US20090100780A1 - Structural insulated panel system - Google Patents
Structural insulated panel system Download PDFInfo
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- US20090100780A1 US20090100780A1 US11/875,307 US87530707A US2009100780A1 US 20090100780 A1 US20090100780 A1 US 20090100780A1 US 87530707 A US87530707 A US 87530707A US 2009100780 A1 US2009100780 A1 US 2009100780A1
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- United States
- Prior art keywords
- panel
- frame member
- siding
- vertical
- corner panel
- Prior art date
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Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
- E04B1/14—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/386—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a frame of unreconstituted or laminated wood
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/38—Connections for building structures in general
- E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
- E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
- E04B1/612—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces
- E04B1/6145—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with recesses in both frontal surfaces co-operating with an additional connecting element
- E04B1/6162—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with recesses in both frontal surfaces co-operating with an additional connecting element the connection made by an additional locking key
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
- F25D23/00—General constructional features
- F25D23/06—Walls
- F25D23/062—Walls defining a cabinet
- F25D23/063—Walls defining a cabinet formed by an assembly of panels
Definitions
- the present invention relates to a structural insulated panel.
- the present invention relates more particularly to a structural insulated panel system for assembling an insulated enclosure.
- the present invention relates more particularly to a prefabricated structural insulated panel system that is quickly and easily assembled and readily accommodates tolerance variations.
- insulated panels or walls for temperature controlled storage areas (e.g. walk-in coolers, etc.) or for other structures or enclosures where a thermal boundary is desired.
- Such known walls or panels typically include wall or paneling structures where a layer of an insulation material is installed (e.g. blankets, sheets, etc.) within a cavity of a wall during construction of the wall or structure, or is applied (e.g. spraying a foam material, etc.) to a surface of the wall or structure after construction is complete.
- a structural insulated panel system that provides pre-fabricated structural insulated panels that connect to one another rapidly, conveniently, and having improved strength and air-tightness qualities.
- a structural insulated panel system includes a frame including a first vertical frame member and a second vertical frame member and a top frame member and a bottom frame member.
- a first siding member is attached to one side of the frame and a second siding member is attached to an opposite side of the frame to form a cavity and an insulation material is provided within the cavity.
- a tongue portion includes a projection formed from the first vertical frame member disposed laterally outward from one vertical edge of the first and second siding members.
- a groove portion includes a recess formed from the second vertical frame member disposed laterally inward from an opposite vertical edge of the first and second siding members, so that the tongue portion from one panel is configured to mate with the groove portion of another panel to provide an assembly of multiple panels.
- a prefabricated structural insulated panel includes a frame and a first siding member attached to a first side of the frame and a second siding member attached to a second side of the frame, and an insulation material provided within a cavity formed by the frame and the first and second siding members.
- the frame includes a first vertical member positioned outwardly of a vertical edge on one side of the first and second siding members to form a tongue portion, and a second vertical frame member is positioned inwardly of a vertical edge on an opposite side of the first and second siding members to form a groove portion.
- a method of making a structural insulated panel system includes the steps of providing a frame including a first vertical frame member and a second vertical frame member and a top frame member and a bottom frame member, attaching a first siding member to one side of the frame and attaching a second siding member to an opposite side of the frame to form a cavity, injecting an insulation material into the cavity, positioning the first vertical member outwardly of a vertical edge on one side of the first and second siding members to form a tongue portion, and positioning a second vertical frame member inwardly of a vertical edge on an opposite side of the first and second siding members to form a groove portion.
- FIGS. 1A-1B are schematic images of a perspective view of a conventional structural insulated panel and connection device.
- FIG. 2A is a schematic image of a front elevation view of a structural insulated panel according to an exemplary embodiment.
- FIG. 2C is a schematic image of a cross sectional view of a structural insulated panel along lines 2 C- 2 C in FIG. 2A , according to an exemplary embodiment.
- FIG. 2D is a schematic image of an exploded perspective view of a structural insulated panel assembly according to an exemplary embodiment.
- FIG. 3A is a schematic image of a perspective view of a structural insulated corner panel assembly according to an exemplary embodiment.
- FIG. 3B is a schematic image of a cross sectional view of a structural insulated corner panel assembly along lines 3 B- 3 B in FIG. 3A , according to an exemplary embodiment.
- FIG. 3C is a schematic image of a cross sectional view of a structural insulated corner panel assembly along lines 3 C- 3 C in FIG. 3A , according to an exemplary embodiment.
