Composite structural building panels and systems and method for erecting a structure using such panels

Abstract

A composite panel includes a first skin including composite material, a second skin including drywall material, and a foam core therebetween. A plastic connector extends along side edges of the skins for connecting the panel to another composite panel including a mating connector. The connector includes a slot extending parallel to the side edges for receiving a pin therein, whereby the panel may be connected to another composite panel having a similar connector and slot. An I-beam is bonded between the skins in the cavity that includes a chase for receiving wiring or other utilities therein. A “U” shaped channel is also bonded between the upper edges of the first and second skins, thereby defining a recess between the upper edges for receiving a top plate to secure a roof structure to the panel.

What is claimed is:  
     
         1 . A composite panel for a structural building system, comprising: 
 a first skin formed from composite material defining upper, lower, and side edges;    an elongate I-beam comprising plastic, the I-beam bonded to the first skin and extending at least partially between the upper and lower edges;    a second skin comprising drywall material defining upper, lower, and side edges, the second skin bonded to the I-beam such that the first and second skins define a cavity therebetween;    a foam core within the cavity; and    a connector comprising plastic extending along the side edges of the first and second skins fore connecting the composite panel to another composite panel including a mating connector.    
     
     
         2 . The composite panel of  claim 1 , wherein the first skin comprises a fiberreinforced plastic comprising a phenolic resin.  
     
     
         3 . The composite panel of  claim 1 , wherein the I-beam comprises a chase therein extending between its ends.  
     
     
         4 . The composite panel of  claim 1 , wherein the I-beam comprises a leg and a web on each end of the leg, the leg defining a width of the cavity between the first and second skins, the first and second skins being bonded to respective webs on opposite ends of the leg.  
     
     
         5 . The composite panel of  claim 1 , wherein the second skin comprises gypsum board.  
     
     
         6 . The composite panel of  claim 1 , wherein the foam core comprises polyisocyanurate foam injected between the first and second skins to substantially fill the cavity.  
     
     
         7 . The composite panel of  claim 1 , wherein the connector includes an elongate slot extending generally parallel to the first edge for receiving a pin therein, whereby the composite panel may be connected to another composite panel having a similar connector and slot.  
     
     
         8 . The composite panel of  claim 7 , wherein the connector comprises an inside face extending generally parallel to a plane defined by the first and second skins, and wherein the slot extends along the inside face between ends of the connector.  
     
     
         9 . The composite panel of  claim 1 , wherein the connector comprises at least one of a tongue and a groove extending along a length of the connector.  
     
     
         10 . The composite panel of  claim 1 , wherein the connector is bonded to the side edges between the first and second skins.  
     
     
         11 . The composite panel of  claim 1 , wherein the connector comprises first and second connectors comprising plastic extending along opposite side edges at least partially defined by the first and second skins.  
     
     
         12 . The composite panel of  claim 1 , further comprising a top plate extending between the upper edges of the first and second skins.  
     
     
         13 . The composite panel of  claim 12 , wherein the top plate comprises polyvinyl chloride, and wherein the top plate is bonded between the upper edges of the first and second skins.  
     
     
         14 . The composite panel of  claim 12 , wherein the top plate comprises a “U” channel inserted between the upper edges of the first and second skins, thereby defining a recess between the upper edges.  
     
     
         15 . The composite panel of  claim 1 , wherein the first skin comprises an exterior surface having a predetermined architectural finish molded directly into the composite material.  
     
     
         16 . A composite panel system for a building structure, comprising: 
 a first panel member comprising a first skin including composite material, a second skin including drywall material, and a foam core between the first and second skins, the first panel member comprising a first side edge;    a second panel member comprising a first skin including composite material, a second skin including drywall material, and a foam core between the first and second skins, the second member comprising a second side edge; and    a connector for securing the first and second members relative to one another along the first and second side edges.    
     
     
         17 . The composite panel system of  claim 16 , wherein the connector comprises a first connector member bonded to the first edge of the first panel member, and a second connector member bonded to the second edge of the second panel member.  
     
     
         18 . The composite panel system of  claim 17 , wherein each of the first and second connector members comprises a tongue and groove connector including a slot extending along a length thereof.  
     
     
         19 . The composite panel system of  claim 17 , wherein the first and second connector members are configured to interlock with one another to secure the first and second panel members to one another in a planar configuration.  
     
     
         20 . The composite panel system of  claim 19 , wherein each of the first and second connector members comprises a slot extending along a length thereof, the slots defining a passage when the first and second panel members are interlocked, and wherein the composite panel system further comprises an elongate pin insertable into the passage to secure the first and second panel members together.  
     
     
         21 . The composite panel system of  claim 17 , wherein the connector further comprises a comer connector configured to interlock with the first and second panel members to secure the first and second panel members transversely with respect to one another.  
     
     
         22 . The composite panel system of  claim 17 , wherein the connector further comprises a “T” connector configured to interlock with the first and second panel members to secure the first and second panel members in a planar configuration, and wherein the composite panel system comprises a third panel member configured to interlock with the “T” connector to secure the third panel member transversely with respect to the first and second panel members.  
     
     
         23 . The composite panel system of  claim 16 , further comprising a “U” shaped base channel member, legs of the base channel spaced for receiving lower edges of the first and second panel members therein.  
     
     
         24 . The composite panel system of  claim 16 , wherein the connector comprises one of plastic and composite material.  
     
     
         25 . A method for manufacturing a composite panel, comprising: 
 bonding a first web of an elongate support member to a first skin, the first skin comprising composite material, the support member comprising plastic;    bonding a second web of the support member to a second skin comprising drywall material;    bonding a connector along side edges of the first and second skins; and    injecting a foam core into a cavity defined between the first and second skins.    
     
     
         26 . The method of  claim 25 , further comprising bonding a top plate between upper edges of the first and second skins.  
     
     
         27 . The method of  claim 25 , comprising the additional step of molding an architectural finish directly into an outer surface of the first skin.  
     
     
         28 . A method for assembling a building structure from a plurality of composite panels comprising connectors extending along side edges thereof, the method comprising: 
 securing “U” shaped base channel to a foundation;    placing a lower edge of a first composite panel into the base channel in a substantially vertical orientation;    placing a lower edge of a second composite panel into the base channel adjacent the first panel member;    interlocking connectors on the first and second composite panels such that the first and second composite panels are disposed in a substantially planar configuration;    securing the first and second panels to the base channel; and    securing the connectors of the first and second composite panels to one another.    
     
     
         29 . The method of  claim 28 , wherein the connectors comprise slots that define an enclosed passage when the connectors are interlocked, and wherein the step of securing the connectors comprises inserting a pin into the passage.  
     
     
         30 . The method of  claim 28 , wherein the first and second composite panels comprise “U” shaped channels between upper edges thereof, and wherein the method further comprises: 
 securing a top plate within the channels; and  
 securing a roof structure to the top plate.  
 
     
     
         31 . The method of  claim 28 , wherein the first composite panel comprises an internal chase disposed vertically therein, and wherein the method further comprises directing a utility accessory along the chase.  
     
     
         32 . The method of claim  31 , wherein the utility accessory comprises one or more electrical wires, and wherein the method further comprises: 
 creating an opening in a surface of the first composite panel to access the wire within the chase; and    securing an electrical box to the surface over the opening.