Insulated structural building panel and assembly system

Abstract

An insulated structural building panel and header system, comprising a rectangular panel body molded of a rigid foam material and a plurality of elongated, channel-shaped framing members oriented parallel to each other and embedded during molding in each first and second face of the panel body. Each framing member is retained in place in the panel body by return lips formed into first and second edges of an open side of the framing members without the use of adhesive or mechanical fasteners. The panels may include utility recesses formed in one face of the panel and mortised edges for keying the panels securely together. The panels may be formed with alternate framing member spacings. Auxiliary framing members are disclosed having T and L shaped cross sections for joining panels together or reinforcing the panels to support greater loads.

1 . An insulated structural building panel, comprising: 
 a rectangular panel body formed of a rigid foam material and having a first defined width, a defined length, first and second ends, and first and second substantially parallel faces;    a plurality of elongated, channel-shaped framing members having an open side and a closed side are oriented parallel to each other and embedded during molding of the rigid foam panel body in each first and second face of the panel body, and    a return lip formed into first and second edges of an open side of each framing member.    
   
   
       2 . The building panel of  claim 1 , wherein each framing member is retained in place in the rigid foam material of the panel body without the use of adhesive or mechanical fasteners.  
   
   
       3 . The building panel of  claim 1 , wherein the rigid foam of the panel body is molded of expanded polystyrene foam having a density in the range of 0.5 to 3.0 pounds per cubic foot.  
   
   
       4 . The building panel of  claim 1 , wherein the framing members are formed of galvanized sheet metal having a minimum tensile strength of 36,000 pounds per square inch.  
   
   
       5 . The building panel of  claim 1 , wherein each channel-shaped framing member is disposed in one face of the panel body with the open side of each framing member in facing relationship with the open side of a like framing member on the opposite face of the panel body.  
   
   
       6 . The building panel of  claim 5 , wherein each framing member having an open side facing the open side of a like framing member on the opposite face of the panel body is separated therefrom by a predetermined distance occupied with the rigid foam material.  
   
   
       7 . The building panel of  claim 6 , wherein the predetermined distance is at least 0.5 inch.  
   
   
       8 . The building panel of  claim 1 , wherein the parallel framing members are spaced on the first and second faces of the panel body according to predetermined centers.  
   
   
       9 . The building panel of  claim 8 , wherein the predetermined centers are selected from the group consisting of 12 inches, 16 inches, 18 inches, and 24 inches.  
   
   
       10 . The building panel of  claim 1 , wherein each framing member is formed to the defined length and the return lips formed into the first and second edges of the open side of the framing members and along the defined length of the framing member extend inward toward each other and substantially parallel to the closed (web) side of the framing member.  
   
   
       11 . The building panel of  claim 1 , wherein a first and second framing member on each first and second face of the panel body are respectively disposed along a first and second edge of the respective first and second faces of the panel body.  
   
   
       12 . The building panel of  claim 11 , wherein a first framing member on a first edge of a first face of the panel body is formed to be wider than a predetermined standard width for a framing member.  
   
   
       13 . The building panel of  claim 11 , wherein a first framing member on a first edge of a first face of the panel body includes openings having a predetermined shape in the closed (web) side of the framing member and disposed at predetermined intervals along the framing member.  
   
   
       14 . The building panel of  claim 1 , wherein a mortise is formed into a first edge of a first panel body along its defined length for receiving a tenon formed into a corresponding edge of a second panel body to join the first edge of the first panel body to the corresponding edge of the second panel body having the tenon formed there along.  
   
   
       15 . An L header system for use in combination with the building panel of  claim 1 , comprising: 
 an elongated L angle header formed of rigid sheet material, for use in pairs as first and second L headers extending across a rough opening in a wall between first and second building panels;    wherein the first and second L headers are installed inverted across the rough opening on corresponding first and second faces of the wall, extending beyond the rough opening over each first and second building panel by a predetermined distance; and    wherein the first and second L headers provide reinforcement above the rough opening.    
   