- a structural insulated panel system 100 for use in assembling an enclosure e.g. walk-in cooler, refrigerated storage area, etc.
- an enclosure e.g. walk-in cooler, refrigerated storage area, etc.
- other type of structure e.g. residential, commercial, industrial, institutional, etc.
- the panels are prefabricated with a frame and siding arrangement that permits rapid and secure assembly of the panels to one another (e.g. in a “plug-and-play” type manner, etc.).
- the system includes a first type of panels intended for use in planar segments of an enclosure, such as for assembling walls, ceilings, roofs, etc., and a second type of panels intended for use in assembling corners or other suitable junctions between the walls, ceiling, or roof of the enclosure.
- the panels may be provided in a wide variety of sizes (e.g. height and width) that may be provided as “standard” sizes (such as within a range of six inches to 48 inches wide, and 8 to 10 feet high) or may also be provided in a wide range of custom order sizes (such as up to 12 feet wide and up to 16 feet high) intended to suit a particular application.
- the panels may also be provided in various thicknesses as “standard” thicknesses corresponding to a range of desired thermal performance characteristics, or may be provided in custom thicknesses intended to suit a particular application.
- the thickness of the panels may be varied by changing the thickness of either or both of the siding and the frame.
- the system is shown and described by way of example as having rectangular shaped panels and right-angle corners, the system may be used with any of a wide variety of shapes and corner assembly configurations.
- the panels may be modified for use in particular areas of the enclosure, such as for use as roof panels, etc. Accordingly, all such modifications are intended to be within the scope of the invention as disclosed in reference to the embodiments illustrated and described herein.
- the conventional panels 10 are shown to include structural frame pieces 12 that are flush with the edges of the siding portion 14 of the panels.
- the conventional connection device includes two wooden strips 16 (e.g. “splines”) that are inserted within slots 18 provided along the frame pieces at the adjoining edge of each of the panels. The strips are then fastened to each of the panels (e.g. by nails or screws) to hold the panels together.
- the conventional panels and connection devices are generally difficult and time-consuming to assemble, and do not provide a desired ease-of-construction.
- the conventional panels are also generally not well suited to adjusting the width of the panels, for example when necessary to accommodate tolerance stack up when combining multiple panels together, or when necessary to accommodate the size requirements of the installation location.
- the conventional panels often require extending the width of the strips between two or more panel joints to expand the width of the panel installation, and then filling the gap between the ends of the panels with a filler or spacer, which tends to weaken the strength and sealing quality of the joint(s).
- the conventional panels When reduced width is desired, the conventional panels often require cutting or trimming the adjoining edges of one or more panels to remove a desired width (which results in the slots becoming more shallow), and then cutting or trimming the strips to fit within the shallower slots to reduce the overall width of the panel installation, which tends to weaken the strength and sealing quality of the joint(s).
- Panels 110 are shown to include a frame 112 having first and second vertical frame members 113 , 114 and a top frame member 115 and a bottom frame member 115 a , a first siding member 116 , a second siding member 120 , and an insulation fill material 130 , and connection devices.
- the frame 112 is formed from structural members, such as “2 ⁇ 4” wood lumber, although other size lumber (e.g.
- the frame 112 is also shown formed in the shape of a rectangle having two vertical and two horizontal structural members, each located generally along a perimeter of the panel. However, additional (i.e. internal) structural members may be included (e.g. within the perimeter and extending side-to-side and/or top-to-bottom and/or corner-to-corner) to provide additional structural support as desired for a particular application.
- the structural members of the frame may be provided by high density foam rails, particularly where exceptional insulating performance is desired.
- the rails may be provided from a material such as steel, aluminum, or suitable composites, particularly where increased strength is desired or higher fire rating is desired.
- First and second siding members 116 , 120 are attached on opposite sides (e.g. front and back, inside and outside, etc.) of the frame 112 to provide a structural panel having a cavity 118 defined by the siding members 116 , 120 and the frame 112 (or multiple cavities in the event that the panel includes one or more internal structural members).
- the siding members may be provided as any type of siding having a desired strength and appearance for a particular application.
- the siding members are oriented strand board (OSB) having a thickness of approximately 7/16 inches (or other thicknesses as determined by performance specifications for a particular enclosure), but may be other types of panels or siding having any suitable thickness and desired architectural appearance to provide a desired thermal, fire and/or environmental boundary performance and appearance for use in a particular application.
