Stiffened Frame Supported Panel

Abstract

Frame supported panels with an increased load carrying capacity derived from inducing newly discovered conditions on panels made from weaker, lighter and thinner materials. The fixed/continuous/dropped condition can increase a panel's load capacity many times based on the panel's interaction with frame members. This enables foam panels, for example, to be used in structural applications. It also enables polyurethane foam with any cladding to provide a comprehensive, structural building panel that provides a finished exterior, continuous and cavity insulation, an air, moisture and vapor barrier and increased uplift resistance while eliminating condensation and thermal expansion/contraction.

1 . A frame supported panel with an increased load capacity comprised of:
 a. a single or a multitude of frame members having a top edge, a bottom edge and two sides and said frame members are spaced a distance apart with one or more spans between said frame members and   b. a panel with a continuous section and one or more dropped sections to comprise one or more thickened sections and   c. said continuous section supported by said frame members and continuous over said top edges and said continuous section has a thickness of 0.02″ to 6″ and has a continuous conditioned load capacity over each said span and   d. said dropped sections situated between said sides and   e. said thickened sections have a flexural stiffness and   f. said panel fixed to said top edges and/or to one or more said sides with a bonding technique and said bonding technique has a bonding capacity of at least 10 psi and   g. said panel has a fixed/continuous/dropped condition with an increased load capacity, over at least half of said spans, that is at least 25% greater than said continuous conditioned load capacity and   h. said frame members have sufficient rotational resistance to facilitate at least said 25% greater load capacity,   i. whereby said panel has an increased load capacity.   
     
     
         2 . A frame supported panel of  claim 1  wherein said increased load capacity is predetermined. 
     
     
         3 . A frame supported panel of  claim 1  wherein said increased load capacity is at least 50% greater than said continuous conditioned load capacity and said increased load capacity is predetermined. 
     
     
         4 . A frame supported panel of  claim 1  wherein said increased load capacity is at least 100% greater than said continuous conditioned load capacity. 
     
     
         5 . A frame supported panel of  claim 1  wherein said dropped sections comprise fillets and said fillets are fixed to said frame members and are optionally bonded to said panel and said increased load capacity is at least 100% greater than said continuous conditioned load capacity and said increased load capacity is predetermined. 
     
     
         6 . A frame supported panel of  claim 1  wherein said panel is a foam backed panel comprising a continuous/dropped configuration with slots for the insertion of said frame members. 
     
     
         7 . A frame supported panel of  claim 1  wherein said panel is a foam composite panel comprised of a cladding with foam adhesively bonded to at least part of said cladding's backside and said foam has a modulus of elasticity of at least 100 psi and provides at least 5% of said flexural stiffness over at least half of said spans. 
     
     
         8 . A frame supported panel of  claim 7  wherein said increased load capacity is at least 100% greater than said continuous conditioned load capacity and said increased load capacity is predetermined. 
     
     
         9 . A frame supported panel of  claim 7  wherein said dropped section comprise fillets and said fillets are fixed to said frame members and said fillets are optionally bonded to said panel and said increased load capacity is at least 100% greater and said increased load capacity is predetermined. 
     
     
         10 . A frame supported panel of  claim 7  wherein said panel is a frame supported ribbed panel. 
     
     
         11 . A frame supported panel of  claim 7  wherein said panel is a ribbed structural section. 
     
     
         12 . A frame supported panel of  claim 7  wherein a mesh is continuous over and bonded to said frame members and embedded in said foam as an anti-penetration layer. 
     
     
         13 . A frame supported panel of  claim 7  wherein cladding spacers situated between said cladding and said frame members provide a spacing and said foam occupies at least part of said spacing. 
     
     
         14 . A frame supported panel of  claim 7  wherein said panel is a foam core slotted sandwich panel having an outside as said continuous section and a slotted inside as said dropped section. 
     
     
         15 . A frame supported panel of  claim 7  wherein said panel is manufactured and fixed to said frame members with a spray-up process. 
     
     
         16 . A frame supported panel of  claim 7  wherein said foam provides at least 20% of said flexural stiffness. 
     
     
         17 . A frame supported panel of  claim 7  wherein two or more said panels are spliced together by polyurethane foam to form a single panel with structural continuity. 
     
     
         18 . A frame supported panel of  claim 7  wherein said foam is a polyurethane foam and said foam is thickened at a later time with additional polyurethane foam whereby said foam has structural continuity thickness. 
     
     
         19 . A frame supported panel of  claim 7  wherein an enhanced continuous condition is induced on said panel and said panel has 2 or more inside spans and an increased load capacity of outside spans to correspond to the load capacity of said inside spans.