Panelized Building System Utilizing Integrated Insulation

Abstract

A panelized building system utilizing structural framing combined with integrated insulation is disclosed. The system may include a roof system, at least one wall panel, a floor panel, at least one corner post and at least one foundational component. The roof system, the wall panel, the floor panel, the corner post and the foundational component are configured to mechanically lock to each to form a panelized building structure consisting of structural framing and composite foam insulation. The roof system, the floor panel, the corner post, and the foundational component of the panelized building system may be configured to mechanically lock to each other through a tongue-and-groove interlocking system.

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         20 . A wall panel comprising:
 a. a structural framing mechanically adhered to a perforated reinforcing layer;   b. a single monolithic layer of foam insulation having a cavity portion and a continuous portion, the cavity portion of the single monolithic layer of foam insulation is partially embedded in the structural framing thereby leaving an open cavity within the panel for the installation of utility elements and panel to panel attachments;   c. the continuous portion of the single monolithic layer of foam insulation encapsulates the reinforcing layer;   d. an exterior layer of building material is adhered to the continuous portion of the single monolithic layer of foam insulation;   e. wherein the single monolithic layer of foam insulation that encapsulates the perforated reinforcing layer and the structural framing act together as a single structural unit to resist an applied load.   
     
     
         21 . The wall panel of  claim 1 , wherein the perforated reinforcing layer is selected from the group consisting of expanded metal and wire mesh. 
     
     
         22 . The wall panel of  claim 1 , wherein the exterior layer of building material is selected from the group consisting of membrane, felt, or plywood. 
     
     
         23 . A panelized building system including the wall panel of  claim 1 , wherein:
 a. the structural framing has a plurality of C-studs positioned between a male vertical stud and a female vertical stud;   b. the system includes a structural corner post, the structural corner post comprising:
 i. a corner tongue that attaches to the female vertical stud; 
 ii. a corner groove that attaches to the male vertical stud; 
   
     
     
         24 . The panelized building system of  claim 23 , wherein the corner tongue mechanically interlocks with the female vertical stud when interested into a groove on an exterior face of the female vertical stud and the corner groove mechanically interlocks with the male vertical stud when the male vertical stud is inserted into the corner groove to prevent the wall panel from shifting once connected to a corner post. 
     
     
         25 . A panelized building system comprising a wall panel, at least one structural corner post, and at least one structural floor panel, wherein:
 a. the wall panel includes:
 i. a vertical male stud having a tongue that extends from a center portion of an exterior surface of the vertical male stud; 
 ii. a vertical female stud having a groove cut into a center portion of an exterior surface of the vertical female stud; 
 iii. a plurality of C-studs positioned between a male vertical stud and a female vertical stud, the C-studs embedded in a first insulation layer; and 
 iv. two horizontal female tracks framing the vertical male and female studs and the C-studs with a top horizontal female track as a top surface of the structural framing and a bottom horizontal female track as a bottom surface of the structural framing, the top and bottom horizontal female tracks each having a groove cut into a center portion of the track; and 
   b. the at least one structural corner post comprising:
 i. a corner exterior layer that forms the external corners of the panelized building system; 
 ii. a corner tongue for inserting the groove cut into the vertical female stud; and 
 iii. a corner groove for receiving the tongue extending from the vertical male stud, the corner groove and the corner tongue are joined to each other and the corner exterior layer by a pair of connectors; 
   c. the at least one structural floor panel comprises:
 i. plurality of floor joists extending between two spandrels, the floor joints embedded in a floor insulation bonded to a floor exterior layer; 
 ii. a first male floor track forming a top surface of a spandrel, the first male floor track having a tongue extending out from a center portion of the first floor track, the tongue on the first male floor track for inserting into a horizontal female track of a wall panel structural framing attached above the structural floor panel; and 
 iii. a second male floor track forming a bottom surface of a spandrel, the second male floor track having a tongue extending out from a center portion of the second male floor track, the tongue on the second male floor track for inserting into a horizontal female track of a wall panel structural framing attached below the structural floor panel.