Insulated wall panel for building construction and method and apparatus for manufacture thereof

Abstract

Pre-fabricated wall, ceiling and roof panels for use in building construction have a metal framework, metal interior bracing as needed and may include internal electrical, water and gas supply conduits enabling simple and efficient building construction. A method for manufacturing the pre-fabricated building panels includes constructing a metal panel framework with internal structural bracing and placing the framework in a machine having relatively moveable foam containment plates. Polyurethane foam panel filler material having efficient thermal insulating quality is injected into the panel frame between the foam containment plates and expands during curing to fill the voids within the panel frame and define parallel exterior and interior panel surfaces. The light-weight polymer foam filled panels are then secured to the panel connectors of a building foundation and are secured to one another to define the walls, ceiling and roof a building structure and provide resistance to storm damage, insect and water damage and heat reflection.

Description

BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] This invention relates generally to pre-fabricated wall, ceiling and roof panel structures for use in building construction. The invention also concerns a method of manufacturing pre-fabricated building panel structures incorporating metal panel framework and structural bracing and having polymer foam panel filler material that is installed in finished metal panel frames enhances the structural integrity of the panels and provides excellent thermal insulation characteristics that minimize the energy requirements for air-conditioning and heating the interior of a building to maintain a comfortable thermal environment. More particularly, the present invention also concerns a machine and manufacturing system for manufacturing the building construction panels and a method for manufacturing pre-fabricated insulated wall and roof panels. [0003] 2. Description of the Prior Art [0004] It is well known that various types of ...

AI Technical Summary

Benefits of technology

[0019] The upper foam expansion resistance plate and the lower support plate essentially close the internal voids of the panel frame structure and define form surfaces establishing planar wall surfaces of the polyurethane foam insulation as the polymer foam expands in-situ. The A and B constituents of the polyurethane foam material are conveyed to the mixing chamber of one or more polymer foam injection guns where the constituents are mixed. A measured quantity of the mixed A and B liquid constituents are then conveyed through injection tubes that are extended through holes in top or bottom perimeter frame members and the mixture is injected to selective internal regions or voids of the framework that is closed by the upper and lower plate members. The A and B constituents of the polyurethane foam material the polymerize within the voids of the framework structure and expand to a foam characteristic during polymerization. As the mixed constituents polymerize a resulting polyurethane foam is generated which expands to fill all of the internal voids of the panel frame structure, including filling the voids of the various hollow sheet metal structural members. The expanding polyurethane foam material also comes into intimate contact with the planar surfaces of the upper and lower plates, thus forming planar internal and external panel wall surfaces and minimize the need for additional preparation for use in the construction of a building.

[0020] The quantity of polyurethane foam mixture that is injected into the framework structure develops an internal foam pressure that is significantly great to force the polyurethane foam into even the smallest interstices within the framework structure and also applies foam pressure to the upper and lower plate members. This polymerization induced foam pressure causes the resulting polyurethane foam to have greater density than if its curing occurred in absence of the foam pressure. Confinement of the polyurethane foam material during its expansion develops an internal foam pressure that enhances complete filling of the panel voids and enhanced the density and structural integrity of the polymer foam body and thus the panel structure. The foam pressure also causes the expanding foam body to engage the flat surfaces of support and foam expansion resistance plates and thus define parallel planar wall surfaces of the panel. This more dense polyurethane foam develops significantly greater structural integrity that enhances the structural integrity of the completed wall and roof panels. By completely filling the interior voids of the panel frame structure during polymerization of the polyurethane foam, voids or channels in the foam material do not occur, thus prevent the possibility of fire propagation through the foam core of the construction panels. The upper and lower plates restrain the expanding polyurethane foam material and function to define substantially flat internal and external panel wall surfaces. Typically, the finished polyurethane filled metal panel framework structures require no additional finishing processes prior to use in the construction of the walls and roof of a building.

[0021] Electrical boxes and conduits maybe incorporated within the polyurethane foam body of the thermally insulated wall panels to simplify the construction procedure and to minimize the costs for buildings that are erected by installation of the prefabricated wall panels of the present invention.

Problems solved by technology

It is known, however, that uncured polyurethane foam material tends to expand non-uniformly, so that it is virtually impossible for polyurethane foam insulation to create planar interior and exterior polymer foam panel surfaces without subsequent panel preparation after the polyurethane foam material has become completely cured.

It is also known that curing and expanding polyurethane foam material will generate very high pressure if curing and expansion takes place within a confined space.

Significant panel manufacturing problems will typically occur if wall and roof framework closure panels are applied to the panel framework in order to confine the expanding polyurethane foam in an attempt to create parallel exterior and exterior planar panel surfaces.

When wood and other organic materials are employed for the development of structural insulated panels for the wall and roof structures of buildings, insect damage, water damage and dry rot are significant problems that affect the durability of such structures.

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