   
       16 . The combination of  claim 15 , wherein the in-fill section is a section of an insulated structural building panel having the defined width and a first thickness, and wherein each L-shaped header is installed along an upper edge of the in-fill section with the narrow side of each L-shaped header oriented across the upper edge of the in-fill section and toward but not touching the narrow side of the other L-shaped header, the wide sides of the first and second L-shaped headers being oriented downward next to each first and second face of the in-fill section, to provide an in-fill assembly.  
   
   
       17 . The combination of  claim 15 , wherein a panel track having an elongated channel section is installed, open side facing downward and in contact with the assembly of the inverted first and second L-shaped headers supporting and encasing the in-fill section above the rough opening, such that the panel track bridges the rough opening and the first and second building panels adjoining either side of the rough opening.  
   
   
       18 . A panel track for use in combination with the building panel of  claim 1 , comprising: 
 an elongated channel section formed of rigid sheet material and having a predetermined length, a first side of predetermined width and second and third sides of predetermined height, each second and third side extending at a right angle from a respective first and second edge of the first side, wherein the channel section includes:    a plurality of access openings spaced at approximately equal intervals along a longitudinal axis of the predetermined length of the first side of the channel section and midway between the second and third sides of the channel section; and    a plurality of mounting holes disposed in the first side along and proximate each respective second and third sides of the channel section.    
   
   
       19 . An attachment plate for use in combination with  claim 18 , comprising: 
 a rectangular plate of rigid material for bridging an end-to-end joint of first and second panel tracks.    
   
   
       20 . A T member for use in combination with the building panel of  claim 1 , comprising: 
 an elongated T strut having a standard length and a T shape in cross section having a vertical bar and a cross bar, formed from a rigid sheet material of a predetermined gauge, for use as a first auxiliary framing member adapted to joining first and second building panels together in an edgewise relationship;    wherein a T strut is disposed in each side of a joint between the first and second building panels, the vertical bar of the T strut inserted between adjoining edges of the first and second building panels.    
   
   
       21 . The T member of  claim 20 , wherein the T strut is formed having a first 180 degree, minimum radius bend in a single blank of sheet metal along a longitudinal centerline such that the metal surfaces adjoining the 180 degree bend are substantially in contact to form the vertical bar, and second and third opposing 90 degree bends in the sheet metal disposed a predetermined equal distance from the longitudinal centerline to form the cross bar, wherein the metal surfaces adjoining the 180 degree bend are attached to each other at predetermined intervals along the standard length.  
   
   
       22 . An L member for use in combination with the building panel of  claim 1 , comprising: 
 an L strut having an standard length and an L shape in cross section, formed from a single blank of rigid sheet material of a predetermined gauge, for use as a second auxiliary framing member adapted to reinforcing an edge of a building panel.    
   
   
       23 . The L member of  claim 22 , wherein the L strut formed of a single blank of sheet metal is characterized by an L-shaped cross section having a long leg and a short leg, wherein further the short leg is formed by a minimum radius 180 degree bend in a reference direction along a first axis disposed a short leg distance from a first edge of the blank and a 90 degree bend in the reference direction along a second axis parallel to the first axis and disposed a long leg distance from a second edge of the blank opposite from and parallel to the first edge of the blank, wherein the metal surfaces adjoining the 180 degree bend are attached to each other at predetermined intervals along the standard length of the L strut.  
   
   
       24 . A T member for use in combination with the building panel of  claim 1 , comprising: 
 a T strut having a standard length and a T shape in cross section having a vertical bar and a cross bar, formed from a single blank of sheet metal of a predetermined gauge, for use as a third auxiliary framing member adapted to reinforcing a joint between first and second building panels to provide additional load capacity.    
   
   
       25 . An angle member for use in combination with the building panel of  claim 1 , comprising: 
 an angle strut having a standard length and formed at an angle less than 180 degrees in cross section, formed from a rigid sheet material of a predetermined gauge, for use as a fascia member adapted to reinforcing or covering an open side of a joint between first and second building panels.    
   
   
       26 . The combination of  claim 25 , wherein at least one of the first and second building panels is used as a roof panel.  
   
