Structural insulated panel interconnecting system

Abstract

The present invention relates to a structural insulated panel interconnecting system having securement and interconnecting apparatuses, which are structural splines and support tracks, for interconnecting prefabricated panel assemblies for walls, floors, and roofs, which can be completely or mostly pre-manufactured off-site and shipped to the construction location for quick and efficient assembly. The securement and interconnecting apparatuses attach to peripheries of structural insulated panels and provide more earthquake-resistant interconnecting system that can be used for building energy efficient buildings that meet Passivhaus standards.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This U.S. non-provisional patent application claims the benefit of U.S. provisional patent application Ser. No. 63 / 740,020, filed Dec. 30, 2024, which is incorporated herein by reference in its entirety.BACKGROUND OF THE INVENTIONFIELD OF THE INVENTION

[0002] The present invention generally relates to panel assemblies such as panels for walls, floors, and roofs for building construction, engineering, or architecture. Specifically, the present invention relates to a structural insulated panel interconnecting system having securement and interconnecting apparatuses for interconnecting prefabricated panel assemblies for walls, floors, and roofs, which can be completely or mostly pre-manufactured off-site and shipped to the construction location for quick and efficient assembly. Further, the present invention relates to interconnecting and securing energy efficient prefabricated panel assemblies for building energy efficient buildings that meet Passivhaus standards. Still further, the present invention relates to structural insulated panel interconnecting system having securement and interconnecting apparatuses for interconnecting prefabricated panel assemblies and buildings made of such prefabricated panel assemblies that are more earthquake-resistant because the structural insulated panel interconnecting system allow for movement between the prefabricated panel assemblies that are joined to form building structures. Still further, the present invention relates to prefabricated panel assemblies that are easily replaced or repurposed by disassembling the structural insulated panel interconnecting system from the prefabricated panel assemblies.DESCRIPTION OF THE PRIOR ART

[0003] The present invention deals with products in the field of building architecture, engineering, construction, or civil engineering. More specifically, it deals with a structural insulated panel interconnecting system for prefabricated panel assemblies that are designed to facilitate constructing buildings that are more energy efficient, sustainable, and that can withstand movement between the prefabricated panel assemblies. Further, it deals with quickly replacing or repurposing prefabricated panel assemblies that are used in a building.

[0004] Transporting building materials to a building construction site uses up a lot of time and resources during construction. Prefabricating building panel assemblies, such as an entire wall panel assembly, roof panel assembly, or floor panel assembly, off-site and shipping to the construction location as easy to put together assemblies saves significant time and decreases labor costs at the site, allowing buildings to be constructed faster with less workers, with more accuracy and affordably.

[0005] Magnesium cement, fiberglass scrim-reinforced materials, magnesium oxide (MgO), magnesium sulfate (MgSO4), and other cementitious boards, panels, or sheets, which are fire resistant, water resistant, non-toxic, termite proof, mold and fungus resistant, thermally efficient (resistant to extreme temperatures), eco-friendly (recyclable and landfill friendly), durable (no rot), lightweight, strong, and affordable, are generally known and used in the building panel industry. Throughout the specification, the abbreviation “MgO” is used to describe this family of materials and derivations thereof. MgO structural insulated panels (SIPs) provide two MgO boards, panels, or sheets with an insulation layer sandwiched in between. However, most magnesium oxide boards do not readily come with multiple layers of insulation, air barriers, or cavities for electrical or pipe systems that may be necessary for a building. Further, typical MgO panels have rigid connections, and may be prone to developing cracks during construction or after building completion due to the building settling and movement.

[0006] Passivhaus, or also called Passive House, design or system use highly insulated wall panels with combinations of materials, such as layers of different insulations and air barriers such as smart vapor barriers. Passivhaus design focuses on proper insulation, elimination of air-leakages and thermal bridges (air and vapor-tight and without thermally conductive elements that transmit energy between the interior and exterior spaces, all of which can lead to condensation, mold, and deterioration), proper windows facing proper orientation, and heat recovery ventilation (HRV) or energy recovery ventilators (ERVs that also recover humidity). A building built with Passivhaus design uses 70-95% less energy, eliminating the need or at least leads to less use of an air conditioning (AC) or a heating system. Energy from body heat, internal sources such as electronics, cooking, or lights, and sunlight are enough to keep the environment within the building warm or cool, providing a healthier (naturally anti-fungal), safer (non-combustible), and more efficient building. However, Passivhaus design does not typically use MgO structural insulated panels and does not consider panels of the building shifting as the building settles or during an earthquake.

[0007] To overcome rigidity and to make Magnesium oxide structural insulated panels (MgO SIPs) more energy efficient and sustainable, and to reduce the complication, speed, and cost of building construction utilizing Passivhaus design, the present invention provides prefabricated panel assemblies that are cost effectively constructed off-site with the structural insulated panel interconnecting system of the present invention. Once constructed, the panels are delivered efficiently to the construction site for fast, simple construction using the structural insulated panel interconnecting system. These panels provide an energy efficient MgO SIP with a service cavity that provides space for any needed electrical or piping and more insulation and an air and vapor barrier. The structural insulated panel interconnecting system for the panels have joints and extension members that allow for building shift without cracking or breaking. Finally, the structural insulated panel interconnecting system and the panel designs provide the possibility of repurposing the prefabricated panel assemblies by easily “disassembling” the panels one from another, removing them from their existing location and moving to a new location so that they can be “reassembled” or used as an addition to another preexisting buildings built using the same or similar prefabricated panel assemblies and the structural insulated panel interconnecting system. Thus, the resulting building envelopes from present invention can be fabricated, transported, and assembled far more quickly than conventional framing while achieving superior energy and environmental performance.

[0008] It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein.

[0009] These and other aspects of the invention will be apparent from and elucidated with reference to the embodiment(s) described hereinafter.SUMMARY OF THE INVENTION

[0010] In view of the foregoing, it is an object of the present invention to provide a structural insulated panel interconnecting system for panel assembly for walls, floors, and roofs. The panel assembly can be completely or mostly prefabricated off-site and shipped to the construction location for quick, simple, and efficient assembly using the structural insulated panel interconnecting system.

[0011] It is another object of the present invention to provide a prefabricated panel assembly using magnesium oxide structural insulated panel (MgO SIP) but overcome its rigidity and need for allowing additional insulation and air barrier, and space for utility services, such as electrical and piping.

[0012] It is yet another object of the present invention to provide a structural insulated panel interconnecting system for connecting an energy efficient prefabricated panel assembly for building energy efficient buildings that meet Passivhaus design standard but overcome cost, and complication associated with Passivhaus design.

[0013] It is still yet another object of the present invention to provide a structural insulated panel interconnecting system for prefabricated panel assembly that is more earthquake-resistant and allows for movements or shifts between the prefabricated panel assemblies that are joined to form a building structure.

[0014] Further still, it is yet another object of the present invention to provide a structural insulated panel interconnecting system for prefabricated panel assembly, so the prefabricated panel assembly is easily replaced or repurposed in a building built with such prefabricated panel assemblies.

[0015] The present invention achieves these objects and other objects that become evident from the following detailed description of the preferred embodiments of the invention by providing a structural insulated panel interconnecting system for a prefabricated panel assembly for floor, wall, and roof. The prefabricated panel assembly comprises a weather resistive barrier membrane, a structural insulated panel, a gypsum or other finish materials board, a smart vapor barrier, and a service cavity. The structural insulated panel interconnecting system comprises at least a first securement and interconnecting apparatus and a second securement and interconnecting apparatus, an attachment member for securing the first securement and interconnecting apparatus to the structural insulated panel and the second securement and interconnecting apparatus, and an attachment member for securing the second securement and interconnecting apparatus to the structural insulated panel.

[0016] The first securement and interconnecting apparatus, also referred to as a spline or a structural spline, has at least a first structural track configured to receive a first periphery of a structural insulated panel and at least a pair of outer retaining edges. The first structural track has a first flange, a second flange, and a web connecting the first flange and the second flange. The pair of outer retaining edges has a first outer retaining edge extending perpendicular to the first flange of the first structural track, and a second outer retaining edge extending perpendicular to the second flange of the first structural track. The pair of outer retaining edges is configured to support protruding edges of the first periphery of the structural insulated panel.

[0017] The second securement and interconnecting apparatus, also referred to as a support track and can include what are commonly known as top tracks, base tracks, and rim joists, has at least a second structural track configured to receive a second periphery of the structural insulated panel and an end of the first structural track of the first securement and interconnecting apparatus, at least one support plate, which can include what are commonly known as top plates, base plates, and mud sills, and at least a second pair of outer retaining edges. The second structural track has a first flange, a second flange, and a web connecting the first flange and the second flange. The at least one support plate is attached to an interior surface of the web and extends along the second structural track. The pair of outer retaining edges has a first outer retaining edge extending perpendicular to the first flange of the second structural track, and a second outer retaining edge extending perpendicular to the second flange of the second structural track. The pair of outer retaining edges is configured to support protruding edges of the second periphery of the structural insulated panel.

[0018] The support plate is secured to at least one structural track of the second securement and interconnecting apparatus by the attachment member. The attachment member also secures the second securement and interconnecting apparatus to the structural insulated panel. This attachment member is also referred to as the support plate connecting member for connecting the support plate with the structural insulated panel. The support plate connecting member may be glue, nails, or other means known in the art for attaching the support plate to the structural insulated panel, or more complex means for connecting the support plate to the structural insulated panel, such as, but not limited to, U or H-shaped members and C and H-shaped tracks, also referred to as the second structural track or the structural track) as will be described throughout the specification. One or more of a plurality of screws, a plurality of latches, at least one pair of L-shaped clips, and an adhesive can be used as attachment member / s for attaching the support plate to the C and H-shaped tracks (the at least one second structural track).

[0019] The structural insulated panel comprises an outer cement board sheet, an insulation layer, an inner cement board sheet, and a structural stud. The structural stud is used for developing additional internal strength inside a panel. It is also called a structural spline or the first securement and interconnecting apparatus of the structural insulated panel interconnecting system when it is used for connecting multiple structural insulated panels together. The first securement and interconnecting apparatus also includes a rectangular corner post when used where wall corners occur. These studs and corner posts are partially recessed into the outer vertical edges of the structural insulated panels or otherwise firmly connected. An air and vapor barrier with the capacity to selectively stop or allow the passage of water vapor depending upon the presence or absence of liquid water, also called a smart vapor barrier or SVB, is located on either the inner or outer face or in the center of the structural insulated panel, depending upon the climate in which the wall is located. In the northern climates where the exterior ambient air is typically drier than it is southern climates, the air and vapor barrier or smart vapor barrier (SVB) is typically located on the interior or room side of the wall panel. In southern climates the exterior weather resistive barrier can also perform the smart vapor barrier role if the correct material is used. In some climates, the smart vapor barrier function may be required on both the exterior and interior sides of the structural insulated panel or may be located in the center of the structural insulated panel. The service cavity is positioned in between the structural insulated panel and the gypsum board that is used as the interior finish substrate on the room side of the assembly. The service cavity is comprised of a stud and may also have thermal insulation. A smart vapor barrier also can be located within the service cavity. Desired utility service can be run in the service cavity. Desired utility service can be water, heat, or drainage piping, electrical wires, cables, data links, and any other utility that may be needed or desired for the purpose of the building. Other materials, such as phase change materials, may be added to either the structural insulated panel, the service cavity, or both.

[0020] In an embodiment of the present invention, the outer cement board sheet and the inner cement board sheet of the structural insulated panel each have recessed insulation edges or protruding edges around a periphery that fit around structural splines (the first securement and interconnecting apparatus) and support plates, such as base plates and top plates, and support tracks (the second securement and interconnecting apparatus). The edges of the insulation layer of the structural insulated panel can be recessed to allow the structural splines, support tracks, support plates, and connecting / attachment members to recess into the edges of the outer and inner cement board sheets or panels so they can be glued and fastened (either nails or screws) in place. With a polymer stud being used as a structural spline and with the expansion / control joint gasket being used, the spline edges that are closest to the panel joint can have at least a pair of outer retaining edges (the protruding edges) occur along the edges that are closest to the joint, with the protrusions occurring both on the room side and the exterior side of the spline. Those outer retaining edges (protruding edges) occur in order to support the edges of the gasket material where they are closest to the room and exterior faces of the joint. When the board joint is finished, the actual joint is sealed with a flexible, but firm caulking material that takes advantage of the straight, protruding edges of the spline to give a more pleasing, uniform, and straight appearance.

[0021] In an embodiment of the present invention, the outer cement board sheet and the inner cement board sheet of the structural insulated panel each have recessed insulation edges or protruding edges around a periphery that fit around structural studs (splines) and support plates (base plates and top plates). In this embodiment, the stud connecting member is an interlocking spline with a control joint capability to control movement and the related potential for cracking of the cement board sheets. The interlocking spline with the control joint capability, which is an embodiment of the first securement and interconnecting apparatus or the structural spline, is comprised of a first structural track (also referred to as C, H, or rectangular-shaped stud), a second structural track (also referred to as C, H, or rectangular-shaped stud), and has a cushioning layer as the core member. The first structural track receives a periphery of a first structural insulated panel, and the second structural track receives a periphery of a second structural insulated panel. The first and the second structural tracks interlock together to form a H-shaped track with the core member sandwiched between the exterior surface of the web of the first structural track and the web of the second structural track. The first and second structural tracks each have a pair of outer retaining edges (also referred to as an outer board trim edge and an inner board trim edge), and a plurality of interlocking connecting apparatuses on the exterior surface, and a plurality of interlocking connecting slots. The outer board trim edge (a first outer retaining edge) supports a protruding edge of the outer cement board sheet. The inner board trim edge (a second outer retaining edge) supports a protruding edge of the inner cement board sheet. The core member is a cushioning layer and is positioned in between the first and the second structural tracks, and the cushioning layer is also an adhesive material that resists delamination under movement.

[0022] In another embodiment of the present invention, the support plate is rectangular with interlocking end pieces. The outer cement board sheet and the inner cement board sheet of the structural insulated panel each have a protruding edge around a periphery that connects with glue and screws as attachment members to the at least one structural track of the second securement and interconnecting apparatus (also referred to as the support track or the H-shaped support plate connecting members) located at the bottom edges of the panel and in some instances also at the top edges of the panels. The second securement and interconnecting apparatus form bottom, and sometimes top, channels with its at least one structural track, forming a C-shaped track with one structural track and an H-shaped track with a first and a second structural tracks mirrored and connected together. The bottom and top channels forming the support tracks are shaped to fit into the protruding edges of the bottom and top edges of the structural insulated panel. The bottom channel of the bottom support track and the top channel of the top support track are shaped to fit over the bottom support plate and the top support plate.

[0023] In an embodiment of the present invention, the outer cement board sheet and the inner cement board sheet of the structural insulated panel each have recessed insulation edge around a periphery, forming a channel between the recessed insulation edge of the outer cement board sheet and the recessed insulation edge of the inner cement board sheet. The channel is shaped to receive a support plate of the second securement and interconnecting apparatus (the support track) of the structural insulated panel interconnecting system. The structural insulated panel interconnecting system can further comprise attachment member for the second securement and interconnecting apparatus, which can be a gasketed movement joint and an L-shaped angle positioned on a corner of the gasketed movement joint, with bolted connections consisting of short plates with slotted holes connected to the ends of adjacent support channels to allow for movement in the support plate between multiple prefabricated panel assemblies.

[0024] In an embodiment of the structural insulated panel interconnecting system, the web of the first structural track of the first securement and interconnecting apparatus form a protruding portion on each end of the first structural track, and the second track of the second securement and interconnecting apparatus is configured to receive the protruding portion on one end of the first structural track of the first securement and interconnecting apparatus.

[0025] In an embodiment of the structural insulated panel interconnecting system, the attachment member for securing the first securement and interconnecting apparatus to the structural insulated panel and the second securement and interconnecting apparatus and the attachment member for securing the second securement and interconnecting apparatus to the structural insulated panel comprises one or more of a plurality of screws, a plurality of latches, at least one pair of L-shaped clips, and an adhesive.

[0026] In an embodiment of the structural insulated panel interconnecting system, the first securement and interconnecting apparatus further comprises at least one core member attached to an exterior surface of the web of the first structural track and extending along the first structural track. In such embodiment, the core member and the web of the first structural track of the first securement and interconnecting apparatus may form a protruding portion on each end of the first structural track, and the second track of the second securement and interconnecting apparatus may be configured to receive the protruding portion on one end of the first structural track of the first securement and interconnecting apparatus. The core member of the first securement and interconnecting apparatus may comprise one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material. The core member of the first securement and interconnecting apparatus may further comprise a tension rod.

[0027] In an embodiment of the present invention, the structural spline for securing and interconnecting structural insulated panels comprises at least one structural track configured to receive a periphery of a structural insulated panel, at least a pair of outer retaining edges configured to support protruding edges of the periphery of the structural insulated panel, and an attachment member for securing the structural spline to the structural insulated panel and a plurality of support tracks. The structural track comprises a first flange, a second flange, and a web connecting the first flange and the second flange. The pair of outer retaining edges has a first outer retaining edge extending perpendicular to the first flange of the structural track and a second outer retaining edge extending perpendicular to the second flange of the structural track. The attachment member may be one or more of a plurality of screws, a plurality of latches, at least one pair of L-shaped clips, and an adhesive.

[0028] In an embodiment of the structural spline, the web of the structural track forms a protruding portion on each end of the structural track, and the attachment member attaches the protruding portion on one end of the structural track to the plurality of support tracks.

[0029] In an embodiment of the structural spline, the structural spline further has at least one core member attached to an exterior surface of the web of the structural track and extending along the structural track, and the core member comprises one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material. In such embodiment, the core member and the web of the structural track may form a protruding portion on each end of the structural track, and the attachment member attaches the protruding portion on one end of the structural track to the plurality of support tracks. The core member may further have a tension rod.

[0030] In an embodiment of the structural spline where the spline an interlocking spline, the spline has a first structural track for receiving a periphery of a first structural insulated panel and a second structural track for receiving a periphery of a second structural insulated panel. The first and the second structural tracks interlock together to form a H-shaped track with the core member sandwiched between the exterior surface of the web of the first structural track and the web of the second structural track. The web of the first structural track and the web of the second structural track each further have a plurality of interlocking connecting apparatuses on the exterior surface, and a plurality of interlocking connecting slots. The plurality of interlocking connecting apparatuses of the first structural track aligns, inserts, and interlocks with the plurality of interlocking connecting slots of the second structural track through the core member and the plurality of interlocking connecting apparatuses of the second structural track aligns, inserts, and interlocks with the plurality of interlocking connecting slots of the first structural track through the core member.

[0031] In an embodiment of the structural spline where the spline is a corner spline, the spline has a first structural track for receiving a periphery of a first structural insulated panel and a second structural track for receiving a periphery of a second structural insulated panel. The spline further has a first core member parallelly attached to the exterior surface of the web of the first structural track and a second core member parallelly attached to the exterior surface of the web of the second structural track. The structural spline further has a rectangular corner post attached to the first core member at a first side and to the second core member at a second side adjacent the first side. The rectangular corner post may have at least one tension rod. The first core member, the second core member, and the rectangular corner post each comprises one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material. In such embodiment, the corner spline further has at least one corner post cap. The corner post cap has a rectangular body, a rectangular slot on a side of the body for aligning and fitting on a top or a bottom surface of the rectangular corner post, a core within the body, and a thermal control material, and at least one tension rod. The core may have one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material. The core may have at least one protruding portion on at least one side of the body.

[0032] In an embodiment of the present invention, a support track for securing and interconnecting structural insulated panels and a plurality of structural splines has at least one structural track configured to receive a periphery of a structural insulated panel and a portion of the plurality of structural splines, at least one support plate, at least a pair of outer retaining edges, and an attachment member. The structural track has a first flange, a second flange, and a web connecting the first flange and the second flange. The support plate is attached to an interior surface of the web and extends along the structural track. The pair of outer retaining edges is configured to support protruding edges of the periphery of the structural insulated panel. A first outer retaining edge extends perpendicular to the first flange of the structural track and a second outer retaining edge extends perpendicular to the second flange of the structural track. The attachment member for securing the support track to the structural insulated panel may be one or more of a plurality of screws, a plurality of latches, at least one pair of L-shaped clips, and an adhesive. In such embodiment, the support plate may further have a tension rod.

[0033] In an embodiment, the support track has a first structural track for receiving the periphery of the structural insulated panel, a second structural track for receiving one of a mud sill and a periphery of a second structural insulated panel, and an attachment member for attaching the second structural track to one of the polymer mud sill and the periphery of the second structural insulated panel.

[0034] In an embodiment of the present invention, the prefabricated panel assembly may further comprise a polymeric header for structural support over openings.

[0035] In an embodiment of the present invention, the service cavity may further comprise a furring strip that clamps the smart vapor barrier to hold the smart vapor barrier in place within the service cavity.

[0036] In an embodiment of the present invention, the corner post (the corner spline) may further have a weather resistive barrier, an insulation layer, and a corner post connecting member to interlock with the structural insulated panel.

[0037] In an embodiment of the present invention, the support plate of the prefabricated panel assembly further comprises a tensioning cable or rod to join multiple structural insulated panels together and support more loads.

[0038] In an embodiment of the present invention, the support plate of the support track, or the second securement and interconnecting apparatus of the structural insulated panel interconnecting system, is one of a bottom support plate / base plate, a top support plate / top plate, and mud sill.

[0039] In an embodiment of the present invention, the insulation layer of the structural insulated panel and the insulation layer of the service cavity is selected from the group of oil-based insulations consisting of expanded polystyrene (EPS or Styrofoam), extruded polystyrene (XPS), and polyisocyanurate (poly Iso or ISO). In an embodiment of the present invention, the insulation layer of the structural insulated pane and the insulation layer of the service cavity is selected from the group of organic-based insulations consisting of hemp, straw, bamboo, cellulose, fungi, rice hulls, or similar, including fabricated structural shapes such as honeycomb and crossing grid-shaped arrangements of materials with insulation, phase change, and selective vapor control materials included in the cells.

[0040] In an embodiment of the present invention, the outer cement board sheet and the inner cement board sheet of the structural insulated panel are selected from the group consisting of magnesium oxide, magnesium sulfate, and other cement and polymer boards known in the art.

[0041] In an embodiment of the present invention, the first and the second securement and interconnecting apparatuses, or the structural spline and support track, are made of a material selected from the group consisting of wood, metal, fiberglass reinforced plastic (FRP), recycled plastic, composite plastic, and other organic and recycled materials.

[0042] In an embodiment of the present invention, the attachment members for the first and the second securement and interconnecting apparatuses are latches and latch receivers.

[0043] In an embodiment of the present invention, the structural stud of the structural insulated panel may further comprise an insulation layer.

[0044] In an embodiment of the present invention, the service cavity may further comprise a furring strip. The furring strip is comprised of a material selected from the group consisting of one of wood, plastic, PVC, fiberglass, and other recycled and composite materials.

[0045] In an embodiment of the present invention, the support plate connecting member of the support plate may comprise a cushioning layer. In an embodiment of the present invention, the stud connecting member of the structural stud of the structural insulated panel may further comprise a cushioning layer.

[0046] In another embodiment of the present invention, a prefabricated panel assembly for floor, wall, and roof, is comprised of a weather resistive barrier membrane, a structural insulated panel, a gypsum board, an insulated or uninsulated service cavity, and a polymer support plate. The structural insulated panel is comprised of an outer non-combustible and carbon sequestering board sheet, an insulation layer, a smart vapor barrier, an inner non-combustible and carbon sequestering board sheet, and a structural stud with a stud connecting member. The service cavity is positioned in between the structural insulated panel and the gypsum board. The service cavity is comprised of a polymer stud with an insulated core, and a smart vapor barrier. Any desired utility service can be run in the service cavity. The polymer support plate is comprised of an insulated core and a support plate connecting member. The polymer stud may further have a tension rod.BRIEF DESCRIPTION OF THE DRAWINGS

[0047] In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the inventive subject matter.

