Straight joint for sandwich panels and method of fabricating same

Abstract

A straight joint and method for connecting two adjacent construction elements, such as sandwich panels, so as to reduce or minimize thermal bridging across the elements. The sandwich panels each have a core, an outer layer, a cavity defined by a portion of the core, and a pathway through the outer layer to the cavity. The panels are erected such that the panel cores are in contact with one another. Bonding material is injected into the cavity through the pathway to seal the joint and maintain the panels in fixed relation to one another.

1 . A straight joint to connect two adjacent construction elements together, the joint comprising:
 two panels, each having a core, an outer layer, and a cavity defined by a portion of the core and a portion of the outer layer, the panels arranged such that the panel cores abut one another;   a pathway through the outer layer of at least one of the panels to the cavity; and   a bonding material injectable through the pathway and into the cavity, the bonding material bonding the panels together.   
     
     
         2 . The straight joint of  claim 1 , wherein the core of each panel includes an edge, and the edges of each panel core are in contact with one another. 
     
     
         3 . The straight joint of  claim 2 , wherein the cavity extends along a length of the outer layer of each panel, wherein the length of the cavity along the outer layer is at least seven times greater than a thickness of the outer layer. 
     
     
         4 . The straight joint of  claim 3 , wherein the cavity extends perpendicularly from the outer layer along a length of the core, wherein the length of the cavity extending perpendicularly into the core is at least seven times greater than the thickness of the outer layer. 
     
     
         5 . The straight joint of  claim 1 , wherein the pathway is a gap between the edges of the adjacent panels 
     
     
         6 . The straight joint of  claim 5 , wherein the gap is defined by an edge of the outer layers of each panel. 
     
     
         7 . The straight joint of  claim 1 , wherein the pathway includes at least one hole. 
     
     
         8 . The straight joint of  claim 1 , wherein each panel further comprises a second outer layer spaced from the first outer layer by the panel core, a second cavity defined by a portion of the core and a portion of the second outer layer, a second pathway through the second outer layer of at least one of the panels to the second cavity, and bonding material in the second cavity. 
     
     
         9 . The straight joint of  claim 8 , wherein the second cavity is thermally separated from the first cavity by the abutment of the panel cores. 
     
     
         10 . The straight joint of  claim 9 , wherein the panel cores inhibit thermal transmissions across the joint. 
     
     
         11 . The straight joint of  claim 1 , wherein the panel cores are insulating materials. 
     
     
         12 . The straight joint of  claim 1 , wherein the outer layer is comprised of composite materials. 
     
     
         13 . A method of joining sandwich panels with a straight joint, wherein each panel has a core and an outer layer, the method comprising:
 forming a cavity between a portion of the outer layer and a portion of the core of each panel;   arranging the panels such that the panel cores abut one another at an edge of each core and the cavities of the respective sandwich panels align to form a combined cavity;   providing a pathway to the combined cavity through the outer layer of at least one of the panels; and   filling the combined cavity with an bonding material.   
     
     
         14 . The method of  claim 13 , wherein the cavities are formed by removing a portion of the core near the outer layer and a portion of the core extending perpendicularly from the outer layer. 
     
     
         15 . The method of  claim 14 , wherein the portion of the core removed near the outer layer has a length that is at least seven times a thickness of the outer layer. 
     
     
         16 . The method of  claim 15 , wherein the portion of the core extending perpendicularly from the outer layer has a length that is at least seven times the thickness of the outer layer. 
     
     
         17 . The method of  claim 13 , wherein the cavity is triangular. 
     
     
         18 . The method of  claim 13 , wherein the step of providing a pathway comprises removing a portion of the outer layer of at least one of the panels. 
     
     
         19 . The method of  claim 18 , wherein the portion removed forms a hole in the outer layer. 
     
     
         20 . The method of  claim 18 , wherein the portion removed is a strip of the outer layer near the edge of the panel core such that a gap is formed between the edges outer layers of each panel. 
     
     
         21 . The method of  claim 13 , wherein the panels are installed as part of a building. 
     
     
         22 . The method of  claim 21 , wherein the building is a monolithic structure. 
     
     
         23 . The method of  claim 13 , wherein the straight joint is resistant to thermal transmissions from one side of the panels to the other side of the panels. 
     
     
         24 . A sandwich panel comprised of:
 a first outer layer and a second outer layer, the outer layers separated from one another by an insulative core;   a cavity formed in the insulative core, the cavity defined by a portion of the first outer layer and a portion of the core; and   a pathway through the first outer layer to the cavity through which a bonding material may be injected to form a joint between the sandwich panel and an adjacent construction element, wherein the insulative core inhibits thermal transfer across the joint from the first outer layer to the second outer layer.   
     
     
         25 . A method of forming a sandwich panel comprising:
 mounting an outer layer to a core;   forming a cavity between a portion of the outer layer and a portion of the core; and   providing access to the cavity through the outer layer with a pathway through which bonding material is injectable to join the sandwich panel to a construction element.