Structural insulated panel construction for building structures

Abstract

A structural insulated laminated construction panel for building structures is described. The panel comprises a rigid core material layer of expanded polymeric material having opposed flat parallel surfaces. An outer skin is adhesively secured to one of the flat surfaces and an inner skin is adhesively secured to the other of the flat surfaces. The core material layer has a density of about 2 lbs/cubic foot. The core material is preferably an expanded polystyrene material. A building structure is constructed from such panels used as exterior and interior wall panels, floor panels and roof panels.

1 . A structural insulated laminated construction panel for building structures, said panel comprising a rigid core material layer of expanded polymeric material having opposed flat parallel surfaces, an outer skin adhesively secured to one of said flat surfaces and an inner skin adhesively secured to the other of said flat surfaces.  
   
   
       2 . A structural insulated laminated construction panel as claimed in  claim 1  wherein said core material layer is a rigid sheet of expanded polystyrene.  
   
   
       3 . A structural insulated laminated construction panel as claimed in  claim 2  wherein said core material layer has a density of about 2 lbs/cubic foot.  
   
   
       4 . A structural insulated laminated construction panel as claimed in  claim 2  wherein said outer skin is a glass fiber-reinforced plastic and constituting an outer surface of said construction panel.  
   
   
       5 . A structural insulated laminated construction panel as claimed in  claim 2  wherein said outer and inner skins are adhesively secured by an adhesive film bonded to said at least one of said flat surfaces.  
   
   
       6 . A structural insulated laminated construction panel as claimed in  claim 2  wherein said construction panel is a continuously laminated panel forming a complete exterior wall of a building structure and having a height of up to about 12 feet and a thickness of from about 2 inches to 9 inches.  
   
   
       7 . A structural insulated laminated construction panel as claimed in  claim 2  wherein said construction panel is an exterior wall panel, said outer skin permitting the attachment of facing tiles or siding by the use of screw fasteners, or the application of exterior or paint, polymer concrete, said interior skin having a fire-retardant material incorporated therein.  
   
   
       8 . A structural insulated laminated construction panel as claimed in  claim 2  wherein said construction panel is an exterior building panel, said outer skin being adapted to retain paint or elastomeric roof material.  
   
   
       9 . A structural insulated laminated construction panel as claimed in  claim 8  wherein there is further provided a conduit in said rigid core material disposed for receiving wiring therein.  
   
   
       10 . A structural insulated laminated construction panel as claimed in  claim 2  wherein two of said panels are interconnected together along a straight flat connecting end edge thereof, one of said flat connecting end edges having at least one elongated projecting tongue element of plastics material secured therein and projecting along said end edge, the other of said flat connecting end edge having an elongated slot therealong and positioned to receive said tongue therein, and a structural adhesive suitable to weld fiber-reinforced plastics for securing said tongue into said slot to interconnect said two connecting end edges together.  
   
   
       11 . A structural insulated laminated construction panel as claimed in  claim 10  wherein said projecting tongue is an elongated flat rigid plastic strip, there being two of said strips each adhesively secured in a routed channel along opposed outer edges of said one of said flat connecting end edges and under an end portion of said outer and inner skins and defining a projection projecting outwardly of said connecting end edge, there also being two of said elongated slots disposed along opposed outer edges of said other of said flat connecting end edge and under an end portion of said outer and inner skins thereof for receiving a respective one of said projections therein.  
   
   
       12 . A structural insulated laminated construction panel as claimed in  claim 11  wherein there is further provided a bead of flexible sealant material disposed along said connecting end edges between said projections and slots, said sealant material, together with said interconnection of said projection in said slots, constituting a thermally insulated structural sealed interconnection.  
   
   
       13 . A structural insulated laminated construction panel as claimed in  claim 2  wherein two of said panels are interconnected together along a straight flat connecting end edge thereof, said inner and outer skins having a projecting connecting end portion extending beyond said flat connecting end edge, a straight rectangular tube of fiber-reinforced plastic is dimensioned for close fit between said flat connecting end edge of said two of said panels and having opposed flat end walls thereof disposed flush under said projecting connecting end portions of said two panels, and a structural adhesive suitable to weld olefin based plastics securing said projecting connecting end portions to respective ones of said opposed flat end walls.  
   
   
       14 . A structural insulated laminated construction panel as claimed in  claim 13  wherein there is further provided a bead of flexible sealant material disposed between each of said flat connecting end edges and opposed flat side walls of said rectangular channel, said sealant material, together with said interconnected projecting end portions of said skins with said channel, constituting a sealed structural interconnection of said two panels, said tube being adapted to receive piping or wiring therein.  
   