[0048] FIG. 1 is a perspective interior (to a building) view of a roof prefabricated panel assembly, a wall prefabricated panel assembly, and a floor prefabricated panel assembly, assembled together using the structural insulated panel interconnecting system to show how prefabricated panel assemblies are connected together to form a building.

[0049] FIG. 2 is a top perspective view of the roof prefabricated panel assembly, the wall prefabricated panel assembly, and the floor prefabricated panel assembly in FIG. 1, showing the weather resistive barrier membrane of the roof prefabricated panel assembly and a weather resistive barrier membrane of the wall prefabricated panel assembly. The panels are connected using the structural insulated panel interconnecting system, and the first securement and interconnecting apparatus (the structural spline) as a corner post is shown as well as the second securement and interconnecting apparatus. An air barrier of the floor prefabricated panel assembly is also shown.

[0050] FIG. 3 is an exploded side perspective view of the roof prefabricated panel assembly, the wall prefabricated panel assembly, and the floor prefabricated panel assembly in FIGS. 1-2. FIG. 3 shows, in addition to what are shown in FIGS. 1-2, a tension rod in the support plate of the second securement and interconnecting apparatus of the structural insulated panel interconnecting system connecting the roof prefabricated panel assembly to the wall prefabricated panel assembly, a tension rod in the support plate (top plate) of another second securement and interconnecting apparatus of the structural insulated panel interconnecting system connecting the wall prefabricated panel assembly to the floor prefabricated panel assembly.

[0051] FIG. 4 is a side exterior (to a building) perspective view of the prefabricated wall assembly in FIGS. 1-3, showing a smart vapor barrier of the service cavity, and how the structural spline (the first securement and interconnecting apparatus) as the corner post would attach to the panel using latches as the attachment member.

[0052] FIG. 5 is a side interior (to a building) perspective view of the wall prefabricated wall assembly in FIGS. 1-4, showing all the parts previously discussed in FIGS. 1-4, and also showing an electrical switch and an electrical receptacle on a surface of the service cavity.

[0053] FIG. 6 is a close-up exploded view of an embodiment of the attachment member, shown as screws and a latch, for attaching a first securement and interconnecting apparatus (a structural spline) to the structural insulated panel of the prefabricated panel assembly according to disclosure, and also showing a second securement and interconnecting apparatus (a support track) on the structural insulated panel on the right, as well as how a support plate of the second securement and interconnecting apparatus may be connected to another support plate for another structural insulated panel.

[0054] FIG. 7A is a close-up exploded view of how two wall prefabricated panel assemblies are joined together to allow shifting using the structural insulated panel interconnecting system. An outer cement board sheet and an inner cement board sheet of a structural insulated panel are shown, with each having recessed insulation edge around a periphery, forming a channel between the recessed insulation edge of the outer cement board sheet and the recessed insulation edge of the inner cement board sheet, which accommodates the structural track of the second securement and interconnecting apparatus (the support track) within the channel, and the structural track can receive the support plate of the second securement and interconnecting apparatus as shown. A gasketed movement joint and an L-shaped angle is positioned on a corner of a portion of the structural insulated panel within the channel to allow for the support plate (top plate / top track) movement and serve as attachment members for attaching the second securement and interconnecting apparatus to the structural insulated panel. The connecting splice channel may be located above or below the top support track depending upon the project requirements.

[0055] FIG. 7B is a close-up exploded view of an embodiment of the second securement and interconnecting apparatus (the support track) of the structural insulated panel interconnecting system, showing the structural track on top and a window header as the support plate in the middle, and how they attach to the structured insulated panel using the screws and L-shaped angle clip (or angle) as the attachment members.

[0056] FIG. 8A is a perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) of the structural insulated panel interconnecting system, showing a first structural track and its components.

[0057] FIG. 8B is an exploded side perspective view of the embodiment of the first securement and interconnecting apparatus (the structural spline) of the structural insulated panel interconnecting system shown in FIG. 8A, showing the first structural track on the right side and further showing a second structural track on the left side and an adhesive gasketed core member in the middle. Screws and L-clips as attachment members for attaching the first securement and interconnecting apparatus to a structural insulated panel are also shown.

[0058] FIG. 8C is an exploded side perspective view of the embodiment of the first securement and interconnecting apparatus (the structural spline) of the structural insulated panel interconnecting system shown in FIGS. 8A-8B, with the attachment members shown in FIG. 8B removed.

[0059] FIG. 8D is a close-up perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) of the structural insulated panel interconnecting system shown in FIGS. 8A-8C without a protruding portion on an end of the web of the first and second structural tracks. The first and second structural tracks are shown attached back-to-back together to form an expansion joint (control joint or interlocking spline with a control joint capability) with a cushioning layer (or gasket) as the core member, positioned in between to allow for movement (from wind, earthquake, vibration, etc.) and settling.

[0060] FIG. 9 is an embodiment of the wall prefabricated panel assembly having a service cavity comprised of a furring strip that acts as a clamp on an edge of a smart vapor barrier to hold the smart vapor barrier in place within the service cavity.

[0061] FIG. 10 is a side, exploded, perspective view of an embodiment of the wall prefabricated panel assembly, showing how four wall prefabricated panels can be assembled together to form a wall prefabricated panel assembly using a first securement and interconnecting apparatus (the structural spline) of the structural insulated panel interconnecting system in between two adjacent panels, a second securement and interconnecting apparatus (the support track) of the structural insulated panel interconnecting system are used on top and bottom of the wall prefabricated panel assembly and attached with U-shaped clips as the attachment members made from the same polymer materials as the first and second securement and interconnecting apparatuses.

[0062] FIG. 11 is a side, exploded, perspective view of another embodiment of the structural insulated panel interconnecting system connecting the wall prefabricated panel assembly and the floor prefabricated panel assembly together.

[0063] FIG. 12 is a side, exploded, perspective view of another embodiment of the structural insulated panel interconnecting system for connecting the structural insulated panels of a wall prefabricated panel assembly, showing an outer non-combustible and carbon sequestering board sheet, an insulation layer, a smart vapor barrier, another insulation layer, an inner non-combustible and carbon sequestering board sheet.

[0064] FIG. 13 is a side exploded perspective view of an embodiment of the structural insulated panel interconnecting system showing how it would be used with the wall prefabricated panel assemblies and a floor prefabricated panel assembly.

[0065] FIG. 14 is a side, exploded, perspective view of another embodiments of the structural insulated panel interconnecting system and the wall prefabricated panel assembly, and how some of them could be configured for varying windows and wall configurations, showing an outer non-combustible and carbon sequestering board sheet, an insulation layer, a smart vapor barrier, a phase change layer, and service cavity configurations, a non-combustible cementitious skins with insulating liners at window and door openings, a polymer first securement and interconnecting apparatus (a structural spline) with insulating core member with a tension rod, and multiple polymer second securement and interconnecting apparatuses (support tracks) with support plates (top plate and base plate) with anchors, insulated core members with tensioning rods, an attachment member as a polymer connecting track with insulating core and a tension rod. A structural header as a structured insulated panel over openings having thermal and control layers as a part of the wall prefabricated panel assembly, and a sill panel with insulated polymer shapes are also shown.

[0066] FIG. 15 is a side, exploded, perspective view of another embodiment of the structural insulated panel interconnecting system for connecting the wall prefabricated panel assembly, showing how the second securement and interconnecting apparatuses (the support tracks) can connect to the structural insulated panels at the top and bottom peripheries, and the first securement and interconnecting apparatuses (the structural splines) can connect to the structural insulated panels at the side peripheries.

[0067] FIG. 16A is a side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) and the attachment member for the first securement and interconnecting apparatus of the structural insulated panel interconnecting system.

[0068] FIG. 16B is a side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) and the attachment member for the first securement and interconnecting apparatus of the structural insulated panel interconnecting system.

[0069] FIG. 16C is a side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) and the attachment member for the first securement and interconnecting apparatus of the structural insulated panel interconnecting system.

[0070] FIG. 16D is a side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) and the attachment member for the first securement and interconnecting apparatus of the structural insulated panel interconnecting system.

[0071] FIG. 17A is an exploded side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) for a corner, further showing a rectangular corner post, a tension cable, a tension rod, attachment members, and an embodiment of the corner post caps with tension rods.

[0072] FIG. 17B is an exploded side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) for a corner, further showing a rectangular corner post, attachment members, and an embodiment of the corner post caps with tension rods.

[0073] FIG. 18A is a close-up perspective view of embodiments of the second securement and interconnecting apparatus (the support track), showing how it can have a H-shaped or U-shaped structural track that attach the structural insulated panel and hold the outer and inner panels that form a periphery of the structural insulated panel by the outer retaining edges, with a support plate or a mud sill attached to the interior of the structural track.

[0074] FIG. 18B is a close-up perspective view of an embodiment of the second securement and interconnecting apparatus (the support track), showing how it can have a H-shaped structural track that attach the structural insulated panel and hold the outer and inner panels that form a periphery of the structural insulated panel by the outer retaining edges, with a support plate (top plate) and triangular shaped support plate (top plate) for connecting to a roof prefabricated panel assembly.

[0075] FIG. 19A is a perspective view of some of the embodiments of the first and second securement and interconnecting apparatuses of the structural insulated panel interconnecting system and some wall structural insulated panels and their components.

[0076] FIG. 19B is a perspective view of some of the embodiments of the first and second securement and interconnecting apparatuses of the structural insulated panel interconnecting system and some wall structural insulated panels and their components.

[0077] FIG. 19C is an exploded perspective view of embodiments of the first and second securement and interconnecting apparatuses of the structural insulated panel interconnecting system and some floor structural insulated panels.

[0078] FIG. 20 is a perspective view of some of the embodiments of the first and second securement and interconnecting apparatuses of the structural insulated panel interconnecting system and some wall structural insulated panels and their components.

[0079] FIG. 21A is a close-up exploded side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) for a corner, further showing a portion of the structural tracks, a portion of the rectangular corner post with four tension rods, attachment members, and an embodiment of the corner post cap with tension rods.

[0080] FIG. 21B is a close-up exploded side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) for a corner, further showing a portion of the structural tracks, a portion of the rectangular corner post with four tension rods, attachment members, and an embodiment of the corner post cap with tension rods.

[0081] FIG. 22 is a close-up view of an embodiment of a window or door header panel and its attachment members.

[0082] FIG. 23 is a close-up exploded view of an embodiment of the second securement and interconnecting apparatus (the support track), to show how the second securement and interconnecting apparatus connect to a structural insulated panel for a wall at the bottom periphery of the structural insulated panel.

[0083] FIG. 24 is a close-up exploded view of embodiments of the first and second securement and interconnecting apparatuses, to show how the first and second securement and interconnecting apparatuses connect to a structural insulated panel for a wall.

[0084] FIG. 25 is a perspective view of an embodiment of a humidity responsive core member for the prefabricated panel assembly.

[0085] FIG. 26 is a close-up perspective view of embodiments of the second securement and interconnecting apparatus (the support track), to show how the second securement and interconnecting apparatuses connect a structural insulated panel for a roof to a structural insulated panel for a wall.

[0086] FIG. 27 is a close-up perspective view of an embodiment of the second securement and interconnecting apparatus (the support track), to show how the second securement and interconnecting apparatus can connect a structural insulated panel for a roof to a structural insulated panel for a wall.

[0087] FIG. 28A is a perspective view of an embodiment of the second securement and interconnecting apparatus (the support track) having a plurality of tension rod or cable anchor for receiving and securing tension rods in the first securement and interconnecting apparatuses (the structural splines), thus acting as attachment members that attach the first securement and interconnecting apparatuses to the second securement and interconnecting apparatus in the structural insulated panel interconnecting system.

[0088] FIG. 28B is a close-up perspective view of the tension rod or cable anchor shown in FIG. 28A, and how it attaches to the second securement and interconnecting apparatus.

[0089] FIG. 28C is a close-up front view of the tension rod or cable anchor shown in FIGS. 28A-28B, and how it attaches to the second securement and interconnecting apparatus.DETAILED DESCRIPTION OF THE EMBODIMENTS

[0090] The disclosed subject matter will become better understood through review of the following detailed description in conjunction with the figures. The detailed description and figures provide example embodiments of the invention described herein. Those skilled in the art will understand that the disclosed examples may be varied, modified, and altered without departing from the scope of the invention described herein.

[0091] Throughout the following detailed description, various examples of the structural insulated panel interconnecting system having at least a first securement and interconnecting apparatus (a structural spline) and at least a second securement and interconnecting apparatus (a support track) for securing and interconnecting prefabricated panel assemblies are provided. Related features in the examples may be identical, similar, or dissimilar in different examples. For the sake of brevity, related features will not be redundantly explained in each example. Instead, the use of related feature names will clue the reader that the feature with a related feature name may be similar to the related feature in an example explained previously. Features specific to a given example will be described in that particular example. The reader should understand that a given feature need not be the same or similar to the specific portrayal of a related feature or example.

[0092] The invention will now be described in detail with reference to the attached drawing FIGS. 1-28C. As described above in the summary, there is a need for a structural insulated panel interconnecting system for securing and interconnecting prefabricated panel assembly for walls, floors, and roofs that can be completely or mostly pre-assembled off-site and shipped to the construction location for quick, simple, and efficient assembly. There is a need for prefabricated panel assembly using a magnesia cement or magnesium oxide structural insulated panel (MgO SIP) that overcomes its rigidity and allows additional insulation and air barrier, and space for utility service, such as electrical wiring and piping. There is a need for a structural insulated panel interconnecting system that interconnects an energy efficient prefabricated panel assembly for building energy efficient buildings that meet Passivhaus design standard but overcome humidity, cost, and complication associated with Passivhaus design. There is a need for a structural insulated panel interconnecting system for a prefabricated panel assembly that is more earthquake-resistant and allows for movements or shifts between the prefabricated panel assemblies that are joined to form a building structure. There is a need for a structural insulated panel interconnecting system that allows prefabricated panel assembly to be easily replaced or repurposed in a building built with such prefabricated panel assemblies.

[0093] Referring to FIGS. 1-28C, there is shown a perspective interior (to a building) view of a roof prefabricated panel assembly 1000a, a wall prefabricated panel assembly 1000b, and a floor prefabricated panel assembly 1000c, assembled together to show how prefabricated panel assemblies 1000a-c are constructed together to form a building. Though we focus on roof, wall, or floor prefabricated panel assembly in FIGS. 1-28C, the present invention could be prefabricated assembly for walls, floors, roofs, decks, fencing, and foundations for many types of buildings, especially those that are low or mid-rise and where the panels can perform most of the primary structural roles. Different embodiments of the panels can also form both structural and non-structural roles in low, mid, and high-rise buildings. A roof, wall, or floor prefabricated panel assembly 1000a-c is connected to each other using a structural insulated panel interconnecting system 100, which has at least one first securement and interconnecting apparatus 200, also called a structural spline 200, at least one second securement and interconnecting apparatus 300, also called a support track 300, an attachment member 250 for securing the first securement and interconnecting apparatus 200, and an attachment member 350 for securing the second securement and interconnecting apparatus 300. The attachment member 250 secures the first securement and interconnecting apparatus 200 to the structural insulated panel 1200 and the second securement and interconnecting apparatus 300. The attachment member 350 secures the second securement and interconnecting apparatus 300 to the structural insulated panel 1200.

[0094] The first securement and interconnecting apparatus 200, also referred to as the structural spline 200, connect two adjacent wall structural insulated panels 1200 together. In an embodiment, the first securement and interconnecting apparatus 200 is comprised of at least a first structural track 210, and at least a first pair of outer retaining edges 241, 242. The structural track 210 is comprised of a first flange 211, a second flange 212, and a web 213 connecting the first flange 211 and the second flange 212. The structural track 210 is configured to receive a first periphery 1240 of a structural insulated panel 1200. The pair of outer retaining edges 241, 242 comprises a first outer retaining edge 241 that extends perpendicular to the first flange 211 of the structural track 210 and a second outer retaining edge 242 that extends perpendicular to the second flange 212 of the structural track 210. The pair of outer retaining edges 241, 242 is configured to support protruding edges of the first periphery 1240 of the structural insulated panel 1200.

[0095] The second securement and interconnecting apparatus 300, also referred to as the support track 300, which can include top tracks, base tracks, and rim joists, connect roof and floor structural insulated panels 1200 to the wall structural insulated panels 1200. In an embodiment, the second securement and interconnecting apparatus 300 is comprised of at least a second structural track 310, at least one support plate 320, and at least a second pair of outer retaining edges 341, 342. The structural track 310 is comprised of a first flange 311, a second flange 312, and a web 313 connecting the first flange 311 and the second flange 312. The structural track 310 is configured to receive a second periphery 1240 of a structural insulated panel 1200. The support plate 320 attaches to an interior surface 314 of the web 310 and extends along the structural track 310. In an embodiment, the support plate 320 could be a top plate, a base plate, or a mud sill. The pair of outer retaining edges 341, 342 comprises a third outer retaining edge 341 that extends perpendicular to the first flange 311 of the structural track 310 and a fourth outer retaining edge 342 that extends perpendicular to the second flange 312 of the structural track 310. The pair of outer retaining edges 341, 342 is configured to support protruding edges of the second periphery 1240 of the structural insulated panel 1200.

[0096] A roof, wall, or floor prefabricated panel assembly 1000a-c is comprised of a weather resistive barrier membrane 1100, a structural insulated panel 1200, a gypsum board 1300 (also known as drywall, plasterboard, dry lining, wallboard, sheet rock, gyp board, buster board, turtles board, slap board, custard board, gypsum panel and gyprock), a service cavity 1400, and a smart vapor barrier 1500. The smart vapor barrier 1500 can be within the structural insulated panel 1200, a face of the structural insulated panel 1200, or within a service cavity 1400, and also could be multiple layers. The prefabricated panel assembly 1000a-c is configured and built so that openings for doors and windows and special panel shapes are completed at the factory, and the simple installation of the prefabricated panel assembly 1000a-c is possible. The prefabricated panel assembly 1000a-c protects the interior spaces and its contents from the exterior climate conditions. An interior of the prefabricated panel assembly 1000a-c is configured to provide sound insulation, physical separation between the interior spaces, and interior structural support when needed.

[0097] In a preferred embodiment, the prefabricated panel assembly 1000a-c is fully assembled off-site and delivered fully assembled. In another embodiment, the components of the prefabricated panel assembly 1000a-c can be shipped separately to be assembled on-site and adjusted as needed. Once a building has been assembled using the prefabricated panel assembly 1000a-c, the building can be finished as one would any building, and exterior finishes and roofing materials as well as interior paint or textures are added. The prefabricated panel assembly1000a-c may also have integral rain screen drainage planes. The prefabricated panel assembly 1000a-c, due to the structural insulated panel interconnecting system 100, may also be designed to be easily dismounted and relocated for extended building life cycles, allowing reuse of the prefabricated panel assembly 1000a-c.

[0098] The second securement and interconnecting apparatus 300, also referred to as the support track 300, comprises at least one support plate 320, which is also referred to as a base plate, top plate, top base plate, bottom base plate, or a mud sill, as shown. The support plate 320 has a tension rod 322 or cable 323 for additional structural connectivity. The support plate 320 is attached to the structural track 310 of the second securement and interconnecting apparatus 300 for connecting the support plate 320 with the structural insulated panel 1200. The structural track 310 can be attached to the panels 1200 by any attachment member 350 or method known and will develop in the art, such as, but not limited to, fasteners, screws, powder driven or actuated fasteners (such as ring shank nails), adhesives, cables, rods, glues, interlocking nubs, sliding and locking edge “tracks”, tongue and groove, quick cam locking devices, and latching mechanism. Further, structural track 310 could be more complex, such as, but not limited to, U or H-shaped members and C and H-shaped tracks in combination with the any connecting method or member known and will develop in the art, such as clips, fasteners, screws, adhesives, rods, and other similar means of connecting known in the art.

[0099] The weather resistive barrier (WRB) membrane 1100 protects the prefabricated panel assembly 1000a-c during shipping and provides a weather resistive barrier until the exterior wall and roof finishes are applied and remains in place to continue to perform this function behind the exterior finishes. It serves to protect the exterior side of the prefabricated panel assembly 1000a-c from weather elements such as wind, water, and heat, but it is vapor permeable and allows drying by evaporation. Any weather resistive and vapor permeable (for northern climates) flexible sheet product known and will develop in the art can be used. The weather resistive barrier membrane 1100 also can be a spray coating or adhesives.

[0100] The structural insulated panel (SIP) 1200 comprises an outer cement board sheet 1210, an insulation layer (a core) 1220, a smart vapor barrier (SVB) 1500, an inner cement board sheet 1230. The structural insulated panel 1200 provides structural frame for load-bearing (such as from seismic, wind, snow, or other live or dead loads) as well as majority of insulation. The structured insulated panel 1200 is preferably fastened and pressed into a single laminated component, so it functions to add significant lateral strength to the wall.

[0101] The insulation layer 1220 is preferably rigid insulation, such as polystyrene (EPS or Styrofoam), extruded polystyrene (XPS), and polyisocyanurate (Poly Iso or ISO), but other types of insulation known and will develop in the art can be used. Preferably, as technology develops, materials with less embodied carbon, such as recycled organic or mineral insulation materials from sources such as hemp, straw, mycelium, etc. will be used. The insulation layer 1220 serves as a core between the outer and inner cement board sheets, and preferably provide a structural coupling between the outer and inner cement board sheets 1210, 1230 and is strong enough to cohesively transfer the loads between the outer and inner cement board sheets 1210, 1230 while providing the desired level of insulation. Preferably, the insulation layer 1220 is able to be assembled and pressed into the structural insulated panel 1200 as one laminated assembly.

[0102] The outer and inner cement board sheets 1210, 1230 are preferably made of magnesium oxide (MgO). The outer and inner cement board sheets 1210, 1230 may also be comprised of magnesium sulfate (MgSO4), other rigid cement board materials or any other material known in the art, such as oriented strand board (OSB) that are treated to be invulnerable to fire and water damage. The outer and inner cement board sheets 1210, 1230 comprised of magnesium oxide are not vapor impermeable, so water vapor can penetrate the wall system and potentially get to locations where the water vapor condenses and even freezes, risking mold, rot, deterioration, loss of thermal resistance properties, and expensive repairs. Having the smart vapor barrier 1500 (also known as “Air Barrier” membrane) stops the moisture vapor from air and water on the more humid side of the panel 1200 (interior room side in northern climates) from migrating into the interior side of the prefabricated panel assembly 1000a-c and generally eliminates air leakage into and out of the prefabricated panel assembly 1000a-c. The smart vapor barrier 1500 preferably is made of material that allows for drying if it senses water. The smart vapor barrier 1500 can be a foam adhesive that also functions as a smart vapor barrier. The structural insulated panel 1200 as designed also uses fewer studs within the structural insulated panel 1200 to limit the number of thermal bridges (less insular), increasing thermal effectiveness. The inner and outer board sheets 1210, 1230 may have sliding and locking board edge “tracks”, which can be considered the structural tracks 210, 310 of the first and second securement and interconnecting apparatuses 200, 300, for rapidly securing the prefabricated panel assembly into place.

[0103] The first securement and interconnecting apparatus 200, also referred to as the structural spline 200 or a structural stud 200, may have two structural tracks 210 forming an H-track 210 (a 2-part stud connecting member) for connecting multiple structural insulated panels 1200 together, or further compose a rectangular corner post 221 with the structural insulated panel 1200. Joists can also be used instead of studs for horizontal or sloping assemblies, such as floors and roofs. The first securement and interconnecting apparatus 200, or the structural spline 200, can be comprised of wood, metal such as steel, fiberglass, reinforced plastic (FRP), recycled plastic, or composite plastic, but other materials known and will develop in the art can be used. As technology develops, organic, recycled, or mineral studs from sources such as hemp, straw, mycelium, recovered plastics, magnesium oxide, etc. can be used. The attachment member 250 can be any connecting method or member known and will develop in the art, such as, but not limited to, fasteners, screws, powder driven or actuated fasteners (such as ring shank nails), adhesives, cables, rods, glues, and also includes more complex fastening means such as, but not limited to, interlocking nubs, tongue and groove, sliding and locking edge “tracks” such as C and H-shaped tracks, quick cam locking devices, latching mechanism, U or H-shaped members, and in combination with the any connecting method or member known and will develop in the art, such as clips, fasteners, screws, adhesives, rods, and other similar means of connecting known in the art. The gypsum board 1300 can be composed of what is known and will develop in the art. As technology develops, organic, recycled, or mineral gypsum boards from sources such as hemp, straw, mycelium, recovered plastics, magnesium oxide, etc. can be used.

