Insulated construction panel and construction kit including same

Abstract

A construction panel kit, comprising: a plurality of construction panels (100), each construction panel (100) including an outer structural layer (102) covering a foam core (104). Each construction panel (100) is delimited by panel edges (112, 114, 116, 118) including first and second edges (112 and 114), the first and second edges (112 and 114) being configured so that when first and second construction panels (100) from the plurality of construction panels (100) are assembled to each other, the first edge (114) of the first construction panel (100) and the second edge (116) of the second construction panel (100) engage each other and overlap such that the first and second panels (100) are securable to each other at the first and second edges (114 and 116).

Description

TITLE OF THE INVENTIONINSULATED CONSTRUCTION PANEL AND CONSTRUCTION KIT INCLUDING SAME.FIELD OF THE INVENTION

[0001] The present invention relates to the general field of construction, and, more particularly, to an insulated construction panel and to modular and prefabricated buildings.BACKGROUND

[0002] The construction of modular and prefabricated buildings often relies on traditional methods using raw materials such as wood, insulation sheets, and fasteners. These conventional approaches can be labor-intensive and timeconsuming, as materials are delivered in standard sizes and require on-site modifications to fit a predetermined design. Additionally, traditional construction methods involve assembling numerous individual components, increasing complexity and the potential for errors. Insulation performance can also be compromised due to improper installation, material settling over time, or gaps between insulating elements.

[0003] Some prefabricated structures utilize frame-based assembly methods, where a skeleton framework is constructed first, and panels are then attached. However, this process can introduce inefficiencies, as it often requires on-site adjustments to fit panels properly. Misalignment between panels and framing elements can lead to air and water infiltration, reducing the overall durability and energy efficiency of the structure.

[0004] Therefore, there is a need for improved construction systems. An objective of the present invention is to provide a such a construction system.SUMMARY OF THE INVENTION

[0005] In a broad aspect, there is provided a construction panel kit, comprising: a plurality of construction panels, each construction panel including an outer structural layer covering a foam core; wherein each construction panel is delimited by panel edges including first and second edges, the first and second edges being configured so that when first and second construction panels from the plurality of construction panels are assembled to each other, the first edge of the first construction panel and the second edge of the second construction panel engage each other and overlap such that the first and second panels are securable to each other at the first and second edges.

[0006] There may also be provided a construction panel kit wherein fasteners are usable to join the first and second panels to each other by being driven through the first and second panels at the first and second edges.

[0007] There may also be provided a construction panel kit wherein an adhesive is usable to join the first and second panels to each other by covering abutting surfaces of the first and second panels at the first and second edges.

[0008] There may also be provided a construction panel kit wherein each construction panel defines opposed internal and external surfaces facing respectively inside and outside when the construction panels are assembled to form at least part of a construction, the first and second edges definingrespectively internal and external flanges protruding from a remainder of the construction panels at respectively the internal and external surfaces, the internal and external flanges overlapping each other when the first and second panels are assembled.

[0009] There may also be provided a construction panel kit wherein the internal surfaces of adjacent and coplanar ones of the construction panels are substantially flush with each other and the external surfaces of the adjacent and coplanar ones of the construction panels are substantially flush with each other when the construction panels are assembled to form the at least part of the construction.

[0010] There may also be provided a construction panel kit wherein the first and second panels are perpendicular to each other, the first edge of the first panel defining a flange protruding therefrom and the second edge of the second panel defining a groove extending thereinto for receiving the flange when the first and second panels are assembled to each other.

[0011] There may also be provided a construction panel kit wherein the first and second panels are perpendicular to each other, the first edge of the first panel defining a flange protruding therefrom and the second edge of the second panel abutting against the flange when the first and second panels are assembled to each other.

[0012] There may also be provided a construction panel kit further comprising an elongated reinforcing members secured to one of the construction panels at at least one of the panel edges thereof.

[0013] There may also be provided a construction panel kit wherein the reinforcing member has a substantially T-shaped transversal configuration defining a planar base and a spine extending perpendicularly from the base laterally centered relative to the base, the spine being inserted in the one of the construction panels and the base extending along the at least one of the panel edges thereof.

[0014] There may also be provided a construction panel kit wherein the spine is provided with apertures extending therethrough for receiving fasteners thereinto.

[0015] There may also be provided a construction panel kit wherein the reinforcing member are provided inside the outer structural layer.

[0016] There may also be provided a construction panel kit wherein the outer structural layer is prestressed.

