Building system and method utilizing integrated insulation, combination

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 panelized building system comprising:
 a. roof system adapted for use in a panelized building system, the roof system comprising:
 i. a first roof panel, the first rafter panel having a top edge, a bottom edge, an interior side and an exterior side; 
 ii. a second roof panel, the second rafter panel having a top edge, a bottom edge, an interior side and an exterior side; 
 iii. a hinge plate connected to the top edge of the first roof panel and the top edge of the second rafter panel thereby establishing a roof apex; 
 iv. a first roof support post connected to the interior side of the first rafter panel; 
 v. a second roof support post connected to the interior side of the second rafter panel; 
   a. at least one wall panel, wherein the wall panel includes a structural framing and the structural framing is encapsulated with foam insulation forming a composite solid piece;   b. at least one floor panel, the floor panel including
 i. a decking; 
 ii. a plurality of structural elements, a top side of each structural element being attached to a bottom side of the decking; 
 iii. wherein the decking and a portion of the channels are encapsulated by composite foam insulation. 
 i. an integrated spandrel attached to the floor panel 
   c. at least one corner post, the corner post including:
 i. a structural vertical corner post element, the vertical corner having a hollow interior, the hollow interior being filled with foam insulation; 
 ii. the vertical corner post element having a first interior side, the first interior side includes a mechanical attachment element, the mechanical attachment element being selected from the group consisting of a tongue and a groove; 
 iii. the vertical corner post element having a second interior side, the second side includes a mechanical attachment element, the mechanical attachment element being selected from the group consisting of a tongue and a groove; 
 iv. a first horizontal supporting member perpendicularly connected to the first side, the horizontal supporting member includes a mechanical attachment element, the mechanical attachment element being selected from the group consisting of a tongue and a groove; 
 v. a second horizontal supporting member perpendicularly connected to the second side, the second horizontal supporting member includes a mechanical attachment element, the mechanical attachment element being selected from the group consisting of a tongue and a groove; 
 ii. the vertical corner post element having a first and a second exterior side; the first and second exterior sides being covered with spray-on composite foam insulation 
   b. at least one foundational alignment component, the foundational alignment component including:
 i. a foundation track having a top side and a bottom side; 
 ii. the bottom side of the foundation track having a plurality of bolt holes thereby allowing the foundation track to be bolted to a foundation; 
   c. wherein the roof panel, the wall panel, the floor panel, the corner post, and the foundational component are configured to mechanically lock to each other forming a panelized structure with integrated composite insulation.