   
       15 . A structural insulated laminated construction panel as claimed in  claim 2  wherein said construction panel is an exterior rectangular wall panel, said outer skin having a projecting connecting end portion extending beyond a lower flat edge surface of said panel for interconnection with attachment means connected to a sill plate of a foundation wall.  
   
   
       16 . A structural insulated laminated construction panel as claimed in  claim 15  wherein said attachment means is comprised by an elongated rectangular tube secured to said sill plate, said tube having opposed top and bottom parallel flat walls and opposed parallel flat end walls, said lower flat edge surface of said panel resting on said top flat wall of said tube with said projecting connecting end portion of said outer skin extending over an exterior one of said opposed parallel end walls and secured thereto by fastening means.  
   
   
       17 . A structural insulated laminated construction panel as claimed in  claim 16  wherein said elongated rectangular tube is a fiber-reinforced plastic tube, said fastening means is comprised of structural adhesive suitable to weld olefin based plastics, and fasteners for connecting said projecting connecting end portion to said exterior end wall of said channel.  
   
   
       18 . A structural insulated laminated construction panel as claimed in  claim 16  wherein floor joists are supported on said sill plate adjacent said interior skin of said exterior rectangular wall panel, each said joist being provided at a free end thereof with a connecting plate for interconnecting said joist to said interior skin and sill plate by the use of fasteners.  
   
   
       19 . A structural insulated laminated construction panel as claimed in  claim 17  wherein said structural adhesive is a 3M Scotch-Weld™ adhesive, said fasteners being screw or rivet fasteners.  
   
   
       20 . A structural insulated laminated construction panel as claimed in  claim 16  wherein said elongated rectangular tube is a wire or plumbing conduit.  
   
   
       21 . A structural insulated laminated construction panel as claimed in  claim 2  wherein said construction panel is a floor panel, a slot routed in said rigid core material adjacent a straight end wall thereof and immediately under said outer skin thereof, said slot being dimensioned to receive a top flange section of a steel I-beam therein, said floor panel resting on a bottom flange section of said I-beam, and a structural adhesive between said top flange section and said outer skin within said slot for interconnection thereof.  
   
   
       22 . A structural insulated laminated construction panel as claimed in  claim 21  wherein there is further provided elongated support tubes secured over said bottom flange section of said I-beam, said floor panel resting on said support blocks.  
   
   
       23 . A structural insulated laminated construction panel as claimed in  claim 22  wherein said support tubes are hollow tubes formed of fiber-reinforced plastic and which also serve as conduits for wiring or plumbing.  
   
   
       24 . A structural insulated laminated construction panel as claimed in  claim 21  wherein at least one free end of said I-beam is disposed on a sill plate of a foundation and connected thereto by fastening means, and further connecting means to connect said fee end to said interior skin of an outside wall constructed with one or more of said panels.  
   
   
       25 . A structural insulated laminated construction panel as claimed in  claim 24  wherein there is further provided a hurricane anchoring system secured to a house support beam on which said I-beam are secured, or directly to said I-beam to thereby anchor same.  
   
   
       26 . A structural insulated laminated construction panel as claimed in  claim 24  wherein said further connecting means is a right-angle metal bracket having a flange thereof connected to said inner skin by fasteners and the other right angle flange connected to a web of said I-beam.  
   
   
       27 . A structural insulated laminated construction panel as claimed in  claim 2  wherein said construction panel is a floor panel, said panel being secured to a top flange of one or more I-beams supported thereunder, and fasteners extending through said top flange and said inner skin of said floor panel.  
   
   
       28 . A structural insulated laminated construction panel as claimed in  claim 2  wherein said construction panel is an exterior rectangular wall panel, said outer and inner skins having a projecting connecting end portion extending beyond a lower flat edge surface of said panel for interconnection with opposed side walls of a rectangular bottom plate of fiber-reinforced plastic material connected to a sill plate of a foundation wall, and a structural adhesive suitable to weld olefin plastics disposed between said projecting connecting end portions of said inner and outer skins and said opposed side walls.  
   
   
       29 . A structural insulated laminated construction panel as claimed in  claim 28  wherein said rectangular bottom plate is an elongated hollow tube, a plurality of aligned holes formed in a top and bottom wall of said tube, said holes formed in said top wall being larger to provide access to said holes in said bottom wall where fasteners are disposed for securing said tube over floor sheeting supported thereunder.  
   
