Prefabricated building panel

Abstract

Prefabricated building panels combine new and unexpected element dimensions and materials with the effect of reducing overall weight and depth while simultaneously improving panel performance such as thermal insulation. As compared to former panels, prefabricated building panels according to exemplary embodiments of the invention generally include thinner concrete slabs, wider separations between concrete and support framing, and new material choices for anchors connecting slabs with framing. Exemplary panels are compliant with energy codes such as the latest ASHRAE and IECC.

1 . A prefabricated building panel, comprising:
 a concrete slab having a thickness equal to or less than  2  inches;   a plurality of stainless steel anchors permanently imbedded in said concrete slab;   framing including a plurality of studs or beams permanently secured to said concrete slab by said plurality of stainless steel anchors for structural reinforcement, said plurality of stainless steel anchors maintaining a spacing between said concrete slab and said framing of at least 2.0 inches; and   a continuous insulation which fills said spacing between said concrete slab and said framing of at least 2.0 inches and extends between the webs of adjacent studs or beams of said framing so that a total insulation thickness is greater than the size of said spacing, wherein said continuous insulation supplies weight bearing support to the prefabricated building panel.   
     
     
         2 - 3 . (canceled) 
     
     
         4 . The prefabricated building panel of  claim 1 , wherein said spacing between said concrete slab and said framing is at least 2.5 inches. 
     
     
         5 . The prefabricated building panel of  claim 1 , wherein said thickness of said concrete slab is between 1.5 and 2 inches. 
     
     
         6 . The prefabricated building panel of  claim 1 , wherein said plurality of beams or studs are spaced apart at intervals of more than 2 feet and up to 4 feet. 
     
     
         7 . The prefabricated building panel of  claim 1 , wherein said plurality of studs or beams of said framing each have a width of 6 inches or less. 
     
     
         8 . The prefabricated building panel of  claim 7 , wherein said width of each of said plurality of studs or beams is 4 to 6 inches. 
     
     
         9 . The prefabricated building panel of  claim 1 , wherein said plurality of stainless steel anchors are welded to said framing. 
     
     
         10 . The prefabricated building panel of  claim 1 , wherein said plurality of studs or beams include C-shaped studs or beams, the continuous insulation extending between the webs of adjacent C-shaped studs or beams. 
     
     
         11 . The prefabricated building panel of  claim 1 , wherein said continuous insulation has a thickness equal to the sum of said spacing and the width of said plurality of studs or beams.