Reinforced Structural Insulated Panel Wall System

Abstract

This invention is designed to allow one to build a structure quickly. The panels could be comprised of lightweight core material; such as Sing Core, U.S. Pat. No. 7,147,741. Each panel can have a solid wood frame and at least one layer of skin material on both sides of each panel. Skin material can be any flat building material or sheet materials; such as plywood, MDF, veneer, metals, plastics or fiberglass. Solid wood blocking can be placed wherever an anchoring point is needed. Panels can be joined together using tension cables/rods and/or dowels to create walls, floors, or a roof. Each panel in the wall, floor, or roof can have wiring, plumbing, HVAC ducting, or even vacuum ducting installed during manufacturing. Utility lines can be surface mounted to the base panel. This means that there is no need to drill studs to run any utility lines. Utility lines can be fabricated in the factory with outlets, switches, lights, and any other accessories installed where they are needed. This means that the utility lines will only need to be mounted to the wall, floor, or roof upon installation. No electrician will be needed on site for installation. This will solve the issue of having to drill and route utility lines through the wall studs. The walls can have furring strips fastened to the rough wall and the final wall skin can be applied to the other side of the furring strips. This allows fast and simple passage for the necessary utility lines.

Description

BACKGROUND OF INVENTION

The premise of the invention is to allow one to quickly build a tiny house or just add a wall, floor, or roof to an existing structure. Panels can have wiring, plumbing, HVAC ducting, or even vacuum ducting installed during manufacturing. This would allow one to simply connect each required system to the next panel and continue building the structure. Structures can be, but not limited to, tiny houses, folding houses, temporary warehouse or structure, emergency housing, room dividers, partition walls, and even permanent homes. This method can be used to replace conventional walls, such as 2″×4″ or 2″×6″ studs. These panels can be added to any type of conventional structural wall or can replace the wall all together, making it the structural wall and housing the utility lines.

Each panel is comprised of an insulated lightweight core; such as Sing Core, U.S. Pat. No. 7,147,741. Each panel can have a solid framing material, such as wood, metals, or extruded aluminum and can have solid blocking placed inside wherever an anchoring point is needed. Each panel has at least one layer of skin material on both sides of the panel. Skins are adhered using an adhesive and either hot or cold pressing until the adhesive is fully cured. Skin material can be made of any flat building material or sheet materials; such as plywood, MDF, laminates, veneer, metals, plastics, honeycomb panels, lightweight core panels, or even fiberglass. Panels can be joined with tension rods/cables, dowels, pressure block connection, biscuit, camlock or other type of connection method to accommodate the application. Temporary applications require connection methods that can be secured and unsecured for repeated assembly and disassembly, while permanent applications require connection methods with no intent of disassembly. Tension rods/cables can run through the interior of each panel for secure placement.

The panels can have solid wood blocking embedded wherever an anchoring point is needed. Small dimensional lumber, similar to furring strips, can be fastened or adhered to either the inside, outside, or both sides of the wall. The dimensional lumber could be any size needed and can be fastened in any orientation to the wall. The furring strips can be fastened to the rough, or unfinished, walls and the finished wall can be fastened to the other side of the furring strips. The furring strips can be made of lumber, metals, plastics, or other materials. The furring strips create a space for the necessary utility lines, like electrical wiring, plumbing, HVAC, or other utilities.

Conventionally, using stud framing, utility lines have to be ran through each stud. This takes much time and increased amounts of labor. With more modern Structural Insulated Panels (SIPs), the core of each panel has to be cut in the correct location for the utility lines to be hidden inside. This new invention can be used to simplify and reduce the amount of time and labor, especially skilled labor.

This new invention allows one to quickly create a building out of reinforced structural insulated panels, structural insulated panels, or any other type of core panel. Once the main structure is built, there is no need for drilling through studs or even the panel. The furring strips allow an easy and simple place to hide the necessary utility lines.

The outer skin attached to the furring strips reinforces the shear strength of the whole panel. Rain screen metal hangers can be fastened to the wall or furring strips.

SUMMARY OF INVENTION

The premise of the invention is to allow one to quickly build a tiny house or just add a wall to an existing structure. Panels can have wiring, plumbing, HVAC ducting, or even vacuum ducting installed during manufacturing. This would allow one to simply connect each required system to the next panel and continue building the structure. Structures can be, but not limited to, tiny houses, folding houses, temporary warehouse or structure, emergency housing, and even permanent homes. This method can be used to replace conventional walls, floors, or roofs such as 2″×4″ or 2″×6″ studs. These panels can be added to any type of conventional structural wall or can replace the wall all together, making it the structural wall and housing the utility lines.