   
       30 . A structural insulated laminated construction panel as claimed in  claim 29  wherein said floor sheeting is secured over flooring joists resting on a foundation wall and connected to said foundation wall through a sill plate.  
   
   
       31 . A structural insulated laminated construction panel as claimed in  claim 29  wherein said hollow tube is a conduit for receiving wiring or piping therethrough.  
   
   
       32 . A structural insulated laminated construction panel as claimed in  claim 29  wherein there is further provided fasteners for securing said projecting connecting end portion of said inner and outer skins to said opposed side walls of said hollow tube.  
   
   
       33 . A structural insulated laminated construction panel as claimed in  claim 2  wherein said construction panel is an exterior rectangular wall panel having connecting means at a lower edge thereof, and a connecting means at an upper edge thereof for receiving fasteners extending through joist hangers and floor sheeting extensions of floor sheeting secured to floor joists secured by said hangers to a top portion of said exterior rectangular wall panel.  
   
   
       34 . A structural insulated laminated construction panel as claimed in  claim 33  wherein said connecting means at said upper edge of said wall panel is an elongated composite fiber-reinforced plastic (FRP) channel having a flat bridge wall and opposed parallel depending connecting arms embedded in said expanded polystyrene core with said connecting arms disposed in slots formed immediately behind said inner and outer skins from said upper edge and said bridge wall resting on said upper edge of said core, and means to secure said FRP channel to said upper edge.  
   
   
       35 . A structural insulated laminated construction panel as claimed in  claim 34  wherein there is further provided an elongated bottom plastic plate of rectangular cross-section secured over said floor sheeting extensions and aligned with said exterior rectangular wall panel for receiving a connecting means of an upper exterior wall panel to be secured thereto and in alignment with said exterior rectangular wall panel therebelow.  
   
   
       36 . A structural insulated laminated construction panel as claimed in  claim 35  wherein said connecting means is a connecting channel formed by projecting connecting end portions of said inner and outer skins of said upper exterior wall panel extending beyond said lower edge thereof, said plastic plate being received in said connecting channel and secured thereto by fastening means.  
   
   
       37 . A structural insulated laminated construction panel as claimed in  claim 36  wherein said fastening means is a structural adhesive suitable to weld olefin based plastics and fasteners extending through said projecting connecting end portions of said inner and outer skins and opposed side walls of said plastics plate.  
   
   
       38 . A structural insulated laminated construction panel as claimed in  claim 37  wherein said plastic plate is a hollow tube for receiving wiring or piping therethrough.  
   
   
       39 . A structural insulated laminated construction panel as claimed in  claim 38  wherein said structural adhesive is a two-part structural strength adhesive formed with a polyurethane liquid and an epoxy.  
   
   
       40 . A structural insulated laminated construction panel as claimed in  claim 2  wherein said panel is provided with connecting means secured to opposed outer edges thereof, said connecting means being constituted by elongated composite fiber-reinforced polymer material (FRP) channels, each channel having a flat bridge wall and opposed parallel right-angle connecting arms, said connecting arms being disposed in slots formed behind said inner and outer skins from said outer edges with said bridge wall resting on said outer edge of said core, and means to secure said FRP channels to said outer edges, said edges constituting reinforced edges.  
   
   
       41 . A structural insulated laminated construction panel as claimed in  claim 40  wherein said means to secure is constituted by one of said fasteners, or a two-part structural adhesive Scotch-Weld™, or both.  
   
   
       42 . A structural insulated laminated construction panel as claimed in  claim 40  wherein said panels are rectangular panels, some of said panels are exterior vertical wall panels interconnected to form a first floor area of a building and are connected at upper ones of said reinforced edge thereof to end portions of horizontal floor panels also having reinforced edges, said floor panels forming on an inner side thereof a ceiling for said first floor area and on an upper side thereof a floor for an upper floor area, and further exterior vertical wall panels disposed over said end portions of said floor panels in alignment with said exterior vertical panels of said first floor area, said exterior panels and floor panels being connected at their matting ends and end portions by connecting plates and angles formed of fiber-reinforced thermoplastic material and bridging said matting ends by fastening means.  
   
   
       43 . A structural insulated laminated construction panel as claimed in  claim 42  wherein said fastening means is constituted by fasteners and said structural adhesive, said fasteners extending into said opposed depending connecting arms of said FRP channels of said panel.  
   
   
       44 . A structural insulated laminated construction panel as claimed in  claim 40  wherein said flat bridge wall and connecting arms are fiber-reinforced to permit the retention of fasteners to secure component parts thereto.  
   
   
       45 . A structural insulated laminated construction panel as claimed in  claim 40  wherein some of said panels have at least one angled outer edge thereof.  
   
