Modular construction and structural panels therefor

Abstract

A prefabricated structural panel for modular building construction comprises a metal corrugated structural wall panel portion extending between a top and bottom plate. The metal corrugated structural wall panel portion includes multiple corrugations. The top plate and the bottom plate are permanently affixed to and perpendicular to a top edge and a bottom edge of the metal corrugated structural wall panel portion. The top and bottom edges of the metal corrugated structural wall panel portions are affixed toward midlines of the top and bottom plates, using welds, adhesives, fasteners, or other joints. A plurality of external studs extend between the top plate and the bottom plate at an external side of the corrugated structural wall panel portion for receiving an external wall covering, and a plurality of internal studs extend between the top plate and the bottom plate at an internal side thereof for receiving an internal wall covering.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 634,893, that was filed on 16 Apr. 2025, which is incorporated by reference herein in its entirety.BACKGROUND

[0002] The technical field generally relates to structural panels, and more specifically, but not exclusively, to prefabricated structural panels for building construction.

[0003] Modular and prefabricated homes have become increasingly popular in the United States due to low construction costs, and significantly reduced build times, relative to traditionally constructed stick frame homes.

[0004] The walls of these modular and prefabricated homes are often constructed from 16-gauge steel studs having an exterior covering (e.g. metal or fiberboard siding) and an interior covering (e.g. drywall or interior panels). Modular and prefabricated homes often have a low wind rating, typically around 140 mph, which is lower than their stick-frame counterparts.

[0005] Updrafts created by swirling winds, such as those occurring during tornadoes and hurricanes, are especially damaging to these modular and prefabricated homes constructed according to the prior art. Tornadoes and hurricanes have caused numerous deaths of those occupying modular and prefabricated homes, and frequently cause significant, often unrepairable, damage to these modular and prefabricated structures. Therefore, further technological developments are desirable in this area. Prior art modular homes exist that are capable of providing suitable, and affordable structures that can be used at homes and offices. However, room for improvement exists.

[0006] One area in which room for improvement exists is to create a design that can be transported more easily than current designs.

[0007] With many known designs for modular structures, transportation costs for shipping the structures are relatively expensive. At current prices, the common belief is that modular homes cannot be shipped for a distance greater than 600 miles before the shipping costs become cost prohibitive, and thereby placing the modular homes at a cost disadvantage to other construction techniques. When properly designed and engineered, it is believed that homes designed according to the present invention can be shipped on two trucks, when compared to the typical four to six trucks required to transport conventional modular designs

[0008] Another limitation is that most prior art modular designs enable the builder to only construct square or rectangular cubicles, which can then be shipped out and stacked up to only create square and rectangular structures. The present invention improves on this by providing a design that enables the builder to employ a significant and wide variety of shapes and wall facings. It is believed that rounded and circular designs can be employed by using the present invention.

[0009] Another drawback with current modular homes, is that they generally have a relatively low resistance to strong winds, and often are unable to sustain winds greater than 140 mph. In contrast, when constructed and engineered appropriately, it is believed that the present invention can permit structures to be constructed that are capable of withstanding the winds of 200 mph, such as those that exist with Level 4 and 5 hurricanes and tornadoes.

[0010] Another area where room for improvement exists with respect to prior modular homes relates to the difficulty of repairing prior modular homes that are damaged in wind storms. In such cases, the damage to the homes often is exacerbated by water and wind getting inside the house, to thereby damage the house so severely that the house cannot be repaired. It is believed that the structural panels of the present invention, when designed and constructed appropriately, will be capable of encapsulating the exterior walls to thereby protect the interior of the structure that would normally be severely damaged by wind and flying debris with known prior art modular homes.

[0011] Another drawback with prior known modular homes, is that they are often not very fire resistant, and it is often difficult to be able to contain a fire within one room of a prior art modular home.

[0012] To overcome this deficiency, the structural wall panels of the present invention are designed to have a steel core that prevents fire from spreading from room to room, as it does in traditionally built homes. Additional fire resistance can be achieved by providing optional fire-resistant enhancements, such as fire-resistant foam insulation and fire-resistant drywall. These options can significantly reduce fire damage, especially when compared to prior art designs. Further, in a most preferred embodiment, a double steel wall, that comprises two layers of corrugated steel, can be utilized to serve as a fire barrier.

[0013] A further feature of the present invention is that it is designed to incorporate recyclable materials into the structure. It is believed that buildings embody the principles of the present invention will contain 60 to 70% more recyclable material, and especially recycled metal material, when compared to prior art homes. Further, the metal construction of the present home has less susceptibility to water damage and mold damage.

[0014] Another advantage of the present invention is that provides a low-cost option that enables a user to perform much of the construction himself, to thereby save money, while having the structure in which he can live. For example, a user can order a structure that comprises just the corrugated steel exterior wall, ceiling and roof structure.

[0015] Because of the manner in which the exterior walls are constructed, such an option will give the user a water proof and weather proof structure in which he can reside quite comfortably, when appropriate plumbing, heat, air conditioning, and electrical services added.

[0016] Many users will prefer this structure with only the exterior walls, because of its esthetic appeal or costs savings.

[0017] However, others will prefer to customize their structure, by adding their own drywall and interior features such as crown moldings, baseboards, chair rails, window frames and the like.

[0018] All of these can be added at any time after the house is constructed, and during which time the house is fully livable. It will be appreciated that the user can live in his house, and make these additional changes on his own time frame, and on his own budget, and hopefully save the labor costs of having things such as drywall and other interior features added by professional contractors.SUMMARY

[0019] One embodiment of the present application includes a corrugated structural wall panel. A further form of the present application includes a structural ceiling panel. Other embodiments include unique corrugated structural panel apparatuses, building systems, and construction methods. Further embodiments, inventions, forms, objects, features, advantages, aspects, and benefits of the present application are otherwise set forth or become apparent from the description and drawings included herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:

[0021] FIGS. 1-8 depict corrugated structural wall panels, and structural ceiling and roof panels, according to one embodiment of the present application;

[0022] FIGS. 9-14 depict an exemplary process to manufacture the structural panels of FIGS. 1-8;

[0023] FIGS. 15-24 are progressive views depicting a construction of a single-story building structure utilizing the structural panels described above; wherein

[0024] FIG. 15 is a perspective view of a completed building structure of the present invention;

[0025] FIG. 16 is a perspective view, showing a base, such as a concrete slab that is prepared and onto which the building structure may be constructed;

[0026] FIG. 17 is a perspective view showing a first exterior left side wall having been coupled to the base;

[0027] FIG. 18 is a perspective view, showing a pair of lateral support walls being coupled to the left side exterior wall;

[0028] FIG. 19 is a perspective view showing the addition of several exterior walls, including a left side wall, rear wall, right side wall, and several interior support walls that are coupled to the base;

[0029] FIG. 20 is a perspective view showing all of the exterior walls coupled together to form the first story of the present invention, and including interior walls; and an exterior garage door;

[0030] FIG. 21 is a perspective view showing all of the exterior walls of the present invention, along with several interior walls, wherein some of the exterior walls have had an exterior facing placed thereon; and others of the exterior walls are shown as having runners and insulation attached thereto;

[0031] FIG. 22 is a perspective view, showing an exterior cladding placed on all of the exterior surfaces of the structure;

[0032] FIG. 23 is a perspective view of the building structure wherein ceiling decking has been coupled to the vertical walls;

[0033] FIG. 24 is a perspective view showing roof panels having been coupled to the exterior walls, to form a peaked roof, having a roof line portion that extends laterally, along with a roof line that extends longitudinally, and showing a gabled roof portion on the left side, and a hip roof portion on the right side;

[0034] FIG. 25 is a perspective view showing a completed house, wherein the roof panels have been overlaid with a roofing material, and landscaping has been added around the exterior of the house;

[0035] FIG. 26 is a perspective view of a two-story version of the house, wherein structural panels have been used as vertical member panels, and decking, both conventional and made according to the present invention have been used for roof panels; andDETAILED DESCRIPTION

[0036] Before the present methods, implementations, and systems are disclosed and described, it is to be understood that this invention is not limited to specific methods, specific components, implementation, or to particular compositions, and as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular implementations only and is not intended to be limiting.