[0017] There may also be provided a construction panel kit wherein the structural polymer includes a thermoplastic.

[0018] There may also be provided a construction panel kit wherein the structural polymer includes fiberglass.

[0019] There may also be provided a construction panel kit wherein each construction panel defines opposed internal and external surfaces facing respectively inside and outside when the construction panels are assembled to form at least part of a construction, at least one of the internal and external surfaces being covered by a finishing layer.

[0020] There may also be provided a construction panel kit wherein the first and second panels are angled relative to each other at an angle of between 95 degrees and 150 degrees.

[0021] In another broad aspect, there is provided a method of manufacturing a construction panel, the method comprising providing a foam core; covering the foam core with a polymer layer to form an unstressed panel, the polymer layer including a polymer selected from the group consisting of thermoplastics, thermoset polymers and combinations thereof; compressing the unstressed panel to provide a compressed panel; and curing the polymer while maintaining compression of the compressed panel to form the construction panel.

[0022] There may also be provided a method further comprising reinforcing at least some edges of the foam core with a reinforcing member before covering the foam core.

[0023] There may also be provided a method wherein the foam core includes polyethylene terephthalate. There may also be provided a method wherein the polymer includes polyethylene terephthalate.

[0024] There may also be provided a method wherein compressing the unstressed panel applies a deformation of between about 0.01 % and 2% to the unstressed panel.

[0025] Advantageously, the proposed construction panels may be manufactured so as to be sturdy while remaining easily and quickly assembled. Once assembled, the construction panels cooperatively provide relatively goodcompressive and flexural strengths, shear and moment resistances, as well as substantially robust water and air infiltration resistance at the connections between the construction panels.

[0026] Further advantageously, the construction panels may be easily adapted to provide prefabricated modular construction solutions designed for cost-effective and efficient assembly. These panels can be used in a variety of modular and prefabricated building applications, including residential and commercial structures, multi-unit housing, and sustainable building projects. The system allows for scalable construction, enabling both small- and large-scale developments while maintaining ease of assembly and high-performance insulation.

[0027] Other objects, advantages and features of the present invention will become more apparent upon reading of the following non-restrictive description of some embodiments thereof, given by way of example only with reference to the accompanying drawings. The present patent application claims priority from UK Request for a Patent GB2404140.2 filed March 22, 2024, the contents of which is hereby incorporated by reference in its entirety.BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 , in a perspective exploded view, illustrates a construction panel according an embodiment of the present invention;

[0029] Figure 2, in a perspective view, illustrates a first manner of attaching construction panels similar to the panel of FIG. 1 ;

[0030] Figure 3, in a perspective view, illustrates a residential building assembled from construction panels similar to the panel of FIG. 1 ;

[0031] Figure 4, in a perspective view, illustrates a second manner of attaching construction panels similar to the panel of FIG. 1 ;

[0032] Figure 5, in a front elevation view, illustrates the second manner of attaching construction panels similar to the panel of FIG. 1 ;

[0033] Figure 6, in a partial perspective view, illustrates a reinforcing member usable along with constructions panels similar to the panel of FIG. 1 ;

[0034] Figure 7, in a perspective view, illustrates a third manner of attaching construction panels similar to the panel of FIG. 1 in combination with the reinforcing member of FIG. 7;

[0035] Figure 8, in a schematic view, illustrates a method of manufacturing a construction panel in accordance with an alternative embodiment of the present invention;

[0036] Figure 9, in a perspective view, illustrates a fourth manner of attaching construction panels manufactured according to the method shown in FIG. 8; and

[0037] Figure 10, in a perspective view, illustrates a module of the residential building shown in FIG. 3DETAILED DESCRIPTION

[0038] FIG. 1 illustrates the structure of a construction panel 100 in accordance with an embodiment of the present invention. The construction panel 100 is typically part of a kit including a plurality of construction panels 100, or of similar panels. These similar panels are designated herein with the reference numeral 100 followed by a letter, and have a layered structure as shown in FIG. 1 , but may differ slightly by their shape, and more specifically by the shape of their edges, as detailed below. The reference numeral 100, without any letter, is used to refer to a generic construction panel 100.