- OSB oriented strand board
- the siding members may include (or be formed from, or have applied thereto) a fire resistant or fire retardant material, and/or an antibacterial or antimicrobial treatment.
- multiple skin options may be used with varying materials and/or thicknesses to provide specific or custom-tailored thermal, fire, or environmental performance boundaries.
- the siding members may be attached to the frame using any suitable method and components such as nails, screws, staples, adhesive (glue, etc.) or combination thereof, to provide a panel “shell”.
- the cavity(ies) 118 of the shell are then filled with the insulation material 130 to provide the first type of structural insulated panel.
- the insulation material is a polyurethane foam that is injected into the cavity(ies) through a suitable small hole (not shown) cut or drilled into one of the siding members at a location corresponding to a generally central location of the cavity.
- the polyurethane foam is injected into the one or more cavities to provide a desired density corresponding to the desired thermal performance characteristic of the panel.
- the density of the insulation foam material is within a range of approximately 2.0-2.6 pounds per cubic foot.
- connection device 140 for joining the structural insulated panels 110 of the system 100 is shown according to an exemplary embodiment.
- Connection device 140 includes a projection (e.g. tab, male portion, etc. —shown as a tongue portion 142 ) and a receptacle (e.g. pocket, recess, female portion, etc. —shown as a groove portion 144 ) that are integrally formed as part of the panel 110 through an arrangement of the frame members 113 , 114 and siding members 116 , 120 relative to one another.
- a projection e.g. tab, male portion, etc. —shown as a tongue portion 142
- a receptacle e.g. pocket, recess, female portion, etc. —shown as a groove portion 144
- Tongue portion 142 having a width A is formed by placing or extending one vertical frame member 114 laterally outward a distance B beyond the side edges 117 , 121 of siding members 116 , 120 .
- the frame member 114 may be located laterally outward and beyond the side edges 117 , 121 , in which case extension members 126 (e.g. spacers, bridges, etc.) may be provided to extend the location of the frame member 114 beyond the side edges 117 , 121 .
- the outwardly extending frame member may overlap the side edges and be attached directly to the siding members.
- multiple vertical frame members may be used (e.g.
- the outward vertical edges on frame member 114 may be beveled or chamfered to enhance the ease of tongue and groove assembly of the panels during field construction.
- Groove portion 144 having a width C is formed by placing or retracting (e.g. insetting, etc.) the vertical frame member 113 laterally inward a distance D within the side edges 118 , 122 of siding members 116 , 120 .
- width A is approximately 31 ⁇ 2 inches and distance B is approximately 17 ⁇ 8 inches and width C is approximately 31 ⁇ 2 inches and distance D is approximately 2 inches.
- the distance dimensions for the tongue and groove portions may be within the range of approximately 1 ⁇ 2 inch to 6 inches.
- each panel is shown to also include a horizontal groove portion 128 along a bottom of the panel 110 for use in positioning and retaining the panel over a sill plate (or other suitable structure—not shown) at the field installation location.
- the bottom frame member may also include a dado (e.g. groove, trench, slot, recess, etc.) to adapt the panel for sill plate bolt/nut clearance.
- each panel 110 are also configured to accommodate the need to expand or contract the overall width of an assembly of panels.
- a reduction in panel width may be accomplished by cutting-off up to 1 inch from the outward face of vertical frame member 114 of tongue portion 142 and cutting the same amount from the edges 118 , 122 of the siding members 116 , 120 extending from the groove portion 144 on the adjoining panel 110 and assembling the two panels 110 together.
- an expansion in panel width may be accomplished by attaching up to 1 inch of filler material (e.g.
- a strip or gap may remain between the siding members on the two panels corresponding to the thickness of the filler material in the groove portion, which may be readily filled with a strip of siding material.
- the connection device 140 may also include a retractable fastener 150 , such as a cam-lock type connector for drawing together and locking the tongue portion 142 and groove portion 144 into engagement with one another.
- the retractable fastener 150 includes a hook-and-pin device where a pin 152 is recessed into the vertical frame member 114 of the tongue portion 142 and a retractable hook 154 is recessed into the vertical frame member 113 of the groove portion 144 .
- the hook 154 may be extended and retracted using a suitable tool, such as a T-wrench or hexagonal wrench extended through a suitable access hole (not shown) cut or drilled into the siding member 120 and frame member 113 to extend and retract the hook 154 .
- a suitable tool such as a T-wrench or hexagonal wrench extended through a suitable access hole (not shown) cut or drilled into the siding member 120 and frame member 113 to extend and retract the hook 154 .