[0037] As used in the specification and the claims, the singular forms “a,”“an” and “the” include plural correspondents unless the context clearly dictates otherwise. Ranges may be expressed in ways including from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another implementation may include from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, for example by use of the antecedent “about,” it will be understood that the particular value forms another implementation. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0038] For purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, any alterations and further modifications in the illustrated device, and any further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

[0039] Referring now to FIG. 1, construction of a structural wall, or panel, 100 is described. This wall 100 may represent a portion of a modular construction and may also be referenced as a metal corrugated structural wall panel portion. As is illustrated, structural wall panels 102, 104, 124, 126, and 128 are joined together to form the structural wall 100.

[0040] Each structural wall panel 102, 104, 124, 126, and 128 includes a metal corrugated portion 122 extending between a top plate 106 and a bottom plate 108.

[0041] The top plate 106 and the bottom plate 108 are permanently affixed to the metal corrugated portion 122. The corrugated portion 122 is depicted as being affixed to the top plate 106 and the bottom plate 108 toward a midline of the respective plates 106, 108, with an overhang portion of the respective plate 106, 108 extending outwardly from the corrugated portion 122.

[0042] Although the top plate 106 and the bottom plate 108 are depicted as being affixed to the metal corrugated portion 122 via welding, in various forms it is contemplated that the top and bottom plates 106, 108 can be affixed to the metal corrugated portion 122 through various fasteners or adhesives. It has been discovered that the integration of the metal corrugated portion 122 with the top plate 106 and the bottom plate 108 provides for a very sturdy structural panel which is highly resistant to bending.

[0043] The metal corrugated portion 122 includes a plurality of vertically extending channels, or corrugations. The metal corrugated portion 122 is depicted as being formed of 16-gauge steel, similar to a standard intermodal shipping container. However, it is contemplated that various steel thickness can be utilized (e.g., thicker steel for a second story, for higher wind resistance, and / or for earthquake resistance). In one specific, non-limiting form, the channels or corrugations are integrated into the panel through a roll forming operation.

[0044] The top plate 106 and the bottom plate 108 can be affixed approximately perpendicular relative to the vertical extending corrugations of the metal corrugated portion 122. The bottom plate 108 serves as a base which is utilized to attach the structural wall panel to a foundation of the structure.

[0045] In a first form, the bottom plate 108 is mounted to the foundation of the structure through a metallic mounting plate with j-hooks. These j-hooks extend outwardly from a lower side of the mounting plate and are inserted into the wet concrete such that when the concrete cures, the mounting plate is fixedly connected thereto.

[0046] The mounting plate can be continuous around the foundation of the structure, or can be placed at intermittent intervals depending upon the specific application. Once the mounting plates are securely attached to the cured concrete, the bottom plate 108 can be welded or adhered to the mounting plate, thereby providing a sturdy connection mounting the bottom plate 108 to the foundation of the structure.

[0047] Alternately, the bottom plate108 can be mounted to the foundation of the structure through a plurality of threaded rods or threaded inserts. A portion of each threaded rod or threaded insert will be inserted, either before or after pouring, into the wet concrete of the foundation. As the concrete cures, the threaded rod or insert will be permanently affixed to the foundation.

[0048] In the case of a threaded rod, the bottom plate 108 can include apertures at predetermined locations. The bottom plate 108 is then placed atop the foundation with the upper end of the threaded rods extending through the apertures in the bottom plate 108. Thread receiving members, such as nuts, are then placed on the threaded rods and are securely tightened, thereby securely retaining the bottom plate 108 to the foundation of the structure.

[0049] In the case of threaded inserts, the bottom plate 108 may include apertures at predetermined locations. The bottom plate 108 and structural wall are then placed atop the foundation with the threaded inserts being aligned with the apertures in the bottom plate 108. Bolts, or other threaded fasteners, are then extended through the apertures in the bottom plate 108, and are securely threaded into the threaded inserts thereby securing the bottom plate 108 to the foundation.

[0050] In yet another embodiment, the bottom plate 108 can be secured to the foundation directly through adhesives; or a lower surface of the bottom plate 108 can include j-hooks or other concrete securing anchors extending downwardly therefrom, such that the structural walls will be interconnected prior to the pouring of the concrete foundation. Once the concrete foundation is poured and cured, the concrete securing anchors will securely retain structural wall to the foundation.

[0051] The top plate 106 serves as a mounting location and support for a ceiling panel and / or roof panel as will be discussed hereinafter. Although the bottom plate 108 and the top plate 106 are depicted as being constructed of 0.25-inch steel. However, the thickness and material of which the top plate 106 and the bottom plate 108 are constructed can be altered depending upon the requirements of specific application.

[0052] Each structural wall panel 102, 104, 124, 126, and 128 is constructed at a location remote from the build site. As is known with regard to prior modular construction, fabrication of the structural wall panels 102, 104, 125, 126, and 126 at an off-site facility permits increased construction efficiency, increased quality, and decreased on-site construction time.

[0053] Doorway openings 120 and window openings 116 can be cut in the structural wall panels at the factory away from the build site. These openings 120 and 116 are shown as including a steel door frame 110 and a steel window frame 118, which are either welded or bolted to the corrugated metal panel 122 (and in the case of a door the bottom plate 108).

[0054] However, the framing for the doors and windows can also be constructed of various polymers or wood. Although the windows and doors are preferably installed prior to arrival at the build site to reduce time on site, depending upon the specific application and design requirements, the windows and doors can be installed in the respective frames 118, 110 at the build site.

[0055] Once the structural wall panels have been shipped to the build site, they are affixed to one another. It is contemplated that the structural wall panels can be directly welded to one another such as by welding the top plate 105, the bottom plate 108, and the corrugated metal portion 122. However, mounting brackets can also be utilized.

[0056] An exemplary 90° mounting bracket is depicted at 112. A first side of the mounting bracket 112 is fixedly attached to the corrugated metal portion 122 of the structural wall panel 102. A second side of the mounting bracket 112 is then fixedly attached to the structural wall panel 124.

[0057] The top plate 106 and bottom plates 108 of the wall panel 102 are then attached with the top and bottom plates 106, 108 of the wall panel 124. As was previously discussed, the mounting bracket is depicted as being attached to the corrugated metal portion 122 via welding, and the top and bottom plates of adjacent wall panels are depicted as being attached through welding. However, in other embodiments, fasteners or adhesives may be utilized, depending upon the specific application.

[0058] An exemplary straight panel-to-straight panel mounting bracket 114 is shown as connecting structural walls 104 and 128. As was discussed with regard to the mounting bracket 112, the mounting bracket 112 is first affixed to the metal corrugated portion 122 of wall 104 such as by welding. The bracket 114 is then connected to the metal corrugated portion 122 of wall 128, thereby fixedly attaching structural wall 104 with structural wall 128.

[0059] FIGS. 1-2 show a variety of footprints that can be constructed via welding, or the previously described mounting brackets. As is illustrated with regard to FIG. 1, the top plates 106 of the structural walls 126 and 104 are depicted as being angled at 130, 132 such that the joining of structural walls 126 and 104 will result in an angle in the wall. Additionally, it is contemplated that one or more structural wall panels can include an arcuate shape or curvature.

[0060] In some forms, it can be desirable to include an exterior wall covering and an interior wall covering on the structural walls. As is illustrated in FIG. 3, the structural wall panel 102 (exploded on the left-hand side; not exploded on the right-hand side) can include a plurality of vertically extending interior studs or furring strips 302 as well as vertically extending exterior studs or furring strips 304. These studs or furring strips 302, 304 (also known as runners) are mounted to the corrugated metal portion 122 and extend between the top plate 106 and the bottom plate 108.