[0039] The construction panel 100 includes an outer structural layer 102, here shown in the form of two parallel sheets, covering a foam core 104. For example, the outer structural layer 102 is made of fiberglass, and the foam core 104 is made of a suitable polyethylene terephthalate (PET) or similar material having good thermal insulation properties, as recognized in the construction industry. In some embodiments, the foam core is made partially or entirely from recycled material and is partially or entirely recyclable. In some embodiments, the outer structural layer 102 is covered by internal and external finishing layers 106 and 108 presenting a desired fire resistance properties, or aesthetic aspect, as well as, in some embodiments, providing protection against the elements for the external finishing layer 108. The outer structural layer 102, foam core 104 and the internal and external finishing layers 106 and 108 are bound to each other, for example using a thermal bonding process, an adhesive, fasteners, or combinations thereof. In the embodiment shown in FIG. 1 , the edges of the foam core 104 are exposed, as the outer structural layer 102 takes the form of two parallel sheets of material covering two opposed surfaces of the foam core 104. In other embodiments, the outer structural layer 102 completely encloses the foam core 104.

[0040] As illustrated collectively in FIGS. 3 and 10, construction panels similar tothe construction panel 100 can be used to assemble residential and commercial structures 110, or similar constructions. The construction panels 100 provide both structural integrity to the residential building 110 and enclose the latter to protect the interior thereof from the elements.

[0041] The residential building 110 may be assembled from a kit including the construction panels similar to the construction panel 100. Typically, such a kit will include floor panels 100b, wall panels 100a and roof panels 100c, all assembled to each other using an adhesive, fasteners 111 , for example screws, or both an adhesive and fasteners 111. The fasteners 111 are driven through the two construction panels 100 that are attached to each other, or inserted through preformed holes formed thereinto, typically at the edge of the construction panels 100. When used, the adhesive is provided between abutting surfaces of adjacent construction panels 100a, 100b and 100c. In alternative embodiments, at least part of the residential building 110 may be manufactured from materials that are not part of the kit. For example, and non-limitingly , the floor panels 100b may be replaced by a concrete slab. In some embodiments, at least some of the wall panels 100b are provided with pre-installed window(s) 113 and / or door(s) 115, so as to optimize the construction time of a project.

[0042] Referring to FIG. 1 , each panel includes edges, typically four edges, that will be referred to generally using reference numerals 112, 114, 116 and 118, with edges 112 and 118 opposed to each other and edges 114 and 116 each extending between edges 112 and 118, opposed to each other. To differentiate between the edges of different types of construction panels 100, a letter corresponding to the type of panel 100 is added after the reference numerals 112 to 118. For example, FIG. 2 illustrates how the wall panels 100a may attach to a floor panel 100d that differs slightly from the floor panel 100b. In this case, the floorpanel 100d is shown having edges 112d, 114d and 116d, the fourth edge being omitted, and the wall panel 100a is shown having edges 112a, 114a and 116a, the fourth edge being omitted. When a generic edge 112, 114, 116 or 118 is referred to, the letter is omitted.

[0043] Edges 112, 114, 116 and 118 are configured so that when two construction panels 100, having either identical of different edge configurations, are assembled to each other, the edges 112, 114, 116 and 118 of adjacent ones of the construction panels 100 engage each other and overlap such that the two adjacent construction panels 100 are securable to each other at these edges 112, 114, 116 and 118. For example, in FIG. 2, the edge 112a of the wall panel 100a is configured to engage and overlap the edge 112d of the floor panel 100d. In some embodiments, the construction panels 100 are linked to each other such that the junction therebetween is water tight and air tight. When simple mechanical interference is unable to achieve this result, caulking may be used at the interface between two construction panels 100.

[0044] Different such overlaps and edge configurations may be used to achieve this link. Notably, the construction panels 100 may be generally perpendicular to each other, generally coplanar, or at an acute or obtuse angle relative to each other. FIG. 2 illustrates attachment of two construction panels that are perpendicular to each other. For example, a wall panel 100a and a floor panel 100d.

[0045] In this embodiment shown in FIG. 2, the floor panel 100d defines opposed internal and external surfaces 120d and 122d. Similarly, the wall panel 100a defines opposed internal and external surfaces 120a and 122a. The floor panel10Od defines an elongated groove 124d extending into its internal surface 120d at the edge 112d. The wall panel 100a defines a flange 126a protruding from the remainder thereof at its edge 112a and configured to be substantially snugly received in the groove 124. For example, the flange 126a is configured so that the external surface 122a ends short of the internal surface 120a, so that the external surface 122a and the floor panel 100d together show a flat continuous surface at the edge 112d once the floor and wall panels 100d and 100a are assembled. In other words, the flange 126a is located at the internal surface 120a of the wall panel 100a. In FIG. 2, fasteners 111 are shown ready to be inserted through the floor panel 100d at the edge 112 to reach the groove 124d to engage the flange 126a once the latter is inserted in the groove 124d.

