Poly-bonded building panels

Abstract

A light weight single layer building panel with a peripheral frame of metal, wood ceramic or plastic, with or without internal members, deriving its structural integrity from the peripheral frame and internal members if used, the layer of expanded foam and the bonding of the expanded foam to the peripheral frame and internal members if used. This unique building panel can be coupled together with more of the like panels and used as a single layer to construct a wall, ceiling, roof, floor or complete building and can be used in conjunction with decorative veneers. The design allows for the building panel to be used in its own building system or as much or as little of the technology as needed can be employed into convention construction projects.

1 . A building panel having structural integrity, comprising: 
 a peripheral frame including a top horizontal stud member, a bottom horizontal stud member, a left vertical stud member, and a right vertical stud member, wherein a first end portion of the top horizontal stud member joins to a first end portion of the left vertical stud member, a second end portion of the top horizontal stud member joins to a first end portion of the right vertical stud member, a first end portion of the bottom horizontal stud member joins to a second end portion of the left vertical stud member, and a second end portion of the bottom horizontal stud member joins to a second end of the right vertical stud member; and an expanded foam member formed at least within the peripheral frame, wherein the expanded foam fills the peripheral frame, and is bonded to the peripheral frame, a first exposed side of the expanded foam defines an exterior building surface of the panel, and a second exposed side of the expanded foam defines an interior building surface of the building panel.    
   
   
       2 . The building panel of  claim 1 , wherein the structural integrity of the building panel is derived from the peripheral frame, the expanded foam member and the bonding of the expanded foam member to the peripheral frame.  
   
   
       3 . The building panel of  claim 1 , wherein the expanded foam is one of a thermoset material.  
   
   
       4 . The building panel of  claim 1 . wherein the top horizontal stud member, the bottom horizontal stud member, the right vertical stud member, and the left vertical stud member is fabricated from one of metal, wood, ceramic, plastic or a combination thereof.  
   
   
       5 . The building panel of  claim 1 , wherein the top horizontal stud member, the bottom horizontal stud member, the right vertical stud member and the left vertical stud member is configured as one of; a conventional stud, a C-shaped stud, a U-shaped channel, a L-shaped angle material, a interlocking stud or a combination thereof.  
   
   
       6 . The building panel of  claim 1 , wherein a first side of the expanded foam defines the exterior building surface of the building panel.  
   
   
       7 . The building panel of  claim 6 , wherein a second side of the expanded foam defines the interior building surface of the building panel.  
   
   
       8 . The building panel of  claim 7 , wherein the expanded foam extends to the outer boundary of the peripheral frame.  
   
   
       9 . The building panel of  claim 1 , wherein at least one of the right vertical stud member and the left vertical stud member is an interlocking stud operable to interlock with an interlocking stud of an adjacent structural component.  
   
   
       10 . An interlocking stud comprising; 
 a face having a Z-shaped configuration    a first side wall extending away from the face and bending toward a second side wall at the farthest point away from the face    a second side wall extending away from the face and bending toward a first side wall at the farthest point away from the face.    
   
   
       11 . The interlocking stud of  claim 10 , wherein the interlocking stud is operable to interlock with another interlocking stud having substantially the same configuration as the face of the interlocking stud.  
   
   
       12 . An interlocking stud with utility conduit comprising; 
 a face having a Z-shaped configuration with a utility conduit extending there thru    a first side wall extending away from the face and bending toward a second side wall at the farthest point away from the face    a second side wall extending away from the face and bending toward a first side wall at the farthest point away from the face.    
   
   
       13 . The interlocking stud of  claim 12 , wherein the interlocking stud with utility conduit is operable to interlock with another interlocking stud having substantially the same configuration as the face of the interlocking stud.  
   
   
       14 . An improved modular building, said building comprising: 
 a first set of building panels defining the perimeter of the modular building, wherein each of the building panels include a peripheral frame having a top horizontal stud member, a bottom horizontal stud member, a left vertical stud member, and a right vertical stud member, wherein a first end portion of the top horizontal stud member joins to a first end portion of the left vertical stud member, a second end portion of the top horizontal stud member joins to a first end portion of the right vertical stud member, a first end portion of the bottom horizontal stud member joins to a second end portion of the left vertical stud member, and a second end portion of the right vertical stud member; and an expanded foam member formed at least within the peripheral frame, wherein the expanded foam member fills the peripheral frame, and is bonded to the peripheral frame, a first exposed side of the expanded foam defines an exterior building surface of the panel, and a second exposed side of the expanded foam defines an interior building surface of the building panel, each of the building panels configured with an interlocking stud as the left vertical stud member and the right vertical stud member for interlocking with an adjacent building panel configured with an interlocking stud as the left vertical stud member and the right vertical stud member; a roof supported by, and secured to, the first set of building panels.    
   
   
       15 . The improved modular building of  claim 14 , wherein the roof is constructed from a second set of panels.  
   
   
       16 . The improved modular building of  claim 14 , further comprising a set of tracks, wherein each track in the set of tracks includes a base portion, a first track sidewall, a second track sidewall and pre-set holes at regular intervals in the base portion and is secured to the foundation of the modular building.  
   
   
       17 . The improved modular building of  claim 14 , further comprising a set of anchors, wherein each anchor in the set of anchors includes a L-shaped metal rod squarely abutting and affixed to the center of a metal disc and each anchor in the set of anchors is inserted L-shaped rod first through one of the pre-set holes in the base portion of the track and into the foundation until the metal disc affixed to the top of the anchor engages the base portion of the track and the base portion of the track engages the foundation.  
   
   
       18 . A system for securing a wall of a building to a foundation, comprising: 
 a track including a base portion, a first track side wall, a second track side wall, and pre-set holes at regular intervals    a set of anchors, wherein each anchor in the set of anchors includes a L-shaped metal rod squarely abutting and affixed to the center of a metal disc.    
   
   
       19 . The system of  claim 18 , wherein each anchor in the set of anchors is inserted L-shaped rod first through one of the pre-set holes in the base portion of the track and into the foundation until the metal disc affixed to the top of the anchor engages the base portion of the track and the base portion of the track engages the foundation.  
   
   
       20 . The system of  claim 18 , wherein the building panel is inserted within the first track side wall and the second track side wall of the track.