[0061] The top plate 106 and bottom plate 108 are shown on either side (top or bottom) of the corrugated metal portion 122 in FIG. 4. These studs or furring strips 302, 304 can be constructed of wood. However, the studs or furring strips 302, 304 may alternately include a metallic or polymeric construction. Such a metallic or polymeric construction of the studs or furring strips 302, 304 has been found to be advantageous in that the risk of termite infestations would be practically non-existent.

[0062] These studs or furring strips 302, 304 can be installed remotely at the factory. It is contemplated that the studs or furring strips 302, 304 can be mated with the corrugated metal portion 122 via welding, adhesives, or fasteners, depending upon the specific material utilized and design specifications.

[0063] The integration of the exterior studs or furring strips 304 provides a mounting location for a more traditional exterior covering, such as siding, or brick or stone veneers. However, some users will prefer the exterior appearance of corrugated metal, especially when covered in a variety of finishes (e.g. paints, varnishes, polymeric coatings, or the like).

[0064] A more traditional covering can be applied after the structural panels are joined, there providing a continuous, aesthetically pleasing appearance that preferably has no breaks in the siding relative the connection points of the underlying structural walls. This traditional exterior covering can be attached to the studs or furring strips 304 through convention means, such as by nailing or screwing.

[0065] The integration of the interior studs or furring strips 302 permits the addition of a traditional wall covering, such as drywall. It is contemplated that the interior covering may be applied at the off-site factory, in the case that the electrical and plumbing is installed at the factory, with any joints in the drywall being taped and mudded after the structural panels are affixed with one another. However, in further forms it is contemplated that the plumbing, electrical, and interior wall coverings can be installed on-site. The interior covering can be attached to the studs or furring strips 302 through conventional means, such as by using drywall screws.

[0066] Referring now to FIG. 7, covering an interior structural wall will now be discussed.

[0067] FIG. 7 depicts an interior structural wall 700 which, is as used herein comprises a wall completely located within the structure where both sides of the wall are visible from within the structure. As is illustrated, the attached studs or furring strips enable drywall 702, 704 to be added to both sides of the interior structural wall, thereby providing an aesthetically pleasing appearance.

[0068] The addition of studs or furring strips 302, 304, such as those shown above with respect to FIG. 3, provides a cavity (e.g. 306) in which insulation can be inserted. In some forms, insulation can be provided on both the interior and exterior of the corrugated metal portion 122. Although standard batt insulation may be utilized, Applicant has discovered that closed cell foam can expedite the manufacture of the structural panels, and is easily applied at the off-site factory. Additionally, closed cell foam provides an airtight and moisture tight barrier, thus completely sealing the structure.

[0069] Referring now to FIGS. 5-6 and 8, ceiling 600 and roof 810 panels will now be discussed. The ceiling panel 600 is depicted as having opposing side portions 604 and opposing end portions 608. These opposing side and end portions 600, 608 are preferably formed of steel.

[0070] Metal supports 602 extend across the ceiling panel 600 between the opposing end portions 608. The opposing side and end portions 600, 608 are shown to include flanges which extend interiorly and exteriorly. The interiorly extending flange provides a location for the metal supports 602 to rest upon, and be mounted to.

[0071] The exteriorly extending flange portions provide a location to mount the ceiling panel 600 to the top plate 106, as is illustrated in FIG. 6. The ceiling panel 600 can be mounted to the top plate via fasteners or through welded joints. A metal covering 802 is welded to the top of the ceiling panel 600. However, the lower portion of the ceiling panel 600 remains open to permit the installation of lighting, and permits a suitable location for electrical, plumbing, and ductwork to be installed.

[0072] Similar to the ceiling panel 600, the roof panel 810 is depicted as extending between opposing sides and ends and includes internal metal supports 804. The opposing sides and ends can each include an exteriorly and interiorly extending flange. Referring now to FIG. 8, these flanges provide a suitable location to either weld or fasten each roof panel 810 to the ceiling panels, and to either weld or fasten opposing roof panels to one another. As with the ceiling panel 600, the roof panel 810 includes a metal covering welded to a top portion, with the lower surface remaining open.

[0073] Although a variety of fastening techniques would function in a workmanlike manner, the use of welding is preferred as it results in a strong, unitary structure, but can also reduce air / moisture permeation into the structure should continuous welds be utilized.

[0074] For example, the corrugated portion 122 can be continuously welded to the top and bottom plates 106, 108 along the entire wall length and around any corners.

[0075] The mounting plate, as was previously described, can extend along the entire perimeter of the foundation, and the bottom plate 108 can be continuously welded to the mounting plate. If the ceiling panels 600 are continuously welded to the top plate 106, an airtight and moisture tight structure will be formed. This can be advantageous in locations where high winds are common. Where continuous welding is utilized, the building will remain sealed even if the roof structure is damaged.

[0076] Referring now to FIGS. 9-14, an exemplary process for manufacturing structural panels will now be discussed. As is illustrated in FIG. 9, the corrugated steel portion 122 and top 106 and bottom 108 plates are welded such as by a seam welder. Referring now to FIG. 10, the corrugated steel portion 122, and top 106 and bottom 108 plates are then cut to the desired length, and to accommodate any desired shapes of the desired building. Openings for the windows and doors are cut such as with a CNC controlled plasma cutter. The widow framing and door framing are then installed, and the stud or furring strips are added. Insulation may then be added to the structural wall panel.

[0077] FIG. 11 depicts an exemplary manufacturing process for the ceiling and roof panels. The opposing sides and ends are welded together, and the metal supports are welded between the opposing end portions. The metal covering is then welded upon the upper surface of the panel and is trimmed to length. After installation of the metal covering, the ceiling or roof panel can be flipped over and insulation can be added as is shown in FIG. 14.

[0078] FIGS. 15-24 depict an exemplary single-story structure 1500 being formed utilizing the structural panels (e.g., 122, 600, 700, 810 described above) according to the present application. In addition, multi-story structures can also be constructed utilizing the structural panels of the present application as shown in FIGS. 25 and 26.

[0079] It has been discovered that “corrugated shapes” give extra strength to walls in almost any building design. The corrugated panels are the basis of this design. It has many other benefits and solves future problems compared to the use of containers or current modular designs.

[0080] Most current modular designs have a low limit of wind rating (e.g., 140 mph), and present modular homes usually have extraordinarily little support to updrafts caused in swirling winds.

[0081] The wall construction of the present disclosure, utilizing corrugated shapes, provides sufficient strength to withstand high winds pushing against the exterior walls. The exterior walls are further supported by the corrugated walls within the interior of the structure that normally extend at 45 to 90 degrees to the exterior wall. As stated above, the process attaches the walls to a concrete floor with the use of different types of fasteners, fastener plates, glues or bolts that set into the concrete when poured. By fastening the vertical walls all along the bottom edges to systems that are anchored into the concrete, the wall is given extra strength to resist pressure created by high winds and uplift forces keeping the walls in place.

[0082] The walls of the present inventive structure have a top and bottom support. The bottom anchors to the concrete. The top plate is welded to the wall, allowing two things: a flat area to set the ceiling panels for welding or bolting, and an added stiffness to the wall when laying down and being stood up.

[0083] The top and bottom flat bars will be welded as needed to ensure the two are coupled securely enough to achieve the desired strength. These top and bottom flat bar plates are wider than the exterior walls to enable insulation to be added to both sides of the exterior walls. Insulation varies in different climates and can be easily attached to fit the desired R-Factor Rating required in the climate of the area wherein the structure is erected.

[0084] Preferably the panels are made in sections in a remote factory plant. The all-steel sheeting on top of the ceiling panels is supported by ceiling joists. These steel sheets are attached to the steel ceiling joist by welding, gluing or other means of attaching them to create a complete exterior wall and ceiling of steel.

[0085] This design and structure create a box that is welded or bolted together to simulate the strength of shipping containers.

