Prefabricated building panels and methods for constructing buildings

Abstract

Example embodiments of the described technology provide a prefabricated building panel. The prefabricated panel may comprise a rigid insulative core having first and second opposing surfaces. A first cementitious material may at least partially cover the first surface of the insulative core. A second cementitious material may at least partially cover the second surface of the insulative core. At least one embedded element may extend along a peripheral edge of the insulative core.

What is claimed is: 
     
         1 . A prefabricated building panel, the panel comprising:
 a rigid insulative core having first and second opposing surfaces;   a first cementitious material at least partially covering the first surface of the insulative core;   a second cementitious material at least partially covering the second surface of the insulative core; and   at least one embedded element extending at least partially along a peripheral edge of the insulative core.   
     
     
         2 . The panel as defined in  claim 1 , wherein the at least one embedded element extends at least partially between the first and second opposing surfaces. 
     
     
         3 . The panel as defined in  claim 1 , wherein the at least one embedded element is selected from the group consisting of a fibreglass channel, a metal channel, a fibreglass extrusion, an aluminum extrusion, a vinyl extrusion, a PVC extrusion, a steel extrusion, a carbon fiber extrusion and a basalt extrusion. 
     
     
         4 . The panel as defined in  claim 3 , wherein the at least one embedded element is generally C-shaped and comprises a wall section and an open end defining a channel. 
     
     
         5 . The panel as defined in  claim 1 , wherein the at least one embedded element comprises a fibreglass channel or fibreglass extrusion. 
     
     
         6 . The panel as defined in  claim 5 , wherein the at least one embedded element further comprises a metal channel. 
     
     
         7 . The panel as defined in  claim 6 , wherein the wall section of the fibreglass channel is aligned with the wall section of the metal channel. 
     
     
         8 . The panel as defined in  claim 6 , wherein the wall section of the fibreglass channel is offset from the wall section of the metal channel. 
     
     
         9 . The panel as defined in  claim 4 , wherein the at least one embedded element comprises a first embedded element and a second embedded element, and wherein the open ends of the first and second embedded elements are oriented in the same direction. 
     
     
         10 . The panel as defined in  claim 4 , wherein the at least one embedded element comprises a first embedded element and a second embedded element, and wherein the open ends of the first and second embedded elements are oriented in opposite directions. 
     
     
         11 . The panel as defined in  claim 3 , wherein the at least one embedded element is a fibreglass extrusion shaped to receive a seal. 
     
     
         12 . The panel as defined in  claim 11 , wherein the seal is a dry seal gasket. 
     
     
         13 . The panel as defined in  claim 1 , comprising at least one reinforcing element located proximate to the at least one embedded element to strengthen the panel in the vicinity of the at least one embedded element. 
     
     
         14 . The panel as defined in  claim 13 , wherein the thickness of the insulative core is reduced in a first region of the panel in the vicinity of the embedded element in comparison to a second region of the panel removed from the embedded element. 
     
     
         15 . The panel as defined in  claim 13 , wherein the at least one reinforcing element is a wire mesh. 
     
     
         16 . The panel as defined in  claim 15 , wherein the wire mesh is selected from the group consisting of a welded wire mesh, an epoxy coated wire mesh, and a glass mesh. 
     
     
         17 . The panel as defined in  claim 13 , wherein the reinforcing element is generally S-shaped. 
     
     
         18 . The panel as defined in  claim 13 , wherein the at least one reinforcing element and the at least one embedded element are individually or together fused to the insulative core. 
     
     
         19 . The panel as defined in  claim 18 , wherein the at least one reinforcing element and the at least one embedded element are individually or together fused to the insulative core with an adhesive or other bonding agent. 
     
     
         20 . The panel as defined in  claim 18 , wherein the at least one reinforcing element and the at least one embedded element are individually or together fused to the insulative core with an epoxy resin. 
     
     
         21 . The panel as defined in  claim 18 , wherein the at least one reinforcing element and the at least one embedded element are individually or together fused to the insulative core with a cementitious material. 
     
     
         22 . The panel as defined in  claim 13 , wherein the at least one reinforcing element extends into one or more of the first cementitious material and the second cementitious material in the vicinity of the at least one embedded element. 
     
     
         23 . The panel as defined in  claim 22 , wherein the at least one reinforcing element extends between the first cementitious material and the second cementitious material. 
     
     
         24 . The panel as defined in  14 , wherein the first region of the panel is configured to be flush-mounted to a support structure. 
     