[0104] The service cavity 1400 is positioned in between the structural insulated panel 1200 and the gypsum board 1300. The service cavity 1400 is comprised of a stud and a thermal insulation, but can include a smart vapor barrier (SVB) 1500. The stud of the service cavity 1400 can be the same material as the first and second securement and interconnecting apparatuses 200, 300, and similar or same means of connecting used for the first and second securement and interconnecting apparatuses 200, 300 can be used for the stud of the service cavity 1400. The stud of the service cavity 1400 can be structural or non-structural. The location of the smart vapor barrier / s 1500 in the prefabricated panel assembly 1000a-c, whether in the structured insulated panel 1200 or the service cavity 1400, vary according to the needs of the building, especially considering the climate. Having the service cavity 1400 helps to avoid penetrating the smart vapor barrier 1500 of the structural insulated panel 1200, unless absolutely necessary. Desired utility service can be run in the service cavity 1400. Desired utility service can be water or heat piping, electrical wires, data links, and any other utility that may be needed or desired for the purpose of the building. The service cavity 1400 size varies according to the needs of the building. The service cavity 1400 size should be wide enough to accommodate desired utility service runs. In a preferred embodiment, the service cavity 1400 is at least 2 inches of space, but smaller, for example, such as 1¾ inches, or less of space or larger, for example, such as 3¼ inches, or more of space could be used to fit the needs of the project. The service cavity 1400 preferably is filled with additional insulation after desired utility service is run. The additional insulation can be rigid or flexible insulation. The service cavity 1400 size can be set at the construction location instead of off-site in some embodiments of present invention. The service cavity 1400 can be structural or non-structural, depending on the need of a building.

[0105] In reference to FIG. 1, a perspective interior (to a building) view of the roof prefabricated panel assembly 1000a, the wall prefabricated panel assembly 1000b, and the floor prefabricated panel assembly 1000c, assembled together using the structural insulated panel interconnecting system 100 is shown to exemplify how prefabricated panel assemblies 1000a-c are constructed together to form a building. FIG. 1 shows the weather resistive barrier membrane 1100 covering the structural insulated panel 1200 of the roof prefabricated panel assembly 1000a. The internal board facer sheet 1230 of the structural insulated panel 1200 can be seen, and the service cavity 1400 and the gypsum board 1300 of the roof prefabricated panel assembly 1000a are shown. The support plate 320 of the second securement and interconnecting apparatus 300 for connecting the roof prefabricated panel assembly 1000a with the wall prefabricated panel assembly 1000b is the top plate. FIG. 1 shows edges, or peripheries 1240, of the structural insulated panel 1200, the service cavity 1400, and the gypsum board 1300 of the wall prefabricated panel assembly 1000b. The support plate 320 of the second securement and interconnecting apparatus 300 for connecting the wall prefabricated panel assembly 1000b with the floor prefabricated panel assembly 1000c is a base plate 320 in FIG. 1. Furring strips in the service cavities 1400 of the wall and roof prefabricated panel assemblies 1000a-b can be seen. Furring strips can be comprised of wood, metal such as steel, or fiberglass, reinforced plastic (FRP), recycled plastic, and composite plastic, but other materials known and will develop in the art can be used. As technology develops, organic, recycled, or mineral studs from sources such as hemp, straw, mycelium, recovered plastics, magnesium oxide, etc. can be used. The attachment members 250 of the first securement and interconnecting apparatuses 200 of the wall prefabricated panel assembly 1000b is shown as three slots in the wall edge for latches, designed for quick assembly and disassembly. As explained above, other connecting means known and will develop in the art can be used. The structural insulated panel 1200 and the support plate 320, which is a rim joist 320 for attachment to the ground and the support plate 320 of the second securement and interconnecting apparatus 200 of the wall prefabricated panel assembly 1000b, for the floor prefabricated panel assembly 1000c is also shown in FIG. 1. The floor prefabricated panel assembly 1000c in FIG. 1 does not show a service cavity, as service cavity could be removed if not needed. A smart vapor barrier also can be removed if not needed. Additionally, the rectangular corner post 221 of the first securement and interconnecting apparatus 200 is also shown with slots for latches as the attachment member 250 as well. Other connecting means known and will develop in the art can be used with the corner post.

[0106] In reference to FIG. 2, there is shown a top perspective view of the roof prefabricated panel assembly 1000a, the wall prefabricated panel assembly 1000b, and the floor prefabricated panel assembly 1000c of FIG. 1. The weather resistive barrier membranes 1100 of the roof prefabricated panel assembly 1000a, the wall prefabricated panel assembly 1000b, and the floor prefabricated panel assembly 1000c (around the rim joist) can be seen. A corner post 221 and an air barrier of the floor prefabricated panel assembly 1000c are also shown. The smart vapor barrier 1500 does not need to cover the entire surface of the prefabricated panel assembly 1000a-c if the MgO or other boards have an acceptably low permeability level, and could be covering only parts of the prefabricated panel assembly 1000a-c as shown in FIG. 2, where the smart vapor barrier 1500 of the structural insulated panel 1200 of the floor prefabricated panel assembly 1000c is covering only a corner of the floor prefabricated panel assembly 1000c. However, the smart vapor barrier 1500 could cover all of the floor prefabricated panel assembly 1000c in another embodiment. The corner post 221 may also have weather resistive barrier as its core.

[0107] In reference to FIG. 3, an exploded side perspective view of the roof prefabricated panel assembly 1000a, the wall prefabricated panel assembly 1000b, and the floor prefabricated panel assembly 1000c in FIGS. 1-2 are shown. In addition to what are shown in FIGS. 1-2, FIG. 3 more clearly shows a tension rod 322 in the support plate 320 of the second securement and interconnecting apparatus 300 connecting the floor prefabricated panel assembly 1000c to the wall prefabricated panel assembly 1000b and the ground, and, additionally, a mud sill 360 of the floor prefabricated panel assembly 1000c is shown. The tension rod 322 could be a tension cable instead. Other devices that assist with tension and stability can be also used.

[0108] In reference to FIG. 4, a side exterior (to a building) perspective view of the wall prefabricated wall assembly 1000b in FIGS. 1-3 is shown. The exterior weather barrier 1100 of the service cavity 1400 is shown to cover a corner of the service cavity 1400 of the wall prefabricated panel assembly 1000b. The corner post 221 of the first securement and interconnecting apparatus 200 is connected using the attachment member 250 (latches and / or otherwise) of the first securement and interconnecting apparatus 200. Additionally, the tension rod 322 of the support plate 320 (top plate 320 in this example) of the second securement and interconnecting apparatus 300 is also shown to connect with the corner post 221 of the first securement and interconnecting apparatus 200.

[0109] In reference to FIG. 5, a side interior (to a building) perspective view of the wall prefabricated wall assembly 1000b in FIGS. 1-4 is shown. FIG. 5 further shows desired utility service, shown as an electrical switch and an electrical receptacle, on a surface of the service cavity 1400 of the wall prefabricated wall assembly 1000b. Wiring for the electrical switch and the electrical receptacle resides inside the service cavity 1400 (not shown).

[0110] In reference to FIG. 6, a close-up exploded view of an embodiment of the first securement and interconnecting apparatus 200, the structural spline 200, according to disclosure is shown. Here, the attachment member 250 is a latch system 250 (also known as cam locking device). In FIG. 6, two wall prefabricated panel assemblies 1000d-e are shown for connecting. While only one latch system 250 is shown, there can be many latch systems per stud. The wall prefabricated panel assembly 1000d on the left side has the receiving portion of the latch system 250 and the wall prefabricated panel assembly 1000e on the right side has the corresponding latching portion of the latch system 250. The latch system 250 is shown to be screwed to each first securement and interconnecting apparatus 200. However, other attachment means known in the art or may develop in the art can be used, such as adhesives. A handle can be on the latching portion of the latch system 250. In a preferred embodiment, the handle is removed once the latch system 250 has been installed onto the first securement and interconnecting apparatus 200. As shown in FIG. 6, the attachment member 350 for the second securement and interconnecting apparatus 300 and its support plate 320 and structural track 310, shown as base plates in FIG. 6, can be screws. Other connecting means known or will develop in the art can be used, such as, but not limited to, adhesives, rods, cables, glue, nails, tongue and groove, or track. There can be a tension rod 322 and cushion(s) 370, or gasket, between any two support plates 320 to allow for stability and movement, respectively, as shown in FIG. 6. In an embodiment, the outer cement board sheet 1210 and the inner cement board sheet 1230 of the structural insulated panel 1200 may each have protruding edge around a periphery 1240, as can be seen in the wall prefabricated panel assembly 1000d on the left side. As shown in the wall prefabricated panel assembly 1000e on the right side, the structural track 310 of the second securement and interconnecting apparatus 300 can be a bottom channel of a H-shaped track 310, and the top channel of the H-shaped track 310 can be used as an attachment member. In such embodiment, the top channel of the H-shaped track 310 is shaped to fit into the protruding edge of a bottom of the structural insulated panel 1200 and the bottom channel of the H-shaped track 310 is shaped to fit over the support plate 320 so the support plate 320 fits into the interior surface 314 of the web 313 of the structural track 310.

[0111] In reference to FIG. 7A, a close-up exploded view of an embodiment of how two wall prefabricated panel assemblies1000f-g are joined together to allow controlled movement is shown. In such embodiment, the outer cement board sheet 1210 and the inner cement board sheet 1230 of the structural insulated panel 1200 of the prefabricated panel assembly 1000f-g will each have recessed insulation edges around a periphery 1240, forming a channel 310, the structural track 310 of the second securement and interconnecting apparatus 300, between the recessed insulation edge of the outer cement board sheet 1210 and the recessed insulation edge of the inner cement board sheet 1230. The structural track 310 formed is shaped to receive a support plate 320 (top plate) of the second securement and interconnecting apparatus 300. A gasketed movement joint 370 and an L-shaped angle 350, also referred to as an L-shaped clip, is added to the corner of a portion of the structural insulated panel 1200 within the structural track 310 to allow for the support plate 320 (top plate) movement. In an embodiment, the attachment member 350 for the structural track 310 and the support plate 320 (top plate) are screws so there may be no movement. However, the structural track 310 and the support plate 320 (top plate) can be solid rubber or other resilient, synthetic gasket to allow for limited movement and controlled movement between the prefabricated panel assemblies 1000f-g. In an embodiment, the L-shaped angle 350 (also called clip angle) is typically a 6 inches composite channel with top portions of flanges clipped to avoid conflict with the support plate 320 and the structural track 310 (top plate / top track). The support plate 320 and the structural track 310 (top plate / top track) may also be screwed to the L-shaped angle 350. Each wall prefabricated panel assembly 1000f-g further may have a gasketed movement joint as the first securement and interconnecting apparatus 200 (the structural spline 200) in between the L-shaped angles 350 to allow limited movement and shifting. Additionally, a caulk joint or a metallic or plastic expansion joint edge trim material is used to seal adjacent outer and inner cement board sheets 1210, 1230 of multiple prefabricated panel assemblies 1000. A slip plate 380, with an attachment means such as a double nutted bolt or a screw, may also be present on top of or below where support plates (top plates / top tracks) join, as shown in FIG. 7A.

[0112] In reference to FIG. 7B, in an embodiment, the second securement and interconnecting apparatus 300 (the support track 300) may have a structural track 310 that receives a door or window header 320 as or instead of a base plate or a top plate. In such a case, the attachment member 350, shown in FIG. 7B as L-shaped clips and screws 350, would secure the header 320 to the structural track 310 of the second securement and interconnecting apparatus 300 (the support track 300). The header 320 can have core member that is comprised of one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material. The second securement and interconnecting apparatus 300 (the support track 300) also may have a second core member (not visible in FIG. 7B) with tension rod 322. FIG. 22 also shows an embodiment that is similar to that of FIG. 7B, also showing how the first securement and interconnecting apparatus 200 may attach to the header 320 using the L-shaped clips and screws 250 as the attachment member 250.

[0113] In reference to FIGS. 8A-D, an embodiment of the first securement and interconnecting apparatus 200, also referred to as the structural spline 200, is shown. As seen in FIGS. 8B-8D, the first securement and interconnecting apparatus 200 has two structural tracks 210a-b that are back-to-back together, by their exterior surfaces 214 of the webs 213, as an expansion joint (control joint or interlocking spline with a control joint capability) with a core member 220, which is a cushioning layer (or flexible gasket), positioned in between to allow for movement (from wind, earthquake, vibration, etc.) and settling. In the embodiment shown in FIGS. 8A-D, each structural track is C-shaped and has a first flange 211, a second flange 212, and a web 213. The first and the second structural tracks 210a-b are interlocking together to form a H-shaped track with the core member 220 sandwiched between the exterior surface 214 of the web 213 of the first structural track 210a and the exterior surface 214 of the web 213 of the second structural track 210b.

[0114] The first securement and interconnecting apparatus 200 further has a pair of outer retaining edges 241, 242 for each structural track 210. The first outer retaining edge 241 on one side supports an inner cement board sheet 1230 of the structural insulated panel 1200 and the second outer retaining edge 242 on the other side for supporting an outer cement board sheet 1210 of the structural insulation panel 1200. In a preferred embodiment, the outer retaining edge, also referred to as a projecting trim edge, is flexible gaskets that are also adhesive. The first structural track 210a receives a periphery 1240 of a first structural insulated panel 1200 (not shown in FIGS. 8A-D) and the second structural track 210b receives a periphery 1240 of a second structural insulated panel 1200 (not shown in FIGS. 8A-8D).

[0115] In the embodiments shown in FIGS. 8A and 8D, the second structural track 210b has a plurality of interlocking connecting slots 218 on the web 213 of the first structural track 210a has a plurality of interlocking connecting apparatuses 217 on the exterior surface 214 of the web 213. In the embodiments shown in FIGS. 8B-8C, both the first and the second structural tracks 210a-b have a plurality of interlocking connecting slots 218 on the web 213 and a plurality of interlocking connecting apparatuses 217 on the exterior surface 214 of the web 213. The plurality of interlocking connecting apparatuses 217 of the first structural track 210a aligns, inserts, and interlocks with the plurality of interlocking connecting slots 218 of the second structural track 210b through the core member 220 and the plurality of interlocking connecting apparatuses 217 of the second structural track 210b aligns, inserts, and interlocks with the plurality of interlocking connecting slots 218 of the first structural track 210a through the core member 220. The interlocking connecting apparatus can be a nub or a button as shown in FIGS. 8A-8D. The interlocking connecting apparatuses 217 and the interlocking connecting slots 218 can be other means known in the art for connecting or attaching two structural tracks 210 together. In another embodiment of the interlocking spline, insulated rectangular tubular shapes with projecting trim edges are used instead of the C-shaped studs. The tubular shapes also provide locations to install vertical tensioning rods.

[0116] In embodiments shown in FIGS. 8A-8C, the webs 213 of the structural tracks 210a-b each form a protruding portion 230 on each end 215 of the structural tracks 210a-b. The attachment member 250 can attach the protruding portion 250 on each of the end 215 of the structural tracks 210a-b to the plurality of support tracks 300, also referred to as the second securement and interconnecting apparatus 300, as shown in FIGS. 8B and 23. FIG. 23 shows an exploded view of an end of the embodiment of the first securement and interconnecting apparatus 200 shown in FIGS. 8B-8C and how it would receive and attach to a structural insulated panel 1200 and to an embodiment of the second securement and interconnecting apparatus 300. The L-shaped clip 250 and a plurality of screws 250 form the attachment member 250 for attachment to the structural track 310 of the second securement and interconnecting apparatus 300 (the support track 300). Once the first securement and interconnecting apparatus 200 is attached to the structural track 310 of the second securement and interconnecting apparatus 300, the support plate 320 of the second securement and interconnecting apparatus 300 would then be inserted into the interior surface 314 of the web 313 of the structural track 310 of the second securement and interconnecting apparatus 300.

[0117] In an embodiment, if the first securement and interconnecting apparatus 200 are not at the control joint, either insulated rectangular tube shaped or H-shaped structural track 210 of the first securement and interconnecting apparatus 200 are used, with the structural track 210 recessed a halfway into the left panel 1200 and a halfway into the right panel 1200, to give places to glue and screw the MgO parts of the panels 1200 to the first securement and interconnecting apparatus 200. The structural tracks 310 of the second securement and interconnecting apparatus 300, which are horizontal tracks, can either be H-shaped structural track 310 that are initially glued and screwed to the MgO panels 1200 in the shop, or they can be C-shaped track 310 that is thickened to add insulation as a core member or support plate 320 and a place to run a tensioning rod 322. When the panels 1200 are shipped to the job in “ganged units” (multiple panels made into a single larger panel), those C- & H-shaped tracks 310 are already built into the ganged unit, and then on the job site the bottom track 310 at the bottom of the ganged panel receives glue, as does the support plate 320, and then the bottom track 310 for the panel 1200 is set over the support plate 320 and screwed into place using attachment member 350. After the ganged panel 1200 is in place and properly aligned, then the top support plate 320 can be set into the cavity of the top structural track 310, and it's all glued and screwed together.

[0118] In reference to FIG. 9, an embodiment of the wall prefabricated panel assembly 1000 having a service cavity 1400 comprised of a furring strip 1600 that acts as a clamp on an edge of a smart vapor barrier (SVB) 1500 to hold the smart vapor barrier 1500 in place within the service cavity 1400 is shown. Other means known in the art or will develop in the art for attaching or holding the smart vapor barrier 1500 within the service cavity 1400, and even the structural insulated panel (SIP) 1200, can be used. In such embodiment, the furring strip 1600 is a 2-piece, interlocking polymer strip that both provides a service cavity 1400 space of the desired depth and also acts as a permanent retainer to hold the SVB 1500 in place. In the factory assembly, the MgO SIP 1200 is laid on the assembly table, the 2-legged base part of the furring strip 1600 is fastened in place to the studs 300 and splines 200, the SVB 1500 is stretched into position over the face of the panel 1200, and the top part of the furring strip 1600 is snapped into place and fastened with a few screws to keep the top part tightly positioned in place. After the furring strip 1600 and SVB 1500 are in place, the panel 1200 can be shipped to the jobsite where any utilities can be installed, the cavity 1400 filled with insulation, and the final layer of gypsum board 1300 screwed in place. With ½″ thick gypsum board 1300, the furring strips 1600 need to be located at 16″ on center (o.c.) and with ⅝″ thick gypsum board 1300, the furring strips 1600 can be located at 24″ o.c.

[0119] In reference to FIG. 10, a side, exploded, perspective view of an embodiment of the wall prefabricated panel assembly 1000 showing how four smaller pieces of wall prefabricated panel assembly 1000 can be assembled together using an embodiment of the structural insulated panel interconnecting system 100 to form a big wall prefabricated panel assembly 1000 is shown. In this embodiment shown, one second securement and interconnecting apparatus 300 having a top support plate 320 (support plate 320) and another second securement and interconnecting apparatus 300 having a bottom support plate 320 (base plate 320) are used for securing and interconnecting the wall prefabricated panel assembly, as well as a corner post 212. The corner post 212 and the first securement and interconnecting apparatuses 200 (the splines 200, not shown) may have a tensioning rod or cable for vertical uplift restraint. Each piece of the wall prefabricated panel assembly 1000 has an outer cement board sheet 1210 and an inner cement board sheet 1230 with recessed insulation edges, thus having peripheries 1240 of the outer and inner cement board sheets 1210, 1230 form protruding edges that wrap around and are glued and screwed using glue and screws as the attachment members 250, 350 to both the structural splines 200 (the first securement and interconnecting apparatus 200) and the second securement and interconnecting apparatus 300 (support track 300), which includes the structural tracks 310 and support plates (top and bottom / base). Individual first securement and interconnecting apparatus 200 (structural splines 200) and corner posts are connected to the top and bottom support plates 320 with U-shaped short structural tracks 310, also referred to as U-shaped polymer clips 310, where a larger short structural track 310 can be used for corner posts and a smaller short structural track 310 can be used to connect individual first securement and interconnecting apparatuses 200 and second securement and interconnecting apparatuses 300 to the top and bottom support plates 320. A differently shaped clip, such as an L-shaped clip (or an angle) can be used as attachment members 250, 350. Structural tracks, clips, or angles can be made of fiberglass, polymer, metal, or any other material known in the art. An insulated, overlapping connecting support plate 320 wraps around the main lower support plate 320 to provide ease of alignment and additional strength at the base of the wall. An inverted upper connecting member can also be used for additional strength at the top of the wall. The corner post 212 in this embodiment has a hollow body that is filled with insulation.

[0120] In reference to FIG. 11, a side, exploded, perspective view of an embodiment of the wall prefabricated panel assembly 1000b and the floor prefabricated panel assembly 1000c showing how the prefabricated panel assemblies would assemble together using the structural insulated panel interconnecting system 100 is shown. The wall prefabricated panel assembly 1000 shows a room-side gypsum or MgO board facer sheet 1300 with holes for electrical receptacles, an insulation layer, a furring strip 1600, and a smart vapor barrier 1500. The wall prefabricated panel assembly 1000b further shows a structural insulated panel 1200 with an inner cement board sheet 1230, an insulation layer 1220, an outer cement board sheet 1210, and an exterior weather resistive barrier membrane 1100. The first securement and interconnecting apparatus 200 and the second securement and interconnecting apparatus 300 of the structural insulated panel interconnecting system 100 are also shown. In this embodiment, shorter structural tracks 310, also referred to as U-shaped stud clips, attaches top and bottom support plates 320 to the structural insulated panel 1200 as shown. Screws are used as attachment members 250, 350 for the first and second securement and interconnecting apparatuses 200, 300. Additional attachment members can also be used as shown in FIG. 10. Additionally, a siding on the outside of the wall prefabricated panel assembly 1000b is shown. The floor prefabricated panel assembly 1000c shows an internal board facer sheet 1230, an insulation layer 1220, and an outer cement board sheet 1210 of a structural insulated panel 1200. A support plate 320 of the second securement and interconnecting apparatus 300 attaches to the structural insulated panel 1200 of the floor prefabricated panel assembly 1000c. In this embodiment, a splice plug 1221 with a tension rod 1222 is added to each support plate 320 for additional security and can also be located horizontally at the top support plates 320 and vertically at selected structural splines 200 and corner posts 212.

[0121] In reference to FIG. 12, a side, exploded, perspective view of an embodiment of the wall prefabricated panel assembly 1000 is shown. The wall prefabricated panel assembly 1000 shows an outer non-combustible and carbon sequestering board sheet 1210, an insulation layer 1220, a smart vapor barrier 1500, an additional layer of insulation in the service cavity 1400, and an inner non-combustible and carbon sequestering board sheet 1230.The first securement and interconnecting apparatus 200 and the second securement and interconnecting apparatus 300 of the structural insulated panel interconnecting system 100 are shown, with the first securement and interconnecting apparatus 200 shown in the structural insulated panel 1200. In a preferred embodiment, the structural insulated panel 1200 further comprises a phase change layer that changes phase to meet the thermal needs of the building. For example, in cold weather, the phase changing layer may absorb heat during daytime hours and then release the heat at nighttime when it is needed for additional comfort. Further, in such embodiment, a support plate of the second securement and interconnecting apparatus 300 may also have an insulation layer and a smart vapor barrier within and may further comprise a tension rod or cable. The wall prefabricated panel assembly 1000 in FIG. 12 additionally has a header shaped to be a structural track 310 for openings such as windows and doors. The structural track 310, or the track header 310, receives a support plate 320 that is slopped for attachment to a roof prefabricated panel assembly 1000. The slopped support plate 320 is also shown in FIGS. 14, 18B, 26, and 27. The track header 310 is comprised of polymer, or any other material known or that will develop in the art. The track header 310 can also have an insulation layer and a smart vapor barrier. Additional insulated connecting members or attachment members between the panels and the plates may also be used, as well as both vertical and horizontal tension rods or cables. Further, FIG. 12 shows a non-combustible wrap around exposed portions of the first securement and interconnecting apparatus 200 (the structural spline) where window and door openings occur if / as needed for finish and fire-resistance reasons. In such embodiment as shown in FIG. 12, a room-side insulation layer is comprised of rigid, high-R materials that may be directly fastened to and routed for desired utility service, minimizing the need for additional furring members in the service cavity 1400.