[0086] Roof Panels will be constructed along the same lines as the ceiling panel and will be raised at the preferred angle to get the desired slope or pitch the customer requires or to get the highest wind rating.

[0087] This design is intended to reduce the cost of producing all the walls, ceiling and roof framework which, when properly designed, has the potential to achieve to achieve wind resistance of 200 mph or more.

[0088] This minimum would be the least anyone can buy and will make production time much shorter. This gives the customer full control of all the add-ons, they would normally benefit from, without giving up the wind strength and speed of erecting the house compared to prior art modular designs.

[0089] FIGS. 15-24 illustrate the sequence of events that will likely be encountered during the building and construction of a building structure 10 of the present invention.

[0090] FIG. 15 shows a finished building structure 900 that is here illustrated as a ranch type single family independent standing structure. It will be appreciated that features discussed herein can also be extended and used in other structures, such as townhome type structures, duplexes and the like.

[0091] The house 900 includes a front side 902, a left side 903, a right side 906, and a rear side 908. As used herein, directional indicators such as left side 903 and right side 906 are chosen arbitrarily, to help the leader better understand the invention, and are not just intended to be limiting.

[0092] As shown in FIG. 16, the structure includes a base 912, on which the building structure sits. The base 912 will often take the form of a concrete slab, but may be constructed of another material, such as a frame that overlays a subterranean portion of the structure, such as a crawl space or basement.

[0093] The base 912 includes an edging portion into which the anchors are embedded that are coupled to the vertical walls 914.

[0094] Turning now to FIG. 17, a vertical wall 924 is shown as being coupled to the left base of the house 912, and is shown as comprising the left exterior wall of the house. The left exterior vertical wall 924 includes cutouts for windows, and may also include cutouts for things such as vents, doors, and other such normal things that one might find in a house.

[0095] FIG. 18 shows a pair of lateral structural wall members 928 that are coupled to the vertical exterior wall 924. A lateral members 928 along with the vertical wall 924 are constructed preferably in accordance with the teachings of the present invention as set forth above.

[0096] FIG. 19 shows additional exterior walls sections added to the house, that include the rear side wall, which includes a rear exterior wall 930 that includes a left side section 934, a middle section 936, and a right section 938. In the particular house shown in the drawings, the left 934, middle 936, and right 938 sections are configured differently, to achieve different architectural aspects of the house. However, it will also be appreciated that the left, middle, and right sides 934, 936, 938 can comprise a unitary wall that is planar from left to right.

[0097] A pair of interior walls 942 are provided that extend generally between the back and front of the house, along with an interior wall 946 that extends in a generally lateral direction. These walls can be constructed in accordance to the teachings of the present invention, or may be constructed in traditional stud containing frame manner. As with most walls, they provide a division between spaces, along with structural support for the building 900.

[0098] FIG. 19 also shows the addition of a right-side wall 929 which is a general analog to the left side wall 924.

[0099] FIG. 20 shows the addition of a front exterior wall 950 that includes a left front exterior wall section 952, a middle front exterior wall section 954, and a right front exterior wall section 956. The middle front exterior wall section includes a front door, and windows that are coupled to the section. The right front exterior wall section includes a cutout for a garage door. Conventional strut containing interior walls, such as walls 960, can be provided by dividing up the spaces defined by the interior structural walls.

[0100] FIG. 21 shows that studs or furling strips 966 can be coupled to the exterior surface of an exterior wall, with insulation 964 being installed between the vertical studs. Additionally, an exterior cladding 968 can be placed over the exterior wall to achieve a desired esthetic effect, along with adding additional strength to the house, depending upon the type of surface chosen.

[0101] As discussed above, the steel structured walls of the present invention provide sufficient structural strength, without additional cladding. However, exterior cladding, even if unnecessary from a structural standpoint, still provides esthetic value, along with potential structural enhancements.

[0102] Turning now to FIG. 22, it will be noted that exterior cladding is placed over all of the exterior surfaces of the vertical walls. Additionally, landscaping 976 is added.

[0103] FIG. 23 shows the addition of ceiling panels 972, that include insulation 974. The ceiling panels 972 can be constructed by conventional means, or can be constructed in accordance with the present invention's use of steel structural panels.

[0104] FIG. 24 shows the addition of roofing panels 978, here on a pitched roof. For a building with a flat roof, the roofing panels 978 may not be necessary, but rather, one may rely on the ceiling panels 972 as shown in FIG. 23. Also, there is shown roofing panels overlaying the roofing material, such as asphalt roofing, steel roofing, or tile numbers.

[0105] A subtle feature shown in FIG. 24 is the fact that the present invention will work well with both houses having gabled roofs, as shown on the left side of the house, and hip roofs as shown on the right side of the house.

[0106] FIG. 25 shows the completed house, with the roof overlayed with an appropriate roofing material.

[0107] FIG. 26 shows the present invention being adapted to a multi-story house 990, such as the two-story house shown in FIG. 26. The multi-story house includes a first-floor vertical exterior panel members 992, and second floor exterior panel members 994. The other components are generally similar to those that are shown in the one-story house, with appropriate adaptations made for size, shape, and configuration.

[0108] While the present disclosure has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment(s), but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as permitted under the law.

[0109] Furthermore, it should be understood that while the use of the word preferable, preferably, or preferred in the description above indicates that feature so described may be more desirable, it nonetheless may not be necessary and any embodiment lacking the same may be contemplated as within the scope of the invention, that scope being defined by the claims that follow. In reading the claims it is intended that when words such as “a,”“an,”“at least one” and “at least a portion” are used, there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim.

[0110] Further, when the language “at least a portion” and / or “a portion” is used the item may include a portion and / or the entire item unless specifically stated to the contrary.

Examples

Embodiment Construction

[0036]Before the present methods, implementations, and systems are disclosed and described, it is to be understood that this invention is not limited to specific methods, specific components, implementation, or to particular compositions, and as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular implementations only and is not intended to be limiting.

[0037]As used in the specification and the claims, the singular forms “a,”“an” and “the” include plural correspondents unless the context clearly dictates otherwise. Ranges may be expressed in ways including from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another implementation may include from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, for example by use of the antecedent “about,” it will be understood that the particul...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 634,893, that was filed on 16 Apr. 2025, which is incorporated by reference herein in its entirety.BACKGROUND

[0002] The technical field generally relates to structural panels, and more specifically, but not exclusively, to prefabricated structural panels for building construction.

[0003] Modular and prefabricated homes have become increasingly popular in the United States due to low construction costs, and significantly reduced build times, relative to traditionally constructed stick frame homes.

[0004] The walls of these modular and prefabricated homes are often constructed from 16-gauge steel studs having an exterior covering (e.g. metal or fiberboard siding) and an interior covering (e.g. drywall or interior panels). Modular and prefabricated homes often have a low wind rating, typically around 140 mph, which is lower than their stick-frame counterparts.

[0005] Updrafts created by swirling winds, such as those occurring during tornadoes and hurricanes, are especially damaging to these modular and prefabricated homes constructed according to the prior art. Tornadoes and hurricanes have caused numerous deaths of those occupying modular and prefabricated homes, and frequently cause significant, often unrepairable, damage to these modular and prefabricated structures. Therefore, further technological developments are desirable in this area. Prior art modular homes exist that are capable of providing suitable, and affordable structures that can be used at homes and offices. However, room for improvement exists.

[0006] One area in which room for improvement exists is to create a design that can be transported more easily than current designs.

[0007] With many known designs for modular structures, transportation costs for shipping the structures are relatively expensive. At current prices, the common belief is that modular homes cannot be shipped for a distance greater than 600 miles before the shipping costs become cost prohibitive, and thereby placing the modular homes at a cost disadvantage to other construction techniques. When properly designed and engineered, it is believed that homes designed according to the present invention can be shipped on two trucks, when compared to the typical four to six trucks required to transport conventional modular designs

[0008] Another limitation is that most prior art modular designs enable the builder to only construct square or rectangular cubicles, which can then be shipped out and stacked up to only create square and rectangular structures. The present invention improves on this by providing a design that enables the builder to employ a significant and wide variety of shapes and wall facings. It is believed that rounded and circular designs can be employed by using the present invention.

