Building structure and components thereof

Abstract

Building components and building structures including structurally insulated panels and cavities for accommodating building services, which cavities are insulated and vapor sealed. The cavity is formed by providing cross beams that accept connection therebetween of structurally insulated panels on one end, but include portions that extend beyond the surface of the structurally insulated panels to accept structural sheating thereon. Building components are also taught that include keyed connections between cross beams and structurally insulated panels.

1 . A planar building component comprising:
 (a) cross beams extending substantially laterally in the planar building component, the cross beams each including an upper portion with a top surface and a lower portion formed at least in part integral with the upper portion;   (b) at least one longitudinal support member each supporting at least a pair of the cross beams in relative position in the building component;   (c) structurally insulated panels, each including a lower sheet material layer, an upper sheet material layer and foam insulation therebetween, the structurally insulated panels being connected to the lower portions of the cross beams to span a space between adjacent cross beams, the connection between the panels and the cross beams leaving the upper portion of the cross beams protruding above the panels; and   (d) component sheathing installed above the top surfaces of the cross beams creating a cavity between the panels and the component sheathing.   
     
     
         2 . The planar building component of  claim 1  wherein the longitudinal support member is positioned to act between the cross beams and a supporting structure below the planar building component. 
     
     
         3 . The planar building component of  claim 1  wherein the upper portions of a plurality of cross beams each include at least one opening therethrough to provide access from one side to the other of those cross beams. 
     
     
         4 . The planar building component of  claim 1  wherein the bottom portion of at least one cross beam includes a protrusion formed thereon to fit into a channel on an edge of a structurally insulated panel and the protrusion is keyed into the channel. 
     
     
         5 . The planar building component of  claim 1  wherein the lower portions of the cross beams each include a protrusion therealong to provide for a jointed connection to a grooved edge of the structurally insulated panels attached thereto. 
     
     
         6 . The planar building component of  claim 1  wherein at least one longitudinal support beam is secured on a perimeter of the planar building component. 
     
     
         7 . The planar building component of  claim 6  wherein the at least one longitudinal support beam includes an opening therethrough for access to the cavity. 
     
     
         8 . The planar building component of  claim 1  further comprising a fill frame installed above the structurally insulated panels and between cross beams to provide further support for component sheathing. 
     
     
         9 . The planar building component of  claim 1  further comprising edging materials applied on a perimeter of the planar building component. 
     
     
         10 . A building structure comprising:
 a horizontal building component including (a) cross beams extending substantially laterally in the planar building component, the cross beams each including an upper portion with a top surface and a lower portion formed at least in part integral with the upper portion; (b) at least one longitudinal support member each supporting at least a pair of the cross beams in relative position in the building component; (c) structurally insulated panels, each including a lower sheet material layer, an upper sheet material layer and foam insulation therebetween, the structurally insulated panels being connected to the lower portions of the cross beams to span a space between adjacent ones of the cross beams, the connection between the panels and the cross beams leaving the upper portion of the cross beams protruding above the panels; and (d) component sheathing installed above the top surfaces of the cross beams creating a cavity between the panels and the component sheathing; and   a wall member extending substantially vertically from the horizontal building component.   
     
     
         11 . The building structure of  claim 10  wherein the longitudinal support member is positioned to act between the cross beams and a supporting structure below the planar building component. 
     
     
         12 . The building structure of  claim 10  wherein the upper portions of a plurality of cross beams each include at least one opening therethrough to provide access from one side to the other of those cross beams. 
     
     
         13 . The building structure of  claim 10  wherein the bottom portion of at least one cross beam includes a protrusion formed thereon to fit into a channel on an edge of a structurally insulated panel and the protrusion is keyed into the channel. 
     
     
         14 . The building structure of  claim 10  wherein the lower portions of the cross beams each include a protrusion therealong to provide for a jointed connection to a grooved edge of the structurally insulated panels attached thereto. 
     
     
         15 . The building structure of  claim 10  wherein at least one longitudinal support beam is secured on a perimeter of the planar building component. 
     
     
         16 . The building structure of  claim 10  wherein the at least one longitudinal support beam includes an opening therethrough for access to the cavity. 
     
     
         17 . The building structure of  claim 10  further comprising a fill frame installed above the structurally insulated panels and between cross beams to provide further support for component sheathing. 
     
     
         18 . The building structure of  claim 10  further comprising edging materials applied on a perimeter of the planar building component. 
     
     
         19 . The building structure of  claim 10  wherein the wall member includes structurally insulated panels. 
     
     
         20 . The building structure of  claim 19  wherein at least some of the wall structurally insulated panels include an outer sheet material layer, an inner sheet material layer and an insulative layer between the sheet material layers. 
     
     
         21 . The building structure of  claim 20  wherein the inner sheet material layer includes interior finishing materials. 
     
     
         22 . The building structure of  claim 20  wherein the wall structurally insulated panels are mounted above the top surfaces of the cross beams and the outer sheet material layer extends down over a perimeter thickness of the horizontal planar member. 
     
     
         23 . The building structure of  claim 20  further comprising a roof including at least one structurally insulated panel. 
     
     
         24 . The building structure of  claim 23  wherein the roof includes a plurality of beams, at least two adjacent beams including a lower portion, an upper portion integral with the lower portion and at least one structurally insulated panel spanning an open area between the adjacent beams, the at least one structurally insulated panel including a skin formed of interior finishing materials positioned to be downward facing. 
     
     
         25 . The building structure of  claim 24  wherein the upper portion of the roof beams are cut to have a depth that decreases from one side to the other, such that a roof slope is formed. 
     
     
         26 . A planar building component comprising:
 (a) cross beams extending substantially laterally in the planar building component, the cross beams each including an upper portion with a top surface, a lower portion and a protrusion extending from at least one side of the lower portion;   (b) at least one longitudinal support member each supporting at least a pair of the cross beams in relative position in the building component;   (c) structurally insulated panels, each including a lower sheet material layer, an upper sheet material layer and foam insulation therebetween, the lower sheet material layer and the upper sheet material layer extending out beyond the foam insulation to form a channel along a panel edge, the structurally insulated panels being connected to the lower portions of the cross beams to span a space between adjacent cross beams, the connection having the protrusion inserted between and connected to the lower sheet material layer and the upper sheet material layer; and   (d) component sheathing installed above the top surfaces of the cross beams creating a cavity between the panels and the component sheathing.   
     
     
         27 . The planar building component of  claim 26  wherein the lower sheet material layer extends out beyond the foam insulation a distance greater than that distance extended by the upper sheet material layer such that the lower sheet material layers from the structurally insulated panels on either side of a cross beam abut below the cross beam. 
     
     
         28 . The planar building component of  claim 26  wherein the longitudinal support member is positioned to act between the cross beams and a supporting structure below the planar building component. 
     
     
         29 . The planar building component of  claim 26  wherein the upper portions of a plurality of cross beams each include at least one opening therethrough to provide access from one side to the other of those cross beams. 
     
     
         30 . The planar building component of  claim 26  wherein at least one longitudinal support beam is secured on a perimeter of the planar building component. 
     
     
         31 . The planar building component of  claim 30  wherein the at least one longitudinal support beam includes an opening therethrough for access to the cavity. 
     
     
         32 . The planar building component of  claim 26  further comprising a fill frame installed above the structurally insulated panels and between cross beams to provide support for component sheathing. 
     
     
         33 . The planar building component of  claim 26  further comprising edging materials applied on a perimeter of the planar building component.