   
       46 . A structural insulated laminated construction panel as claimed in  claim 45  wherein some of said panels are gable wall panels.  
   
   
       47 . A structural insulated laminated construction panel as claimed in  claim 40  wherein said flat bridge wall is a beveled bridge wall to constitute a beveled FRP channel.  
   
   
       48 . A structural insulated laminated construction panel as claimed in  claim 47  wherein said beveled FRP channel is secured to a top outer edge of said panel constituting an exterior wall panel to provide interconnection with a further one of said panel constituting and angled roof panel, and fastening means to secure said angled roof panel to said flat beveled bridge wall.  
   
   
       49 . A structural insulated laminated construction panel as claimed in  claim 48  wherein said fastening means is constituted by fasteners and a structural adhesive suitable to weld olefin base plastics.  
   
   
       50 . A structural insulated laminated construction panel as claimed in  claim 49  wherein said structural adhesive is a two-part structural strength adhesive formed with polyurethane liquid and epoxy.  
   
   
       51 . A structural insulated laminated construction panel as claimed in  claim 40  wherein said panels are vertical wall panels, some of said vertical wall panels forming right angle corners of a building structure, and right angle connectors for interconnecting said vertical wall panels at said right angle corners.  
   
   
       52 . A structural insulated laminated construction panel as claimed in  claim 51  wherein said right angle connectors are elongated connectors formed of composite fiber-reinforced polymer material.  
   
   
       53 . A structural insulated laminated construction panel as claimed in  claim 52  wherein said right angle corners are formed by a vertical protrusion column of fiber-reinforced plastics material and of square cross-section defining opposed elongated flat walls, a first vertical panel forming said right angle corner being disposed in abutment with one of said opposed flat walls, and a second of said vertical panels disposed at right angle to said first vertical panel and in abutment with an adjacent one of said opposed flat walls, an outer one of said right angle connectors embracing the other two outer ones of said opposed flat walls and having an extension edge portion extending over a longitudinal edge portion of said outer skin of said first and second vertical panels, fasteners interconnecting said extension edge portion to said longitudinal edge portion of said first and second vertical panel and extending into a connecting arm of said FRP channel, and a structural adhesive suitable to weld olefin based plastics interposed on an inside face of said outer one of said rigid angle connectors, and an inner right angle connector secured to said first and second vertical panel inner skin along an inner corner thereof.  
   
   
       54 . A structural insulated laminated construction panel as claimed in  claim 53  wherein said protrusion column is a hollow column, said inner right angle connector being secured to said first and second vertical panel by fasteners extending into connecting arms of said FRP channel of each panel with said structural adhesive disposed on an inside face thereof.  
   
   
       55 . A structural insulated laminated construction panel as claimed in  claim 52  wherein said rigid angle corners are formed by abutting an outer vertical edge of a first panel with a side end edge portion of a second panel disposed at right angles thereof, an outer one of said rigid angle connectors embracing an outer corner formed by said first and second panels and extending over a longitudinal edge portion of said outer skin of said first and second vertical panels, fasteners interconnecting said outer right angle connector to said first and second panels and extending into a connecting arm of said FRP channels, and a structural adhesive suitable to weld olefin based plastics interposed on an inside face of said outer right angle connector, and an inner right angle connector secured to said first and second vertical panel inner skin along an inner corner thereof.  
   
   
       56 . A structural insulated laminated construction panel as claimed in  claim 55  wherein said inner right angle connector is secured along said inner corner by fasteners extending into said inner skin and into the connecting arm of said FRP channel of said first panel, said structural adhesive being disposed on an inside face of said inner right angle connector.  
   
   
       57 . A structural insulated laminated construction panel as claimed in  claim 2  wherein two of said panels are vertical rectangular wall panels, said panels having outer straight edges, a vertical one of said outer edges being mitered at a 45° angle, said mitered outer edges of said two panels being interconnected together in facial contact by two elongated right angle connectors formed of composite fiber-reinforced polymer material, connecting slots formed in said core material in said outer mitered edges immediately behind said inner and outer skins, said elongated right angle connectors forming two right angle flanges received in respective ones of adjacent slots when said mitered outer edges are placed in said facial contact, and a structural adhesive suitable to weld olefin based plastics interposed in said slots to connect said right angle connector therein.  
   
   
       58 . A structural insulated laminated construction panel as claimed in  claim 57  wherein there is further provided fasteners disposed in said inner and outer skin adjacent said connector flanges and engaged in said flanges.  
   
