Composite foam panel housing unit

Abstract

A foam panel housing erection method and utility distribution system is disclosed. Metal skin composite foam panels with matching side joint profiles are structurally engaged side by side. A stud running in the transverse direction of the panel span is secured to the wall near the interior panel side joint using a fastener penetrating through the interior female metal skin profile of the panel on the right side and the interior male metal skin profile of the panel on the left side. The hat shaped stud is secured in position to the panel using a fastener. The interior finish panel is fastened to the lower flange of the stud creating continuous utility distribution cavities in the transverse direction to the panel span. Since the spacing of the stud is in the longitudinal direction of the panel span, uniform stud spacing can be maintained regardless of the panel cover-width.

1 . A foam panel housing erection method comprising:
 engaging a first metal skin composite foam panel and a second metal skin composite foam panel with matching side joint profiles side by side;   positioning a stud running in a transverse direction of a panel span of the first metal skin composite foam panel and the second metal skin composite foam panel;   securing the stud in a position near an interior panel side joint using a fastener, the fastener penetrating through an interior female metal skin profile of the first metal skin composite foam panel and an interior male metal skin profile of the second metal skin composite foam panel; and   securing an interior finish panel in position.   
     
     
         2 . The foam panel housing erection method of  claim 1 , where the stud is hat shaped. 
     
     
         3 . The foam panel housing erection method of  claim 1 , where the fastener is a screw. 
     
     
         4 . The foam panel housing erection method of  claim 1 , where the interior finish panel is secured using a screw. 
     
     
         5 . The foam panel housing erection method of  claim 1 , where the interior finish panel is fastened to a lower flange of the stud to create a continuous utility distribution cavity in a transverse direction of the panel span. 
     
     
         6 . The foam panel housing erection method of  claim 1 , further comprising:
 forming a wall panel by engaging additional metal skin composite foam panels to the first metal skin composite foam panel and the second metal skin composite foam panel and positioning and securing another stud for each additional metal skin composite foam panel.   
     
     
         7 . The foam panel housing erection method of  claim 6 , further comprising:
 forming a wall corner by butting two wall panels together and fastening the two wall panels together with interior corner trim on an interior surface of the wall corner.   
     
     
         8 . The foam panel housing erection method of  claim 7 , further comprising:
 fastening exterior corner trim with weather seal to an exterior surface of the wall corner.   
     
     
         9 . The foam panel housing erection method of  claim 8 , where the interior corner trim and the exterior corner trim are fastened using space apart fasteners. 
     
     
         10 . The foam panel housing erection method of  claim 1 , where, prior to securing the interior finish panel in position, utility wires, cables, and pipes are installed. 
     
     
         11 . The foam panel housing erection method of  claim 6 , further comprising:
 forming a roof panel and a wall panel junction by inter-connecting the roof panel and the wall panel with a corner member.   
     
     
         12 . The foam panel housing erection method of  claim 11 , where the wall panel is fastened to the corner member using spaced apart fasteners and the roof panel is fastened to the corner member using spaced apart fasteners and clips. 
     
     
         13 . The foam panel housing erection method of  claim 11 , where the interior finishing panel is fastened to extended flanges of the corner member. 
     
     
         14 . The foam panel housing erection method of  claim 11 , where roof panels have over-lapping ribbed side joints secured to the corner member. 
     
     
         15 . The foam panel housing erection method of  claim 1 , further comprising:
 forming a roof ridge by securing roof panels and interior finishing panels on both sides of the roof ridge to a ridge member.   
     
     
         16 . The foam panel housing erection method of  claim 6 , further comprising:
 forming a wall base by fastening a thermally broken aluminum extrusion to a concrete floor; and   fastening wall panels to the wall base.   
     
     
         17 . A foam panel housing erection method comprising:
 engaging a first metal skin composite foam panel and a second metal skin composite foam panel with matching side joint profiles side by side;   positioning a stud running in a transverse direction of a panel span of the first metal skin composite foam panel and the second metal skin composite foam panel;   securing the stud in a position near an interior panel side joint using a fastener, the fastener penetrating through an interior female metal skin profile of the first metal skin composite foam panel and an interior male metal skin profile of the second metal skin composite foam panel;   forming a wall panel by engaging additional metal skin composite foam panels to the first metal skin composite foam panel and the second metal skin composite foam panel and positioning and securing another stud for each additional metal skin composite foam panel; and   securing an interior finish panel to the wall panel.   
     
     
         18 . The foam panel housing erection method of  claim 17 , further comprising:
 forming a roof panel and a wall panel junction by inter-connecting the roof panel and the wall panel with a corner member.   
     
     
         19 . The foam panel housing erection method of  claim 17 , further comprising:
 forming a roof ridge by securing roof panels on both sides of the roof ridge to a ridge member.   
     
     
         20 . A foam panel housing erection method comprising:
 engaging a first metal skin composite foam panel and a second metal skin composite foam panel with matching side joint profiles side by side;   positioning a stud running in a transverse direction of a panel span of the first metal skin composite foam panel and the second metal skin composite foam panel;   securing the stud in a position near an interior panel side joint using a fastener, the fastener penetrating through an interior female metal skin profile of the first metal skin composite foam panel and an interior male metal skin profile of the second metal skin composite foam panel;   forming a wall panel by engaging additional metal skin composite foam panels to the first metal skin composite foam panel and the second metal skin composite foam panel and positioning and securing another stud for each additional metal skin composite foam panel;   forming a wall base by fastening a thermally broken aluminum extrusion to a concrete floor;   fastening the wall panel to the wall base;   forming a roof panel and a wall panel junction by inter-connecting the roof panel and the wall panel with a corner member;   forming a roof ridge by securing roof panels on both sides of the roof ridge to a ridge member; and   securing an interior finish panel to the wall panel and roof panel.