the Drawings:
Referring now to the drawings and first to the isometric illustration of
Each of the pre-manufactured reinforced wall panels defines an upper connection section 28 on which is received a wall alignment cap 30 in the form of a generally U-shaped channel member which may, if desired, be substantially identical to the panel bottom mounting channel 22. Screws, bolts or any other suitable fasteners 32 are employed to secure the channels 22 and 30 to respective bottom and top connection sections 24 and 28 of the pre-manufactured reinforced panel structures. The specific structure of the wall panels of the present invention are described in detail herein below in connection with the method or process by which the wall panels are pre-manufactured by a molding process of the present invention that is described in detail.
For connection of a roof structure shown generally at 34 to the building 10, the pre-manufactured reinforced wall panels 26 will have roof mounting hardware integral therewith and projecting therefrom. The pre-manufactured reinforced wall panels 26 are also provided with lifting and handling hardware, enabling the hardened panels to be removed from a mold and moved to a curing site for complete curing of the molding medium and then handled by equipment during transportation to a construction site and further handled during installation on a foundation at the construction site. As shown particularly in
A plurality of pre-manufactured roof panels, shown generally at 46, are supported by and fixed to the roof rafters 42 and may have interior surface treatment 48, such as an integral decorative or moisture proofing panel that is an integral component of the roof panel as pre-manufactured, thus ensuring that post-installation surface treatment of the roof panel is not required under circumstances where the roof panels are intended to be exposed internally of the building structure. The pre-manufactured roof panels are provided with an integral weather resistant exterior surface material 50 which, in the preferred embodiment, is preferably a metal panel, such as corrugated galvanized sheet steel or galvanized standing seam galvanized metal roofing material. For purposes of the present invention, and for simplicity of understanding of the present invention, the various figures of the drawings illustrate the weather resistant exterior surface material 50 as being corrugated steel roofing panels. The specific structure of the roof panels of the present invention are described in detail herein below in connection with the method or process by which the roof panels are pre-manufactured by a molding process that comprises a part of the present invention.
The eves of the building structure 10 are finished in the manner shown in
The wall panel structure 26 also defines a bottom trim recess 60 which is provided to receive a bottom trim panel 62 which is fixed to the wall panel 26 by panel adhesive and means of fasteners of any suitable character. The bottom trim panel defines an outwardly spaced depending section 64 that is spaced from and extends downwardly beyond the wall panel bottom mounting channel 22 and extends near the bottom edge of the wall mounting foundation strip 14. The bottom trim panel ensures that water descending along the exterior surface of the wall panel structure does not enter the panel/foundation joint.
The pre-manufactured wall panels 26 are reinforced by means of internal structural members such as metal or non-metal wall panel studs 66 that are molded within the wall panels during the panel molding process. The wall panel studs 66 are of generally rectangular configuration and have a U-shaped cross-sectional configuration being defined by generally parallel stud flanges 63 which are integral with and extend from opposite sides of a central stud web 65. The central stud web defines a plurality of stud web openings 67 that permit the polyurethane and Portland cement molding medium to extend through them and establish mechanically interlocking or integral relationship with the wall studs, further ensuring the structural integrity of the pre-manufactured reinforced wall panel structure. As shown best in
The pre-manufactured reinforced wall panels are also reinforced by one or more panels of structural mesh material 71 which is completely embedded within the polyurethane and Portland cement body structure of the wall panels and is located in spaced and substantially parallel relation with the outer planar surface of the wall panels. Preferably, the structural mesh material comprises wire mesh, preferably steel wire mesh, but may be composed of expanded metal panels or porous panels of non metal material having desired structural integrity for desirably enhancing the structural integrity of the reinforced wall panels. If desired, as shown in
Referring now to the isometric illustration
Referring now to
To provide for efficient roof structure support at the exterior corners of the building structure, as shown in
Though corner wall panels may be oriented at 90° as shown in
The corner wall panels 118 and 120 are oriented at an angle less than 90° as is evident from
The exterior corners of the building structure, as shown in
To provide an external closure for a panel joint space 164 that is defined by the corner wall panels 154 and 156 an angled closure strip 166 is positioned with opposed flanges overlapping the ends of the corner wall panels 154 and 156 as shown. The opposed flanges are disposed and the same relative angles as the angular relations of the wall panels. Fasteners 168, such as screws extend through the angulated flanges of the corner wall panels and affix the angled closure strip to respective corner wall panels. One of the corner wall panels will typically be provided with an anchor member 36, such as an anchor bolt which has a lower laterally extending anchor end 38 embedded within the polyurethane and Portland cement body thereof during the molding process for the corner wall panel.