[0122] In reference to FIG. 13, a side exploded perspective view of an embodiment of the wall prefabricated panel assembly 1000 showing how two wall prefabricated panel assemblies 1000b and one floor prefabricated panel assembly 1000c are combined is shown. The first securement and interconnecting apparatus 200 and the second securement and interconnecting apparatus 300 of the structural insulated panel interconnecting system 100 are also shown. In such embodiment, the second securement and interconnecting apparatus 300 has an H-shaped bracket as the structural track 310. The structural track 310 fits between the support plate 320 (base plate 320) and a bottom of the structural insulated panel 1200 at both floor levels and at the roof level. The structural insulated panel 1200 has recessed insulation edges around a periphery 1240 that allows the H-shaped structural track 310 to fit into the bottom. A polymeric header is also used for support.

[0123] In reference to FIG. 14, a side, exploded, perspective view of an embodiment of the wall prefabricated panel assembly 1000 is shown. The wall prefabricated panel assembly 1000 shows a structural insulated panel 1200 comprised of an outer non-combustible and carbon sequestering board sheet 1210 (referred to as skins in FIG. 14) and the smart vapor barrier 1500 and the phase change layer (together referred to as structural insulating cores 1220). The wall prefabricated panel assembly 1000 further comprises the service cavity 1400. The wall prefabricated panel assembly 1000 can have a sill panel with insulated polymer shapes for varying window and wall configurations, and a structural header over openings. The sill panel can have a tension rod if needed. The structural header in this embodiment is also considered a wall prefabricated panel assembly 1000, as it can have thermal and control layers such as the smart vapor barrier, the phase change layer, and with insulating liners can be used at window and door openings for further insulation. the thermal insulation. In FIG. 14, the structural header is a polymer header with thermal control layers and can also have a tension rod as needed. A non-combustible cementitious panel or skin may be used. FIG. 14 shows two support plates 320 for the second securement and interconnecting apparatus 300, the top support plate 320 and the bottom support plate 320. The top support plate 320 shown is an adjustable tapered structural polymeric top plate with insulated cores and tension rod 322, if needed. The structural track 310 of the second securement and interconnecting apparatus 300 shown in FIG. 14 for the top support plate 320 is a polymer connecting track 310 with an insulating core and a tension rod. The base support plate 320 is shown in FIG. 14 as having anchors and tensioning rods, if needed. The structural track 310 of the second securement and interconnecting apparatus 300 for the bottom support plate 320 in FIG. 14 is a polymer connecting track 310 with an insulating core and a tension rod, if needed. FIG. 14 also shows that the first securement and interconnecting apparatus 200 can also have insulating core members 220 and tensions rods 222, if needed.

[0124] In reference to FIG. 15, a side, exploded, perspective view of an embodiment of the wall prefabricated panel assembly 1000 is shown to show how the first securement and interconnecting apparatus 200 and the second securement and interconnecting apparatus 300 can connect the structural insulated panel 1200. The support plates 320 of the second securement and interconnecting apparatus 300 shown in FIG. 15 are the top support plate 320 and the bottom support plate 320 (also referred to as the bottom plate). The top support plate 320 as shown in FIG. 15 further comprises tension rods 322 and gasketed spring lock ends as attachment member 350. The top support plate 320, when in use in a building, can be fastened to a floor (can be a floor prefabricated panel assembly) or a roof (can be a roof prefabricated panel assembly) above the top support plate 320. The structural track 310 of the second securement and interconnecting apparatus 300 for the top support plate 320 is a U-shaped track (referred to as a top structural track 310) as shown in FIG. 15. The U-shaped track 320 can further comprise tension rods, gasketed butt ends, clips, and a fastener, such as an adhesive or glue, or any other fastening means known in the art as the attachment member 350. A clip may be an L-shaped clip 250, 350 as shown, preferably 2×2×3 in dimension, which can attach to both the support plate 320 and an adjacent structure, such as a structural track (not shown in FIG. 15), core member 220, or a corner post 212 of the first securement and interconnecting apparatus 200, another structural insulated panel 1200, or an adjacent wall prefabricated panel assembly 1000. The top U-shaped structural track 310 fastens the top support plate 320 with the structural insulated panel 1200.

[0125] The bottom support plate 320 as shown in FIG. 15, when in use in a building, can be directly bolted to a floor structure (can be a floor prefabricated panel assembly) or foundation. The structural track 310 for the support plate 320 is also the U-shaped track (referred to as a bottom structural track 310) as shown in FIG. 15. The bottom U-shaped structural track 310 for the bottom support plate 320 can further comprise tension rods, clips, and a fastener, such as an adhesive or glue, or any other fastening means known in the art as the attachment member 350, similar to the top U-shaped structural track 310. The U-shaped structural track 310 fastens the bottom support plate 320 with the structural insulated panel 1200. In the embodiment shown, the outer cement board sheet (referred to as a cement panel) 1210 of the structural insulated panel 1200 and the inner cement board sheet 1230 form recessed insulation edges at peripheries 1240 that are fastened over the bottom structural track 310 (the U-shaped track). Recessed insulation edges at peripheries 1240 are also fastened to the first securement and interconnecting apparatus 200, and an attachment member 250 for the first securement and interconnecting apparatus 200 can be comprised of clips and fasteners, such as an adhesive or screws, or any other fastening means known in the art. A turnkey locking mechanism and an adhesive expansion join gasket as the attachment member 250 may be used on a joining edge to join two wall prefabricated panel assembly 1000 or two structural insulated panels 1200 together within a wall prefabricated panel assembly 1000.

[0126] In references to FIGS. 16A-16D, various embodiments of the structural track 210a-d of the first securement and interconnecting apparatus 200 (the structural spline 200) of the structural insulated panel interconnecting system 100 and the attachment members 250 for the first securement and interconnecting apparatus 200 are shown. All embodiments of the structural track 210a-d have same basic structure. The basic structure for a structural track 210a-d includes a first flange 211, a second flange 212, and a web 213 that connects the first flange 212 and the second flange 212, and a pair of outer retaining edges 241, 242. In the views shown in FIGS. 16A-D, only the first outer retaining edge 241 for each structural track 210a-d is visible. In the embodiment shown in FIGS. 16B-16D, the structural track 210 further comprises a core member 220 of various thicknesses as needed for the purpose of the building. The core member may be comprised of one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material. As shown in FIG. 16A, an embodiment of the structural track 210 may not have a core member. The core member 220 may further have one or more tension rods 222 as shown in FIG. 16D, or it can have tension cables. In the embodiments shown in FIGS. 16A-16D, each end 215 of the web 213 and the core member 220, if any, form a protruding portion 230 on the structural track 210. In such embodiments, the attachment members 250 attach the protruding portion 230 on the ends 215 of the structural tracks 210 to the plurality of support tracks 300 (the second securement and interconnecting apparatus 300), as shown in FIG. 23. As shown in FIG. 8D, some embodiments of the structural track 210 may not have protruding portions.

[0127] In reference to FIGS. 17A-17B and 21A-21B, embodiments of the first securement and interconnecting apparatus 200 (the structural spline 200) for corners are shown. Such embodiments have a first structural track 210a for receiving a periphery 1240 of a first structural insulated panel 1200, a second structural track 210b for receiving a periphery 1240 of a second structural insulated panel 1200, a first core member 220a parallelly attached to the exterior surface 214 of the web 213 of the first structural track 210a, and a second core member 220b parallelly attached to the exterior surface 214 of the web 213 of the second structural track 210b. Such embodiments further comprise a rectangular corner post 221 attached to the first core member 220a at a first side and to the second core member 220b at a second side adjacent the first side. The first core member 220a, the second core member 220b, and the rectangular corner post 221 each comprises one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material.

[0128] In some embodiments, and as shown in FIGS. 17A-17B, the first securement and interconnecting apparatus 200 (the structural spline 200) for corners may further have at least one corner post cap 225. The corner post cap 225 has rectangular body with a rectangular slot on a side of the body facing the ends of the rectangular post 221 for aligning and fitting on a top or a bottom surface of the rectangular corner post 221. The corner spline cap may have a core within the body, comprising one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material. Further, as shown in FIGS. 17A-17B, the corner spline cap 225 core can further have at least one protruding portion 226 on at least one side of the body, and the protruding portions 226 may have tension rods 227. However, the protruding portion 226 can be optional as shown in FIGS. 21A-21B, where corner post cap 225 with holes are shown for accepting tension rods but no protruding portions 226 are present. Attachment members 250 can be similar to those mentioned for other embodiments of the first securement and interconnecting apparatus 200 (the structural spline 200), such as screws and L-clips as shown in FIGS. 17A-17B and 21A-21B. As shown in FIG. 17A, the rectangular corner post 221 may have tension rods 222 or tension cables 223 for strength and stability. Outer cover board 224 can be used to cover the sides of the rectangular post 221 that the structural tracks 210a-b did not attach to. FIGS. 21A-21B shows an example with four tension rods within the rectangular corner post 221 of the first securement and interconnecting apparatus 200 (the structural spline 200) for corners.

[0129] In reference to FIG. 18A, a close-up perspective view of embodiments of the second securement and interconnecting apparatus 300 (the support track 300) of the structural insulated panel interconnecting system 100, showing how the structural tracks 310 can be H-shaped or U-shaped. The structural track 310, whether H-shaped or U-shaped, has a first flange 311, a second flange 312, and a web 313 connecting the first flange 311 and the second flange 312. The second securement and interconnecting apparatus 300 (the support track 300) further has at least one support plate 320, or support plate like components 320 such as mud sills and headers, which can attach to an interior surface of the web 313 and extend along the structural track 310. In a preferred embodiment, the second securement and interconnecting apparatus 300 (the support track 300) has at least a pair of outer retaining edges 341, 342 configured to support protruding edges of the periphery 1240 of the structural insulated panel 1200, as shown in FIG. 18A for the H-shaped structural track 310 for the wall prefabricated panel assembly 1000b. A first outer retaining edge 341 extends perpendicular to the first flange 311 of the structural track 310 and a second outer retaining edge 342 extends perpendicular to the second flange 312 of the structural track 310. The attachment member 350 for securing the second securement and interconnecting apparatus 300 (the support track 300) to the structural insulated panel 1200 is not shown in FIGS. 18A-18B but was described and shown throughout the application.

[0130] The second securement and interconnecting apparatus 300 (the support track 300) attached to the floor prefabricated panel assembly 1000c in FIG. 18A, often described as a rim joint, has a U-shaped structural track 310, and has the parts described above. As shown, the core member of the support plate 320 can have one or more tension rods 322. In some embodiments, the structural track 310 may further comprise a core member that can accommodate tension rods.

[0131] In embodiments where the structural tracks 310 can be described as H-shaped as shown attached to the wall prefabricated wall assembly 1000b in FIG. 18A, the second securement and interconnecting apparatus 300 (the support track 300) has a first structural track 310a for receiving the bottom periphery 1240 of the structural insulated panel 1200, and a second structural track 310b for receiving one of a mud sill 320 (or a base support plate) and a periphery of a second structural insulated panel 1200. The attachment member 350 already discussed previously can be used for attaching the first structural track 310a to the structural insulated panel 1200 and the second structural track 310b to one of the mud sill 320 (or the base support plate) and the periphery of the second structural insulated panel 1200. In the embodiment shown, the first and second structural track 310a-b share the same web 313 and the mud sill 320 (or a base support plate) is received and attached to the interior surface of the web 313 of the second structural track 310b. As shown, the core member of the support plate 320 can have one or more tension rods 322. In some embodiments, the structural track 310 may further comprise a core member that can accommodate tension rods. FIG. 24 also shows H-shaped second securement and interconnecting apparatus 300 as described, showing how the attachment member 250 can be screws.

[0132] FIG. 18B is a close-up perspective view of another embodiment of the second securement and interconnecting apparatus 300 (the support track 300) attached on the top periphery 1240 of the structural insulated panel 1200 of the wall prefabricated panel assembly 1000b, for use with a roof prefabricated panel assembly 1000a. Embodiment of the second securement and interconnecting apparatus 300 (the support track 300) as shown as a H-shaped structural track 310 that has a first structural track 310a for receiving and attaching to the structural insulated panel 1200 and has a pair of outer retaining edges 341, 342 for holding the outer and inner panels 1210, 1230 that form the periphery 1240 of the structural insulated panel 1200. The second structural track 310b receives and attaches to a support plate 320a, which further attaches to a triangular shaped support plate 320b for supporting and connecting to the roof prefabricated panel assembly 1000a. FIG. 27 also shows another embodiment, where a U-shaped structural track 310 that has a core member with tension rod built in is used instead of the H-shaped second securement and interconnecting apparatus 300 (the support track 300).

[0133] In reference to FIGS. 19A-19C, and 20, FIG. 19A, various perspective views of some of the embodiments of the first and second securement and interconnecting apparatuses 200, 300 (the structural splines 200 and the support track 300) of the structural insulated panel interconnecting system 100 and some structural insulated panels 1200 and their components are shown, which were discussed in detail in preceding paragraphs.

[0134] FIG. 25 is a perspective view of an embodiment of a core member for the prefabricated panel assembly.

[0135] FIG. 26 is a close-up perspective view of embodiments of the second securement and interconnecting apparatus 300, where the recess or channel between the protruding edges of the structural insulated panel may be used as “the structural track”, and the support plate 320 can attach into the channel instead.

[0136] In reference to FIGS. 28A-28C, the second securement and interconnecting apparatus 300, or the support track 300, has a plurality of tension rod anchors 500 for receiving and securing tension rods 222 of the plurality of first securement and interconnecting apparatuses 200, or the structural splines 200, or a plurality of cable anchors 500 for receiving and securing tension cables 223 of the plurality of first securement and interconnecting apparatuses 200, or the structural splines 200. Thus, the plurality of tension rod or tension cable anchors 500 acting as attachment members 250 that attach the plurality of first securement and interconnecting apparatuses 200 to one or more second securement and interconnecting apparatuses 300 in the structural insulated panel interconnecting system 100.

[0137] As shown in FIG. 28B, the second securement and interconnecting apparatus 300, or the support track 300, can be shaped to fit the tension rod or cable anchors 500, either by molding into the second securement and interconnecting apparatus 300, or the support track 300, spaces 510 for the tension rod or cable anchors or by cutting out the tension rod or cable anchor shapes 510 onto the surface of the second securement and interconnecting apparatus 300, or the support track 300. The tension rod or cable anchors 500 can be then attached by any means known in the art, such as adhesives and screws.

[0138] Existing computer software such as MiTek Sapphire can be used to design the prefabricated panel assembly. A computerized saw or power hand tool can be used to pre-cut components of the prefabricated panel assembly, according to the needs of the construction project. For example, the splines and other structural studs can be pre-cut with a computerized saw or with power hand tools to suit the panel sizes and configurations according to a building design. The structural panel and service cavity parts can also be made with powered hand tools to sizes to meet the needs of the building design. It is possible to first produce many structural insulated panels of the same size, and then specially configure some of the structural insulated panels for doors, windows, corners, etc. The structural insulated panels can be fitted with the latches and cabling / rod position materials. The service cavity is assembled in sizes to fit the structural insulated panels.

[0139] The structural insulated panels can be assembled either by hand or by using automated machinery. The steps of making the structural insulated panels can be: laying the outer cement board sheet flat on a table configured to aid in position of parts as the parts are assembled, affixing an insulation layer and a smart vapor barrier (with or without furring members depending upon the system design being utilized), then adhering the outer cement board sheet, placing the structural stud and other structural members (such as headers) into the gaps, pressing the assembled structural insulated panel, and detailing the assembled structural insulated panel (Ex. for acceptance of other edge and face materials, such as recessing the foam in the panel edges to accept splines and support plates). A weather resistive barrier can be applied to the exterior facing side of the structural insulated board after lamination and pressing and prior to shipping.

[0140] The service cavity can be assembled by hand or by automation. One method of making the service cavity is: installing the smart vapor barrier, and fastening the furring strips to the panel, installing utility service, and filling the service cavity with insulation. If structural insulation is used, then the furring strips are typically only used at the perimeter of the panel. The service cavity is then sealed with the gypsum board at the jobsite.

[0141] For designing and building customized versions of the prefabricated panel assembly, a prefabricated panel assembly design software containing climate data is preferably used to calculate the total required thicknesses of the prefabricated panel assembly to meet the project requirements, considering climate needs required thermal and air infiltration performance levels of the building envelope and the windows and doors. The prefabricated panel assembly design software can also be used to adjust designs for the prefabricated panel assembly as needed to achieve a balance between cost and performance. The prefabricated panel assembly design software preferably is used to calculate the optimum amount of insulation desired. The prefabricated panel assembly design software can be used to design mechanical systems that eliminate traditional furnaces and air conditioning systems, resulting in less initial costs, and less energy usage over time in comparison to conventional buildings not built with the prefabricated panel assemblies or utilizing Passive House design approaches. The prefabricated panel assembly design software can be used to create fabrication drawings and to send instructions to smart devices such as “smart saws” and CNC tools. The prefabricated panel assembly design software can perform other architectural analyses, such as solar gain and fenestration (windows and doors) sizing and assessment, in 3D virtual reality format. The prefabricated panel assembly design software preferably has Artificial Intelligence (AI) to assist in designing the prefabricated panel assembly.

[0142] The prefabricated panel assembly design software is preferably linked to local building codes and updates automatically as codes change. Further, the prefabricated panel assembly design software can search the web for new building products, prices, where to purchase, availability, how they perform, how “green” they are, and automatically include building material recommendations to the architect. The prefabricated panel assembly design software preferably has artificial intelligence capabilities, and learn “how” the architect designs, such as contemporary, classical, utilitarian, etc. and include suggestions, changes, locations for building materials, HVAC runs, where to put heat pump units, where to run wires, ducts, etc. The prefabricated panel assembly design software can review plans and learn the best places to put these, minimizing materials by placing them correctly, etc. The prefabricated panel assembly design software can preferably track energy credit points. For example, city of Edmonds now requires 5 energy credits for small addition - through insulation, heat pump, less windows / openings, windows with higher R value, etc.

[0143] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0144] The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.”

[0145] The phrase “and / or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and / or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and / or” clause, whether related or unrelated to those elements specifically identified.

[0146] As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when separating items in a list, “or” or “and / or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,”“one of,”“only one of,” or “exactly one of.”

[0147] As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified.

[0148] It should also be understood that, unless clearly indicated to the contrary, in any methods claimed herein that include more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited.

[0149] In the claims, as well as in the specification above, all transitional phrases such as “comprising,”“including,”“carrying,”“having,”“containing,”“involving,”“holding,”“composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to.

[0150] While several inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and / or structures for performing the function and / or obtaining the results and / or one or more of the advantages described herein, and each of such variations and / or modifications is deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and / or configurations will depend upon the specific application or applications for which the inventive teachings is / are used. Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and / or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and / or methods, if such features, systems, articles, materials, kits, and / or methods are not mutually inconsistent, is included within the inventive scope of the present disclosure.

[0151] Having thus described the various embodiments of the invention, what is claimed as new and desired to be protected by letters patent is a structural insulated panel interconnecting system with a first securement and interconnecting apparatus (a structural spline), a second securement and interconnecting apparatus (a support track), an attachment member for securing the first securement and interconnecting apparatus to the structural insulated panel and the second securement and interconnecting apparatus, and an attachment member for securing the second securement and interconnecting apparatus to the structural insulated panel.

Examples

Embodiment Construction

[0090]The disclosed subject matter will become better understood through review of the following detailed description in conjunction with the figures. The detailed description and figures provide example embodiments of the invention described herein. Those skilled in the art will understand that the disclosed examples may be varied, modified, and altered without departing from the scope of the invention described herein.

[0091]Throughout the following detailed description, various examples of the structural insulated panel interconnecting system having at least a first securement and interconnecting apparatus (a structural spline) and at least a second securement and interconnecting apparatus (a support track) for securing and interconnecting prefabricated panel assemblies are provided. Related features in the examples may be identical, similar, or dissimilar in different examples. For the sake of brevity, related features will not be redundantly explained in each example. Instead, t...

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This U.S. non-provisional patent application claims the benefit of U.S. provisional patent application Ser. No. 63 / 740,020, filed Dec. 30, 2024, which is incorporated herein by reference in its entirety.BACKGROUND OF THE INVENTIONFIELD OF THE INVENTION

[0002] The present invention generally relates to panel assemblies such as panels for walls, floors, and roofs for building construction, engineering, or architecture. Specifically, the present invention relates to a structural insulated panel interconnecting system having securement and interconnecting apparatuses for interconnecting prefabricated panel assemblies for walls, floors, and roofs, which can be completely or mostly pre-manufactured off-site and shipped to the construction location for quick and efficient assembly. Further, the present invention relates to interconnecting and securing energy efficient prefabricated panel assemblies for building energy efficient buildings that meet Passivhaus standards. Still further, the present invention relates to structural insulated panel interconnecting system having securement and interconnecting apparatuses for interconnecting prefabricated panel assemblies and buildings made of such prefabricated panel assemblies that are more earthquake-resistant because the structural insulated panel interconnecting system allow for movement between the prefabricated panel assemblies that are joined to form building structures. Still further, the present invention relates to prefabricated panel assemblies that are easily replaced or repurposed by disassembling the structural insulated panel interconnecting system from the prefabricated panel assemblies.DESCRIPTION OF THE PRIOR ART

[0003] The present invention deals with products in the field of building architecture, engineering, construction, or civil engineering. More specifically, it deals with a structural insulated panel interconnecting system for prefabricated panel assemblies that are designed to facilitate constructing buildings that are more energy efficient, sustainable, and that can withstand movement between the prefabricated panel assemblies. Further, it deals with quickly replacing or repurposing prefabricated panel assemblies that are used in a building.

[0004] Transporting building materials to a building construction site uses up a lot of time and resources during construction. Prefabricating building panel assemblies, such as an entire wall panel assembly, roof panel assembly, or floor panel assembly, off-site and shipping to the construction location as easy to put together assemblies saves significant time and decreases labor costs at the site, allowing buildings to be constructed faster with less workers, with more accuracy and affordably.

[0005] Magnesium cement, fiberglass scrim-reinforced materials, magnesium oxide (MgO), magnesium sulfate (MgSO4), and other cementitious boards, panels, or sheets, which are fire resistant, water resistant, non-toxic, termite proof, mold and fungus resistant, thermally efficient (resistant to extreme temperatures), eco-friendly (recyclable and landfill friendly), durable (no rot), lightweight, strong, and affordable, are generally known and used in the building panel industry. Throughout the specification, the abbreviation “MgO” is used to describe this family of materials and derivations thereof. MgO structural insulated panels (SIPs) provide two MgO boards, panels, or sheets with an insulation layer sandwiched in between. However, most magnesium oxide boards do not readily come with multiple layers of insulation, air barriers, or cavities for electrical or pipe systems that may be necessary for a building. Further, typical MgO panels have rigid connections, and may be prone to developing cracks during construction or after building completion due to the building settling and movement.

