Construction System Using Interlocking Panels

Abstract

A system for constructing a structure, such as a wall, by assembling a plurality of interlocking panels together, is provided. Each of the panels includes a core made of an insulating material, preferably, an expanded polystyrene (EPS). Importantly, the panels include stiffeners (studs) on the outer surfaces; each spaced, preferably, about 24 inches on center (OC), to form a rigid exoskeleton. Preferably, the studs are made of galvanized steel. Unlike in conventional wood framing, the studs do not extend from the exterior surface to the interior surface. Instead, the studs are each structured as C-shaped supports wherein each stud is inserted into a grove pair cut into the core. Accordingly, conduction across the studs from the exterior to the interior, and vice versa, does not occur because the studs do not extend through the panels. Preferably, each of the panels has a top track and a bottom track, these tracks made from steel. Preferably, the bottom panels are attachable to a floor, such as a concrete floor, using suitable fasteners. Preferably, the top tracks are attachable to a ceiling using suitable fasteners. Preferably, the panels can be joined together by fitting complementary L-shaped edges together.

1 . A panel, comprising:
 a polymeric insulated core; and   an exoskeleton, including at least one pair of studs, each of the pair of studs including a first stud and a second stud, the first stud and the second stud attached to opposing outer surfaces and not touching each other.   
     
     
         2 . The panel of  claim 1 , wherein the polymeric insulated core is expanded polystyrene (EPS). 
     
     
         3 . The panel of  claim 1 , wherein the at least one pair of studs is made from a rigid material. 
     
     
         4 . The panel of  claim 4 , wherein the rigid material is galvanized steel. 
     
     
         5 . The panel of  claim 1 , wherein each one of the studs is C-shaped, secured to an outer surface of the panel via at least one groove formed in the core. 
     
     
         6 . The panel of  claim 5 , wherein each of the C-shaped studs includes extending tabs. 
     
     
         7 . The panel of  claim 1 , wherein the polymeric insulated core is flame retardant. 
     
     
         8 . The panel of  claim 1 , where each of the panels includes at least one channel useable to receive utility runs. 
     
     
         9 . The panel of  claim 1 , wherein the panel is attachable to a bottom track, the bottom track attachable to a floor. 
     
     
         10 . The panel of  claim 1 , wherein the panel is attachable to a top track, the bottom track attachable to a floor. 
     
     
         11 . The panel of  claim 1 , wherein the panel includes L-shaped edges. 
     
     
         12 . The panel of  claim 1 , wherein the panel is constructed from parts that are in accordance with ICC code requirements. 
     
     
         13 . A method for constructing a structure, comprising:
 assembling a plurality of panels together, each of the panels including a polymeric insulated core and having at least one pair of studs, each of the pair of studs including a first stud and a second stud, the first stud and the second stud attached to opposing outer surfaces and not touching each other.   
     
     
         14 . The method of  claim 13 , wherein the polymeric insulated core is an expanded polystyrene (EPS). 
     
     
         15 . The method of  claim 13 , wherein the at least one pair of studs is made from a rigid material. 
     
     
         16 . The method of  claim 15 , wherein the rigid material is galvanized steel. 
     
     
         17 . The method of  claim 13 , wherein each one of the studs is C-shaped, secured to an outer surface of a panel via at least one groove formed in the core. 
     
     
         18 . The method of  claim 17 , wherein the C-shaped studs include extending tabs. 
     
     
         19 . The method of  claim 13 , further comprising the step of attaching a bottom track a floor, the track bottom track also attached to the assembled panel structure. 
     
     
         20 . The method of  claim 13 , further comprising the step of attaching a top track to a ceiling, the top track also attached to the assembled panel structure. 
     
     
         21 . The method of  claim 20 , further comprising the step of attaching at least one splice plate to the top track. 
     
     
         22 . The method of  claim 13 , wherein the panels include jamb pieces. 
     
     
         23 . The method of  claim 13 , wherein the panels are assembled together by joining complementary edges.