[0009] Another drawback with current modular homes, is that they generally have a relatively low resistance to strong winds, and often are unable to sustain winds greater than 140 mph. In contrast, when constructed and engineered appropriately, it is believed that the present invention can permit structures to be constructed that are capable of withstanding the winds of 200 mph, such as those that exist with Level 4 and 5 hurricanes and tornadoes.

[0010] Another area where room for improvement exists with respect to prior modular homes relates to the difficulty of repairing prior modular homes that are damaged in wind storms. In such cases, the damage to the homes often is exacerbated by water and wind getting inside the house, to thereby damage the house so severely that the house cannot be repaired. It is believed that the structural panels of the present invention, when designed and constructed appropriately, will be capable of encapsulating the exterior walls to thereby protect the interior of the structure that would normally be severely damaged by wind and flying debris with known prior art modular homes.

[0011] Another drawback with prior known modular homes, is that they are often not very fire resistant, and it is often difficult to be able to contain a fire within one room of a prior art modular home.

[0012] To overcome this deficiency, the structural wall panels of the present invention are designed to have a steel core that prevents fire from spreading from room to room, as it does in traditionally built homes. Additional fire resistance can be achieved by providing optional fire-resistant enhancements, such as fire-resistant foam insulation and fire-resistant drywall. These options can significantly reduce fire damage, especially when compared to prior art designs. Further, in a most preferred embodiment, a double steel wall, that comprises two layers of corrugated steel, can be utilized to serve as a fire barrier.

[0013] A further feature of the present invention is that it is designed to incorporate recyclable materials into the structure. It is believed that buildings embody the principles of the present invention will contain 60 to 70% more recyclable material, and especially recycled metal material, when compared to prior art homes. Further, the metal construction of the present home has less susceptibility to water damage and mold damage.

[0014] Another advantage of the present invention is that provides a low-cost option that enables a user to perform much of the construction himself, to thereby save money, while having the structure in which he can live. For example, a user can order a structure that comprises just the corrugated steel exterior wall, ceiling and roof structure.

[0015] Because of the manner in which the exterior walls are constructed, such an option will give the user a water proof and weather proof structure in which he can reside quite comfortably, when appropriate plumbing, heat, air conditioning, and electrical services added.

[0016] Many users will prefer this structure with only the exterior walls, because of its esthetic appeal or costs savings.

[0017] However, others will prefer to customize their structure, by adding their own drywall and interior features such as crown moldings, baseboards, chair rails, window frames and the like.

[0018] All of these can be added at any time after the house is constructed, and during which time the house is fully livable. It will be appreciated that the user can live in his house, and make these additional changes on his own time frame, and on his own budget, and hopefully save the labor costs of having things such as drywall and other interior features added by professional contractors.SUMMARY

[0019] One embodiment of the present application includes a corrugated structural wall panel. A further form of the present application includes a structural ceiling panel. Other embodiments include unique corrugated structural panel apparatuses, building systems, and construction methods. Further embodiments, inventions, forms, objects, features, advantages, aspects, and benefits of the present application are otherwise set forth or become apparent from the description and drawings included herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:

[0021] FIGS. 1-8 depict corrugated structural wall panels, and structural ceiling and roof panels, according to one embodiment of the present application;

[0022] FIGS. 9-14 depict an exemplary process to manufacture the structural panels of FIGS. 1-8;

[0023] FIGS. 15-24 are progressive views depicting a construction of a single-story building structure utilizing the structural panels described above; wherein

[0024] FIG. 15 is a perspective view of a completed building structure of the present invention;

[0025] FIG. 16 is a perspective view, showing a base, such as a concrete slab that is prepared and onto which the building structure may be constructed;

[0026] FIG. 17 is a perspective view showing a first exterior left side wall having been coupled to the base;

[0027] FIG. 18 is a perspective view, showing a pair of lateral support walls being coupled to the left side exterior wall;

[0028] FIG. 19 is a perspective view showing the addition of several exterior walls, including a left side wall, rear wall, right side wall, and several interior support walls that are coupled to the base;

[0029] FIG. 20 is a perspective view showing all of the exterior walls coupled together to form the first story of the present invention, and including interior walls; and an exterior garage door;

[0030] FIG. 21 is a perspective view showing all of the exterior walls of the present invention, along with several interior walls, wherein some of the exterior walls have had an exterior facing placed thereon; and others of the exterior walls are shown as having runners and insulation attached thereto;

[0031] FIG. 22 is a perspective view, showing an exterior cladding placed on all of the exterior surfaces of the structure;

[0032] FIG. 23 is a perspective view of the building structure wherein ceiling decking has been coupled to the vertical walls;

[0033] FIG. 24 is a perspective view showing roof panels having been coupled to the exterior walls, to form a peaked roof, having a roof line portion that extends laterally, along with a roof line that extends longitudinally, and showing a gabled roof portion on the left side, and a hip roof portion on the right side;

[0034] FIG. 25 is a perspective view showing a completed house, wherein the roof panels have been overlaid with a roofing material, and landscaping has been added around the exterior of the house;

[0035] FIG. 26 is a perspective view of a two-story version of the house, wherein structural panels have been used as vertical member panels, and decking, both conventional and made according to the present invention have been used for roof panels; andDETAILED DESCRIPTION

[0036] Before the present methods, implementations, and systems are disclosed and described, it is to be understood that this invention is not limited to specific methods, specific components, implementation, or to particular compositions, and as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular implementations only and is not intended to be limiting.

[0037] As used in the specification and the claims, the singular forms “a,”“an” and “the” include plural correspondents unless the context clearly dictates otherwise. Ranges may be expressed in ways including from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another implementation may include from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, for example by use of the antecedent “about,” it will be understood that the particular value forms another implementation. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0038] For purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, any alterations and further modifications in the illustrated device, and any further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

[0039] Referring now to FIG. 1, construction of a structural wall, or panel, 100 is described. This wall 100 may represent a portion of a modular construction and may also be referenced as a metal corrugated structural wall panel portion. As is illustrated, structural wall panels 102, 104, 124, 126, and 128 are joined together to form the structural wall 100.

[0040] Each structural wall panel 102, 104, 124, 126, and 128 includes a metal corrugated portion 122 extending between a top plate 106 and a bottom plate 108.

[0041] The top plate 106 and the bottom plate 108 are permanently affixed to the metal corrugated portion 122. The corrugated portion 122 is depicted as being affixed to the top plate 106 and the bottom plate 108 toward a midline of the respective plates 106, 108, with an overhang portion of the respective plate 106, 108 extending outwardly from the corrugated portion 122.

[0042] Although the top plate 106 and the bottom plate 108 are depicted as being affixed to the metal corrugated portion 122 via welding, in various forms it is contemplated that the top and bottom plates 106, 108 can be affixed to the metal corrugated portion 122 through various fasteners or adhesives. It has been discovered that the integration of the metal corrugated portion 122 with the top plate 106 and the bottom plate 108 provides for a very sturdy structural panel which is highly resistant to bending.

[0043] The metal corrugated portion 122 includes a plurality of vertically extending channels, or corrugations. The metal corrugated portion 122 is depicted as being formed of 16-gauge steel, similar to a standard intermodal shipping container. However, it is contemplated that various steel thickness can be utilized (e.g., thicker steel for a second story, for higher wind resistance, and / or for earthquake resistance). In one specific, non-limiting form, the channels or corrugations are integrated into the panel through a roll forming operation.

[0044] The top plate 106 and the bottom plate 108 can be affixed approximately perpendicular relative to the vertical extending corrugations of the metal corrugated portion 122. The bottom plate 108 serves as a base which is utilized to attach the structural wall panel to a foundation of the structure.