[0006] Passivhaus, or also called Passive House, design or system use highly insulated wall panels with combinations of materials, such as layers of different insulations and air barriers such as smart vapor barriers. Passivhaus design focuses on proper insulation, elimination of air-leakages and thermal bridges (air and vapor-tight and without thermally conductive elements that transmit energy between the interior and exterior spaces, all of which can lead to condensation, mold, and deterioration), proper windows facing proper orientation, and heat recovery ventilation (HRV) or energy recovery ventilators (ERVs that also recover humidity). A building built with Passivhaus design uses 70-95% less energy, eliminating the need or at least leads to less use of an air conditioning (AC) or a heating system. Energy from body heat, internal sources such as electronics, cooking, or lights, and sunlight are enough to keep the environment within the building warm or cool, providing a healthier (naturally anti-fungal), safer (non-combustible), and more efficient building. However, Passivhaus design does not typically use MgO structural insulated panels and does not consider panels of the building shifting as the building settles or during an earthquake.

[0007] To overcome rigidity and to make Magnesium oxide structural insulated panels (MgO SIPs) more energy efficient and sustainable, and to reduce the complication, speed, and cost of building construction utilizing Passivhaus design, the present invention provides prefabricated panel assemblies that are cost effectively constructed off-site with the structural insulated panel interconnecting system of the present invention. Once constructed, the panels are delivered efficiently to the construction site for fast, simple construction using the structural insulated panel interconnecting system. These panels provide an energy efficient MgO SIP with a service cavity that provides space for any needed electrical or piping and more insulation and an air and vapor barrier. The structural insulated panel interconnecting system for the panels have joints and extension members that allow for building shift without cracking or breaking. Finally, the structural insulated panel interconnecting system and the panel designs provide the possibility of repurposing the prefabricated panel assemblies by easily “disassembling” the panels one from another, removing them from their existing location and moving to a new location so that they can be “reassembled” or used as an addition to another preexisting buildings built using the same or similar prefabricated panel assemblies and the structural insulated panel interconnecting system. Thus, the resulting building envelopes from present invention can be fabricated, transported, and assembled far more quickly than conventional framing while achieving superior energy and environmental performance.

[0008] It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein.

[0009] These and other aspects of the invention will be apparent from and elucidated with reference to the embodiment(s) described hereinafter.SUMMARY OF THE INVENTION

[0010] In view of the foregoing, it is an object of the present invention to provide a structural insulated panel interconnecting system for panel assembly for walls, floors, and roofs. The panel assembly can be completely or mostly prefabricated off-site and shipped to the construction location for quick, simple, and efficient assembly using the structural insulated panel interconnecting system.

[0011] It is another object of the present invention to provide a prefabricated panel assembly using magnesium oxide structural insulated panel (MgO SIP) but overcome its rigidity and need for allowing additional insulation and air barrier, and space for utility services, such as electrical and piping.

[0012] It is yet another object of the present invention to provide a structural insulated panel interconnecting system for connecting an energy efficient prefabricated panel assembly for building energy efficient buildings that meet Passivhaus design standard but overcome cost, and complication associated with Passivhaus design.

[0013] It is still yet another object of the present invention to provide a structural insulated panel interconnecting system for prefabricated panel assembly that is more earthquake-resistant and allows for movements or shifts between the prefabricated panel assemblies that are joined to form a building structure.

[0014] Further still, it is yet another object of the present invention to provide a structural insulated panel interconnecting system for prefabricated panel assembly, so the prefabricated panel assembly is easily replaced or repurposed in a building built with such prefabricated panel assemblies.

[0015] The present invention achieves these objects and other objects that become evident from the following detailed description of the preferred embodiments of the invention by providing a structural insulated panel interconnecting system for a prefabricated panel assembly for floor, wall, and roof. The prefabricated panel assembly comprises a weather resistive barrier membrane, a structural insulated panel, a gypsum or other finish materials board, a smart vapor barrier, and a service cavity. The structural insulated panel interconnecting system comprises at least a first securement and interconnecting apparatus and a second securement and interconnecting apparatus, an attachment member for securing the first securement and interconnecting apparatus to the structural insulated panel and the second securement and interconnecting apparatus, and an attachment member for securing the second securement and interconnecting apparatus to the structural insulated panel.

[0016] The first securement and interconnecting apparatus, also referred to as a spline or a structural spline, has at least a first structural track configured to receive a first periphery of a structural insulated panel and at least a pair of outer retaining edges. The first structural track has a first flange, a second flange, and a web connecting the first flange and the second flange. The pair of outer retaining edges has a first outer retaining edge extending perpendicular to the first flange of the first structural track, and a second outer retaining edge extending perpendicular to the second flange of the first structural track. The pair of outer retaining edges is configured to support protruding edges of the first periphery of the structural insulated panel.

[0017] The second securement and interconnecting apparatus, also referred to as a support track and can include what are commonly known as top tracks, base tracks, and rim joists, has at least a second structural track configured to receive a second periphery of the structural insulated panel and an end of the first structural track of the first securement and interconnecting apparatus, at least one support plate, which can include what are commonly known as top plates, base plates, and mud sills, and at least a second pair of outer retaining edges. The second structural track has a first flange, a second flange, and a web connecting the first flange and the second flange. The at least one support plate is attached to an interior surface of the web and extends along the second structural track. The pair of outer retaining edges has a first outer retaining edge extending perpendicular to the first flange of the second structural track, and a second outer retaining edge extending perpendicular to the second flange of the second structural track. The pair of outer retaining edges is configured to support protruding edges of the second periphery of the structural insulated panel.

[0018] The support plate is secured to at least one structural track of the second securement and interconnecting apparatus by the attachment member. The attachment member also secures the second securement and interconnecting apparatus to the structural insulated panel. This attachment member is also referred to as the support plate connecting member for connecting the support plate with the structural insulated panel. The support plate connecting member may be glue, nails, or other means known in the art for attaching the support plate to the structural insulated panel, or more complex means for connecting the support plate to the structural insulated panel, such as, but not limited to, U or H-shaped members and C and H-shaped tracks, also referred to as the second structural track or the structural track) as will be described throughout the specification. One or more of a plurality of screws, a plurality of latches, at least one pair of L-shaped clips, and an adhesive can be used as attachment member / s for attaching the support plate to the C and H-shaped tracks (the at least one second structural track).

[0019] The structural insulated panel comprises an outer cement board sheet, an insulation layer, an inner cement board sheet, and a structural stud. The structural stud is used for developing additional internal strength inside a panel. It is also called a structural spline or the first securement and interconnecting apparatus of the structural insulated panel interconnecting system when it is used for connecting multiple structural insulated panels together. The first securement and interconnecting apparatus also includes a rectangular corner post when used where wall corners occur. These studs and corner posts are partially recessed into the outer vertical edges of the structural insulated panels or otherwise firmly connected. An air and vapor barrier with the capacity to selectively stop or allow the passage of water vapor depending upon the presence or absence of liquid water, also called a smart vapor barrier or SVB, is located on either the inner or outer face or in the center of the structural insulated panel, depending upon the climate in which the wall is located. In the northern climates where the exterior ambient air is typically drier than it is southern climates, the air and vapor barrier or smart vapor barrier (SVB) is typically located on the interior or room side of the wall panel. In southern climates the exterior weather resistive barrier can also perform the smart vapor barrier role if the correct material is used. In some climates, the smart vapor barrier function may be required on both the exterior and interior sides of the structural insulated panel or may be located in the center of the structural insulated panel. The service cavity is positioned in between the structural insulated panel and the gypsum board that is used as the interior finish substrate on the room side of the assembly. The service cavity is comprised of a stud and may also have thermal insulation. A smart vapor barrier also can be located within the service cavity. Desired utility service can be run in the service cavity. Desired utility service can be water, heat, or drainage piping, electrical wires, cables, data links, and any other utility that may be needed or desired for the purpose of the building. Other materials, such as phase change materials, may be added to either the structural insulated panel, the service cavity, or both.

[0020] In an embodiment of the present invention, the outer cement board sheet and the inner cement board sheet of the structural insulated panel each have recessed insulation edges or protruding edges around a periphery that fit around structural splines (the first securement and interconnecting apparatus) and support plates, such as base plates and top plates, and support tracks (the second securement and interconnecting apparatus). The edges of the insulation layer of the structural insulated panel can be recessed to allow the structural splines, support tracks, support plates, and connecting / attachment members to recess into the edges of the outer and inner cement board sheets or panels so they can be glued and fastened (either nails or screws) in place. With a polymer stud being used as a structural spline and with the expansion / control joint gasket being used, the spline edges that are closest to the panel joint can have at least a pair of outer retaining edges (the protruding edges) occur along the edges that are closest to the joint, with the protrusions occurring both on the room side and the exterior side of the spline. Those outer retaining edges (protruding edges) occur in order to support the edges of the gasket material where they are closest to the room and exterior faces of the joint. When the board joint is finished, the actual joint is sealed with a flexible, but firm caulking material that takes advantage of the straight, protruding edges of the spline to give a more pleasing, uniform, and straight appearance.

[0021] In an embodiment of the present invention, the outer cement board sheet and the inner cement board sheet of the structural insulated panel each have recessed insulation edges or protruding edges around a periphery that fit around structural studs (splines) and support plates (base plates and top plates). In this embodiment, the stud connecting member is an interlocking spline with a control joint capability to control movement and the related potential for cracking of the cement board sheets. The interlocking spline with the control joint capability, which is an embodiment of the first securement and interconnecting apparatus or the structural spline, is comprised of a first structural track (also referred to as C, H, or rectangular-shaped stud), a second structural track (also referred to as C, H, or rectangular-shaped stud), and has a cushioning layer as the core member. The first structural track receives a periphery of a first structural insulated panel, and the second structural track receives a periphery of a second structural insulated panel. The first and the second structural tracks interlock together to form a H-shaped track with the core member sandwiched between the exterior surface of the web of the first structural track and the web of the second structural track. The first and second structural tracks each have a pair of outer retaining edges (also referred to as an outer board trim edge and an inner board trim edge), and a plurality of interlocking connecting apparatuses on the exterior surface, and a plurality of interlocking connecting slots. The outer board trim edge (a first outer retaining edge) supports a protruding edge of the outer cement board sheet. The inner board trim edge (a second outer retaining edge) supports a protruding edge of the inner cement board sheet. The core member is a cushioning layer and is positioned in between the first and the second structural tracks, and the cushioning layer is also an adhesive material that resists delamination under movement.

[0022] In another embodiment of the present invention, the support plate is rectangular with interlocking end pieces. The outer cement board sheet and the inner cement board sheet of the structural insulated panel each have a protruding edge around a periphery that connects with glue and screws as attachment members to the at least one structural track of the second securement and interconnecting apparatus (also referred to as the support track or the H-shaped support plate connecting members) located at the bottom edges of the panel and in some instances also at the top edges of the panels. The second securement and interconnecting apparatus form bottom, and sometimes top, channels with its at least one structural track, forming a C-shaped track with one structural track and an H-shaped track with a first and a second structural tracks mirrored and connected together. The bottom and top channels forming the support tracks are shaped to fit into the protruding edges of the bottom and top edges of the structural insulated panel. The bottom channel of the bottom support track and the top channel of the top support track are shaped to fit over the bottom support plate and the top support plate.

[0023] In an embodiment of the present invention, the outer cement board sheet and the inner cement board sheet of the structural insulated panel each have recessed insulation edge around a periphery, forming a channel between the recessed insulation edge of the outer cement board sheet and the recessed insulation edge of the inner cement board sheet. The channel is shaped to receive a support plate of the second securement and interconnecting apparatus (the support track) of the structural insulated panel interconnecting system. The structural insulated panel interconnecting system can further comprise attachment member for the second securement and interconnecting apparatus, which can be a gasketed movement joint and an L-shaped angle positioned on a corner of the gasketed movement joint, with bolted connections consisting of short plates with slotted holes connected to the ends of adjacent support channels to allow for movement in the support plate between multiple prefabricated panel assemblies.

[0024] In an embodiment of the structural insulated panel interconnecting system, the web of the first structural track of the first securement and interconnecting apparatus form a protruding portion on each end of the first structural track, and the second track of the second securement and interconnecting apparatus is configured to receive the protruding portion on one end of the first structural track of the first securement and interconnecting apparatus.

[0025] In an embodiment of the structural insulated panel interconnecting system, the attachment member for securing the first securement and interconnecting apparatus to the structural insulated panel and the second securement and interconnecting apparatus and the attachment member for securing the second securement and interconnecting apparatus to the structural insulated panel comprises one or more of a plurality of screws, a plurality of latches, at least one pair of L-shaped clips, and an adhesive.

[0026] In an embodiment of the structural insulated panel interconnecting system, the first securement and interconnecting apparatus further comprises at least one core member attached to an exterior surface of the web of the first structural track and extending along the first structural track. In such embodiment, the core member and the web of the first structural track of the first securement and interconnecting apparatus may form a protruding portion on each end of the first structural track, and the second track of the second securement and interconnecting apparatus may be configured to receive the protruding portion on one end of the first structural track of the first securement and interconnecting apparatus. The core member of the first securement and interconnecting apparatus may comprise one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material. The core member of the first securement and interconnecting apparatus may further comprise a tension rod.

[0027] In an embodiment of the present invention, the structural spline for securing and interconnecting structural insulated panels comprises at least one structural track configured to receive a periphery of a structural insulated panel, at least a pair of outer retaining edges configured to support protruding edges of the periphery of the structural insulated panel, and an attachment member for securing the structural spline to the structural insulated panel and a plurality of support tracks. The structural track comprises a first flange, a second flange, and a web connecting the first flange and the second flange. The pair of outer retaining edges has a first outer retaining edge extending perpendicular to the first flange of the structural track and a second outer retaining edge extending perpendicular to the second flange of the structural track. The attachment member may be one or more of a plurality of screws, a plurality of latches, at least one pair of L-shaped clips, and an adhesive.

[0028] In an embodiment of the structural spline, the web of the structural track forms a protruding portion on each end of the structural track, and the attachment member attaches the protruding portion on one end of the structural track to the plurality of support tracks.

[0029] In an embodiment of the structural spline, the structural spline further has at least one core member attached to an exterior surface of the web of the structural track and extending along the structural track, and the core member comprises one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material. In such embodiment, the core member and the web of the structural track may form a protruding portion on each end of the structural track, and the attachment member attaches the protruding portion on one end of the structural track to the plurality of support tracks. The core member may further have a tension rod.

[0030] In an embodiment of the structural spline where the spline an interlocking spline, the spline has a first structural track for receiving a periphery of a first structural insulated panel and a second structural track for receiving a periphery of a second structural insulated panel. The first and the second structural tracks interlock together to form a H-shaped track with the core member sandwiched between the exterior surface of the web of the first structural track and the web of the second structural track. The web of the first structural track and the web of the second structural track each further have a plurality of interlocking connecting apparatuses on the exterior surface, and a plurality of interlocking connecting slots. The plurality of interlocking connecting apparatuses of the first structural track aligns, inserts, and interlocks with the plurality of interlocking connecting slots of the second structural track through the core member and the plurality of interlocking connecting apparatuses of the second structural track aligns, inserts, and interlocks with the plurality of interlocking connecting slots of the first structural track through the core member.

[0031] In an embodiment of the structural spline where the spline is a corner spline, the spline has a first structural track for receiving a periphery of a first structural insulated panel and a second structural track for receiving a periphery of a second structural insulated panel. The spline further has a first core member parallelly attached to the exterior surface of the web of the first structural track and a second core member parallelly attached to the exterior surface of the web of the second structural track. The structural spline further has a rectangular corner post attached to the first core member at a first side and to the second core member at a second side adjacent the first side. The rectangular corner post may have at least one tension rod. The first core member, the second core member, and the rectangular corner post each comprises one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material. In such embodiment, the corner spline further has at least one corner post cap. The corner post cap has a rectangular body, a rectangular slot on a side of the body for aligning and fitting on a top or a bottom surface of the rectangular corner post, a core within the body, and a thermal control material, and at least one tension rod. The core may have one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material. The core may have at least one protruding portion on at least one side of the body.

[0032] In an embodiment of the present invention, a support track for securing and interconnecting structural insulated panels and a plurality of structural splines has at least one structural track configured to receive a periphery of a structural insulated panel and a portion of the plurality of structural splines, at least one support plate, at least a pair of outer retaining edges, and an attachment member. The structural track has a first flange, a second flange, and a web connecting the first flange and the second flange. The support plate is attached to an interior surface of the web and extends along the structural track. The pair of outer retaining edges is configured to support protruding edges of the periphery of the structural insulated panel. A first outer retaining edge extends perpendicular to the first flange of the structural track and a second outer retaining edge extends perpendicular to the second flange of the structural track. The attachment member for securing the support track to the structural insulated panel may be one or more of a plurality of screws, a plurality of latches, at least one pair of L-shaped clips, and an adhesive. In such embodiment, the support plate may further have a tension rod.

[0033] In an embodiment, the support track has a first structural track for receiving the periphery of the structural insulated panel, a second structural track for receiving one of a mud sill and a periphery of a second structural insulated panel, and an attachment member for attaching the second structural track to one of the polymer mud sill and the periphery of the second structural insulated panel.

[0034] In an embodiment of the present invention, the prefabricated panel assembly may further comprise a polymeric header for structural support over openings.

[0035] In an embodiment of the present invention, the service cavity may further comprise a furring strip that clamps the smart vapor barrier to hold the smart vapor barrier in place within the service cavity.

[0036] In an embodiment of the present invention, the corner post (the corner spline) may further have a weather resistive barrier, an insulation layer, and a corner post connecting member to interlock with the structural insulated panel.

[0037] In an embodiment of the present invention, the support plate of the prefabricated panel assembly further comprises a tensioning cable or rod to join multiple structural insulated panels together and support more loads.

[0038] In an embodiment of the present invention, the support plate of the support track, or the second securement and interconnecting apparatus of the structural insulated panel interconnecting system, is one of a bottom support plate / base plate, a top support plate / top plate, and mud sill.

[0039] In an embodiment of the present invention, the insulation layer of the structural insulated panel and the insulation layer of the service cavity is selected from the group of oil-based insulations consisting of expanded polystyrene (EPS or Styrofoam), extruded polystyrene (XPS), and polyisocyanurate (poly Iso or ISO). In an embodiment of the present invention, the insulation layer of the structural insulated pane and the insulation layer of the service cavity is selected from the group of organic-based insulations consisting of hemp, straw, bamboo, cellulose, fungi, rice hulls, or similar, including fabricated structural shapes such as honeycomb and crossing grid-shaped arrangements of materials with insulation, phase change, and selective vapor control materials included in the cells.

[0040] In an embodiment of the present invention, the outer cement board sheet and the inner cement board sheet of the structural insulated panel are selected from the group consisting of magnesium oxide, magnesium sulfate, and other cement and polymer boards known in the art.

[0041] In an embodiment of the present invention, the first and the second securement and interconnecting apparatuses, or the structural spline and support track, are made of a material selected from the group consisting of wood, metal, fiberglass reinforced plastic (FRP), recycled plastic, composite plastic, and other organic and recycled materials.

[0042] In an embodiment of the present invention, the attachment members for the first and the second securement and interconnecting apparatuses are latches and latch receivers.

[0043] In an embodiment of the present invention, the structural stud of the structural insulated panel may further comprise an insulation layer.

[0044] In an embodiment of the present invention, the service cavity may further comprise a furring strip. The furring strip is comprised of a material selected from the group consisting of one of wood, plastic, PVC, fiberglass, and other recycled and composite materials.

[0045] In an embodiment of the present invention, the support plate connecting member of the support plate may comprise a cushioning layer. In an embodiment of the present invention, the stud connecting member of the structural stud of the structural insulated panel may further comprise a cushioning layer.

[0046] In another embodiment of the present invention, a prefabricated panel assembly for floor, wall, and roof, is comprised of a weather resistive barrier membrane, a structural insulated panel, a gypsum board, an insulated or uninsulated service cavity, and a polymer support plate. The structural insulated panel is comprised of an outer non-combustible and carbon sequestering board sheet, an insulation layer, a smart vapor barrier, an inner non-combustible and carbon sequestering board sheet, and a structural stud with a stud connecting member. The service cavity is positioned in between the structural insulated panel and the gypsum board. The service cavity is comprised of a polymer stud with an insulated core, and a smart vapor barrier. Any desired utility service can be run in the service cavity. The polymer support plate is comprised of an insulated core and a support plate connecting member. The polymer stud may further have a tension rod.BRIEF DESCRIPTION OF THE DRAWINGS

[0047] In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the inventive subject matter.

[0048] FIG. 1 is a perspective interior (to a building) view of a roof prefabricated panel assembly, a wall prefabricated panel assembly, and a floor prefabricated panel assembly, assembled together using the structural insulated panel interconnecting system to show how prefabricated panel assemblies are connected together to form a building.

[0049] FIG. 2 is a top perspective view of the roof prefabricated panel assembly, the wall prefabricated panel assembly, and the floor prefabricated panel assembly in FIG. 1, showing the weather resistive barrier membrane of the roof prefabricated panel assembly and a weather resistive barrier membrane of the wall prefabricated panel assembly. The panels are connected using the structural insulated panel interconnecting system, and the first securement and interconnecting apparatus (the structural spline) as a corner post is shown as well as the second securement and interconnecting apparatus. An air barrier of the floor prefabricated panel assembly is also shown.

[0050] FIG. 3 is an exploded side perspective view of the roof prefabricated panel assembly, the wall prefabricated panel assembly, and the floor prefabricated panel assembly in FIGS. 1-2. FIG. 3 shows, in addition to what are shown in FIGS. 1-2, a tension rod in the support plate of the second securement and interconnecting apparatus of the structural insulated panel interconnecting system connecting the roof prefabricated panel assembly to the wall prefabricated panel assembly, a tension rod in the support plate (top plate) of another second securement and interconnecting apparatus of the structural insulated panel interconnecting system connecting the wall prefabricated panel assembly to the floor prefabricated panel assembly.

[0051] FIG. 4 is a side exterior (to a building) perspective view of the prefabricated wall assembly in FIGS. 1-3, showing a smart vapor barrier of the service cavity, and how the structural spline (the first securement and interconnecting apparatus) as the corner post would attach to the panel using latches as the attachment member.

[0052] FIG. 5 is a side interior (to a building) perspective view of the wall prefabricated wall assembly in FIGS. 1-4, showing all the parts previously discussed in FIGS. 1-4, and also showing an electrical switch and an electrical receptacle on a surface of the service cavity.

[0053] FIG. 6 is a close-up exploded view of an embodiment of the attachment member, shown as screws and a latch, for attaching a first securement and interconnecting apparatus (a structural spline) to the structural insulated panel of the prefabricated panel assembly according to disclosure, and also showing a second securement and interconnecting apparatus (a support track) on the structural insulated panel on the right, as well as how a support plate of the second securement and interconnecting apparatus may be connected to another support plate for another structural insulated panel.

[0054] FIG. 7A is a close-up exploded view of how two wall prefabricated panel assemblies are joined together to allow shifting using the structural insulated panel interconnecting system. An outer cement board sheet and an inner cement board sheet of a structural insulated panel are shown, with each having recessed insulation edge around a periphery, forming a channel between the recessed insulation edge of the outer cement board sheet and the recessed insulation edge of the inner cement board sheet, which accommodates the structural track of the second securement and interconnecting apparatus (the support track) within the channel, and the structural track can receive the support plate of the second securement and interconnecting apparatus as shown. A gasketed movement joint and an L-shaped angle is positioned on a corner of a portion of the structural insulated panel within the channel to allow for the support plate (top plate / top track) movement and serve as attachment members for attaching the second securement and interconnecting apparatus to the structural insulated panel. The connecting splice channel may be located above or below the top support track depending upon the project requirements.

[0055] FIG. 7B is a close-up exploded view of an embodiment of the second securement and interconnecting apparatus (the support track) of the structural insulated panel interconnecting system, showing the structural track on top and a window header as the support plate in the middle, and how they attach to the structured insulated panel using the screws and L-shaped angle clip (or angle) as the attachment members.

[0056] FIG. 8A is a perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) of the structural insulated panel interconnecting system, showing a first structural track and its components.

