Ceiling support construction and methods

Abstract

A ceiling construction and method for supporting an upper level of structure using sandwich panels having insulative cores. The ceiling construction has a lower level wall sandwich panel and an upper level wall sandwich panel, each of which with two outer layers and a core separating the outer layers and an upper level wall sandwich panel. Adhered to the lower level wall sandwich panel is a beam configured to support the upper level of the structure.

What is claimed is: 
     
         1 . A ceiling construction comprising:
 a lower level wall sandwich panel having two outer layers and a core separating the outer layers;   an upper level wall sandwich panel above the lower level wall sandwich panel, the upper level wall sandwich panel having two outer layers and a core separating the outer layers;   a beam adjacent to the lower level wall sandwich panel, the beam being configured to support an upper level and having a top, a bottom, two minor sides, two major sides, an outer layer on each of the two major sides, and a core between the two outer layers; and   bonding material adhering a minor side of the beam to an outer layer of the lower level wall sandwich panel.   
     
     
         2 . The ceiling construction of  claim 1  wherein the first wall sandwich panel is comprised of at least two sandwich panels and wherein the upper level is partially supported by at least one of the at least two sandwich panels. 
     
     
         3 . The ceiling construction of  claim 1  further comprising:
 a first U-profile wall bracket bonded to the outer layers of the lower level wall sandwich panel and positioned between the lower level wall sandwich panel and the upper level wall sandwich panel; and 
 a second U-profile wall bracket bonded to the outer layers of the upper level wall sandwich panel and positioned between the upper level wall sandwich panel and the lower level wall sandwich panel. 
 
     
     
         4 . The ceiling construction of  claim 3  further comprising bonding material between the first U-profile wall bracket and the second U-profile wall bracket. 
     
     
         5 . The ceiling construction of  claim 3  wherein the first U-profile wall bracket and the second U-profile wall bracket form a single H-profile wall bracket. 
     
     
         6 . The ceiling construction of  claim 3  wherein the distance that the first U-profile bracket extends along the outer layers of the lower level wall sandwich panel is at least approximately seven times the thickness of the outer layers of the lower level wall sandwich panel. 
     
     
         7 . The ceiling construction of  claim 1  further comprising a U-profile beam bracket bonded to the outer layers of the beam and positioned between the beam and the upper level. 
     
     
         8 . The ceiling construction of  claim 1  wherein outer layers of the lower level wall sandwich panel extend beyond the top of the core of the lower wall sandwich panel, wherein the outer layers of the upper level wall sandwich panel extend beyond the bottom of the upper level wall sandwich panel, and further comprising bonding material in a space created between the core of the lower level wall sandwich panel and the core of the upper level wall sandwich panel. 
     
     
         9 . The ceiling construction of  claim 8  wherein the distance that the outer layers of the lower level wall sandwich panel extend beyond the top of the core of the lower wall sandwich panel is at least approximately seven times the thickness of the outer layers of the lower level wall sandwich panel. 
     
     
         10 . The ceiling construction of  claim 1  further comprising a second lower level wall sandwich panel below the lower level wall sandwich panel. 
     
     
         11 . The ceiling construction of  claim 10  further comprising:
 a third U-profile wall bracket bonded to the outer layers of the lower level wall sandwich panel and positioned between the lower level wall sandwich panel and the second lower level wall sandwich panel; and 
 a fourth U-profile wall bracket bonded to the outer layers of the second lower level wall sandwich panel and positioned between the second lower level wall sandwich panel and the lower level wall sandwich panel. 
 
     
     
         12 . The ceiling construction of  claim 10  wherein the outer layers of the lower level wall sandwich panel extend beyond the bottom of the core of the lower wall sandwich panel and wherein the outer layers of the second lower level wall sandwich panel extend beyond the top of the second lower level wall sandwich panel, and further comprising bonding material in a space created between the core of the lower level wall sandwich panel and the core of the second lower level wall sandwich panel. 
     
     
         13 . The ceiling construction of  claim 1  wherein the distance from top to bottom of the lower level sandwich panel is approximately the same as the distance from top to bottom of the beam. 
     
     
         14 . The ceiling construction of  claim 1  wherein the distance from the top to the bottom of the beam ranges from approximately 200 mm to approximately 600 mm. 
     
     
         15 . The ceiling construction of  claim 1  wherein the beam is a sandwich panel having two outer layers and a core separating the outer layers. 
     
     
         16 . The ceiling construction of  claim 1  wherein the beam comprises multiple sandwich panels arranged side by side, each sandwich panel having two outer layers and a core separating the outer layers. 
     
     
         17 . The ceiling construction of  claim 1  wherein the lower level wall sandwich panel and the upper level wall sandwich panel are a single wall sandwich panel, part of which is in a lower level and part of which is in an upper level. 
     
     
         18 . A method for forming a ceiling construction from a plurality of panels comprising:
 placing an upper level wall sandwich panel having two outer layers and a core separating the outer layers above a lower level wall sandwich panel having two outer layers and a core separating the outer layers;   fixing the upper level wall sandwich panel with respect to the lower level wall sandwich panel;   placing a beam adjacent to the lower level wall sandwich panel, the beam having a top, a bottom, two minor sides, two major sides, an outer layer on each of the two major sides, and a core between the two outer layers;   adhering a minor side of the beam to an outer layer of the lower level wall sandwich panel using bonding material; and   placing a second level adjacent the upper level wall sandwich panel such that the second level is at least partially supported by the beam.   
     
     
         19 . The method of  claim 18  further comprising adhering an opposing minor side of the beam to another lower level wall sandwich panel. 
     
     
         20 . The method of  claim 18  further comprising placing a U-profile wall bracket between the beam and the second level. 
     
     
         21 - 24 . (canceled)