[0045] In a first form, the bottom plate 108 is mounted to the foundation of the structure through a metallic mounting plate with j-hooks. These j-hooks extend outwardly from a lower side of the mounting plate and are inserted into the wet concrete such that when the concrete cures, the mounting plate is fixedly connected thereto.

[0046] The mounting plate can be continuous around the foundation of the structure, or can be placed at intermittent intervals depending upon the specific application. Once the mounting plates are securely attached to the cured concrete, the bottom plate 108 can be welded or adhered to the mounting plate, thereby providing a sturdy connection mounting the bottom plate 108 to the foundation of the structure.

[0047] Alternately, the bottom plate108 can be mounted to the foundation of the structure through a plurality of threaded rods or threaded inserts. A portion of each threaded rod or threaded insert will be inserted, either before or after pouring, into the wet concrete of the foundation. As the concrete cures, the threaded rod or insert will be permanently affixed to the foundation.

[0048] In the case of a threaded rod, the bottom plate 108 can include apertures at predetermined locations. The bottom plate 108 is then placed atop the foundation with the upper end of the threaded rods extending through the apertures in the bottom plate 108. Thread receiving members, such as nuts, are then placed on the threaded rods and are securely tightened, thereby securely retaining the bottom plate 108 to the foundation of the structure.

[0049] In the case of threaded inserts, the bottom plate 108 may include apertures at predetermined locations. The bottom plate 108 and structural wall are then placed atop the foundation with the threaded inserts being aligned with the apertures in the bottom plate 108. Bolts, or other threaded fasteners, are then extended through the apertures in the bottom plate 108, and are securely threaded into the threaded inserts thereby securing the bottom plate 108 to the foundation.

[0050] In yet another embodiment, the bottom plate 108 can be secured to the foundation directly through adhesives; or a lower surface of the bottom plate 108 can include j-hooks or other concrete securing anchors extending downwardly therefrom, such that the structural walls will be interconnected prior to the pouring of the concrete foundation. Once the concrete foundation is poured and cured, the concrete securing anchors will securely retain structural wall to the foundation.

[0051] The top plate 106 serves as a mounting location and support for a ceiling panel and / or roof panel as will be discussed hereinafter. Although the bottom plate 108 and the top plate 106 are depicted as being constructed of 0.25-inch steel. However, the thickness and material of which the top plate 106 and the bottom plate 108 are constructed can be altered depending upon the requirements of specific application.

[0052] Each structural wall panel 102, 104, 124, 126, and 128 is constructed at a location remote from the build site. As is known with regard to prior modular construction, fabrication of the structural wall panels 102, 104, 125, 126, and 126 at an off-site facility permits increased construction efficiency, increased quality, and decreased on-site construction time.

[0053] Doorway openings 120 and window openings 116 can be cut in the structural wall panels at the factory away from the build site. These openings 120 and 116 are shown as including a steel door frame 110 and a steel window frame 118, which are either welded or bolted to the corrugated metal panel 122 (and in the case of a door the bottom plate 108).

[0054] However, the framing for the doors and windows can also be constructed of various polymers or wood. Although the windows and doors are preferably installed prior to arrival at the build site to reduce time on site, depending upon the specific application and design requirements, the windows and doors can be installed in the respective frames 118, 110 at the build site.

[0055] Once the structural wall panels have been shipped to the build site, they are affixed to one another. It is contemplated that the structural wall panels can be directly welded to one another such as by welding the top plate 105, the bottom plate 108, and the corrugated metal portion 122. However, mounting brackets can also be utilized.

[0056] An exemplary 90° mounting bracket is depicted at 112. A first side of the mounting bracket 112 is fixedly attached to the corrugated metal portion 122 of the structural wall panel 102. A second side of the mounting bracket 112 is then fixedly attached to the structural wall panel 124.

[0057] The top plate 106 and bottom plates 108 of the wall panel 102 are then attached with the top and bottom plates 106, 108 of the wall panel 124. As was previously discussed, the mounting bracket is depicted as being attached to the corrugated metal portion 122 via welding, and the top and bottom plates of adjacent wall panels are depicted as being attached through welding. However, in other embodiments, fasteners or adhesives may be utilized, depending upon the specific application.

[0058] An exemplary straight panel-to-straight panel mounting bracket 114 is shown as connecting structural walls 104 and 128. As was discussed with regard to the mounting bracket 112, the mounting bracket 112 is first affixed to the metal corrugated portion 122 of wall 104 such as by welding. The bracket 114 is then connected to the metal corrugated portion 122 of wall 128, thereby fixedly attaching structural wall 104 with structural wall 128.

[0059] FIGS. 1-2 show a variety of footprints that can be constructed via welding, or the previously described mounting brackets. As is illustrated with regard to FIG. 1, the top plates 106 of the structural walls 126 and 104 are depicted as being angled at 130, 132 such that the joining of structural walls 126 and 104 will result in an angle in the wall. Additionally, it is contemplated that one or more structural wall panels can include an arcuate shape or curvature.

[0060] In some forms, it can be desirable to include an exterior wall covering and an interior wall covering on the structural walls. As is illustrated in FIG. 3, the structural wall panel 102 (exploded on the left-hand side; not exploded on the right-hand side) can include a plurality of vertically extending interior studs or furring strips 302 as well as vertically extending exterior studs or furring strips 304. These studs or furring strips 302, 304 (also known as runners) are mounted to the corrugated metal portion 122 and extend between the top plate 106 and the bottom plate 108.

[0061] The top plate 106 and bottom plate 108 are shown on either side (top or bottom) of the corrugated metal portion 122 in FIG. 4. These studs or furring strips 302, 304 can be constructed of wood. However, the studs or furring strips 302, 304 may alternately include a metallic or polymeric construction. Such a metallic or polymeric construction of the studs or furring strips 302, 304 has been found to be advantageous in that the risk of termite infestations would be practically non-existent.

[0062] These studs or furring strips 302, 304 can be installed remotely at the factory. It is contemplated that the studs or furring strips 302, 304 can be mated with the corrugated metal portion 122 via welding, adhesives, or fasteners, depending upon the specific material utilized and design specifications.

[0063] The integration of the exterior studs or furring strips 304 provides a mounting location for a more traditional exterior covering, such as siding, or brick or stone veneers. However, some users will prefer the exterior appearance of corrugated metal, especially when covered in a variety of finishes (e.g. paints, varnishes, polymeric coatings, or the like).

[0064] A more traditional covering can be applied after the structural panels are joined, there providing a continuous, aesthetically pleasing appearance that preferably has no breaks in the siding relative the connection points of the underlying structural walls. This traditional exterior covering can be attached to the studs or furring strips 304 through convention means, such as by nailing or screwing.

[0065] The integration of the interior studs or furring strips 302 permits the addition of a traditional wall covering, such as drywall. It is contemplated that the interior covering may be applied at the off-site factory, in the case that the electrical and plumbing is installed at the factory, with any joints in the drywall being taped and mudded after the structural panels are affixed with one another. However, in further forms it is contemplated that the plumbing, electrical, and interior wall coverings can be installed on-site. The interior covering can be attached to the studs or furring strips 302 through conventional means, such as by using drywall screws.

[0066] Referring now to FIG. 7, covering an interior structural wall will now be discussed.

[0067] FIG. 7 depicts an interior structural wall 700 which, is as used herein comprises a wall completely located within the structure where both sides of the wall are visible from within the structure. As is illustrated, the attached studs or furring strips enable drywall 702, 704 to be added to both sides of the interior structural wall, thereby providing an aesthetically pleasing appearance.

[0068] The addition of studs or furring strips 302, 304, such as those shown above with respect to FIG. 3, provides a cavity (e.g. 306) in which insulation can be inserted. In some forms, insulation can be provided on both the interior and exterior of the corrugated metal portion 122. Although standard batt insulation may be utilized, Applicant has discovered that closed cell foam can expedite the manufacture of the structural panels, and is easily applied at the off-site factory. Additionally, closed cell foam provides an airtight and moisture tight barrier, thus completely sealing the structure.