[0057] FIG. 8B is an exploded side perspective view of the embodiment of the first securement and interconnecting apparatus (the structural spline) of the structural insulated panel interconnecting system shown in FIG. 8A, showing the first structural track on the right side and further showing a second structural track on the left side and an adhesive gasketed core member in the middle. Screws and L-clips as attachment members for attaching the first securement and interconnecting apparatus to a structural insulated panel are also shown.

[0058] FIG. 8C is an exploded side perspective view of the embodiment of the first securement and interconnecting apparatus (the structural spline) of the structural insulated panel interconnecting system shown in FIGS. 8A-8B, with the attachment members shown in FIG. 8B removed.

[0059] FIG. 8D is a close-up perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) of the structural insulated panel interconnecting system shown in FIGS. 8A-8C without a protruding portion on an end of the web of the first and second structural tracks. The first and second structural tracks are shown attached back-to-back together to form an expansion joint (control joint or interlocking spline with a control joint capability) with a cushioning layer (or gasket) as the core member, positioned in between to allow for movement (from wind, earthquake, vibration, etc.) and settling.

[0060] FIG. 9 is an embodiment of the wall prefabricated panel assembly having a service cavity comprised of a furring strip that acts as a clamp on an edge of a smart vapor barrier to hold the smart vapor barrier in place within the service cavity.

[0061] FIG. 10 is a side, exploded, perspective view of an embodiment of the wall prefabricated panel assembly, showing how four wall prefabricated panels can be assembled together to form a wall prefabricated panel assembly using a first securement and interconnecting apparatus (the structural spline) of the structural insulated panel interconnecting system in between two adjacent panels, a second securement and interconnecting apparatus (the support track) of the structural insulated panel interconnecting system are used on top and bottom of the wall prefabricated panel assembly and attached with U-shaped clips as the attachment members made from the same polymer materials as the first and second securement and interconnecting apparatuses.

[0062] FIG. 11 is a side, exploded, perspective view of another embodiment of the structural insulated panel interconnecting system connecting the wall prefabricated panel assembly and the floor prefabricated panel assembly together.

[0063] FIG. 12 is a side, exploded, perspective view of another embodiment of the structural insulated panel interconnecting system for connecting the structural insulated panels of a wall prefabricated panel assembly, showing an outer non-combustible and carbon sequestering board sheet, an insulation layer, a smart vapor barrier, another insulation layer, an inner non-combustible and carbon sequestering board sheet.

[0064] FIG. 13 is a side exploded perspective view of an embodiment of the structural insulated panel interconnecting system showing how it would be used with the wall prefabricated panel assemblies and a floor prefabricated panel assembly.

[0065] FIG. 14 is a side, exploded, perspective view of another embodiments of the structural insulated panel interconnecting system and the wall prefabricated panel assembly, and how some of them could be configured for varying windows and wall configurations, showing an outer non-combustible and carbon sequestering board sheet, an insulation layer, a smart vapor barrier, a phase change layer, and service cavity configurations, a non-combustible cementitious skins with insulating liners at window and door openings, a polymer first securement and interconnecting apparatus (a structural spline) with insulating core member with a tension rod, and multiple polymer second securement and interconnecting apparatuses (support tracks) with support plates (top plate and base plate) with anchors, insulated core members with tensioning rods, an attachment member as a polymer connecting track with insulating core and a tension rod. A structural header as a structured insulated panel over openings having thermal and control layers as a part of the wall prefabricated panel assembly, and a sill panel with insulated polymer shapes are also shown.

[0066] FIG. 15 is a side, exploded, perspective view of another embodiment of the structural insulated panel interconnecting system for connecting the wall prefabricated panel assembly, showing how the second securement and interconnecting apparatuses (the support tracks) can connect to the structural insulated panels at the top and bottom peripheries, and the first securement and interconnecting apparatuses (the structural splines) can connect to the structural insulated panels at the side peripheries.

[0067] FIG. 16A is a side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) and the attachment member for the first securement and interconnecting apparatus of the structural insulated panel interconnecting system.

[0068] FIG. 16B is a side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) and the attachment member for the first securement and interconnecting apparatus of the structural insulated panel interconnecting system.

[0069] FIG. 16C is a side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) and the attachment member for the first securement and interconnecting apparatus of the structural insulated panel interconnecting system.

[0070] FIG. 16D is a side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) and the attachment member for the first securement and interconnecting apparatus of the structural insulated panel interconnecting system.

[0071] FIG. 17A is an exploded side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) for a corner, further showing a rectangular corner post, a tension cable, a tension rod, attachment members, and an embodiment of the corner post caps with tension rods.

[0072] FIG. 17B is an exploded side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) for a corner, further showing a rectangular corner post, attachment members, and an embodiment of the corner post caps with tension rods.

[0073] FIG. 18A is a close-up perspective view of embodiments of the second securement and interconnecting apparatus (the support track), showing how it can have a H-shaped or U-shaped structural track that attach the structural insulated panel and hold the outer and inner panels that form a periphery of the structural insulated panel by the outer retaining edges, with a support plate or a mud sill attached to the interior of the structural track.

[0074] FIG. 18B is a close-up perspective view of an embodiment of the second securement and interconnecting apparatus (the support track), showing how it can have a H-shaped structural track that attach the structural insulated panel and hold the outer and inner panels that form a periphery of the structural insulated panel by the outer retaining edges, with a support plate (top plate) and triangular shaped support plate (top plate) for connecting to a roof prefabricated panel assembly.

[0075] FIG. 19A is a perspective view of some of the embodiments of the first and second securement and interconnecting apparatuses of the structural insulated panel interconnecting system and some wall structural insulated panels and their components.

[0076] FIG. 19B is a perspective view of some of the embodiments of the first and second securement and interconnecting apparatuses of the structural insulated panel interconnecting system and some wall structural insulated panels and their components.

[0077] FIG. 19C is an exploded perspective view of embodiments of the first and second securement and interconnecting apparatuses of the structural insulated panel interconnecting system and some floor structural insulated panels.

[0078] FIG. 20 is a perspective view of some of the embodiments of the first and second securement and interconnecting apparatuses of the structural insulated panel interconnecting system and some wall structural insulated panels and their components.

[0079] FIG. 21A is a close-up exploded side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) for a corner, further showing a portion of the structural tracks, a portion of the rectangular corner post with four tension rods, attachment members, and an embodiment of the corner post cap with tension rods.

[0080] FIG. 21B is a close-up exploded side perspective view of an embodiment of the first securement and interconnecting apparatus (the structural spline) for a corner, further showing a portion of the structural tracks, a portion of the rectangular corner post with four tension rods, attachment members, and an embodiment of the corner post cap with tension rods.

[0081] FIG. 22 is a close-up view of an embodiment of a window or door header panel and its attachment members.

[0082] FIG. 23 is a close-up exploded view of an embodiment of the second securement and interconnecting apparatus (the support track), to show how the second securement and interconnecting apparatus connect to a structural insulated panel for a wall at the bottom periphery of the structural insulated panel.

[0083] FIG. 24 is a close-up exploded view of embodiments of the first and second securement and interconnecting apparatuses, to show how the first and second securement and interconnecting apparatuses connect to a structural insulated panel for a wall.

[0084] FIG. 25 is a perspective view of an embodiment of a humidity responsive core member for the prefabricated panel assembly.

[0085] FIG. 26 is a close-up perspective view of embodiments of the second securement and interconnecting apparatus (the support track), to show how the second securement and interconnecting apparatuses connect a structural insulated panel for a roof to a structural insulated panel for a wall.

[0086] FIG. 27 is a close-up perspective view of an embodiment of the second securement and interconnecting apparatus (the support track), to show how the second securement and interconnecting apparatus can connect a structural insulated panel for a roof to a structural insulated panel for a wall.

[0087] FIG. 28A is a perspective view of an embodiment of the second securement and interconnecting apparatus (the support track) having a plurality of tension rod or cable anchor for receiving and securing tension rods in the first securement and interconnecting apparatuses (the structural splines), thus acting as attachment members that attach the first securement and interconnecting apparatuses to the second securement and interconnecting apparatus in the structural insulated panel interconnecting system.

[0088] FIG. 28B is a close-up perspective view of the tension rod or cable anchor shown in FIG. 28A, and how it attaches to the second securement and interconnecting apparatus.

[0089] FIG. 28C is a close-up front view of the tension rod or cable anchor shown in FIGS. 28A-28B, and how it attaches to the second securement and interconnecting apparatus.DETAILED DESCRIPTION OF THE EMBODIMENTS

[0090] The disclosed subject matter will become better understood through review of the following detailed description in conjunction with the figures. The detailed description and figures provide example embodiments of the invention described herein. Those skilled in the art will understand that the disclosed examples may be varied, modified, and altered without departing from the scope of the invention described herein.

[0091] Throughout the following detailed description, various examples of the structural insulated panel interconnecting system having at least a first securement and interconnecting apparatus (a structural spline) and at least a second securement and interconnecting apparatus (a support track) for securing and interconnecting prefabricated panel assemblies are provided. Related features in the examples may be identical, similar, or dissimilar in different examples. For the sake of brevity, related features will not be redundantly explained in each example. Instead, the use of related feature names will clue the reader that the feature with a related feature name may be similar to the related feature in an example explained previously. Features specific to a given example will be described in that particular example. The reader should understand that a given feature need not be the same or similar to the specific portrayal of a related feature or example.

[0092] The invention will now be described in detail with reference to the attached drawing FIGS. 1-28C. As described above in the summary, there is a need for a structural insulated panel interconnecting system for securing and interconnecting prefabricated panel assembly for walls, floors, and roofs that can be completely or mostly pre-assembled off-site and shipped to the construction location for quick, simple, and efficient assembly. There is a need for prefabricated panel assembly using a magnesia cement or magnesium oxide structural insulated panel (MgO SIP) that overcomes its rigidity and allows additional insulation and air barrier, and space for utility service, such as electrical wiring and piping. There is a need for a structural insulated panel interconnecting system that interconnects an energy efficient prefabricated panel assembly for building energy efficient buildings that meet Passivhaus design standard but overcome humidity, cost, and complication associated with Passivhaus design. There is a need for a structural insulated panel interconnecting system for a prefabricated panel assembly that is more earthquake-resistant and allows for movements or shifts between the prefabricated panel assemblies that are joined to form a building structure. There is a need for a structural insulated panel interconnecting system that allows prefabricated panel assembly to be easily replaced or repurposed in a building built with such prefabricated panel assemblies.

[0093] Referring to FIGS. 1-28C, there is shown a perspective interior (to a building) view of a roof prefabricated panel assembly 1000a, a wall prefabricated panel assembly 1000b, and a floor prefabricated panel assembly 1000c, assembled together to show how prefabricated panel assemblies 1000a-c are constructed together to form a building. Though we focus on roof, wall, or floor prefabricated panel assembly in FIGS. 1-28C, the present invention could be prefabricated assembly for walls, floors, roofs, decks, fencing, and foundations for many types of buildings, especially those that are low or mid-rise and where the panels can perform most of the primary structural roles. Different embodiments of the panels can also form both structural and non-structural roles in low, mid, and high-rise buildings. A roof, wall, or floor prefabricated panel assembly 1000a-c is connected to each other using a structural insulated panel interconnecting system 100, which has at least one first securement and interconnecting apparatus 200, also called a structural spline 200, at least one second securement and interconnecting apparatus 300, also called a support track 300, an attachment member 250 for securing the first securement and interconnecting apparatus 200, and an attachment member 350 for securing the second securement and interconnecting apparatus 300. The attachment member 250 secures the first securement and interconnecting apparatus 200 to the structural insulated panel 1200 and the second securement and interconnecting apparatus 300. The attachment member 350 secures the second securement and interconnecting apparatus 300 to the structural insulated panel 1200.

[0094] The first securement and interconnecting apparatus 200, also referred to as the structural spline 200, connect two adjacent wall structural insulated panels 1200 together. In an embodiment, the first securement and interconnecting apparatus 200 is comprised of at least a first structural track 210, and at least a first pair of outer retaining edges 241, 242. The structural track 210 is comprised of a first flange 211, a second flange 212, and a web 213 connecting the first flange 211 and the second flange 212. The structural track 210 is configured to receive a first periphery 1240 of a structural insulated panel 1200. The pair of outer retaining edges 241, 242 comprises a first outer retaining edge 241 that extends perpendicular to the first flange 211 of the structural track 210 and a second outer retaining edge 242 that extends perpendicular to the second flange 212 of the structural track 210. The pair of outer retaining edges 241, 242 is configured to support protruding edges of the first periphery 1240 of the structural insulated panel 1200.

[0095] The second securement and interconnecting apparatus 300, also referred to as the support track 300, which can include top tracks, base tracks, and rim joists, connect roof and floor structural insulated panels 1200 to the wall structural insulated panels 1200. In an embodiment, the second securement and interconnecting apparatus 300 is comprised of at least a second structural track 310, at least one support plate 320, and at least a second pair of outer retaining edges 341, 342. The structural track 310 is comprised of a first flange 311, a second flange 312, and a web 313 connecting the first flange 311 and the second flange 312. The structural track 310 is configured to receive a second periphery 1240 of a structural insulated panel 1200. The support plate 320 attaches to an interior surface 314 of the web 310 and extends along the structural track 310. In an embodiment, the support plate 320 could be a top plate, a base plate, or a mud sill. The pair of outer retaining edges 341, 342 comprises a third outer retaining edge 341 that extends perpendicular to the first flange 311 of the structural track 310 and a fourth outer retaining edge 342 that extends perpendicular to the second flange 312 of the structural track 310. The pair of outer retaining edges 341, 342 is configured to support protruding edges of the second periphery 1240 of the structural insulated panel 1200.

[0096] A roof, wall, or floor prefabricated panel assembly 1000a-c is comprised of a weather resistive barrier membrane 1100, a structural insulated panel 1200, a gypsum board 1300 (also known as drywall, plasterboard, dry lining, wallboard, sheet rock, gyp board, buster board, turtles board, slap board, custard board, gypsum panel and gyprock), a service cavity 1400, and a smart vapor barrier 1500. The smart vapor barrier 1500 can be within the structural insulated panel 1200, a face of the structural insulated panel 1200, or within a service cavity 1400, and also could be multiple layers. The prefabricated panel assembly 1000a-c is configured and built so that openings for doors and windows and special panel shapes are completed at the factory, and the simple installation of the prefabricated panel assembly 1000a-c is possible. The prefabricated panel assembly 1000a-c protects the interior spaces and its contents from the exterior climate conditions. An interior of the prefabricated panel assembly 1000a-c is configured to provide sound insulation, physical separation between the interior spaces, and interior structural support when needed.

[0097] In a preferred embodiment, the prefabricated panel assembly 1000a-c is fully assembled off-site and delivered fully assembled. In another embodiment, the components of the prefabricated panel assembly 1000a-c can be shipped separately to be assembled on-site and adjusted as needed. Once a building has been assembled using the prefabricated panel assembly 1000a-c, the building can be finished as one would any building, and exterior finishes and roofing materials as well as interior paint or textures are added. The prefabricated panel assembly1000a-c may also have integral rain screen drainage planes. The prefabricated panel assembly 1000a-c, due to the structural insulated panel interconnecting system 100, may also be designed to be easily dismounted and relocated for extended building life cycles, allowing reuse of the prefabricated panel assembly 1000a-c.

[0098] The second securement and interconnecting apparatus 300, also referred to as the support track 300, comprises at least one support plate 320, which is also referred to as a base plate, top plate, top base plate, bottom base plate, or a mud sill, as shown. The support plate 320 has a tension rod 322 or cable 323 for additional structural connectivity. The support plate 320 is attached to the structural track 310 of the second securement and interconnecting apparatus 300 for connecting the support plate 320 with the structural insulated panel 1200. The structural track 310 can be attached to the panels 1200 by any attachment member 350 or method known and will develop in the art, such as, but not limited to, fasteners, screws, powder driven or actuated fasteners (such as ring shank nails), adhesives, cables, rods, glues, interlocking nubs, sliding and locking edge “tracks”, tongue and groove, quick cam locking devices, and latching mechanism. Further, structural track 310 could be more complex, such as, but not limited to, U or H-shaped members and C and H-shaped tracks in combination with the any connecting method or member known and will develop in the art, such as clips, fasteners, screws, adhesives, rods, and other similar means of connecting known in the art.

[0099] The weather resistive barrier (WRB) membrane 1100 protects the prefabricated panel assembly 1000a-c during shipping and provides a weather resistive barrier until the exterior wall and roof finishes are applied and remains in place to continue to perform this function behind the exterior finishes. It serves to protect the exterior side of the prefabricated panel assembly 1000a-c from weather elements such as wind, water, and heat, but it is vapor permeable and allows drying by evaporation. Any weather resistive and vapor permeable (for northern climates) flexible sheet product known and will develop in the art can be used. The weather resistive barrier membrane 1100 also can be a spray coating or adhesives.

[0100] The structural insulated panel (SIP) 1200 comprises an outer cement board sheet 1210, an insulation layer (a core) 1220, a smart vapor barrier (SVB) 1500, an inner cement board sheet 1230. The structural insulated panel 1200 provides structural frame for load-bearing (such as from seismic, wind, snow, or other live or dead loads) as well as majority of insulation. The structured insulated panel 1200 is preferably fastened and pressed into a single laminated component, so it functions to add significant lateral strength to the wall.

[0101] The insulation layer 1220 is preferably rigid insulation, such as polystyrene (EPS or Styrofoam), extruded polystyrene (XPS), and polyisocyanurate (Poly Iso or ISO), but other types of insulation known and will develop in the art can be used. Preferably, as technology develops, materials with less embodied carbon, such as recycled organic or mineral insulation materials from sources such as hemp, straw, mycelium, etc. will be used. The insulation layer 1220 serves as a core between the outer and inner cement board sheets, and preferably provide a structural coupling between the outer and inner cement board sheets 1210, 1230 and is strong enough to cohesively transfer the loads between the outer and inner cement board sheets 1210, 1230 while providing the desired level of insulation. Preferably, the insulation layer 1220 is able to be assembled and pressed into the structural insulated panel 1200 as one laminated assembly.

[0102] The outer and inner cement board sheets 1210, 1230 are preferably made of magnesium oxide (MgO). The outer and inner cement board sheets 1210, 1230 may also be comprised of magnesium sulfate (MgSO4), other rigid cement board materials or any other material known in the art, such as oriented strand board (OSB) that are treated to be invulnerable to fire and water damage. The outer and inner cement board sheets 1210, 1230 comprised of magnesium oxide are not vapor impermeable, so water vapor can penetrate the wall system and potentially get to locations where the water vapor condenses and even freezes, risking mold, rot, deterioration, loss of thermal resistance properties, and expensive repairs. Having the smart vapor barrier 1500 (also known as “Air Barrier” membrane) stops the moisture vapor from air and water on the more humid side of the panel 1200 (interior room side in northern climates) from migrating into the interior side of the prefabricated panel assembly 1000a-c and generally eliminates air leakage into and out of the prefabricated panel assembly 1000a-c. The smart vapor barrier 1500 preferably is made of material that allows for drying if it senses water. The smart vapor barrier 1500 can be a foam adhesive that also functions as a smart vapor barrier. The structural insulated panel 1200 as designed also uses fewer studs within the structural insulated panel 1200 to limit the number of thermal bridges (less insular), increasing thermal effectiveness. The inner and outer board sheets 1210, 1230 may have sliding and locking board edge “tracks”, which can be considered the structural tracks 210, 310 of the first and second securement and interconnecting apparatuses 200, 300, for rapidly securing the prefabricated panel assembly into place.

[0103] The first securement and interconnecting apparatus 200, also referred to as the structural spline 200 or a structural stud 200, may have two structural tracks 210 forming an H-track 210 (a 2-part stud connecting member) for connecting multiple structural insulated panels 1200 together, or further compose a rectangular corner post 221 with the structural insulated panel 1200. Joists can also be used instead of studs for horizontal or sloping assemblies, such as floors and roofs. The first securement and interconnecting apparatus 200, or the structural spline 200, can be comprised of wood, metal such as steel, fiberglass, reinforced plastic (FRP), recycled plastic, or composite plastic, but other materials known and will develop in the art can be used. As technology develops, organic, recycled, or mineral studs from sources such as hemp, straw, mycelium, recovered plastics, magnesium oxide, etc. can be used. The attachment member 250 can be any connecting method or member known and will develop in the art, such as, but not limited to, fasteners, screws, powder driven or actuated fasteners (such as ring shank nails), adhesives, cables, rods, glues, and also includes more complex fastening means such as, but not limited to, interlocking nubs, tongue and groove, sliding and locking edge “tracks” such as C and H-shaped tracks, quick cam locking devices, latching mechanism, U or H-shaped members, and in combination with the any connecting method or member known and will develop in the art, such as clips, fasteners, screws, adhesives, rods, and other similar means of connecting known in the art. The gypsum board 1300 can be composed of what is known and will develop in the art. As technology develops, organic, recycled, or mineral gypsum boards from sources such as hemp, straw, mycelium, recovered plastics, magnesium oxide, etc. can be used.

[0104] The service cavity 1400 is positioned in between the structural insulated panel 1200 and the gypsum board 1300. The service cavity 1400 is comprised of a stud and a thermal insulation, but can include a smart vapor barrier (SVB) 1500. The stud of the service cavity 1400 can be the same material as the first and second securement and interconnecting apparatuses 200, 300, and similar or same means of connecting used for the first and second securement and interconnecting apparatuses 200, 300 can be used for the stud of the service cavity 1400. The stud of the service cavity 1400 can be structural or non-structural. The location of the smart vapor barrier / s 1500 in the prefabricated panel assembly 1000a-c, whether in the structured insulated panel 1200 or the service cavity 1400, vary according to the needs of the building, especially considering the climate. Having the service cavity 1400 helps to avoid penetrating the smart vapor barrier 1500 of the structural insulated panel 1200, unless absolutely necessary. Desired utility service can be run in the service cavity 1400. Desired utility service can be water or heat piping, electrical wires, data links, and any other utility that may be needed or desired for the purpose of the building. The service cavity 1400 size varies according to the needs of the building. The service cavity 1400 size should be wide enough to accommodate desired utility service runs. In a preferred embodiment, the service cavity 1400 is at least 2 inches of space, but smaller, for example, such as 1¾ inches, or less of space or larger, for example, such as 3¼ inches, or more of space could be used to fit the needs of the project. The service cavity 1400 preferably is filled with additional insulation after desired utility service is run. The additional insulation can be rigid or flexible insulation. The service cavity 1400 size can be set at the construction location instead of off-site in some embodiments of present invention. The service cavity 1400 can be structural or non-structural, depending on the need of a building.

[0105] In reference to FIG. 1, a perspective interior (to a building) view of the roof prefabricated panel assembly 1000a, the wall prefabricated panel assembly 1000b, and the floor prefabricated panel assembly 1000c, assembled together using the structural insulated panel interconnecting system 100 is shown to exemplify how prefabricated panel assemblies 1000a-c are constructed together to form a building. FIG. 1 shows the weather resistive barrier membrane 1100 covering the structural insulated panel 1200 of the roof prefabricated panel assembly 1000a. The internal board facer sheet 1230 of the structural insulated panel 1200 can be seen, and the service cavity 1400 and the gypsum board 1300 of the roof prefabricated panel assembly 1000a are shown. The support plate 320 of the second securement and interconnecting apparatus 300 for connecting the roof prefabricated panel assembly 1000a with the wall prefabricated panel assembly 1000b is the top plate. FIG. 1 shows edges, or peripheries 1240, of the structural insulated panel 1200, the service cavity 1400, and the gypsum board 1300 of the wall prefabricated panel assembly 1000b. The support plate 320 of the second securement and interconnecting apparatus 300 for connecting the wall prefabricated panel assembly 1000b with the floor prefabricated panel assembly 1000c is a base plate 320 in FIG. 1. Furring strips in the service cavities 1400 of the wall and roof prefabricated panel assemblies 1000a-b can be seen. Furring strips can be comprised of wood, metal such as steel, or fiberglass, reinforced plastic (FRP), recycled plastic, and composite plastic, but other materials known and will develop in the art can be used. As technology develops, organic, recycled, or mineral studs from sources such as hemp, straw, mycelium, recovered plastics, magnesium oxide, etc. can be used. The attachment members 250 of the first securement and interconnecting apparatuses 200 of the wall prefabricated panel assembly 1000b is shown as three slots in the wall edge for latches, designed for quick assembly and disassembly. As explained above, other connecting means known and will develop in the art can be used. The structural insulated panel 1200 and the support plate 320, which is a rim joist 320 for attachment to the ground and the support plate 320 of the second securement and interconnecting apparatus 200 of the wall prefabricated panel assembly 1000b, for the floor prefabricated panel assembly 1000c is also shown in FIG. 1. The floor prefabricated panel assembly 1000c in FIG. 1 does not show a service cavity, as service cavity could be removed if not needed. A smart vapor barrier also can be removed if not needed. Additionally, the rectangular corner post 221 of the first securement and interconnecting apparatus 200 is also shown with slots for latches as the attachment member 250 as well. Other connecting means known and will develop in the art can be used with the corner post.

