Building system and method utilizing integrated insulation, method to construct wall panel

Abstract

A panelized building system and method of construction utilizing a rigid framing combined with foam insulation is disclosed. The system may include a metal roof panel, at least one metal wall panel, a floor panel, at least one metal corner post and at least one foundational component. A single layer of foam insulation encapsulates partially fills a rigid framing and may be molded against a non-stick surface or bonded to an exterior building material. In either case, a single monolithic piece is formed. A utility cavity may be formed interior to the single layer of foam insulation. The exterior face may be textured, undulated, radiused, or shaped in myriad ways.

What is claimed is: 
     
         1 . A method of constructing a wall panel comprising the steps of:
 a. providing a rigid framing;   b. elevating the rigid framing above a non-stick surface such that a predetermined amount of space is formed between the rigid framing and the non-stick surface;   c. applying a single layer of foam insulation, the single layer of foam insulation:
 i. fills the predetermined amount of space between the rigid framing and the non-stick surface; 
 ii. fills an interior section rigid framing; 
 iii. encapsulates an exterior flange of the rigid framing; 
   d. leaving a utility cavity between an interior face of the single layer of foam insulation and an interior surface of the rigid framing; and   e. allowing the single layer of foam insulation to dry wherein a solid monolithic piece is formed comprising the single layer of foam insulation fused to the rigid framing.   
     
     
         2 . The method of  claim 1 , further comprising the step of removing the wall panel from the non-stick surface. 
     
     
         3 . The method of  claim 1 , further comprising the steps of:
 a. adhering, using mechanical attachment, an insulation reinforcement mesh to the rigid framing; and   b. encapsulating the insulation reinforcement mesh with the single layer of foam insulation wherein the solid monolithic piece includes the insulation reinforcement mesh.   
     
     
         4 . The method of  claim 1 , further comprising the step of modifying the predetermined about of space between the rigid framing and the non-stick surface to achieve a desired level of insulation. 
     
     
         5 . The method of  claim 1 , further comprising the step of undulating an exterior face of the single layer of foam insulation. 
     
     
         6 . The method of  claim 1 , wherein the non-stick surface is corrugated. 
     
     
         7 . The method of  claim 1 , wherein the non-stick surface is textured. 
     
     
         8 . The method of  claim 1 , wherein the non-stick surface is radiused.