[0069] Referring now to FIGS. 5-6 and 8, ceiling 600 and roof 810 panels will now be discussed. The ceiling panel 600 is depicted as having opposing side portions 604 and opposing end portions 608. These opposing side and end portions 600, 608 are preferably formed of steel.

[0070] Metal supports 602 extend across the ceiling panel 600 between the opposing end portions 608. The opposing side and end portions 600, 608 are shown to include flanges which extend interiorly and exteriorly. The interiorly extending flange provides a location for the metal supports 602 to rest upon, and be mounted to.

[0071] The exteriorly extending flange portions provide a location to mount the ceiling panel 600 to the top plate 106, as is illustrated in FIG. 6. The ceiling panel 600 can be mounted to the top plate via fasteners or through welded joints. A metal covering 802 is welded to the top of the ceiling panel 600. However, the lower portion of the ceiling panel 600 remains open to permit the installation of lighting, and permits a suitable location for electrical, plumbing, and ductwork to be installed.

[0072] Similar to the ceiling panel 600, the roof panel 810 is depicted as extending between opposing sides and ends and includes internal metal supports 804. The opposing sides and ends can each include an exteriorly and interiorly extending flange. Referring now to FIG. 8, these flanges provide a suitable location to either weld or fasten each roof panel 810 to the ceiling panels, and to either weld or fasten opposing roof panels to one another. As with the ceiling panel 600, the roof panel 810 includes a metal covering welded to a top portion, with the lower surface remaining open.

[0073] Although a variety of fastening techniques would function in a workmanlike manner, the use of welding is preferred as it results in a strong, unitary structure, but can also reduce air / moisture permeation into the structure should continuous welds be utilized.

[0074] For example, the corrugated portion 122 can be continuously welded to the top and bottom plates 106, 108 along the entire wall length and around any corners.

[0075] The mounting plate, as was previously described, can extend along the entire perimeter of the foundation, and the bottom plate 108 can be continuously welded to the mounting plate. If the ceiling panels 600 are continuously welded to the top plate 106, an airtight and moisture tight structure will be formed. This can be advantageous in locations where high winds are common. Where continuous welding is utilized, the building will remain sealed even if the roof structure is damaged.

[0076] Referring now to FIGS. 9-14, an exemplary process for manufacturing structural panels will now be discussed. As is illustrated in FIG. 9, the corrugated steel portion 122 and top 106 and bottom 108 plates are welded such as by a seam welder. Referring now to FIG. 10, the corrugated steel portion 122, and top 106 and bottom 108 plates are then cut to the desired length, and to accommodate any desired shapes of the desired building. Openings for the windows and doors are cut such as with a CNC controlled plasma cutter. The widow framing and door framing are then installed, and the stud or furring strips are added. Insulation may then be added to the structural wall panel.

[0077] FIG. 11 depicts an exemplary manufacturing process for the ceiling and roof panels. The opposing sides and ends are welded together, and the metal supports are welded between the opposing end portions. The metal covering is then welded upon the upper surface of the panel and is trimmed to length. After installation of the metal covering, the ceiling or roof panel can be flipped over and insulation can be added as is shown in FIG. 14.

[0078] FIGS. 15-24 depict an exemplary single-story structure 1500 being formed utilizing the structural panels (e.g., 122, 600, 700, 810 described above) according to the present application. In addition, multi-story structures can also be constructed utilizing the structural panels of the present application as shown in FIGS. 25 and 26.

[0079] It has been discovered that “corrugated shapes” give extra strength to walls in almost any building design. The corrugated panels are the basis of this design. It has many other benefits and solves future problems compared to the use of containers or current modular designs.

[0080] Most current modular designs have a low limit of wind rating (e.g., 140 mph), and present modular homes usually have extraordinarily little support to updrafts caused in swirling winds.

[0081] The wall construction of the present disclosure, utilizing corrugated shapes, provides sufficient strength to withstand high winds pushing against the exterior walls. The exterior walls are further supported by the corrugated walls within the interior of the structure that normally extend at 45 to 90 degrees to the exterior wall. As stated above, the process attaches the walls to a concrete floor with the use of different types of fasteners, fastener plates, glues or bolts that set into the concrete when poured. By fastening the vertical walls all along the bottom edges to systems that are anchored into the concrete, the wall is given extra strength to resist pressure created by high winds and uplift forces keeping the walls in place.

[0082] The walls of the present inventive structure have a top and bottom support. The bottom anchors to the concrete. The top plate is welded to the wall, allowing two things: a flat area to set the ceiling panels for welding or bolting, and an added stiffness to the wall when laying down and being stood up.

[0083] The top and bottom flat bars will be welded as needed to ensure the two are coupled securely enough to achieve the desired strength. These top and bottom flat bar plates are wider than the exterior walls to enable insulation to be added to both sides of the exterior walls. Insulation varies in different climates and can be easily attached to fit the desired R-Factor Rating required in the climate of the area wherein the structure is erected.

[0084] Preferably the panels are made in sections in a remote factory plant. The all-steel sheeting on top of the ceiling panels is supported by ceiling joists. These steel sheets are attached to the steel ceiling joist by welding, gluing or other means of attaching them to create a complete exterior wall and ceiling of steel.

[0085] This design and structure create a box that is welded or bolted together to simulate the strength of shipping containers.

[0086] Roof Panels will be constructed along the same lines as the ceiling panel and will be raised at the preferred angle to get the desired slope or pitch the customer requires or to get the highest wind rating.

[0087] This design is intended to reduce the cost of producing all the walls, ceiling and roof framework which, when properly designed, has the potential to achieve to achieve wind resistance of 200 mph or more.

[0088] This minimum would be the least anyone can buy and will make production time much shorter. This gives the customer full control of all the add-ons, they would normally benefit from, without giving up the wind strength and speed of erecting the house compared to prior art modular designs.

[0089] FIGS. 15-24 illustrate the sequence of events that will likely be encountered during the building and construction of a building structure 10 of the present invention.

[0090] FIG. 15 shows a finished building structure 900 that is here illustrated as a ranch type single family independent standing structure. It will be appreciated that features discussed herein can also be extended and used in other structures, such as townhome type structures, duplexes and the like.

[0091] The house 900 includes a front side 902, a left side 903, a right side 906, and a rear side 908. As used herein, directional indicators such as left side 903 and right side 906 are chosen arbitrarily, to help the leader better understand the invention, and are not just intended to be limiting.

[0092] As shown in FIG. 16, the structure includes a base 912, on which the building structure sits. The base 912 will often take the form of a concrete slab, but may be constructed of another material, such as a frame that overlays a subterranean portion of the structure, such as a crawl space or basement.

[0093] The base 912 includes an edging portion into which the anchors are embedded that are coupled to the vertical walls 914.

[0094] Turning now to FIG. 17, a vertical wall 924 is shown as being coupled to the left base of the house 912, and is shown as comprising the left exterior wall of the house. The left exterior vertical wall 924 includes cutouts for windows, and may also include cutouts for things such as vents, doors, and other such normal things that one might find in a house.

[0095] FIG. 18 shows a pair of lateral structural wall members 928 that are coupled to the vertical exterior wall 924. A lateral members 928 along with the vertical wall 924 are constructed preferably in accordance with the teachings of the present invention as set forth above.

[0096] FIG. 19 shows additional exterior walls sections added to the house, that include the rear side wall, which includes a rear exterior wall 930 that includes a left side section 934, a middle section 936, and a right section 938. In the particular house shown in the drawings, the left 934, middle 936, and right 938 sections are configured differently, to achieve different architectural aspects of the house. However, it will also be appreciated that the left, middle, and right sides 934, 936, 938 can comprise a unitary wall that is planar from left to right.