[0106] In reference to FIG. 2, there is shown a top perspective view of the roof prefabricated panel assembly 1000a, the wall prefabricated panel assembly 1000b, and the floor prefabricated panel assembly 1000c of FIG. 1. The weather resistive barrier membranes 1100 of the roof prefabricated panel assembly 1000a, the wall prefabricated panel assembly 1000b, and the floor prefabricated panel assembly 1000c (around the rim joist) can be seen. A corner post 221 and an air barrier of the floor prefabricated panel assembly 1000c are also shown. The smart vapor barrier 1500 does not need to cover the entire surface of the prefabricated panel assembly 1000a-c if the MgO or other boards have an acceptably low permeability level, and could be covering only parts of the prefabricated panel assembly 1000a-c as shown in FIG. 2, where the smart vapor barrier 1500 of the structural insulated panel 1200 of the floor prefabricated panel assembly 1000c is covering only a corner of the floor prefabricated panel assembly 1000c. However, the smart vapor barrier 1500 could cover all of the floor prefabricated panel assembly 1000c in another embodiment. The corner post 221 may also have weather resistive barrier as its core.

[0107] In reference to FIG. 3, an exploded side perspective view of the roof prefabricated panel assembly 1000a, the wall prefabricated panel assembly 1000b, and the floor prefabricated panel assembly 1000c in FIGS. 1-2 are shown. In addition to what are shown in FIGS. 1-2, FIG. 3 more clearly shows a tension rod 322 in the support plate 320 of the second securement and interconnecting apparatus 300 connecting the floor prefabricated panel assembly 1000c to the wall prefabricated panel assembly 1000b and the ground, and, additionally, a mud sill 360 of the floor prefabricated panel assembly 1000c is shown. The tension rod 322 could be a tension cable instead. Other devices that assist with tension and stability can be also used.

[0108] In reference to FIG. 4, a side exterior (to a building) perspective view of the wall prefabricated wall assembly 1000b in FIGS. 1-3 is shown. The exterior weather barrier 1100 of the service cavity 1400 is shown to cover a corner of the service cavity 1400 of the wall prefabricated panel assembly 1000b. The corner post 221 of the first securement and interconnecting apparatus 200 is connected using the attachment member 250 (latches and / or otherwise) of the first securement and interconnecting apparatus 200. Additionally, the tension rod 322 of the support plate 320 (top plate 320 in this example) of the second securement and interconnecting apparatus 300 is also shown to connect with the corner post 221 of the first securement and interconnecting apparatus 200.

[0109] In reference to FIG. 5, a side interior (to a building) perspective view of the wall prefabricated wall assembly 1000b in FIGS. 1-4 is shown. FIG. 5 further shows desired utility service, shown as an electrical switch and an electrical receptacle, on a surface of the service cavity 1400 of the wall prefabricated wall assembly 1000b. Wiring for the electrical switch and the electrical receptacle resides inside the service cavity 1400 (not shown).

[0110] In reference to FIG. 6, a close-up exploded view of an embodiment of the first securement and interconnecting apparatus 200, the structural spline 200, according to disclosure is shown. Here, the attachment member 250 is a latch system 250 (also known as cam locking device). In FIG. 6, two wall prefabricated panel assemblies 1000d-e are shown for connecting. While only one latch system 250 is shown, there can be many latch systems per stud. The wall prefabricated panel assembly 1000d on the left side has the receiving portion of the latch system 250 and the wall prefabricated panel assembly 1000e on the right side has the corresponding latching portion of the latch system 250. The latch system 250 is shown to be screwed to each first securement and interconnecting apparatus 200. However, other attachment means known in the art or may develop in the art can be used, such as adhesives. A handle can be on the latching portion of the latch system 250. In a preferred embodiment, the handle is removed once the latch system 250 has been installed onto the first securement and interconnecting apparatus 200. As shown in FIG. 6, the attachment member 350 for the second securement and interconnecting apparatus 300 and its support plate 320 and structural track 310, shown as base plates in FIG. 6, can be screws. Other connecting means known or will develop in the art can be used, such as, but not limited to, adhesives, rods, cables, glue, nails, tongue and groove, or track. There can be a tension rod 322 and cushion(s) 370, or gasket, between any two support plates 320 to allow for stability and movement, respectively, as shown in FIG. 6. In an embodiment, the outer cement board sheet 1210 and the inner cement board sheet 1230 of the structural insulated panel 1200 may each have protruding edge around a periphery 1240, as can be seen in the wall prefabricated panel assembly 1000d on the left side. As shown in the wall prefabricated panel assembly 1000e on the right side, the structural track 310 of the second securement and interconnecting apparatus 300 can be a bottom channel of a H-shaped track 310, and the top channel of the H-shaped track 310 can be used as an attachment member. In such embodiment, the top channel of the H-shaped track 310 is shaped to fit into the protruding edge of a bottom of the structural insulated panel 1200 and the bottom channel of the H-shaped track 310 is shaped to fit over the support plate 320 so the support plate 320 fits into the interior surface 314 of the web 313 of the structural track 310.

[0111] In reference to FIG. 7A, a close-up exploded view of an embodiment of how two wall prefabricated panel assemblies1000f-g are joined together to allow controlled movement is shown. In such embodiment, the outer cement board sheet 1210 and the inner cement board sheet 1230 of the structural insulated panel 1200 of the prefabricated panel assembly 1000f-g will each have recessed insulation edges around a periphery 1240, forming a channel 310, the structural track 310 of the second securement and interconnecting apparatus 300, between the recessed insulation edge of the outer cement board sheet 1210 and the recessed insulation edge of the inner cement board sheet 1230. The structural track 310 formed is shaped to receive a support plate 320 (top plate) of the second securement and interconnecting apparatus 300. A gasketed movement joint 370 and an L-shaped angle 350, also referred to as an L-shaped clip, is added to the corner of a portion of the structural insulated panel 1200 within the structural track 310 to allow for the support plate 320 (top plate) movement. In an embodiment, the attachment member 350 for the structural track 310 and the support plate 320 (top plate) are screws so there may be no movement. However, the structural track 310 and the support plate 320 (top plate) can be solid rubber or other resilient, synthetic gasket to allow for limited movement and controlled movement between the prefabricated panel assemblies 1000f-g. In an embodiment, the L-shaped angle 350 (also called clip angle) is typically a 6 inches composite channel with top portions of flanges clipped to avoid conflict with the support plate 320 and the structural track 310 (top plate / top track). The support plate 320 and the structural track 310 (top plate / top track) may also be screwed to the L-shaped angle 350. Each wall prefabricated panel assembly 1000f-g further may have a gasketed movement joint as the first securement and interconnecting apparatus 200 (the structural spline 200) in between the L-shaped angles 350 to allow limited movement and shifting. Additionally, a caulk joint or a metallic or plastic expansion joint edge trim material is used to seal adjacent outer and inner cement board sheets 1210, 1230 of multiple prefabricated panel assemblies 1000. A slip plate 380, with an attachment means such as a double nutted bolt or a screw, may also be present on top of or below where support plates (top plates / top tracks) join, as shown in FIG. 7A.

[0112] In reference to FIG. 7B, in an embodiment, the second securement and interconnecting apparatus 300 (the support track 300) may have a structural track 310 that receives a door or window header 320 as or instead of a base plate or a top plate. In such a case, the attachment member 350, shown in FIG. 7B as L-shaped clips and screws 350, would secure the header 320 to the structural track 310 of the second securement and interconnecting apparatus 300 (the support track 300). The header 320 can have core member that is comprised of one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material. The second securement and interconnecting apparatus 300 (the support track 300) also may have a second core member (not visible in FIG. 7B) with tension rod 322. FIG. 22 also shows an embodiment that is similar to that of FIG. 7B, also showing how the first securement and interconnecting apparatus 200 may attach to the header 320 using the L-shaped clips and screws 250 as the attachment member 250.

[0113] In reference to FIGS. 8A-D, an embodiment of the first securement and interconnecting apparatus 200, also referred to as the structural spline 200, is shown. As seen in FIGS. 8B-8D, the first securement and interconnecting apparatus 200 has two structural tracks 210a-b that are back-to-back together, by their exterior surfaces 214 of the webs 213, as an expansion joint (control joint or interlocking spline with a control joint capability) with a core member 220, which is a cushioning layer (or flexible gasket), positioned in between to allow for movement (from wind, earthquake, vibration, etc.) and settling. In the embodiment shown in FIGS. 8A-D, each structural track is C-shaped and has a first flange 211, a second flange 212, and a web 213. The first and the second structural tracks 210a-b are interlocking together to form a H-shaped track with the core member 220 sandwiched between the exterior surface 214 of the web 213 of the first structural track 210a and the exterior surface 214 of the web 213 of the second structural track 210b.

[0114] The first securement and interconnecting apparatus 200 further has a pair of outer retaining edges 241, 242 for each structural track 210. The first outer retaining edge 241 on one side supports an inner cement board sheet 1230 of the structural insulated panel 1200 and the second outer retaining edge 242 on the other side for supporting an outer cement board sheet 1210 of the structural insulation panel 1200. In a preferred embodiment, the outer retaining edge, also referred to as a projecting trim edge, is flexible gaskets that are also adhesive. The first structural track 210a receives a periphery 1240 of a first structural insulated panel 1200 (not shown in FIGS. 8A-D) and the second structural track 210b receives a periphery 1240 of a second structural insulated panel 1200 (not shown in FIGS. 8A-8D).

[0115] In the embodiments shown in FIGS. 8A and 8D, the second structural track 210b has a plurality of interlocking connecting slots 218 on the web 213 of the first structural track 210a has a plurality of interlocking connecting apparatuses 217 on the exterior surface 214 of the web 213. In the embodiments shown in FIGS. 8B-8C, both the first and the second structural tracks 210a-b have a plurality of interlocking connecting slots 218 on the web 213 and a plurality of interlocking connecting apparatuses 217 on the exterior surface 214 of the web 213. The plurality of interlocking connecting apparatuses 217 of the first structural track 210a aligns, inserts, and interlocks with the plurality of interlocking connecting slots 218 of the second structural track 210b through the core member 220 and the plurality of interlocking connecting apparatuses 217 of the second structural track 210b aligns, inserts, and interlocks with the plurality of interlocking connecting slots 218 of the first structural track 210a through the core member 220. The interlocking connecting apparatus can be a nub or a button as shown in FIGS. 8A-8D. The interlocking connecting apparatuses 217 and the interlocking connecting slots 218 can be other means known in the art for connecting or attaching two structural tracks 210 together. In another embodiment of the interlocking spline, insulated rectangular tubular shapes with projecting trim edges are used instead of the C-shaped studs. The tubular shapes also provide locations to install vertical tensioning rods.

[0116] In embodiments shown in FIGS. 8A-8C, the webs 213 of the structural tracks 210a-b each form a protruding portion 230 on each end 215 of the structural tracks 210a-b. The attachment member 250 can attach the protruding portion 250 on each of the end 215 of the structural tracks 210a-b to the plurality of support tracks 300, also referred to as the second securement and interconnecting apparatus 300, as shown in FIGS. 8B and 23. FIG. 23 shows an exploded view of an end of the embodiment of the first securement and interconnecting apparatus 200 shown in FIGS. 8B-8C and how it would receive and attach to a structural insulated panel 1200 and to an embodiment of the second securement and interconnecting apparatus 300. The L-shaped clip 250 and a plurality of screws 250 form the attachment member 250 for attachment to the structural track 310 of the second securement and interconnecting apparatus 300 (the support track 300). Once the first securement and interconnecting apparatus 200 is attached to the structural track 310 of the second securement and interconnecting apparatus 300, the support plate 320 of the second securement and interconnecting apparatus 300 would then be inserted into the interior surface 314 of the web 313 of the structural track 310 of the second securement and interconnecting apparatus 300.

[0117] In an embodiment, if the first securement and interconnecting apparatus 200 are not at the control joint, either insulated rectangular tube shaped or H-shaped structural track 210 of the first securement and interconnecting apparatus 200 are used, with the structural track 210 recessed a halfway into the left panel 1200 and a halfway into the right panel 1200, to give places to glue and screw the MgO parts of the panels 1200 to the first securement and interconnecting apparatus 200. The structural tracks 310 of the second securement and interconnecting apparatus 300, which are horizontal tracks, can either be H-shaped structural track 310 that are initially glued and screwed to the MgO panels 1200 in the shop, or they can be C-shaped track 310 that is thickened to add insulation as a core member or support plate 320 and a place to run a tensioning rod 322. When the panels 1200 are shipped to the job in “ganged units” (multiple panels made into a single larger panel), those C- & H-shaped tracks 310 are already built into the ganged unit, and then on the job site the bottom track 310 at the bottom of the ganged panel receives glue, as does the support plate 320, and then the bottom track 310 for the panel 1200 is set over the support plate 320 and screwed into place using attachment member 350. After the ganged panel 1200 is in place and properly aligned, then the top support plate 320 can be set into the cavity of the top structural track 310, and it's all glued and screwed together.

[0118] In reference to FIG. 9, an embodiment of the wall prefabricated panel assembly 1000 having a service cavity 1400 comprised of a furring strip 1600 that acts as a clamp on an edge of a smart vapor barrier (SVB) 1500 to hold the smart vapor barrier 1500 in place within the service cavity 1400 is shown. Other means known in the art or will develop in the art for attaching or holding the smart vapor barrier 1500 within the service cavity 1400, and even the structural insulated panel (SIP) 1200, can be used. In such embodiment, the furring strip 1600 is a 2-piece, interlocking polymer strip that both provides a service cavity 1400 space of the desired depth and also acts as a permanent retainer to hold the SVB 1500 in place. In the factory assembly, the MgO SIP 1200 is laid on the assembly table, the 2-legged base part of the furring strip 1600 is fastened in place to the studs 300 and splines 200, the SVB 1500 is stretched into position over the face of the panel 1200, and the top part of the furring strip 1600 is snapped into place and fastened with a few screws to keep the top part tightly positioned in place. After the furring strip 1600 and SVB 1500 are in place, the panel 1200 can be shipped to the jobsite where any utilities can be installed, the cavity 1400 filled with insulation, and the final layer of gypsum board 1300 screwed in place. With ½″ thick gypsum board 1300, the furring strips 1600 need to be located at 16″ on center (o.c.) and with ⅝″ thick gypsum board 1300, the furring strips 1600 can be located at 24″ o.c.

[0119] In reference to FIG. 10, a side, exploded, perspective view of an embodiment of the wall prefabricated panel assembly 1000 showing how four smaller pieces of wall prefabricated panel assembly 1000 can be assembled together using an embodiment of the structural insulated panel interconnecting system 100 to form a big wall prefabricated panel assembly 1000 is shown. In this embodiment shown, one second securement and interconnecting apparatus 300 having a top support plate 320 (support plate 320) and another second securement and interconnecting apparatus 300 having a bottom support plate 320 (base plate 320) are used for securing and interconnecting the wall prefabricated panel assembly, as well as a corner post 212. The corner post 212 and the first securement and interconnecting apparatuses 200 (the splines 200, not shown) may have a tensioning rod or cable for vertical uplift restraint. Each piece of the wall prefabricated panel assembly 1000 has an outer cement board sheet 1210 and an inner cement board sheet 1230 with recessed insulation edges, thus having peripheries 1240 of the outer and inner cement board sheets 1210, 1230 form protruding edges that wrap around and are glued and screwed using glue and screws as the attachment members 250, 350 to both the structural splines 200 (the first securement and interconnecting apparatus 200) and the second securement and interconnecting apparatus 300 (support track 300), which includes the structural tracks 310 and support plates (top and bottom / base). Individual first securement and interconnecting apparatus 200 (structural splines 200) and corner posts are connected to the top and bottom support plates 320 with U-shaped short structural tracks 310, also referred to as U-shaped polymer clips 310, where a larger short structural track 310 can be used for corner posts and a smaller short structural track 310 can be used to connect individual first securement and interconnecting apparatuses 200 and second securement and interconnecting apparatuses 300 to the top and bottom support plates 320. A differently shaped clip, such as an L-shaped clip (or an angle) can be used as attachment members 250, 350. Structural tracks, clips, or angles can be made of fiberglass, polymer, metal, or any other material known in the art. An insulated, overlapping connecting support plate 320 wraps around the main lower support plate 320 to provide ease of alignment and additional strength at the base of the wall. An inverted upper connecting member can also be used for additional strength at the top of the wall. The corner post 212 in this embodiment has a hollow body that is filled with insulation.

[0120] In reference to FIG. 11, a side, exploded, perspective view of an embodiment of the wall prefabricated panel assembly 1000b and the floor prefabricated panel assembly 1000c showing how the prefabricated panel assemblies would assemble together using the structural insulated panel interconnecting system 100 is shown. The wall prefabricated panel assembly 1000 shows a room-side gypsum or MgO board facer sheet 1300 with holes for electrical receptacles, an insulation layer, a furring strip 1600, and a smart vapor barrier 1500. The wall prefabricated panel assembly 1000b further shows a structural insulated panel 1200 with an inner cement board sheet 1230, an insulation layer 1220, an outer cement board sheet 1210, and an exterior weather resistive barrier membrane 1100. The first securement and interconnecting apparatus 200 and the second securement and interconnecting apparatus 300 of the structural insulated panel interconnecting system 100 are also shown. In this embodiment, shorter structural tracks 310, also referred to as U-shaped stud clips, attaches top and bottom support plates 320 to the structural insulated panel 1200 as shown. Screws are used as attachment members 250, 350 for the first and second securement and interconnecting apparatuses 200, 300. Additional attachment members can also be used as shown in FIG. 10. Additionally, a siding on the outside of the wall prefabricated panel assembly 1000b is shown. The floor prefabricated panel assembly 1000c shows an internal board facer sheet 1230, an insulation layer 1220, and an outer cement board sheet 1210 of a structural insulated panel 1200. A support plate 320 of the second securement and interconnecting apparatus 300 attaches to the structural insulated panel 1200 of the floor prefabricated panel assembly 1000c. In this embodiment, a splice plug 1221 with a tension rod 1222 is added to each support plate 320 for additional security and can also be located horizontally at the top support plates 320 and vertically at selected structural splines 200 and corner posts 212.

[0121] In reference to FIG. 12, a side, exploded, perspective view of an embodiment of the wall prefabricated panel assembly 1000 is shown. The wall prefabricated panel assembly 1000 shows an outer non-combustible and carbon sequestering board sheet 1210, an insulation layer 1220, a smart vapor barrier 1500, an additional layer of insulation in the service cavity 1400, and an inner non-combustible and carbon sequestering board sheet 1230.The first securement and interconnecting apparatus 200 and the second securement and interconnecting apparatus 300 of the structural insulated panel interconnecting system 100 are shown, with the first securement and interconnecting apparatus 200 shown in the structural insulated panel 1200. In a preferred embodiment, the structural insulated panel 1200 further comprises a phase change layer that changes phase to meet the thermal needs of the building. For example, in cold weather, the phase changing layer may absorb heat during daytime hours and then release the heat at nighttime when it is needed for additional comfort. Further, in such embodiment, a support plate of the second securement and interconnecting apparatus 300 may also have an insulation layer and a smart vapor barrier within and may further comprise a tension rod or cable. The wall prefabricated panel assembly 1000 in FIG. 12 additionally has a header shaped to be a structural track 310 for openings such as windows and doors. The structural track 310, or the track header 310, receives a support plate 320 that is slopped for attachment to a roof prefabricated panel assembly 1000. The slopped support plate 320 is also shown in FIGS. 14, 18B, 26, and 27. The track header 310 is comprised of polymer, or any other material known or that will develop in the art. The track header 310 can also have an insulation layer and a smart vapor barrier. Additional insulated connecting members or attachment members between the panels and the plates may also be used, as well as both vertical and horizontal tension rods or cables. Further, FIG. 12 shows a non-combustible wrap around exposed portions of the first securement and interconnecting apparatus 200 (the structural spline) where window and door openings occur if / as needed for finish and fire-resistance reasons. In such embodiment as shown in FIG. 12, a room-side insulation layer is comprised of rigid, high-R materials that may be directly fastened to and routed for desired utility service, minimizing the need for additional furring members in the service cavity 1400.

[0122] In reference to FIG. 13, a side exploded perspective view of an embodiment of the wall prefabricated panel assembly 1000 showing how two wall prefabricated panel assemblies 1000b and one floor prefabricated panel assembly 1000c are combined is shown. The first securement and interconnecting apparatus 200 and the second securement and interconnecting apparatus 300 of the structural insulated panel interconnecting system 100 are also shown. In such embodiment, the second securement and interconnecting apparatus 300 has an H-shaped bracket as the structural track 310. The structural track 310 fits between the support plate 320 (base plate 320) and a bottom of the structural insulated panel 1200 at both floor levels and at the roof level. The structural insulated panel 1200 has recessed insulation edges around a periphery 1240 that allows the H-shaped structural track 310 to fit into the bottom. A polymeric header is also used for support.

[0123] In reference to FIG. 14, a side, exploded, perspective view of an embodiment of the wall prefabricated panel assembly 1000 is shown. The wall prefabricated panel assembly 1000 shows a structural insulated panel 1200 comprised of an outer non-combustible and carbon sequestering board sheet 1210 (referred to as skins in FIG. 14) and the smart vapor barrier 1500 and the phase change layer (together referred to as structural insulating cores 1220). The wall prefabricated panel assembly 1000 further comprises the service cavity 1400. The wall prefabricated panel assembly 1000 can have a sill panel with insulated polymer shapes for varying window and wall configurations, and a structural header over openings. The sill panel can have a tension rod if needed. The structural header in this embodiment is also considered a wall prefabricated panel assembly 1000, as it can have thermal and control layers such as the smart vapor barrier, the phase change layer, and with insulating liners can be used at window and door openings for further insulation. the thermal insulation. In FIG. 14, the structural header is a polymer header with thermal control layers and can also have a tension rod as needed. A non-combustible cementitious panel or skin may be used. FIG. 14 shows two support plates 320 for the second securement and interconnecting apparatus 300, the top support plate 320 and the bottom support plate 320. The top support plate 320 shown is an adjustable tapered structural polymeric top plate with insulated cores and tension rod 322, if needed. The structural track 310 of the second securement and interconnecting apparatus 300 shown in FIG. 14 for the top support plate 320 is a polymer connecting track 310 with an insulating core and a tension rod. The base support plate 320 is shown in FIG. 14 as having anchors and tensioning rods, if needed. The structural track 310 of the second securement and interconnecting apparatus 300 for the bottom support plate 320 in FIG. 14 is a polymer connecting track 310 with an insulating core and a tension rod, if needed. FIG. 14 also shows that the first securement and interconnecting apparatus 200 can also have insulating core members 220 and tensions rods 222, if needed.