Each panel is comprised of an insulated lightweight core; such as Sing Core, U.S. Pat. No. 7,147,741. Each panel can have a solid framing material, such as wood, metals, or extruded aluminum and can have solid blocking placed inside wherever an anchoring point is needed. Each panel has at least one layer of skin material on both sides of the panel. Skins are adhered using an adhesive and either hot or cold pressing until the adhesive is fully cured. Skin material can be made of any flat building material or sheet materials; such as plywood, MDF, laminates, veneer, metals, plastics, honeycomb panels, lightweight core panels, or even fiberglass. Panels can be joined with tension rods/cables, dowels, pressure block connection, biscuit, camlock or other type of connection method to accommodate the application. Temporary applications require connection methods that can be secured and unsecured for repeated assembly and disassembly, while permanent applications require connection methods with no intent of disassembly. Tension rods/cables can run through the interior of each panel for secure placement.

Conventionally, using stud framing, utility lines have to be ran through each stud. This takes much time and increased amounts of labor. With more modern Structural Insulated Panels (SIPs), the core of each panel has to be cut in the correct location for the utility lines to be hidden inside. This new invention can be used to simplify and reduce the amount of time and labor, especially skilled labor.

This invention allows one to quickly create a building out of reinforced structural insulated panels, structural insulated panels, or any other type of core panel. Once the main structure is built, there is no need for drilling through studs or even the panel. The furring strips allow an easy and simple place to hide the necessary utility lines

The panels can have solid wood blocking embedded wherever an anchoring point is needed. Small dimensional lumber, similar to furring strips, can be fastened or adhered to either the inside, outside, or both sides of the wall. The dimensional lumber could be any size needed and can be fastened in any orientation to the wall. The furring strips can be fastened to the rough, or unfinished, walls and the finished wall can be fastened to the other side of the furring strips. The furring strips create a space for the necessary utility lines, like electrical wiring, plumbing, HVAC, or other utilities.

This can use any kind of hardware to hang the outer walls. The outer or finished walls can easily be removed for easy access. This system can be applied to flooring and roofing. The additional lumber can increase the strength and insulation value while providing easy access to what lays beneath the surface. When used for exterior applications, this can provide ventilation to reduce the amount of moisture in contact with the structure. Any combination of furring strips and direct skin fastening can be used.

SHORT FIGURE DESCRIPTION OF DRAWINGS

FIG. 1 is a front view of a wall create by joining structural insulated panels.

FIG. 2 is a front view of the panel wall with the small dimensional lumber attached.

FIG. 3 is a front view of the panel wall with wiring running between the small dimensional lumber.

FIG. 4 is a front view of the panel wall with wiring running between the small dimensional lumber including sections removed for vertical wiring.

FIG. 5 is a front view of the panel wall with wiring, outlets, and a switch installed with the finished wall.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

This invention is comprised of reinforced structural insulated panels or any structural panels joined together as a wall FIG. 1. The panels can be permanently or temporarily joined by mechanical fasteners and/or an adhesive. Small dimensional lumber, like furring strips, can be fastened to the surface of the panel to either or both sides using mechanical fasteners or an adhesive FIG. 2. The small dimensional lumber can run horizontally or vertically. Necessary utility lines such as electrical wiring, plumbing, HVAC ducting, or other utility lines can be ran in between the small dimensional lumber FIG. 3. The small dimensional lumber can have cut outs or be fastened in sections to allow utility lines to run vertically FIG. 4. The finished wall can be fastened to the small dimensional lumber enclosing any utility lines behind the fastened wall FIG. 5.

Claims

1. This invention comprises of a wall created from structural panels with various types of core material. This could be hollow core, paper core, honeycomb core, foam core, or any other type of core materials.

2. In accordance with claim 1, the wall panels can be joined permanently, temporarily, or semi-permanently using mechanical fasteners, adhesives, or other means of fastening.

3. In accordance with claim 1, the wall can have small dimensional lumber, like furring strips, either horizontal or vertically fastened to the panels surface. The finished wall material can be fastened to the small dimensional lumber. The space created by the small dimensional lumber can be used to house necessary utility lines such as electrical wiring, plumbing, HVAC, or other necessary utilities.

4. In accordance with claim 1, the small dimensional lumber can be used for the interior or exterior side of the wall. The thickness of the small dimensional lumber can vary depending on the size of the utility line.