[0097] A pair of interior walls 942 are provided that extend generally between the back and front of the house, along with an interior wall 946 that extends in a generally lateral direction. These walls can be constructed in accordance to the teachings of the present invention, or may be constructed in traditional stud containing frame manner. As with most walls, they provide a division between spaces, along with structural support for the building 900.

[0098] FIG. 19 also shows the addition of a right-side wall 929 which is a general analog to the left side wall 924.

[0099] FIG. 20 shows the addition of a front exterior wall 950 that includes a left front exterior wall section 952, a middle front exterior wall section 954, and a right front exterior wall section 956. The middle front exterior wall section includes a front door, and windows that are coupled to the section. The right front exterior wall section includes a cutout for a garage door. Conventional strut containing interior walls, such as walls 960, can be provided by dividing up the spaces defined by the interior structural walls.

[0100] FIG. 21 shows that studs or furling strips 966 can be coupled to the exterior surface of an exterior wall, with insulation 964 being installed between the vertical studs. Additionally, an exterior cladding 968 can be placed over the exterior wall to achieve a desired esthetic effect, along with adding additional strength to the house, depending upon the type of surface chosen.

[0101] As discussed above, the steel structured walls of the present invention provide sufficient structural strength, without additional cladding. However, exterior cladding, even if unnecessary from a structural standpoint, still provides esthetic value, along with potential structural enhancements.

[0102] Turning now to FIG. 22, it will be noted that exterior cladding is placed over all of the exterior surfaces of the vertical walls. Additionally, landscaping 976 is added.

[0103] FIG. 23 shows the addition of ceiling panels 972, that include insulation 974. The ceiling panels 972 can be constructed by conventional means, or can be constructed in accordance with the present invention's use of steel structural panels.

[0104] FIG. 24 shows the addition of roofing panels 978, here on a pitched roof. For a building with a flat roof, the roofing panels 978 may not be necessary, but rather, one may rely on the ceiling panels 972 as shown in FIG. 23. Also, there is shown roofing panels overlaying the roofing material, such as asphalt roofing, steel roofing, or tile numbers.

[0105] A subtle feature shown in FIG. 24 is the fact that the present invention will work well with both houses having gabled roofs, as shown on the left side of the house, and hip roofs as shown on the right side of the house.

[0106] FIG. 25 shows the completed house, with the roof overlayed with an appropriate roofing material.

[0107] FIG. 26 shows the present invention being adapted to a multi-story house 990, such as the two-story house shown in FIG. 26. The multi-story house includes a first-floor vertical exterior panel members 992, and second floor exterior panel members 994. The other components are generally similar to those that are shown in the one-story house, with appropriate adaptations made for size, shape, and configuration.

[0108] While the present disclosure has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment(s), but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as permitted under the law.

[0109] Furthermore, it should be understood that while the use of the word preferable, preferably, or preferred in the description above indicates that feature so described may be more desirable, it nonetheless may not be necessary and any embodiment lacking the same may be contemplated as within the scope of the invention, that scope being defined by the claims that follow. In reading the claims it is intended that when words such as “a,”“an,”“at least one” and “at least a portion” are used, there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim.

[0110] Further, when the language “at least a portion” and / or “a portion” is used the item may include a portion and / or the entire item unless specifically stated to the contrary.

Examples

Embodiment Construction

[0036]Before the present methods, implementations, and systems are disclosed and described, it is to be understood that this invention is not limited to specific methods, specific components, implementation, or to particular compositions, and as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular implementations only and is not intended to be limiting.

[0037]As used in the specification and the claims, the singular forms “a,”“an” and “the” include plural correspondents unless the context clearly dictates otherwise. Ranges may be expressed in ways including from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another implementation may include from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, for example by use of the antecedent “about,” it will be understood that the particul...

Claims

1. A prefabricated structural panel for modular building construction, comprising:a metal corrugated structural wall panel portion extending between a top plate and a bottom plate, wherein the metal corrugated structural wall panel portion includes multiple corrugations;wherein the top plate and the bottom plate are permanently affixed to and perpendicular to a top edge and a bottom edge, respectively, of the metal corrugated structural wall panel portion;wherein top and bottom edges of the metal corrugated structural wall panel portions are affixed toward midlines of the respective top and bottom plates, using welds, adhesives, fasteners, or other joints;a plurality of external studs extending between the top plate and the bottom plate at an external side, according to an installation orientation, of the corrugated structural wall panel portion for receiving an external wall covering; anda plurality of internal studs extending between the top plate and the bottom plate at an internal side, according to the installation orientation, thereof for receiving an internal wall covering.

2. The prefabricated structural panel of claim 1, wherein tops and bottoms of the internal studs are welded to the top plate and the bottom plate, respectively, on the internal side.

3. The prefabricated structural panel of claim 1, wherein tops and bottoms of the external studs are welded to the top plate and the bottom plate, respectively, on the external side.

4. The prefabricated structural panel of claim 1, wherein, in an installed configuration, the bottom plate can be securely threaded into the threaded inserts of a foundation thereby securing the bottom plate to the foundation.

5. The prefabricated structural panel of claim 1, wherein, in an installed configuration, the bottom plate can include j-hooks or other concrete securing anchors extending downwardly therefrom, such that the structural walls will be interconnected prior to the pouring of a concrete foundation.

6. The prefabricated structural panel of claim 1, wherein recesses defined by the corrugations receive insulation therein for insulating a modular building.

7. The prefabricated structural panel of claim 1, wherein the metal corrugated structural wall panel portion includes a cutout defined with a frame defining a doorway or a window.

8. The prefabricated structural panel of claim 1, wherein the prefabricated structural panel may be used as a ceiling panel or a roof panel.

9. The prefabricated structural panel of claim 1, wherein the ceiling panel or the roof panel are welded or bolted to the top plate.

10. A modular building construction, including:a plurality of prefabricated structural panels fastened together in an arrangement;wherein each prefabricated structural panel includes:a metal corrugated structural wall panel portion extending between a top plate and a bottom plate, wherein the metal corrugated structural wall panel portion includes multiple corrugations;wherein the top plate and the bottom plate are permanently affixed to and perpendicular to a top edge and a bottom edge, respectively, of the metal corrugated structural wall panel portion;wherein top and bottom edges of the metal corrugated structural wall panel portions are affixed toward midlines of the respective top and bottom plates, using welds, adhesives, fasteners, or other joints;a plurality of external studs extending between the top plate and the bottom plate at an external side, according to an installation orientation, of the corrugated structural wall panel portion for receiving an external wall covering; anda plurality of internal studs extending between the top plate and the bottom plate at an internal side, according to the installation orientation, thereof for receiving an internal wall covering.

11. The prefabricated structural panel of claim 10, wherein tops and bottoms of the internal studs are welded to the top plate and the bottom plate, respectively, on the internal side.

12. The prefabricated structural panel of claim 10, wherein tops and bottoms of the external studs are welded to the top plate and the bottom plate, respectively, on the external side.

13. The prefabricated structural panel of claim 10, wherein, in an installed configuration, the bottom plate can be securely threaded into the threaded inserts of a foundation thereby securing the bottom plate to the foundation.

14. The prefabricated structural panel of claim 10, wherein, in an installed configuration, the bottom plate can include j-hooks or other concrete securing anchors extending downwardly therefrom, such that the structural walls will be interconnected prior to the pouring of a concrete foundation.

15. The prefabricated structural panel of claim 10, wherein recesses defined by the corrugations receive insulation therein for insulating a modular building.

16. The prefabricated structural panel of claim 10, wherein the metal corrugated structural wall panel portion includes a cutout defined with a frame defining a doorway or a window.

17. The prefabricated structural panel of claim 10, wherein the prefabricated structural panel may be used as a ceiling panel or a roof panel.

18. The prefabricated structural panel of claim 10, wherein the ceiling panel or the roof panel are welded or bolted to the top plate.

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