[0124] In reference to FIG. 15, a side, exploded, perspective view of an embodiment of the wall prefabricated panel assembly 1000 is shown to show how the first securement and interconnecting apparatus 200 and the second securement and interconnecting apparatus 300 can connect the structural insulated panel 1200. The support plates 320 of the second securement and interconnecting apparatus 300 shown in FIG. 15 are the top support plate 320 and the bottom support plate 320 (also referred to as the bottom plate). The top support plate 320 as shown in FIG. 15 further comprises tension rods 322 and gasketed spring lock ends as attachment member 350. The top support plate 320, when in use in a building, can be fastened to a floor (can be a floor prefabricated panel assembly) or a roof (can be a roof prefabricated panel assembly) above the top support plate 320. The structural track 310 of the second securement and interconnecting apparatus 300 for the top support plate 320 is a U-shaped track (referred to as a top structural track 310) as shown in FIG. 15. The U-shaped track 320 can further comprise tension rods, gasketed butt ends, clips, and a fastener, such as an adhesive or glue, or any other fastening means known in the art as the attachment member 350. A clip may be an L-shaped clip 250, 350 as shown, preferably 2×2×3 in dimension, which can attach to both the support plate 320 and an adjacent structure, such as a structural track (not shown in FIG. 15), core member 220, or a corner post 212 of the first securement and interconnecting apparatus 200, another structural insulated panel 1200, or an adjacent wall prefabricated panel assembly 1000. The top U-shaped structural track 310 fastens the top support plate 320 with the structural insulated panel 1200.

[0125] The bottom support plate 320 as shown in FIG. 15, when in use in a building, can be directly bolted to a floor structure (can be a floor prefabricated panel assembly) or foundation. The structural track 310 for the support plate 320 is also the U-shaped track (referred to as a bottom structural track 310) as shown in FIG. 15. The bottom U-shaped structural track 310 for the bottom support plate 320 can further comprise tension rods, clips, and a fastener, such as an adhesive or glue, or any other fastening means known in the art as the attachment member 350, similar to the top U-shaped structural track 310. The U-shaped structural track 310 fastens the bottom support plate 320 with the structural insulated panel 1200. In the embodiment shown, the outer cement board sheet (referred to as a cement panel) 1210 of the structural insulated panel 1200 and the inner cement board sheet 1230 form recessed insulation edges at peripheries 1240 that are fastened over the bottom structural track 310 (the U-shaped track). Recessed insulation edges at peripheries 1240 are also fastened to the first securement and interconnecting apparatus 200, and an attachment member 250 for the first securement and interconnecting apparatus 200 can be comprised of clips and fasteners, such as an adhesive or screws, or any other fastening means known in the art. A turnkey locking mechanism and an adhesive expansion join gasket as the attachment member 250 may be used on a joining edge to join two wall prefabricated panel assembly 1000 or two structural insulated panels 1200 together within a wall prefabricated panel assembly 1000.

[0126] In references to FIGS. 16A-16D, various embodiments of the structural track 210a-d of the first securement and interconnecting apparatus 200 (the structural spline 200) of the structural insulated panel interconnecting system 100 and the attachment members 250 for the first securement and interconnecting apparatus 200 are shown. All embodiments of the structural track 210a-d have same basic structure. The basic structure for a structural track 210a-d includes a first flange 211, a second flange 212, and a web 213 that connects the first flange 212 and the second flange 212, and a pair of outer retaining edges 241, 242. In the views shown in FIGS. 16A-D, only the first outer retaining edge 241 for each structural track 210a-d is visible. In the embodiment shown in FIGS. 16B-16D, the structural track 210 further comprises a core member 220 of various thicknesses as needed for the purpose of the building. The core member may be comprised of one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material. As shown in FIG. 16A, an embodiment of the structural track 210 may not have a core member. The core member 220 may further have one or more tension rods 222 as shown in FIG. 16D, or it can have tension cables. In the embodiments shown in FIGS. 16A-16D, each end 215 of the web 213 and the core member 220, if any, form a protruding portion 230 on the structural track 210. In such embodiments, the attachment members 250 attach the protruding portion 230 on the ends 215 of the structural tracks 210 to the plurality of support tracks 300 (the second securement and interconnecting apparatus 300), as shown in FIG. 23. As shown in FIG. 8D, some embodiments of the structural track 210 may not have protruding portions.

[0127] In reference to FIGS. 17A-17B and 21A-21B, embodiments of the first securement and interconnecting apparatus 200 (the structural spline 200) for corners are shown. Such embodiments have a first structural track 210a for receiving a periphery 1240 of a first structural insulated panel 1200, a second structural track 210b for receiving a periphery 1240 of a second structural insulated panel 1200, a first core member 220a parallelly attached to the exterior surface 214 of the web 213 of the first structural track 210a, and a second core member 220b parallelly attached to the exterior surface 214 of the web 213 of the second structural track 210b. Such embodiments further comprise a rectangular corner post 221 attached to the first core member 220a at a first side and to the second core member 220b at a second side adjacent the first side. The first core member 220a, the second core member 220b, and the rectangular corner post 221 each comprises one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material.

[0128] In some embodiments, and as shown in FIGS. 17A-17B, the first securement and interconnecting apparatus 200 (the structural spline 200) for corners may further have at least one corner post cap 225. The corner post cap 225 has rectangular body with a rectangular slot on a side of the body facing the ends of the rectangular post 221 for aligning and fitting on a top or a bottom surface of the rectangular corner post 221. The corner spline cap may have a core within the body, comprising one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material. Further, as shown in FIGS. 17A-17B, the corner spline cap 225 core can further have at least one protruding portion 226 on at least one side of the body, and the protruding portions 226 may have tension rods 227. However, the protruding portion 226 can be optional as shown in FIGS. 21A-21B, where corner post cap 225 with holes are shown for accepting tension rods but no protruding portions 226 are present. Attachment members 250 can be similar to those mentioned for other embodiments of the first securement and interconnecting apparatus 200 (the structural spline 200), such as screws and L-clips as shown in FIGS. 17A-17B and 21A-21B. As shown in FIG. 17A, the rectangular corner post 221 may have tension rods 222 or tension cables 223 for strength and stability. Outer cover board 224 can be used to cover the sides of the rectangular post 221 that the structural tracks 210a-b did not attach to. FIGS. 21A-21B shows an example with four tension rods within the rectangular corner post 221 of the first securement and interconnecting apparatus 200 (the structural spline 200) for corners.

[0129] In reference to FIG. 18A, a close-up perspective view of embodiments of the second securement and interconnecting apparatus 300 (the support track 300) of the structural insulated panel interconnecting system 100, showing how the structural tracks 310 can be H-shaped or U-shaped. The structural track 310, whether H-shaped or U-shaped, has a first flange 311, a second flange 312, and a web 313 connecting the first flange 311 and the second flange 312. The second securement and interconnecting apparatus 300 (the support track 300) further has at least one support plate 320, or support plate like components 320 such as mud sills and headers, which can attach to an interior surface of the web 313 and extend along the structural track 310. In a preferred embodiment, the second securement and interconnecting apparatus 300 (the support track 300) has at least a pair of outer retaining edges 341, 342 configured to support protruding edges of the periphery 1240 of the structural insulated panel 1200, as shown in FIG. 18A for the H-shaped structural track 310 for the wall prefabricated panel assembly 1000b. A first outer retaining edge 341 extends perpendicular to the first flange 311 of the structural track 310 and a second outer retaining edge 342 extends perpendicular to the second flange 312 of the structural track 310. The attachment member 350 for securing the second securement and interconnecting apparatus 300 (the support track 300) to the structural insulated panel 1200 is not shown in FIGS. 18A-18B but was described and shown throughout the application.

[0130] The second securement and interconnecting apparatus 300 (the support track 300) attached to the floor prefabricated panel assembly 1000c in FIG. 18A, often described as a rim joint, has a U-shaped structural track 310, and has the parts described above. As shown, the core member of the support plate 320 can have one or more tension rods 322. In some embodiments, the structural track 310 may further comprise a core member that can accommodate tension rods.

[0131] In embodiments where the structural tracks 310 can be described as H-shaped as shown attached to the wall prefabricated wall assembly 1000b in FIG. 18A, the second securement and interconnecting apparatus 300 (the support track 300) has a first structural track 310a for receiving the bottom periphery 1240 of the structural insulated panel 1200, and a second structural track 310b for receiving one of a mud sill 320 (or a base support plate) and a periphery of a second structural insulated panel 1200. The attachment member 350 already discussed previously can be used for attaching the first structural track 310a to the structural insulated panel 1200 and the second structural track 310b to one of the mud sill 320 (or the base support plate) and the periphery of the second structural insulated panel 1200. In the embodiment shown, the first and second structural track 310a-b share the same web 313 and the mud sill 320 (or a base support plate) is received and attached to the interior surface of the web 313 of the second structural track 310b. As shown, the core member of the support plate 320 can have one or more tension rods 322. In some embodiments, the structural track 310 may further comprise a core member that can accommodate tension rods. FIG. 24 also shows H-shaped second securement and interconnecting apparatus 300 as described, showing how the attachment member 250 can be screws.

[0132] FIG. 18B is a close-up perspective view of another embodiment of the second securement and interconnecting apparatus 300 (the support track 300) attached on the top periphery 1240 of the structural insulated panel 1200 of the wall prefabricated panel assembly 1000b, for use with a roof prefabricated panel assembly 1000a. Embodiment of the second securement and interconnecting apparatus 300 (the support track 300) as shown as a H-shaped structural track 310 that has a first structural track 310a for receiving and attaching to the structural insulated panel 1200 and has a pair of outer retaining edges 341, 342 for holding the outer and inner panels 1210, 1230 that form the periphery 1240 of the structural insulated panel 1200. The second structural track 310b receives and attaches to a support plate 320a, which further attaches to a triangular shaped support plate 320b for supporting and connecting to the roof prefabricated panel assembly 1000a. FIG. 27 also shows another embodiment, where a U-shaped structural track 310 that has a core member with tension rod built in is used instead of the H-shaped second securement and interconnecting apparatus 300 (the support track 300).

[0133] In reference to FIGS. 19A-19C, and 20, FIG. 19A, various perspective views of some of the embodiments of the first and second securement and interconnecting apparatuses 200, 300 (the structural splines 200 and the support track 300) of the structural insulated panel interconnecting system 100 and some structural insulated panels 1200 and their components are shown, which were discussed in detail in preceding paragraphs.

[0134] FIG. 25 is a perspective view of an embodiment of a core member for the prefabricated panel assembly.

[0135] FIG. 26 is a close-up perspective view of embodiments of the second securement and interconnecting apparatus 300, where the recess or channel between the protruding edges of the structural insulated panel may be used as “the structural track”, and the support plate 320 can attach into the channel instead.

[0136] In reference to FIGS. 28A-28C, the second securement and interconnecting apparatus 300, or the support track 300, has a plurality of tension rod anchors 500 for receiving and securing tension rods 222 of the plurality of first securement and interconnecting apparatuses 200, or the structural splines 200, or a plurality of cable anchors 500 for receiving and securing tension cables 223 of the plurality of first securement and interconnecting apparatuses 200, or the structural splines 200. Thus, the plurality of tension rod or tension cable anchors 500 acting as attachment members 250 that attach the plurality of first securement and interconnecting apparatuses 200 to one or more second securement and interconnecting apparatuses 300 in the structural insulated panel interconnecting system 100.

[0137] As shown in FIG. 28B, the second securement and interconnecting apparatus 300, or the support track 300, can be shaped to fit the tension rod or cable anchors 500, either by molding into the second securement and interconnecting apparatus 300, or the support track 300, spaces 510 for the tension rod or cable anchors or by cutting out the tension rod or cable anchor shapes 510 onto the surface of the second securement and interconnecting apparatus 300, or the support track 300. The tension rod or cable anchors 500 can be then attached by any means known in the art, such as adhesives and screws.

[0138] Existing computer software such as MiTek Sapphire can be used to design the prefabricated panel assembly. A computerized saw or power hand tool can be used to pre-cut components of the prefabricated panel assembly, according to the needs of the construction project. For example, the splines and other structural studs can be pre-cut with a computerized saw or with power hand tools to suit the panel sizes and configurations according to a building design. The structural panel and service cavity parts can also be made with powered hand tools to sizes to meet the needs of the building design. It is possible to first produce many structural insulated panels of the same size, and then specially configure some of the structural insulated panels for doors, windows, corners, etc. The structural insulated panels can be fitted with the latches and cabling / rod position materials. The service cavity is assembled in sizes to fit the structural insulated panels.

[0139] The structural insulated panels can be assembled either by hand or by using automated machinery. The steps of making the structural insulated panels can be: laying the outer cement board sheet flat on a table configured to aid in position of parts as the parts are assembled, affixing an insulation layer and a smart vapor barrier (with or without furring members depending upon the system design being utilized), then adhering the outer cement board sheet, placing the structural stud and other structural members (such as headers) into the gaps, pressing the assembled structural insulated panel, and detailing the assembled structural insulated panel (Ex. for acceptance of other edge and face materials, such as recessing the foam in the panel edges to accept splines and support plates). A weather resistive barrier can be applied to the exterior facing side of the structural insulated board after lamination and pressing and prior to shipping.

[0140] The service cavity can be assembled by hand or by automation. One method of making the service cavity is: installing the smart vapor barrier, and fastening the furring strips to the panel, installing utility service, and filling the service cavity with insulation. If structural insulation is used, then the furring strips are typically only used at the perimeter of the panel. The service cavity is then sealed with the gypsum board at the jobsite.

[0141] For designing and building customized versions of the prefabricated panel assembly, a prefabricated panel assembly design software containing climate data is preferably used to calculate the total required thicknesses of the prefabricated panel assembly to meet the project requirements, considering climate needs required thermal and air infiltration performance levels of the building envelope and the windows and doors. The prefabricated panel assembly design software can also be used to adjust designs for the prefabricated panel assembly as needed to achieve a balance between cost and performance. The prefabricated panel assembly design software preferably is used to calculate the optimum amount of insulation desired. The prefabricated panel assembly design software can be used to design mechanical systems that eliminate traditional furnaces and air conditioning systems, resulting in less initial costs, and less energy usage over time in comparison to conventional buildings not built with the prefabricated panel assemblies or utilizing Passive House design approaches. The prefabricated panel assembly design software can be used to create fabrication drawings and to send instructions to smart devices such as “smart saws” and CNC tools. The prefabricated panel assembly design software can perform other architectural analyses, such as solar gain and fenestration (windows and doors) sizing and assessment, in 3D virtual reality format. The prefabricated panel assembly design software preferably has Artificial Intelligence (AI) to assist in designing the prefabricated panel assembly.

[0142] The prefabricated panel assembly design software is preferably linked to local building codes and updates automatically as codes change. Further, the prefabricated panel assembly design software can search the web for new building products, prices, where to purchase, availability, how they perform, how “green” they are, and automatically include building material recommendations to the architect. The prefabricated panel assembly design software preferably has artificial intelligence capabilities, and learn “how” the architect designs, such as contemporary, classical, utilitarian, etc. and include suggestions, changes, locations for building materials, HVAC runs, where to put heat pump units, where to run wires, ducts, etc. The prefabricated panel assembly design software can review plans and learn the best places to put these, minimizing materials by placing them correctly, etc. The prefabricated panel assembly design software can preferably track energy credit points. For example, city of Edmonds now requires 5 energy credits for small addition - through insulation, heat pump, less windows / openings, windows with higher R value, etc.

[0143] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0144] The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.”

[0145] The phrase “and / or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and / or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and / or” clause, whether related or unrelated to those elements specifically identified.

[0146] As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when separating items in a list, “or” or “and / or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,”“one of,”“only one of,” or “exactly one of.”

[0147] As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified.

[0148] It should also be understood that, unless clearly indicated to the contrary, in any methods claimed herein that include more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited.

[0149] In the claims, as well as in the specification above, all transitional phrases such as “comprising,”“including,”“carrying,”“having,”“containing,”“involving,”“holding,”“composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to.

[0150] While several inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and / or structures for performing the function and / or obtaining the results and / or one or more of the advantages described herein, and each of such variations and / or modifications is deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and / or configurations will depend upon the specific application or applications for which the inventive teachings is / are used. Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and / or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and / or methods, if such features, systems, articles, materials, kits, and / or methods are not mutually inconsistent, is included within the inventive scope of the present disclosure.

[0151] Having thus described the various embodiments of the invention, what is claimed as new and desired to be protected by letters patent is a structural insulated panel interconnecting system with a first securement and interconnecting apparatus (a structural spline), a second securement and interconnecting apparatus (a support track), an attachment member for securing the first securement and interconnecting apparatus to the structural insulated panel and the second securement and interconnecting apparatus, and an attachment member for securing the second securement and interconnecting apparatus to the structural insulated panel.

Examples

Embodiment Construction

[0090]The disclosed subject matter will become better understood through review of the following detailed description in conjunction with the figures. The detailed description and figures provide example embodiments of the invention described herein. Those skilled in the art will understand that the disclosed examples may be varied, modified, and altered without departing from the scope of the invention described herein.

[0091]Throughout the following detailed description, various examples of the structural insulated panel interconnecting system having at least a first securement and interconnecting apparatus (a structural spline) and at least a second securement and interconnecting apparatus (a support track) for securing and interconnecting prefabricated panel assemblies are provided. Related features in the examples may be identical, similar, or dissimilar in different examples. For the sake of brevity, related features will not be redundantly explained in each example. Instead, t...

Claims

1. A structural insulated panel interconnecting system comprising:at least a first securement and interconnecting apparatus comprising:at least a first structural track configured to receive a first periphery of a structural insulated panel, the first structural track comprising:a first flange;a second flange; anda web connecting the first flange and the second flange; andat least a pair of outer retaining edges configured to support protruding edges of the first periphery of the structural insulated panel, whereina first outer retaining edge extends perpendicular to the first flange of the first structural track and a second outer retaining edge extends perpendicular to the second flange of the first structural track;at least a second securement and interconnecting apparatus comprising:at least a second structural track configured to receive a second periphery of the structural insulated panel and an end of the first structural track of the first securement and interconnecting apparatus, the second structural track comprising:a first flange;a second flange; anda web connecting the first flange and the second flange;at least one support plate attached to an interior surface of the web and extending along the second structural track; andat least a second pair of outer retaining edges configured to support the protruding edges of the second periphery of the structural insulated panel, whereina third outer retaining edge extends perpendicular to the first flange of the second structural track and a fourth outer retaining edge extends perpendicular to the second flange of the second structural track;an attachment member for securing the first securement and interconnecting apparatus to the structural insulated panel and the second securement and interconnecting apparatus; andan attachment member for securing the second securement and interconnecting apparatus to the structural insulated panel.

2. The structural insulated panel interconnecting system of claim 1, wherein the web of the first structural track of the first securement and interconnecting apparatus form a protruding portion on each end of the first structural track, and the second track of the second securement and interconnecting apparatus is configured to receive the protruding portion on one end of the first structural track of the first securement and interconnecting apparatus.

3. The structural insulated panel interconnecting system of claim 1, wherein the first securement and interconnecting apparatus further comprisesat least one core member attached to an exterior surface of the web of the first structural track and extending along the first structural track.

4. The structural insulated panel interconnecting system of claim 3, wherein the core member and the web of the first structural track of the first securement and interconnecting apparatus form a protruding portion on each end of the first structural track, and the second track of the second securement and interconnecting apparatus is configured to receive the protruding portion on one end of the first structural track of the first securement and interconnecting apparatus.

5. The structural insulated panel interconnecting system of claim 3, wherein the core member of the first securement and interconnecting apparatus comprises one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material.

6. The structural insulated panel interconnecting system of claim 3, wherein the core member of the first securement and interconnecting apparatus further comprises a tension rod.

7. The structural insulated panel interconnecting system of claim 1, wherein the attachment member for securing the first securement and interconnecting apparatus to the structural insulated panel and the second securement and interconnecting apparatus and the attachment member for securing the second securement and interconnecting apparatus to the structural insulated panel comprises one or more of a plurality of screws, a plurality of latches, at least one pair of L-shaped clips, and an adhesive.

8. A structural spline for securing and interconnecting structural insulated panels, the structural spline comprising:at least one structural track configured to receive a periphery of a structural insulated panel, the structural track comprising:a first flange;a second flange; anda web connecting the first flange and the second flange;at least a pair of outer retaining edges configured to support protruding edges of the periphery of the structural insulated panel, whereina first outer retaining edge extends perpendicular to the first flange of the structural track and a second outer retaining edge extends perpendicular to the second flange of the structural track; andan attachment member for securing the structural spline to the structural insulated panel and a plurality of support tracks, the attachment member comprising one or more of a plurality of screws, a plurality of latches, at least one pair of L-shaped clips, and an adhesive.

9. The structural spline of claim 8, wherein the web of the structural track forms a protruding portion on each end of the structural track, and the attachment member attaches the protruding portion on one end of the structural track to the plurality of support tracks.

10. The structural spline of claim 8, wherein the structural spline further comprisesat least one core member attached to an exterior surface of the web of the structural track and extending along the structural track, and wherein the core member comprisesone or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material.

11. The structural spline of claim 10, wherein the core member and the web of the structural track form a protruding portion on each end of the structural track, and the attachment member attaches the protruding portion on one end of the structural track to the plurality of support tracks.

12. The structural spline of claim 10, wherein the core member further comprises a tension rod.

13. The structural spline of claim 10, wherein the at least one structural track comprisesa first structural track for receiving a periphery of a first structural insulated panel anda second structural track for receiving a periphery of a second structural insulated panel, wherein the first and the second structural tracks interlocking together to form a H-shaped track with the core member sandwiched between the exterior surface of the web of the first structural track and the web of the second structural track, the web of the first structural track and the web of the second structural track each comprising:a plurality of interlocking connecting apparatuses on the exterior surface, anda plurality of interlocking connecting slots, wherein the plurality of interlocking connecting apparatuses of the first structural track aligns, inserts, and interlocks with the plurality of interlocking connecting slots of the second structural track through the core member and the plurality of interlocking connecting apparatuses of the second structural track aligns, inserts, and interlocks with the plurality of interlocking connecting slots of the first structural track through the core member.

14. The structural spline of claim 10, wherein the at least one structural track comprises:a first structural track for receiving a periphery of a first structural insulated panel anda second structural track for receiving a periphery of a second structural insulated panel,the at least one core member comprises:a first core member parallelly attached to the exterior surface of the web of the first structural track, anda second core member parallelly attached to the exterior surface of the web of the second structural track, andthe structural spline further comprises a rectangular corner post attached to the first core member at a first side and to the second core member at a second side adjacent the first side, wherein the first core member, the second core member, and the rectangular corner post each comprises one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material.

15. The structural spline of claim 14, wherein the structural spline further comprises at least one corner post cap, the corner post cap comprising:a rectangular body;a rectangular slot on a side of the body for aligning and fitting on a top or a bottom surface of the rectangular corner post;a core within the body, comprising one or more of a cushioning layer, a phase change layer, a smart vapor barrier, an air flow control material, an insulation layer, a moisture control material, and a thermal control material; andat least one tension rod.

16. The structural spline of claim 15, wherein the core comprises at least one protruding portion on at least one side of the body.

17. The structural spline of claim 14, wherein the rectangular corner post further comprises at least one tension rod.

18. A support track for securing and interconnecting structural insulated panels and a plurality of structural splines, the support track comprising:at least one structural track configured to receive a periphery of a structural insulated panel and a portion of the plurality of structural splines, the structural track comprising:a first flange;a second flange; anda web connecting the first flange and the second flange;at least one support plate attached to an interior surface of the web and extending along the structural track;at least a pair of outer retaining edges configured to support protruding edges of the periphery of the structural insulated panel, wherein a first outer retaining edge extends perpendicular to the first flange of the structural track and a second outer retaining edge extends perpendicular to the second flange of the structural track; andan attachment member for securing the support track to the structural insulated panel, the attachment member comprising one or more of a plurality of screws, a plurality of latches, at least one pair of L-shaped clips, and an adhesive.

19. The support track of claim 18, wherein the support plate further comprises a tension rod.

20. The support track of claim 18, wherein the structural track further comprises:a first structural track for receiving the periphery of the structural insulated panel,a second structural track for receiving one of a mud sill and a periphery of a second structural insulated panel, andan attachment member for attaching the second structural track to one of the polymer mud sill and the periphery of the second structural insulated panel.

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