     
         25 . The panel as defined in  claim 1 , wherein the at least one embedded element stiffens the panel along the peripheral edge. 
     
     
         26 . The panel as defined in  claim 1 , wherein the at least one embedded element provides a thermal break between the first and second opposing faces. 
     
     
         27 . The panel as defined in  claim 1 , wherein the at least one embedded element at least partially encloses the insulative core to enhance the fire resistance of the panel. 
     
     
         28 . The panel of  claim 1 , wherein the insulative core is thinner on one side of the peripheral edge than the other side of the peripheral edge. 
     
     
         29 . A composite prefabricated load-bearing panel, the panel comprising:
 a rigid insulative core having first and second opposing surfaces;   a first structural post at least partially embedded on a first side of the insulative core;   a second structural post at least partially embedded on a second side of the insulative core, the second side opposite the first side;   a beam extending from an upper portion of the first post to an upper portion of the second post, the beam at least partially embedded in the insulative core;   a first cementitious material at least partially covering the first surface of the insulative core; and   a second cementitious material at least partially covering the second surface of the insulative core;   wherein the first and second cementitious materials at least partially bond the insulative core, the first and second structural posts and the beam together.   
     
     
         30 . The panel of  claim 29  further comprising cross-bracing coupled to at least two of the first post, the second post and the beam. 
     
     
         31 . The panel of  claim 30  wherein the cross-bracing is X-shaped. 
     
     
         32 . The panel of  claim 30  wherein the cross-bracing is chevron-shaped. 
     
     
         33 . The panel of  claim 29 , wherein at least one of the first post, the second post, the beam and the cross-bracing may move relative to one or both of the first and second cementitious materials. 
     
     
         34 . An assembly comprising a first non-load bearing panel and a second load-bearing panel, wherein the first non-load-bearing panel comprises:
 a rigid insulative core having first and second opposing surfaces;   a first cementitious material at least partially covering the first surface of the insulative core;   a second cementitious material at least partially covering the second surface of the insulative core; and   at least one embedded element extending at least partially along a peripheral edge of the insulative core.   
     
     
         35 . The assembly as defined in  claim 34 , wherein the first non-load bearing panel is mechanically connected to the second load-bearing panel. 
     
     
         36 . The assembly as defined in  claim 35 , wherein the second load-bearing panel comprises embedded structural elements, wherein the embedded structural elements are selected from the group consisting of structural posts, beams and cross-bracing. 
     
     
         37 . The assembly as defined in  claim 34 , wherein the second load-bearing panel comprises:
 a second rigid insulative core having first and second opposing surfaces;   a first structural post at least partially embedded on a first side of the second insulative core;   a second structural post at least partially embedded on a second side of the second insulative core, the second side opposite the first side;   a beam extending from an upper portion of the first post to an upper portion of the second post, the beam at least partially embedded in the second insulative core;   a third cementitious material at least partially covering the first surface of the second insulative core; and   a fourth cementitious material at least partially covering the second surface of the second insulative core;   wherein the third and fourth cementitious materials at least partially bond the second insulative core, the first and second structural posts and the beam together.   
     
     
         38 . The assembly as defined in  claim 34 , wherein the first non-load bearing panel and the second load-bearing panel are pre-fabricated. 
     
     
         39 . The assembly as defined in  claim 37 , wherein the first non-load bearing panel and the second load-bearing panel are pre-fabricated. 
     
     
         40 . A building comprising a plurality of wall components, wherein at least some of the wall components comprise:
 (a) a panel comprising:
 a rigid insulative core having first and second opposing surfaces; 
 a first cementitious material at least partially covering the first surface of the insulative core; 
 a second cementitious material at least partially covering the second surface of the insulative core; and 
 at least one embedded element extending at least partially along a peripheral edge of the insulative core; and/or 
   (b) a panel comprising:
 a second rigid insulative core having first and second opposing surfaces; 
 a first structural post at least partially embedded on a first side of the second insulative core; 
 a second structural post at least partially embedded on a second side of the second insulative core, the second side opposite the first side; 
 a beam extending from an upper portion of the first post to an upper portion of the second post, the beam at least partially embedded in the second insulative core; 
 a third cementitious material at least partially covering the first surface of the second insulative core; and 
 a fourth cementitious material at least partially covering the second surface of the second insulative core; 
 wherein the third and fourth cementitious materials at least partially bond the second insulative core, the first and second structural posts and the beam together; and/or 
   (c) an assembly as defined in  claim 34 .   
     
