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. 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.

1 . A panel, comprising:
 a polymeric insulated core comprising a first groove and a second groove cut out of the core configured to receive a first stud; and   the polymeric insulated core further comprising a third groove and a fourth groove cut out of the core configured to receive a second stud, wherein the first stud and the second stud are attached to opposing outer surfaces of the core such that the first stud is not in contact with the second stud, wherein the first stud and the second stud are C-shaped with a first inwardly extending tab and a second inwardly extending tab configured to be friction fit in the first groove and the second groove respectively.   
     
     
         2 . The panel of  claim 1 , wherein the polymeric insulated core is expanded polystyrene (EPS). 
     
     
         3 . The panel of  claim 1 , wherein at least one of the first stud and the second stud is made from galvanized steel. 
     
     
         4 . The panel of  claim 1 , wherein the polymeric insulated core is flame retardant. 
     
     
         5 . The panel of  claim 1 , wherein each of the panels includes at least one channel useable to receive utility runs. 
     
     
         6 . The panel of  claim 5 , wherein the channel depth in the core is greater than depth of the first groove. 
     
     
         7 . The panel of  claim 1 , wherein the panel further comprises a vertical channel and a first horizontal channel and a second horizontal channel, wherein each channel is configured to span the respective length or width of the panel. 
     
     
         8 . The panel of  claim 1 , wherein the panel is configured to be coupled to a second panel. 
     
     
         9 . The panel of  claim 1 , wherein polymeric insulated core material is removed from between the first groove and a second groove to receive the first stud flush mounted with the face of the panel. 
     
     
         10 . The panel of  claim 1 , wherein the panel is constructed from parts in accordance with ICC code requirements. 
     
     
         11 . The panel of  claim 1 , wherein the interior of the C shaped first stud defines a channel, and wherein a portion of core material between the first groove and the second groove substantially fills the channel upon the insertion of the C shaped first stud in the first groove and the second groove. 
     
     
         12 . The panel of  claim 1 , wherein the panel is attachable to a bottom track, the bottom track attachable to a floor. 
     
     
         13 . The panel of  claim 1 , wherein the panel is attachable to a top track, the top track attachable to a structure above the top track. 
     
     
         14 . The panel of  claim 1 , wherein the panel comprises L-shaped edges. 
     
     
         15 . The panel of  claim 1 , wherein the tabs are configured to at least one of crush and catch the polymeric insulated core upon insertion of the C shaped first stud to the polymeric insulated core. 
     
     
         16 . The panel of  claim 1 , wherein the panel is configured to be coupled to a jamb section. 
     
     
         17 . The panel of  claim 1 , wherein the polymeric insulated core further comprises carbon fiber. 
     
     
         18 . A method for constructing a structure, comprising:
 assembling a plurality of panels together, each of the panels including a polymeric insulated core comprising a first groove and a second groove cut out of the core configured to receive a first stud; and   each of the panels comprising a third groove and a fourth groove cut out of the core configured to receive a second stud, wherein the first stud and the second stud are attached to opposing outer surfaces of the core such that the first stud is not in contact with the second stud, wherein the first stud and the second stud are C-shaped with a first inwardly extending tab and a second inwardly extending tab configured to be friction fit in the first groove and the second groove respectively.   
     
     
         19 . The method of  claim 18 , wherein each panel further comprises a vertical channel and a first horizontal channel and a second horizontal channel, wherein each channel is configured to span the respective length or width of the panel, wherein the channel depth in the polymeric insulated core of the first horizontal channel and the second horizontal channel are greater than depth of the first groove as measured from the face of the panel. 
     
     
         20 . A method for constructing a structure, comprising:
 assembling a plurality of panels together, each of the panels including a polymeric insulated core comprising a first groove and a second groove cut out of the core configured to receive a first stud; and   each of the panels comprising a third groove and a fourth groove cut out of the core configured to receive a second stud, wherein the first stud and the second stud are attached to opposing outer surfaces of the core such that the first stud is not in contact with the second stud, wherein the first stud and the second stud are C-shaped with a first inwardly extending tab and a second inwardly extending tab configured to be friction fit in the first groove and the second groove respectively, wherein the polymeric insulated core between the first groove and the second groove is configured to receive the flush mounted first stud by polymeric insulated core material being removed between the first groove and the second groove.