[0046] In other embodiments, as seen in FIG. 7, for wall panel 100e and floor panel 100f, the floor panel 100f does not define the groove 124d, but instead defines a flange 128f protruding at the external surface thereof 122f from the remainder of the floor panel 10Of at the edge 112f, and the edge 112e of the wall panel 100e is flat and received on this flange 128f and abuts thereonto.

[0047] FIGS. 4 and 5 illustrate how two side-by-side, or coplanar, similar wall panels 100g can be secured to each other. A similar assembly can be provided for floor and ceiling panels. The wall panels 100g each define a flanges 128g at its lower end, to attach for example to the floor panel 100d similarly to the flange 126a. The wall panels 100g also each define flanges 126g and 128g on opposite sides thereof, at edges 114g and 116g respectively. The flanges 126a are internal flanges, and the flanges 128a are external flanges, meaning that they are respectively adjacent the face of the wall panels 100g that face the inside and the outside of the construction that is assembled. The internal flange 126g of one of the wall panels 100g overlaps the external flange 128g of the other wall panel100g, and the fasteners 111 can be driven through both the overlapping internal and external flanges 126g and 128g when the wall panels 100g are assembled.

[0048] Typically, the wall panels 100g are configured such that their internal and external surfaces 120g and 122g are pairwise coplanar and flush relative to each other when the wall panels 100g are assembled. Also, the internal and external flanges 126g and 128g are complementarily shaped, such that when assembled they form a solid unit, without any significant empty space therebetween.

[0049] The reader skilled in the art will appreciate that other types of complementary shapes for adjacent ones of the construction panels 100 may be used. Also, a specific panel 100 may include one or more of the features described hereinabove, and these features can therefore be combined at will, depending on the manufacturing and structural constraints faced for specific construction panels 100.

[0050] Referring collectively to FIGS. 6 and 7, the wall panel 100e is shown incorporating an elongated reinforcing member 140 secured to the edge 112e. The reinforcing member 140 is used to increase the structural integrity of the wall panel 100e, and is for example made of metal. The reinforcing member 140 is mounted to the wall panel 100e in any suitable manner and extends along its edge 112e. The other edges of the wall panel 100e may also incorporate similar reinforcing members 140. The reinforcing member 140 is made of a material that is more rigid than the material composing the foam core 104. For example, the reinforcing member is made of a metal, wood, a polymer, combinations thereof or any other suitable material.

[0051] In the specific embodiment shown in the drawings, the reinforcing member 140 has a substantially T-shaped transversal configuration and defines a planar base 142 and a spine 144 extending perpendicularly from the base 142 laterally centered relative to the base 142. In use, the spine 144 is inserted in construction panel 100e through its edge 112e and the base 142 extends along the edge 112e, parallel thereto. To that effect, the edge 112e may define a slit 129 shaped to snugly receive the In some embodiments, the spine 144 is provided with apertures 146 extending therethrough for receiving fasteners 111 thereinto to secure the reinforcing member to the remainder of the wall panel 100e. The fasteners 111 may only partially traverse the wall panel 100e, or as seen in FIG. 9 for the wall panel 100a, may extend therethrough so as to protrude therefrom on both sides thereof. Other shaped of the reinforcing member 140 are also within the scope of the invention. For example, the reinforcing member 140 may be rectangular or L -shaped, among other possibilities.

[0052] In some embodiments, as seen in FIG. 9 for the wall panel 100a, the reinforcing member 140 is provided inside the outer structural layer 102, which then completely encloses the foam core 104. In such embodiments, the outer structural layer 102 is prestressed. Referring to FIG. 8, such prestress can be achieved using the following method of manufacturing the wall panel 100a.

[0053] First, the foam core 104 is provided. Then, the reinforcing members 146 are secured to the foam core 104, after which the assembly thus obtained is covered with a material including a thermoplastic, for example polyethylene terephthalate. Glass fibers may also be provided mixed with the thermoplastic. This covered assembly is then compressed, as shown by arrows 148, and the thermoplastic is cured while maintaining compression. In some embodiments, compression is obtained by compressing an unstressed panel by about 0.01% toabout 2%. Once the curing process is completed, the pressure is released. Such prestressed construction panels 100 will better resist cycles of compression / release experienced by the construction panels 100 when in use, due for example to the wind or weight of accumulated snow.