     
         41 . The building as defined in  claim 40 , wherein at least some of the structural framework of the building is selected from the group consisting of columns, posts, beams, anchors, bracing, and frames is embedded within the panel(s) and/or the assembly. 
     
     
         42 . A prefabricated composite roofing panel, the panel comprising:
 a rigid insulative core; and   Q-deck sheeting coupled to a first surface of the insulative core with a cementitious material.   
     
     
         43 . The panel of  claim 42 , wherein inner surfaces of the Q-deck sheeting which oppose the first surface of the insulative core comprise one or more textured elements. 
     
     
         44 . The panel of  claim 42 , wherein the textured elements increase a bond strength of the cementitious material with the Q-deck sheeting. 
     
     
         45 . The panel as defined in  claim 42 , wherein the Q-deck sheeting comprises a plurality of troughs, wherein only some of the troughs are filled with the cementitious material. 
     
     
         46 . The panel as defined in  claim 42 , wherein the thickness of the cementitious material located above the inner surface of the Q-deck sheeting immediately adjacent the first surface of the insulative core is less than 0.5 inches. 
     
     
         47 . The panel as defined in  claim 46 , wherein the thickness of the cementitious material is approximately 0.25 inches. 
     
     
         48 . The panel as defined in  claim 42 , comprising a roofing element coupled to a second surface of the insulative core, the second surface opposite the first surface. 
     
     
         49 . The panel as defined in  claim 48 , wherein the roofing element comprises a cementitious material. 
     
     
         50 . The panel as defined in  claim 48 , wherein the roofing element comprises a weather-resistant roofing membrane. 
     
     
         51 . The panel as defined in  claim 48 , wherein the roofing element extends past outer edges of the second surface of the insulative core for overlapping with adjacent roofing panels or other adjacent structures when the panel is installed. 
     
     
         52 . The panel as defined in  claim 48  wherein the second surface of the insulative core is shaped to direct water according to a desired specification. 
     
     
         53 . The panel as defined in  claim 52  wherein the insulative core is wedge-shaped. 
     
     
         54 . The panel as defined in  claim 42 , wherein the panel has a weight that is less than about 20 pounds per square foot. 
     
     
         55 . A building assembly comprising:
 a foundation; and   a load bearing panel coupled to the foundation, the panel providing a shear wall for the building, the panel comprising:
 a rigid insulative core having first and second opposing surfaces; 
 a first structural post at least partially embedded on a first side of the insulative core; 
 a second structural post at least partially embedded on a second side of the insulative core, the second side opposite the first side; 
 a beam extending from an upper portion of the first post to an upper portion of the second post, the beam at least partially embedded in the insulative core; 
 a first cementitious material at least partially covering the first surface of the insulative core; and 
 a second cementitious material at least partially covering the second surface of the insulative core; 
 wherein the first and second cementitious materials at least partially bond the insulative core, the first and second structural posts and the beam together. 
   
     
     
         56 . The building assembly of  claim 55  further comprising a non-load bearing panel, the non-load bearing panel comprising:
 a second rigid insulative core having first and second opposing surfaces; 
 a third cementitious material at least partially covering the first surface of the second insulative core; 
 a fourth cementitious material at least partially covering the second surface of the second insulative core; and 
 at least one embedded element extending at least partially along a peripheral edge of the second insulative core. 
 
     
     
         57 . The building assembly of  claim 56  wherein the non-load bearing panel is coupled to the load-bearing panel. 
     
     
         58 . The building assembly of  claim 55  wherein the non-load bearing panel is coupled to a structural post of the building assembly, the structural post coupled to the foundation. 
     
     
         59 . The building assembly of  claim 58  wherein a surface of the non-load bearing panel is coupled generally flush against the structural post. 
     
     
         60 . The building assembly of  claim 55  comprising a roof panel, the roof panel comprising:
 a third rigid insulative core; and 
 Q-deck sheeting coupled to a first surface of the third insulative core with a fifth cementitious material. 
 
     
     
         61 . A building, the building comprising:
 a structural post coupled to a foundation; and   a panel according to  claim 1 , the panel coupled to the structural post, the structural post pivotable relative to the panel.   
     
     
         62 . The building of  claim 61  wherein coupling the panel to the structural post leaves a gap between the structural post and the panel.