- the retractable fastener 150 is a Kason PanelockTM fastener commercially available from Kason Industries, Inc.
- the orientation of the pin and the hook on the tongue and groove portions may be reversed, and multiple retractable fasteners may be provided on each of the tongue and groove portions to provide increased strength and air tightness at the joint between the panels.
- Two or more of the structural insulated panels 110 may be assembled together by mating (e.g. joining, nesting, connecting, etc.) the tongue portion 142 and groove portion 144 of adjacent panels 110 to provide an extended assembly of multiple panels such as may be used for a wall, floor, ceiling or roof of an enclosure.
- the siding members 116 , 120 corresponding to the groove 144 of the second panel 110 overlie the vertical frame member 114 of the tongue portion 142 on the frame 112 of the first panel 110 .
- the hook 154 from one panel 110 is extended and placed in position over the pin 152 on the other panel 110 as the tongue and groove portions 142 , 144 are joined, then a suitable tool is inserted through an access hole (not shown) in one of the siding members to actuate the hook 154 to a closed position that captures and draws the pin 152 to “pull” and lock the two panels 110 together into a tight fitting engagement.
- the access hole may be subsequently filled with a suitable insulating material.
- the panels may then be more permanently joined by fastening the siding members 116 , 120 of the groove portion 144 to the vertical frame member 114 of the tongue portion 142 using suitable components (e.g. nails, screws, staples, adhesives, etc.).
- suitable components e.g. nails, screws, staples, adhesives, etc.
- a layer e.g. “bead”, etc.
- a sealant may be provided along the height of the vertical frame member 114 of tongue portion 142 and/or the vertical frame member 113 of groove portion 144 to enhance the air-tightness of the joint between the panels 110 (e.g. in the manner of a gasket or weather-strip or the like).
- the sealant may be an adhesive material or have adhesive qualities, and may also have desired thermal insulation properties.
- the sealant is a polyurethane foam material that may be compressed between the tongue portion 142 and the groove portion 144 during assembly of the panels 110 to one another.
- Corner assembly 160 includes a first corner panel 162 and a second corner panel 180 .
- First corner panel 162 and second corner panel 180 are similar to panel 110 as previously described (including an insulation fill material 130 ), but include additional features adapted to form a corner assembly.
- First corner panel 162 includes a groove portion 164 on one vertical side (shown as a “free” side, adapted to engage a tongue portion 142 from a panel 110 in a wall section of an enclosure), and a tongue portion 166 on an opposite vertical side, where the tongue portion 166 is formed by an extension of siding member 168 that extends beyond vertical frame member 172 .
- the second corner panel 180 includes a tongue portion 182 formed from a vertical frame member 192 on one vertical side (shown as a “free” side, adapted to engage a groove portion 144 from a panel 110 in a wall section of an enclosure), and a flat surface 184 on an opposite vertical side, where a frame member 186 is generally flush with the edges of the siding members 188 , 190 .
- first and second corner panels 162 and 180 are readily assembled by mating the flat surface 184 of the second corner panel 180 with the tongue portion 166 of the first corner panel 162 , and joining them with suitable fastening components (as previously described).
- the free side of the first and second panels may be provided with either a tongue portion or a groove portion as appropriate for mating with other panels of the enclosure.
- the first and second corner panels of the corner assembly may also include retractable fasteners as previously described.
- the structural insulated panel system provides a system of panels for use in planar segments and corner assemblies of an enclosure having a thermal boundary, and connectors that are provided as integral members of the prefabricated panel.
- the panels are formed as a single integrated unit to include a frame and siding members that are arranged to form a tongue and groove portion on each panel.
- the tongue and groove members of the frame and the siding members form a shell with one or more cavities that are filled with a thermal insulation material to provide stand-alone panels that are readily connectable to one another in a simplified and expedient manner.
- the panels of the assembly are conveniently and readily assembled into a desired structure or enclosure by mating the tongue and groove portions of the various panels and securing them in place, without the use of additional strips or splines.
- the widths of the panels may also be adjusted in a simple manner to accommodate tolerance variations or unanticipated conditions at an installation location.
- the system may include any suitable type of siding members attached to frame members made from wood, foam or other suitable material to form one or more cavities filled with any type of suitable thermal insulation material, where the frame and siding members of the panel are arranged to provide a tongue and groove type fastening system for joining the panel segments together and may further include retractable fasteners for further strengthening joints between the panels.