[0054] Although the present invention has been described hereinabove by way of exemplary embodiments thereof, it will be readily appreciated that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, the scope of the claims should not be limited by the exemplary embodiments, but should be given the broadest interpretation consistent with the description as a whole. The present invention can thus be modified without departing from the spirit and nature of the subject invention as defined in the appended claims.WHAT IS CLAIMED IS1. A construction panel kit, comprising: a plurality of construction panels, each construction panel including an outer structural layer covering a foam core; wherein each construction panel is delimited by panel edges including first and second edges, the first and second edges being configured so that when first and second construction panels from the plurality of construction panels are assembled to each other, the first edge of the first construction panel and the second edge of the second construction panel engage each other and overlap such that the first and second panels are securable to each other at the first and second edges.2. The construction panel kit as defined in claim 1 , wherein fasteners are usable to join the first and second panels to each other by being driven through the first and second panels at the first and second edges.3. The construction panel kit as defined in claim 1 or 2, wherein an adhesive is usable to join the first and second panels to each other by covering abutting surfaces of the first and second panels at the first and second edges.4. The construction panel kit as defined in any one of claims 1 to 3, wherein each construction panel defines opposed internal and external surfaces facing respectively inside and outside when the construction panels are assembled to form at least part of a construction, the first and second edges defining respectively internal and external flanges protruding from a remainder of the construction panels at respectively the internal and external surfaces, the internal and external flanges overlapping each other

Claims

when the first and second panels are assembled.

5. The construction panel kit as defined in claim 4, wherein the internal surfaces of adjacent and coplanar ones of the construction panels are substantially flush with each other and the external surfaces of the adjacent and coplanar ones of the construction panels are substantially flush with each other when the construction panels are assembled to form the at least part of the construction.

6. The construction panel kit as defined in any one of claims 1 to 5, wherein the first and second panels are perpendicular to each other, the first edge of the first panel defining a flange protruding therefrom and the second edge of the second panel defining a groove extending thereinto for receiving the flange when the first and second panels are assembled to each other.

7. The construction panel kit as defined in any one of claims 1 to 5, wherein the first and second panels are perpendicular to each other, the first edge of the first panel defining a flange protruding therefrom and the second edge of the second panel abutting against the flange when the first and second panels are assembled to each other.

8. The construction panel kit as defined in any one of claims 1 to 7, further comprising an elongated reinforcing members secured to one of the construction panels at at least one of the panel edges thereof.

9. The construction panel kit as defined in claim 8, wherein the reinforcing member has a substantially T-shaped transversal configuration defining a planar base and a spine extending perpendicularly from the base laterallycentered relative to the base, the spine being inserted in the one of the construction panels and the base extending along the at least one of the panel edges thereof.

10. The construction panel kit as defined in claim 9, wherein the spine is provided with apertures extending therethrough for receiving fasteners thereinto.

11. The construction panel kit as defined in claim 8, 9 or 10, wherein the reinforcing member are provided inside the outer structural layer.

12. The construction panel kit as defined in claim 11 , wherein the outer structural layer is prestressed.

13. The construction panel kit as defined in claim 12, wherein the outer structural layer includes a polymer, the polymer being selected from the group consisting of thermoplastics, thermoset polymers and combinations thereof.

14. The construction panel kit as defined in claim 12, wherein the outer structural layer includes fiberglass.

15. The construction panel kit as defined in any one of claims 1 to 14, wherein each construction panel defines opposed internal and external surfaces facing respectively inside and outside when the construction panels are assembled to form at least part of a construction, at least one of the internal and external surfaces being covered by a finishing layer.

16. The construction panel kit as defined in any one of claims 1 to 5, wherein the first and second panels are angled relative to each other at an angle of between 95 degrees and 150 degrees.

17. A method of manufacturing a construction panel, the method comprising- providing a foam core; covering the foam core with a polymer layer to form an unstressed panel, the polymer layer including a polymer selected from the group consisting of thermoplastics, thermoset polymers and combinations thereof; compressing the unstressed panel to provide a compressed panel; and curing the polymer while maintaining compression of the compressed panel to form the construction panel.

18. The method as defined in claim 17, further comprising reinforcing at least some edges of the foam core with a reinforcing member before covering the foam core19. The method as defined in claim 17 or 18, wherein the foam core includes polyethylene terephthalate.

20. The method as defined in claim 17, 18 or 19, wherein compressing the unstressed panel applies a deformation of between about 0.01 % and 2% to the unstressed panel.

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