Each of the corner wall panels 154 and 156 define exterior trim recesses 168 and 170 that receive opposite side portions of an exterior corner trim member 172. The exterior corner trim member 172 also defines an interior angulated recess 174 within which the angular panel joint strip member 166 is located. The exterior corner trim member 172 also defines corner projection flanges 176 and 178 that are disposed in overlapping relation with exterior side portions of the respective corner wall panels 154 and 156. In the same manner as the corner trim members of
The isometric illustration of
Referring now to
Referring now to
Window frame members 234 and 236 of rectangular cross-sectional configuration have mounting flanges through which fasteners 240 such as nails or screws extend for securing the window frame members to the reinforced window panel wall 224 as best seen in
The reinforced window panel wall 224 defines a rectangular window trim recess 246 within which one or more exterior window trim members 248 is seated. The window trim members are fastened in place by nails or screws and panel adhesive and are applied with joint seal cement to cement the exterior trim members in place and to seal any joints that might otherwise permit leakage of air into or out of the building. The fasteners provide for temporary fastening of the window trim members until the joint seal cement has become cured. The window trim members define internal window frame recesses 250 that accommodate the thickness of the mounting flanges 238 and the heads of the fasteners 240.
As mentioned above, it is a feature of the present invention to provide pre-manufactured reinforced wall and roof panels that are transported to a building site and used for rapid, low cost construction of buildings. It is also a feature of this invention to provide pre-manufactured reinforced wall and roof panels that include exterior weather resistant materials that are made integral with the panels by a molding process so that installation of the various wall, door, window and roof panels will result in a building structure that needs no exterior preparation in order to constitute a weather resistant building. As is evident from
The weather resistant roof panel member 256 is shown in
Panel Pre-Manufacturing Method
An important aspect of the present invention is the method or process by which the pre-manufactured wall and roof panels are manufactured. As indicated by the simplified partial cross-sectional illustration of
The molding method or process is initiated by fixing the structural members, such as wall studs, wall frame members, door or window frame members, wire mesh or expanded metal reinforcing panels, roof anchor members and the like within the mold cavity 284. In this regard, it is to be understood that different molds or mold alterations will be utilized for molding the various wall, door, window and roof panels due to the need for fixing the reinforcing components, door frames, window frames an the like within the respective molds. A mold is then filled with a molding mixture or composition composed of two part polyurethane and Portland cement and the filled mold is subjected to further treatment, such as vibration, to ensure intimate contact of the molding mixture or composition with the reinforcing components of the panel structure and with the internal wall surfaces of the mold walls 276 and 278.
Either before or after the mold cavity 284 is filled with the molding mixture or composition, the mold is placed within a mold press shown generally at 286 having relatively moveable press wall members 288 and 289. If desired, the press wall member 289 may be a fixed wall and the press wall member 288 may be a moveable wall which is employed to apply sufficient force to the mold wall 276 to prevent transverse movement of one or both of the mold walls 276 and 278 by any internal force that may be developed within the mold cavity, such as by expansion of the molding mixture or composition 282, by hydrostatic pressure of the molding medium or by the injection pressure of the molding medium. By restraining the mold walls 276 and 278 as the molding medium is becoming cured, the finished dimensions of the resulting pre-manufactured panel will be accurately maintained and thus the panels may be easily assembled to form a building structure.
To impart mechanical pressure or force to the mold walls or to resist movement of the mold walls a number of force applying systems may be employed. As shown in
After the molding mixture or composition 282 has become sufficiently cured so that it has become hardened and its physical dimensions have become stabilized, though the pre-manufactured panel has not become completely cured, the mold press is retracted sufficiently to permit the mold to be removed. If desired, the mold, with the partially cured wall or roof panel inside, may be transported to a curing site for further curing. Alternatively, if the wall or roof panel has become sufficiently cured for removal from the mold, the mold is opened and the wall or roof panel is extracted. The partially cured, dimensionally stabilized wall or roof panel will then be moved to a site for further curing and the mold is then prepared for molding of another like wall or roof panel. Pre-manufacturing of numerous substantially identical wall and roof panels are pre-manufactured in this manner at a panel manufacturing site. Subsequently, the wall and roof panels are transported to a construction site having one or more foundations and are simply and efficiently installed to form building structures. These pre-manufactured wall and roof panels are especially useful when temporary housing is needed to accommodate conditions caused by a natural disaster or to accommodate the urgent human needs of a locality.
In view of the foregoing it is evident that the present invention is one well adapted to attain all of the objects and features hereinabove set forth, together with other objects and features which are inherent in the apparatus disclosed herein.
As will be readily apparent to those skilled in the art, the present invention may easily be produced in other specific forms without departing from its spirit or essential characteristics. The present embodiment is, therefore, to be considered as merely illustrative and not restrictive, the scope of the invention being indicated by the claims rather than the foregoing description, and all changes which come within the meaning and range of equivalence of the claims are therefore intended to be embraced therein.