- the frame members may include one or more internal members forming multiple cavities within a shell of the panel for filling with the insulation material. Accordingly, all such modifications are intended to be included within the scope of the present invention. Other substitutions, modifications, changes and omissions may be made in the design, construction, assembly, and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present invention.
- any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures.
- Other substitutions, modifications, changes and omissions may be made in the design, operating configuration and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present inventions as expressed in the appended claims.
Abstract
Description
- The present invention relates to a structural insulated panel. The present invention relates more particularly to a structural insulated panel system for assembling an insulated enclosure. The present invention relates more particularly to a prefabricated structural insulated panel system that is quickly and easily assembled and readily accommodates tolerance variations.
- It is generally known to provide insulated panels or walls for temperature controlled storage areas (e.g. walk-in coolers, etc.) or for other structures or enclosures where a thermal boundary is desired. Such known walls or panels typically include wall or paneling structures where a layer of an insulation material is installed (e.g. blankets, sheets, etc.) within a cavity of a wall during construction of the wall or structure, or is applied (e.g. spraying a foam material, etc.) to a surface of the wall or structure after construction is complete. Accordingly, it would be desirable to provide a structural insulated panel system that provides pre-fabricated structural insulated panels that connect to one another rapidly, conveniently, and having improved strength and air-tightness qualities.
- According to one embodiment, a structural insulated panel system includes a frame including a first vertical frame member and a second vertical frame member and a top frame member and a bottom frame member. A first siding member is attached to one side of the frame and a second siding member is attached to an opposite side of the frame to form a cavity and an insulation material is provided within the cavity. A tongue portion includes a projection formed from the first vertical frame member disposed laterally outward from one vertical edge of the first and second siding members. A groove portion includes a recess formed from the second vertical frame member disposed laterally inward from an opposite vertical edge of the first and second siding members, so that the tongue portion from one panel is configured to mate with the groove portion of another panel to provide an assembly of multiple panels.
- According to another embodiment, a prefabricated structural insulated panel includes a frame and a first siding member attached to a first side of the frame and a second siding member attached to a second side of the frame, and an insulation material provided within a cavity formed by the frame and the first and second siding members. The frame includes a first vertical member positioned outwardly of a vertical edge on one side of the first and second siding members to form a tongue portion, and a second vertical frame member is positioned inwardly of a vertical edge on an opposite side of the first and second siding members to form a groove portion.
- According to another embodiment, a method of making a structural insulated panel system includes the steps of providing a frame including a first vertical frame member and a second vertical frame member and a top frame member and a bottom frame member, attaching a first siding member to one side of the frame and attaching a second siding member to an opposite side of the frame to form a cavity, injecting an insulation material into the cavity, positioning the first vertical member outwardly of a vertical edge on one side of the first and second siding members to form a tongue portion, and positioning a second vertical frame member inwardly of a vertical edge on an opposite side of the first and second siding members to form a groove portion.
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FIGS. 1A-1B are schematic images of a perspective view of a conventional structural insulated panel and connection device. -
FIG. 2A is a schematic image of a front elevation view of a structural insulated panel according to an exemplary embodiment. -
FIG. 2C is a schematic image of a cross sectional view of a structural insulated panel alonglines 2C-2C inFIG. 2A , according to an exemplary embodiment. -
FIG. 2D is a schematic image of an exploded perspective view of a structural insulated panel assembly according to an exemplary embodiment. -
FIG. 3A is a schematic image of a perspective view of a structural insulated corner panel assembly according to an exemplary embodiment. -
FIG. 3B is a schematic image of a cross sectional view of a structural insulated corner panel assembly alonglines 3B-3B inFIG. 3A , according to an exemplary embodiment. -
FIG. 3C is a schematic image of a cross sectional view of a structural insulated corner panel assembly alonglines 3C-3C inFIG. 3A , according to an exemplary embodiment. - Referring to
