Multilayered structural insulated panel

Abstract

A structural insulated panel includes an internal foam (EPS) core, oriented strand board (OSB) faces on the core, and a sheet of magnesium oxide (MagOx) on one or both of the faces for environmental purposes of either weather resistance and / or fire protection. The outer faces incorporate interior and exterior surfaces that need little more than a finish top coat paint. The combination of core, oriented strand board, and outer sheets provide a thermally efficient insulating structure that is a fully nationally code approved building structure.

Description

[0001]This application claims benefit under 35 U.S.C. §119(e) of provisional application Ser. No. 61 / 075,054, filed Jun. 24, 2008, entitled MULTILAYERED STRUCTURAL INSULATED PANEL, the entire contents of which are incorporated herein in its entirety.BACKGROUND[0002]The present invention relates to structural insulated panels useable in buildings.[0003]The building industry continues to be challenged by increasing costs of construction, including material and labor. Large structural insulated panels (e.g., 8 foot×24 foot panels) can help by reducing the number of components and pieces that must be handled during construction, and further by reducing energy costs in the buildings once constructed. However, further improvements are desired to reduce on-site work and reduce components costs, and to reduce the risk of poor assembly / construction. For example, insulating systems are known for use with studded wall constructions (e.g., fiberglass batting, cellulose, and / or sprayed urethane ...

AI Technical Summary

Benefits of technology

[0009]An object of the present invention is to provide an improved structural insulated panel that is energy efficient and insulative (e.g., 50% more energy efficient over conventional “stick” wood-stud-built construction), goes up quickly, and incorporates interior and exterior surfaces that need little more than a finish top coat paint . . . and which are fully nationally code-approved structures.

[0010]An object of the present invention is to provide an improved structural insulated panel of large size (e.g. 8 feet×24 feet), and which can be custom cut (e.g., by using CNC-type equipment) to match a building plan.

[0011]An object of the present invention is to provide a large panel having a highly insulative value and hence excellent energy efficiency, but competitive price when compared to other products (including their required on-site construction work such as the cost and labor and secondary processes required when using studs).

[0012]An object and function of this invention is to provide a light, smooth, thin layer of material over the OSB that will meet the fire code requirements and interior surface finish requirements.

[0013]An object and function of the present invention is to provide layering of a smooth layer of fire resistant material over the OSB that allows the SIP panels to meet the common code requirements for a thermal barrier or over the foam core of the SIP.

Problems solved by technology

The building industry continues to be challenged by increasing costs of construction, including material and labor.

For example, insulating systems are known for use with studded wall constructions (e.g., fiberglass batting, cellulose, and / or sprayed urethane products), however these systems are prone to have gaps that allow drafts and / or they can be squeezed thin such that they do not provide the insulative “R” value advertised.

In particular, it has been challenging to make structural insulated panels (SIPs) that meet cost, weight, code, environmental and structural requirements.

Oriented strand board (OSB) by itself can potentially meet cost, structural and weight requirements, but it does not meet environmental needs for weather or code requirements for fire unless it is further covered or treated.

Structural products made of foam are advantageous since they have low weight, but foam by itself potentially lacks strength.

Further, when a fire occurs in a room lined with bare foam, the room heats up very quickly to a point where the foam may explode in flames.

Notably, it is not acceptable to simply construct a structural insulated panel using a foam core covered with oriented strand board, since fire codes are not met.

However, available materials might include cementous materials or intermessent paints that, when they are machined in the factory or later cut in the paint, produce fine particles of silicon dust which are a health hazard (silicosis) or are destructive to cutting machines.

Images