Insulating panel and method for building and insulating walls and ceilings

Abstract

A method for manufacturing insulated structural panels for walls, roofs, ceilings, and floors with fixed structural members inserted in to machined cavities that allows for seamless joining of adjacent panels, all stud distances are at industry standard, for sheet hanging simultaneously with truss support without needing top plates for load distribution. The panels yield extreme insulation, sound attenuation, and structural values, while remaining light weight and economical. The composites are non out gassing and zero flame spread, also free from deterioration, and are air, vapor and moisture impermeable. Additional stiffener web is inserted at every four feet of height for higher shear, wind, snow, live and dead loads, and attached to the foundation with a “U” shaped steel channel or track secured with screws to the bottom and top of the panel. Track is also attached at doors and windows openings. All finishes, can be attached to the panels.

1 . An insulating panel for a building structure, the panel comprising of: A rigid body made of thermoplastic foam; two opposed outer surfaces; and a plurality of spaced-apart elongated framing members embedded in said body, each framing member having a U-shaped cross-section with a bottom surface parallel to both said outer surfaces and interconnecting a pair of oppositely disposed arms extending into the body, each of said arms being provided along the framing member with a plurality of grooves machined in to the foam of the body and thereby, anchoring said framing member in said body and held in position by the stiffener web ( FIG. 4 ), the bottom surface being adapted along its length to receive and hold a plurality of fasteners to secure the panel to a “U” shaped steel channel and this to the building. 
   
   
       2 . An insulating panel as claimed in  claim 1 , wherein the bottom surface of each framing members is flush with one of said outer surfaces of the panel. 
   
   
       3 . An insulating ceiling structure for installation under a load-bearing structure of a building, the insulating ceiling structure comprising: A first layer of panel as claimed in  claim 2 , the bottom surface of the framing members of each of said panels opposing the load-bearing structure; and a first set of fasteners for securing the panels of the first layer to the load-bearing structure via the framing members. 
   
   
       4 . An insulating ceiling structure as claimed in  claim 4 , further comprising: A second layer of panels similar to the panels of the first layer, the bottom surface of the framing members of each said panels of the second layer opposing the first layer of panels, and a second set of fasteners for securing the panels of the second layer via the framing members thereof to the framing members of the first layer. 
   
   
       5 . An insulating ceiling structure as claimed in  claim 4 , further comprising: A layer of sheathing comprising a plurality of sheathing panels for covering the second layer of panels; and a third set of fasteners for securing said sheathing panels to the second layer via the framing members thereof. 
   
   
       6 . An insulating ceiling structure as claimed in  claim 5  further comprising of: An upper layer of plywood sheet lying between the load bearing structure and the first layer of panels.