FIGS. 2A-3C , a structural insulatedpanel system 100 for use in assembling an enclosure (e.g. walk-in cooler, refrigerated storage area, etc.) or other type of structure (e.g. residential, commercial, industrial, institutional, etc.) having a thermal boundary is shown according to one embodiment. The panels are prefabricated with a frame and siding arrangement that permits rapid and secure assembly of the panels to one another (e.g. in a “plug-and-play” type manner, etc.). The system includes a first type of panels intended for use in planar segments of an enclosure, such as for assembling walls, ceilings, roofs, etc., and a second type of panels intended for use in assembling corners or other suitable junctions between the walls, ceiling, or roof of the enclosure. The panels may be provided in a wide variety of sizes (e.g. height and width) that may be provided as “standard” sizes (such as within a range of six inches to 48 inches wide, and 8 to 10 feet high) or may also be provided in a wide range of custom order sizes (such as up to 12 feet wide and up to 16 feet high) intended to suit a particular application. The panels may also be provided in various thicknesses as “standard” thicknesses corresponding to a range of desired thermal performance characteristics, or may be provided in custom thicknesses intended to suit a particular application. The thickness of the panels may be varied by changing the thickness of either or both of the siding and the frame. Although the system is shown and described by way of example as having rectangular shaped panels and right-angle corners, the system may be used with any of a wide variety of shapes and corner assembly configurations. Further, the panels may be modified for use in particular areas of the enclosure, such as for use as roof panels, etc. Accordingly, all such modifications are intended to be within the scope of the invention as disclosed in reference to the embodiments illustrated and described herein. - Referring to
FIGS. 1A-1B , a conventional structural insulated panel and connection device are shown. Theconventional panels 10 are shown to includestructural frame pieces 12 that are flush with the edges of thesiding portion 14 of the panels. The conventional connection device includes two wooden strips 16 (e.g. “splines”) that are inserted withinslots 18 provided along the frame pieces at the adjoining edge of each of the panels. The strips are then fastened to each of the panels (e.g. by nails or screws) to hold the panels together. The conventional panels and connection devices are generally difficult and time-consuming to assemble, and do not provide a desired ease-of-construction. The conventional panels are also generally not well suited to adjusting the width of the panels, for example when necessary to accommodate tolerance stack up when combining multiple panels together, or when necessary to accommodate the size requirements of the installation location. For example, when additional width is desired, the conventional panels often require extending the width of the strips between two or more panel joints to expand the width of the panel installation, and then filling the gap between the ends of the panels with a filler or spacer, which tends to weaken the strength and sealing quality of the joint(s). When reduced width is desired, the conventional panels often require cutting or trimming the adjoining edges of one or more panels to remove a desired width (which results in the slots becoming more shallow), and then cutting or trimming the strips to fit within the shallower slots to reduce the overall width of the panel installation, which tends to weaken the strength and sealing quality of the joint(s). - Referring to
FIGS. 2A-2C , a first type of prefabricated structural insulatedpanels 110 andconnection device 140 of thesystem 100 intended for use in assembling wall, ceilings, roofs, etc., is shown according to an exemplary embodiment.Panels 110 are shown to include aframe 112 having first and secondvertical frame members top frame member 115 and abottom frame member 115 a, afirst siding member 116, asecond siding member 120, and aninsulation fill material 130, and connection devices. According to one embodiment, theframe 112 is formed from structural members, such as “2×4” wood lumber, although other size lumber (e.g. 2×2, 2×6, 2×8, etc.) may be used to provide panels having a greater or lesser width (e.g. thickness) to suit a desired thermal, fire and/or environmental boundary performance. Theframe 112 is also shown formed in the shape of a rectangle having two vertical and two horizontal structural members, each located generally along a perimeter of the panel. However, additional (i.e. internal) structural members may be included (e.g. within the perimeter and extending side-to-side and/or top-to-bottom and/or corner-to-corner) to provide additional structural support as desired for a particular application. According to alternative embodiments, the structural members of the frame may be provided by high density foam rails, particularly where exceptional insulating performance is desired. According to further alternative embodiments, the rails may be provided from a material such as steel, aluminum, or suitable composites, particularly where increased strength is desired or higher fire rating is desired. - First and
second siding members frame 112 to provide a structural panel having acavity 118 defined by thesiding members insulation material 130 to provide the first type of structural insulated panel. According to one embodiment, the insulation material is a polyurethane foam that is injected into the cavity(ies) through a suitable small hole (not shown) cut or drilled into one of the siding members at a location corresponding to a generally central location of the cavity. The polyurethane foam is injected into the one or more cavities to provide a desired density corresponding to the desired thermal performance characteristic of the panel. According to one embodiment, the density of the insulation foam material is within a range of approximately 2.0-2.6 pounds per cubic foot. - Referring further to