   
       27 . An insulated structural building panel, comprising: 
 a rectangular panel body formed on a rigid foam material and having a first defined width, a defined length, first and second ends, and first and second substantially parallel faces;    a plurality of elongated, channel-shaped framing members, having an open side and a closed side, oriented parallel to each other and embedded during molding of the rigid foam panel body in each first and second face of the panel body; and    a longitudinal utility recess is formed into at least one face of the panel body between and parallel to the framing members and extending along the defined length of the panel body.    
   
   
       28 . The building panel of  claim 27 , wherein further comprising: 
 a return lip formed into a first and second edge of each open side of each framing member.    
   
   
       29 . The building panel of  claim 27 , wherein the longitudinal utility duct is formed to a depth from the at least one face not exceeding one-half the thickness of the panel body.  
   
   
       30 . An insulated structural building panel, comprising: 
 a rectangular panel body formed of a rigid foam material and having a first defined width, a defined length, first and second ends, and first and second substantially parallel faces; and    a plurality of elongated, channel-shaped framing members, having an open side and a closed side, oriented parallel to each other and embedded during molding of the rigid foam panel body in each first and second face of the panel body; and    a mortise formed into at least one edge of the panel body along its defined length for receiving a key to join the at least one edge of the panel body to a facing edge of a second panel body having a like mortise in the facing edge of the second panel body.    
   
   
       31 . The building panel of  claim 30 , wherein further comprising: 
 a return lip formed into a first and second edge of each open side of each framing member.    
   
   
       32 . The building panel of  claim 30 , wherein the key has a length approximately equal to the length of the mortise and is formed of rigid foam having a density of at least 1.5 pounds per cubic foot.  
   
   
       33 . The building panel of  claim 30 , wherein the key is a tenon formed on the facing edge of the second panel body in place of a mortise in the facing edge of the second panel body.  
   
   
       34 . An insulated structural building panel, comprising: 
 a rectangular panel body formed of a rigid foam material and having a first defined width and first and second sides, a defined length, first and second ends, and first and second substantially parallel faces;    a plurality of elongated, channel-shaped framing members, having an open side and a closed side, oriented parallel to each other and embedded during molding of the rigid foam panel body in each first and second face of the panel body; and    a spacing disposed between the framing members of the building panel along predetermined centers such that the building panel may be cut longitudinally along one framing member to provide a panel having a second defined width less than the first defined width and bordered by a framing member along each side thereof.    
   
   
       35 . The building panel of  claim 34 , wherein further comprising: 
 a return lip formed into a first and second edge of each open side of each framing member.    
   
   
       36 . The building panel of  claim 34 , wherein the framing members of the building panel are disposed according to predetermined spacings disposed between the framing members such that the building panel may be cut longitudinally to a 12 inch width, an 18 inch width, a 30 inch width, or a 36 inch width section having a framing member bounding each side of the first and second faces of the building panel.  
   
   
       37 . The building panel of  claim 34 , wherein the framing members of the building panel are disposed according to predetermined spacings disposed between the framing members such that the building panel may be cut longitudinally to a 16 inch width or a 32 inch width section having a framing member bounding each side of the first and second faces of the building panel.  
   
   
       38 . An L header system for use in a wall constructed of manufactured building panels, comprising: 
 an elongated L angle header formed of rigid sheet material, for use in pairs as first and second L headers extending across a rough opening in a wall between first and second building panels;    wherein the first and second L headers are installed inverted across the rough opening on corresponding first and second faces of the wall, extending beyond the rough opening over each first and second building panel by a predetermined distance; and    wherein the first and second L headers support an in-fill section of a building panel across an uppermost portion of the rough opening.    
   
   
       39 . The combination of  claim 38 , wherein the in-fill section is a section of a building panel having the defined width and a first thickness, and wherein each L-shaped header is installed along an upper edge of the in-fill section with the narrow side of each L-shaped header oriented across the upper edge of the in-fill section and toward but not touching the narrow side of the other L-shaped header, the wide sides of the first and second L-shaped headers being oriented downward next to each first and second face of the in-fill section, to provide an in-fill assembly.  
   
   
       40 . The combination of  claim 38 , wherein a panel track having an elongated channel section is installed, open side facing downward and in contact with the assembly of the inverted first and second L-shaped headers supporting and encasing the in-fill section above the rough opening, such that the panel track bridges the rough opening and the first and second building panels adjoining either side of the rough opening.