   
       59 . A structural insulated laminated construction panel as claimed in  claim 20  wherein an opening is formed in said panel, a composite fiber-reinforced polymer material (FRP) channel disposed about said opening, said FRP channel having a flat bridge wall and opposed parallel right angle connecting arms, said bridge wall extending the full width of said panel and said connecting arm overlapping said inner and outer skins about said opening, and fastening means to secure said FRP channel in said opening.  
   
   
       60 . A structural insulated laminated construction panel as claimed in  claim 59  wherein said fastening means is constituted by fasteners disposed in said connecting arms and a structural adhesive suitable to weld olefin based plastics disposed behind said connecting arms.  
   
   
       61 . A structural insulated laminated construction panel as claimed in  claim 60  wherein said structural adhesive is a two-part structural strength adhesive formed with polyurethane liquid and epoxy.  
   
   
       62 . A structural insulated laminated construction panel as claimed in  claim 60  wherein said opening is a window opening.  
   
   
       63 . A structural insulated laminated construction panel as claimed in  claim 60  wherein said opening is a rectangular door opening or window opening and wherein a thermoplastic header is embedded in said wall panel adjacent a top edge of said opening, and one or more composite fiber-reinforced plastic studs embedded into said panel along opposed side edges of said opening, said header being connected to an upper end of said reinforced studs.  
   
   
       64 . A structural insulated laminated construction panel as claimed in  claim 60  wherein said panel is further provided with an elongated composite fiber-reinforced polymer material (FRP) channel secured along a top and bottom edge thereof, each channel having a flat bridge wall and opposed right-angle connecting arms, said connecting arms being disposed in slots formed behind said inner and outer skins from said outer edges with said bridge wall resting on said outer edge of said core, and said structural adhesive securing said connecting arms in said slots.  
   
   
       65 . A building structure comprising a plurality of structural insulated laminated panels interconnecting together, each said panels having a rigid core material layer of expanded polystyrene having opposed flat parallel surfaces, an outer skin and an inner skin adhesively laminated to a respective one of said surfaces, said panels having connecting means secured to at least one of outer edges thereof and constituted by an elongated composite fiber-reinforced polymer material (FRP) channel to provide connection to said panel.  
   
   
       66 . A building structure as claimed in  claim 65  wherein said FRP channel has a flat bridge wall and opposed parallel right-angle connecting arms, said connecting arms being disposed in slots formed behind said inner and outer skins from said outer edge with said bridge wall resting on said outer edge of said core, and a structural adhesive suitable to weld olefin based plastics disposed in said slots, said at least one outer edge being a reinforced edge.  
   
   
       67 . A building structure as claimed in  claim 65  wherein said core material layer is a two inch thick material having a density of about 2 lbs/cubic foot.  
   
   
       68 . A building structure as claimed in  claim 65  wherein said outer skin is a continuous sheet of fiber-reinforeced plastic and constituting an outer surface of said construction panel.  
   
   
       69 . A building structure as claimed in  claim 65  wherein said outer and inner skins are adhesively secured by an adhesive film bonded to said at least one of said flat surfaces.  
   
   
       70 . A building structure as claimed in  claim 65  wherein said construction panel is a continuously laminated panel forming a complete exterior wall of a building structure and having a height of up to about 12 feet and a thickness of from about 2 inches to 9 inches.  
   
   
       71 . A building structure as claimed in  claim 69  wherein said inner skin is adhesively secured by an adhesive film-bonded to said at least one of said flat surfaces.  
   
   
       72 . A building structure as claimed in  claim 71  wherein said outer and inner skin are adhesively secured by controlled heat lamination with said core material layer.  
   
   
       73 . A building structure as claimed in  claim 71  wherein said inner skin comprises a fire-retardant material skin.  
   
   
       74 . A building structure as claimed in  claim 65  wherein said plurality of panels comprise vertical exterior wall panels, floor panels and roof panels interconnected together through said connecting means, said exterior wall panels being immovably secured by attachment means to a sill plate of a foundation wall, said foundation wall supporting floor joists connected to said attachment means, said floor joists being secured to one or more building support means, and a seismic anchor device secured to said one or more support means and anchored in a bearing soil.  
   
   
       75 . A building structure as claimed in  claim 74  wherein said seismic anchor device comprises a support base, a vertical cylinder secured to said base, an adjustable post adjustably connected with said vertical cylinder, a connecting member at a free top end of said adjustable post for connection to said one or more support beams, an anchor rod having anchoring means for anchoring in said bearing soil and connected at a fee end thereof to a heavy-duty spring secured to said vertical cylinder.