FIGS. 2A-2C , aconnection device 140 for joining the structuralinsulated panels 110 of thesystem 100 is shown according to an exemplary embodiment.Connection device 140 includes a projection (e.g. tab, male portion, etc. —shown as a tongue portion 142) and a receptacle (e.g. pocket, recess, female portion, etc. —shown as a groove portion 144) that are integrally formed as part of thepanel 110 through an arrangement of theframe members siding members Tongue portion 142 having a width A is formed by placing or extending onevertical frame member 114 laterally outward a distance B beyond the side edges 117, 121 ofsiding members frame member 114 may be located laterally outward and beyond the side edges 117, 121, in which case extension members 126 (e.g. spacers, bridges, etc.) may be provided to extend the location of theframe member 114 beyond the side edges 117, 121. Alternatively, the outwardly extending frame member may overlap the side edges and be attached directly to the siding members. According to another alternative embodiment, multiple vertical frame members may be used (e.g. “stacked”, etc.) to obtain the desired extension distance for the tongue portion and the extension members may be eliminated. According to one embodiment, the outward vertical edges onframe member 114 may be beveled or chamfered to enhance the ease of tongue and groove assembly of the panels during field construction. -
Groove portion 144 having a width C is formed by placing or retracting (e.g. insetting, etc.) thevertical frame member 113 laterally inward a distance D within the side edges 118, 122 ofsiding members horizontal groove portion 128 along a bottom of thepanel 110 for use in positioning and retaining the panel over a sill plate (or other suitable structure—not shown) at the field installation location. The bottom frame member may also include a dado (e.g. groove, trench, slot, recess, etc.) to adapt the panel for sill plate bolt/nut clearance. - The tongue and
groove portions panel 110 are also configured to accommodate the need to expand or contract the overall width of an assembly of panels. For example, in the illustrated embodiment using 2×4 lumber and OSB siding members, a reduction in panel width may be accomplished by cutting-off up to 1 inch from the outward face ofvertical frame member 114 oftongue portion 142 and cutting the same amount from theedges siding members groove portion 144 on the adjoiningpanel 110 and assembling the twopanels 110 together. Similarly, an expansion in panel width may be accomplished by attaching up to 1 inch of filler material (e.g. wood strip, blocks, spacer, shim, etc.) to thevertical frame member 113 in thegroove 144 and then assembling the two panels together; a strip or gap may remain between the siding members on the two panels corresponding to the thickness of the filler material in the groove portion, which may be readily filled with a strip of siding material. - Referring further to
FIGS. 2A-2C , theconnection device 140 may also include aretractable fastener 150, such as a cam-lock type connector for drawing together and locking thetongue portion 142 andgroove portion 144 into engagement with one another. According to one embodiment, theretractable fastener 150 includes a hook-and-pin device where apin 152 is recessed into thevertical frame member 114 of thetongue portion 142 and aretractable hook 154 is recessed into thevertical frame member 113 of thegroove portion 144. Thehook 154 may be extended and retracted using a suitable tool, such as a T-wrench or hexagonal wrench extended through a suitable access hole (not shown) cut or drilled into thesiding member 120 andframe member 113 to extend and retract thehook 154. According to a preferred embodiment, theretractable fastener 150 is a Kason Panelock™ fastener commercially available from Kason Industries, Inc. According to alternative embodiments, the orientation of the pin and the hook on the tongue and groove portions may be reversed, and multiple retractable fasteners may be provided on each of the tongue and groove portions to provide increased strength and air tightness at the joint between the panels. - Two or more of the structural insulated panels 110 (having any desired width) may be assembled together by mating (e.g. joining, nesting, connecting, etc.) the
tongue portion 142 andgroove portion 144 ofadjacent panels 110 to provide an extended assembly of multiple panels such as may be used for a wall, floor, ceiling or roof of an enclosure. As thetongue portion 142 of afirst panel 110 is inserted into thegroove portion 144 of asecond panel 110, thesiding members groove 144 of thesecond panel 110 overlie thevertical frame member 114 of thetongue portion 142 on theframe 112 of thefirst panel 110. For embodiments that includeretractable fasteners 150, thehook 154 from onepanel 110 is extended and placed in position over thepin 152 on theother panel 110 as the tongue andgroove portions hook 154 to a closed position that captures and draws thepin 152 to “pull” and lock the twopanels 110 together into a tight fitting engagement. The access hole may be subsequently filled with a suitable insulating material. - The panels may then be more permanently joined by fastening the
