Modular building system utilizing composite, foam core panels

Abstract

A system for constructing a structure comprises a plurality of composite panels having a laminate structure comprising a foam core to which are attached cover layers of the same or different material. One or both of the cover layers may be comprised of composite sub-layers. The system includes a number elongate and preferably extruded components for connecting the panels to form walls, roofs or floors for the structure. The system is modular, thereby allowing for a time and cost efficient means of erecting a structure.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]The present application claims priority from U.S. Application No. 61 / 310,991, filed Mar. 5, 2010, the entire contents of which are incorporated herein by reference.FIELD OF THE INVENTION[0002]The present invention relates to composite, foam core panels and to systems for constructing buildings using such panels.BACKGROUND OF THE INVENTION[0003]There is a demand for modular building systems that allow a building to be erected in a simple and time efficient manner. To address this need, various systems have been proposed that incorporate prefabricated structural members that are transported to a building site and assembled together to form a building. In some cases, the structural members are completed wall units that are generally large and difficult to transport and handle. It is also known to use structural insulated panels in the construction of walls, roofs etc. Such panels comprise a “sandwich” structure made of an insulative foam cor...

AI Technical Summary

Benefits of technology

The present invention provides a system for constructing a structure comprising multiple generally planar building panels, which may be wall panels, roof panels, or floor panels, and panel connecting components for joining the panels to form walls, roofs, floors, or combinations thereof. The connecting components include means for receiving ends of adjacent panels, as well as corner joint, and roof joint components for engaging the walls and roof panels, respectively. Additionally, the invention provides sill components, ridge joint, and seam connecting components for further supporting and connecting the panels. The laminate structure of the panels includes a rigid foam core sandwiched between first and second cover layers for improved thermal insulation and durability.

Problems solved by technology

In some cases, the structural members are completed wall units that are generally large and difficult to transport and handle.

Although such panels provide the desired insulation function (due to the foam core), the wood based “skins” are subject to deterioration due to elemental exposure (i.e. water) or infestation by insects, microorganisms (e.g. mold).

One issue to address in such systems is to ensure a complete seal around the enclosure to prevent water penetration and / or heat loss.

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