Modular building system utilizing composite, foam core panels

Abstract

A system is for constructing a structure and includes composite panels having a laminate structure. The laminate structure includes a foam core to which are attached cover layers of the same or different material. One or both of the cover layers may include composite sub-layers. The system includes a number elongate and preferably extruded components for connecting the panels to form walls, roofs or floors for the structure. The system is modular, thereby providing a time and cost efficient approach for erecting a structure.

1 . A system for constructing a structure comprising:
 a plurality of generally planar wall panels, each of said wall panels having a laminate structure comprising a rigid foam core slab sandwiched between first and second cover layers, the wall panels defining at least one of wall panels, roof panels or floor panels; and,   a plurality of panel connecting components for connecting the wall panels to form at least one of walls, roofs, floors or combinations thereof; the connecting members including means for receiving ends of adjacent wall panels.   
     
     
         2 . The system of  claim 1 , wherein the panel connecting components include at least two slots for receiving and retaining ends of adjacent wall panels. 
     
     
         3 . The system of  claim 1 , wherein the connecting components comprise elongate, extruded bodies. 
     
     
         4 . The system of  claim 1 , wherein the connecting components include corner connecting components, each of said corner connecting components comprising a pair of angularly separated slots adapted to receive ends of said wall panels forming a corner of the structure. 
     
     
         5 . The system of  claim 1 , wherein the connecting components include first roof panel connecting components, each of said first roof panel connecting components comprising a first engagement means for engaging an upper end of a wall panel, and a second engagement means adapted to engage ends of roof panels. 
     
     
         6 . The system of  claim 1 , wherein the connecting components include second roof panel connecting components, each of said second roof panel connecting components comprising oppositely directed ledges or slots for receiving ends of adjacent roof panels for forming a ridge of a roof for the structure. 
     
     
         7 . The system of  claim 1 , wherein the connecting components include sill components, each of said sill components comprising a first end for resting on a surface and a second end including a first engagement means for engaging bottom ends of the wall panels. 
     
     
         8 . The system of  claim 7 , wherein each of said sill components includes a second engagement means for supporting ends of said floor panels. 
     
     
         9 . The system of  claim 5 , wherein the first engagement means of each first roof panel connecting component comprises a bearing surface for resting on the upper ends of the wall panels or ceiling joints attached to the upper ends of the wall panels. 
     
     
         10 . The system of  claim 5 , wherein the second engagement means of each first roof panel connecting component is angled with respect to the first engagement means for orienting the roof panel at a desired pitch. 
     
     
         11 . The system according to  claim 1 , wherein the first and second cover layers of the wall panels are formed of the same or different material. 
     
     
         12 . The system of  claim 11 , wherein at least one of the first and second cover layers comprises a composite layer comprising a sub foam core covered by sub cover layers. 
     
     
         13 . The system of  claim 11 , wherein the outer cover layer of the roof panels comprises a metal sheet. 
     
     
         14 . The system of  claim 1 , wherein the panel connecting components comprise pins and corresponding keyholes provided on opposing ends of wall panels, the pins being shaped to fit within the keyholes in a locking arrangement to form a connection between adjacent wall panels. 
     
     
         15 . The system of  claim 1 , wherein the wall panels include reinforcement members at opposed ends for providing at least one of an attachment means or a strengthening means for the panels. 
     
     
         16 . The system of  claim 15 , wherein the panel connecting components are adapted to receive or engage the reinforcement members of adjacent wall panels. 
     
     
         17 . (canceled) 
     
     
         18 . An I-beam comprising:
 a pair of support elements separated by a web element,   wherein the web element comprises a laminate structure comprising a rigid foam core slab sandwiched between first and second cover layers.   
     
     
         19 . The I-beam of  claim 18 , wherein the support elements comprise at least one of composite materials, extruded materials or wood. 
     
     
         20 . The I-beam of  claim 19 , wherein the support elements include slots to receive opposing edges of the panel.