siding members groove portion 144 to thevertical frame member 114 of thetongue portion 142 using suitable components (e.g. nails, screws, staples, adhesives, etc.). According to one embodiment, prior to mating of thetongue portion 142 and thegroove portion 144, a layer (e.g. “bead”, etc.) of a sealant (not shown) may be provided along the height of thevertical frame member 114 oftongue portion 142 and/or thevertical frame member 113 ofgroove portion 144 to enhance the air-tightness of the joint between the panels 110 (e.g. in the manner of a gasket or weather-strip or the like). The sealant may be an adhesive material or have adhesive qualities, and may also have desired thermal insulation properties. According to one embodiment, the sealant is a polyurethane foam material that may be compressed between thetongue portion 142 and thegroove portion 144 during assembly of thepanels 110 to one another. - Referring to
FIGS. 3A-3C , a structural insulatedpanel corner assembly 160 of thesystem 110 is provided for use in corner locations of an enclosure or other structure, according to an exemplary embodiment.Corner assembly 160 includes afirst corner panel 162 and asecond corner panel 180.First corner panel 162 andsecond corner panel 180 are similar topanel 110 as previously described (including an insulation fill material 130), but include additional features adapted to form a corner assembly.First corner panel 162 includes agroove portion 164 on one vertical side (shown as a “free” side, adapted to engage atongue portion 142 from apanel 110 in a wall section of an enclosure), and atongue portion 166 on an opposite vertical side, where thetongue portion 166 is formed by an extension ofsiding member 168 that extends beyondvertical frame member 172. Thesecond corner panel 180 includes atongue portion 182 formed from avertical frame member 192 on one vertical side (shown as a “free” side, adapted to engage agroove portion 144 from apanel 110 in a wall section of an enclosure), and aflat surface 184 on an opposite vertical side, where aframe member 186 is generally flush with the edges of thesiding members - The first and
second corner panels flat surface 184 of thesecond corner panel 180 with thetongue portion 166 of thefirst corner panel 162, and joining them with suitable fastening components (as previously described). According to alternative embodiments, the free side of the first and second panels may be provided with either a tongue portion or a groove portion as appropriate for mating with other panels of the enclosure. The first and second corner panels of the corner assembly may also include retractable fasteners as previously described. - According to any preferred embodiment, the structural insulated panel system provides a system of panels for use in planar segments and corner assemblies of an enclosure having a thermal boundary, and connectors that are provided as integral members of the prefabricated panel. The panels are formed as a single integrated unit to include a frame and siding members that are arranged to form a tongue and groove portion on each panel. The tongue and groove members of the frame and the siding members form a shell with one or more cavities that are filled with a thermal insulation material to provide stand-alone panels that are readily connectable to one another in a simplified and expedient manner. The panels of the assembly are conveniently and readily assembled into a desired structure or enclosure by mating the tongue and groove portions of the various panels and securing them in place, without the use of additional strips or splines. The widths of the panels may also be adjusted in a simple manner to accommodate tolerance variations or unanticipated conditions at an installation location.
- It is also important to note that the construction and arrangement of the elements of the structural insulated panel system as shown schematically in the FIGURES is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in location and orientation of tongue and groove portions, locations of retractable fasteners, configurations of panel elements in corner assemblies, etc.) without materially departing from the novel teachings and advantages of the subject matter recited.
- It should also be noted that the system may include any suitable type of siding members attached to frame members made from wood, foam or other suitable material to form one or more cavities filled with any type of suitable thermal insulation material, where the frame and siding members of the panel are arranged to provide a tongue and groove type fastening system for joining the panel segments together and may further include retractable fasteners for further strengthening joints between the panels. Further, the frame members may include one or more internal members forming multiple cavities within a shell of the panel for filling with the insulation material. Accordingly, all such modifications are intended to be included within the scope of the present invention. Other substitutions, modifications, changes and omissions may be made in the design, construction, assembly, and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present invention.
- The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present inventions as expressed in the appended claims.
Claims (20)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US11/875,307 US20090100780A1 (en) | 2007-10-19 | 2007-10-19 | Structural insulated panel system |
CA002607432A CA2607432A1 (en) | 2007-10-19 | 2007-10-23 | Structural insulated panel system |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US11/875,307 US20090100780A1 (en) | 2007-10-19 | 2007-10-19 | Structural insulated panel system |
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US20090100780A1 true US20090100780A1 (en) | 2009-04-23 |
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US11/875,307 Abandoned US20090100780A1 (en) | 2007-10-19 | 2007-10-19 | Structural insulated panel system |
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US (1) | US20090100780A1 (en) |
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