Structural insulated panel

Abstract: A generally flat structural panel includes a center foam core and opposed outer facings, or sheets, with a metal insert disposed about and attached to the edges of the core and at least one of the outer facings. The metal edge insert provides high strength for the insulated foam panel, eliminates the need for structural members such as studs which act as thermal conductors, and facilitates coupling between adjacent panels, ceilings and floors using various connection arrangements. The structural insulated panels also form the basis of a modular construction system that allows for the use of standard size inside and outside panels of the same size which form a grid in which the outside panels always enclose an area that is a multiple of the module. In one embodiment, a lateral surface of the foam core is provided with a linear array of recesses, or grooves, and a facing is attached to that surface in the field to permit electrical wire routing in the recesses, as required, at the construction site. In another embodiment, metal strips attached to the surface of the core and adapted for secure attachment to a facing such as of drywall provide a space between the foam core and drywall sheet for wire routing.

Abstract: A generally planar structural insulated panel for use in the wall of a building structure includes an inner core of insulating material such as plastic foam. Disposed on and attached to opposed surfaces of the insulating core are outer facings in the form of thick sheets of paper impregnated with plastic such as urethane, polystyrene or polyisocyanurate. The plastic impregnated paper (PIP) sheets are 0.14″ to 0.70″ thick and extend several inches beyond the edges of the panel's insulating core. The PIP sheets provide the panel with high tensile strength and the peripheral edges of the PIP sheets are adapted to receive coupling pins such as nails, screws or staples for mounting the panel to 2× dimensional lumber members in the building structure. The high tensile strength of the PIP sheets also provides secure mounting of the panel to the adjacent structural members. Compression struts are provided within the panel's insulating foam core and inside the panel's outer PIP facings to accommodate large axial loading on the panel. The inner PIP sheet may have attached thereto a gypsum or cementous composite sheet to provide a finished panel when installed in a building structure. Adjacent PIP facings of a pair of structural panels may be arranged in an overlapping manner and connected to a structural member such as a spline or stud to provide a high strength, sealed connection between the panels.

Abstract: A generally planar structural insulated panel for building construction includes interior and exterior facings of weather resistant plastic impregnated paper (PIP) disposed on opposed outer surfaces of an inner insulating core such as of plastic foam or an agricultural product such as wheatboard or strawboard. Spaced elongated, linear studs are attached to either the outer or inner surface of one or both of the PIP facings. The spaced studs, which are preferably comprised of metal or wood, increase the panel's strength, facilitate connecting the panel to a building structure in a secure manner, and facilitate attachment of a structural facing such as of gypsum or cementous composite or exterior siding to the panel. When attached to the inner surface of a PIP facing, the stud is disposed in the panel's insulating core. When disposed on the outer surface of a PIP facing, the studs provide a gap between a PIP facing and an outer facing such as of exterior siding to allow for water drainage. In one embodiment, slots are provided between the insulating core and the interior and exterior facings on one or more edges of the panel or about the entire periphery of the panel for receiving a metal C-shaped channel, or spline. The peripheral C-shaped channel substantially increases panel strength, and facilitates connecting adjacent panels together as well as installing the panel in a building structure with or without the use of 2× dimensional structural lumber.

Abstract: A generally planar, structural insulated panel for building construction includes a pair of outer facings disposed on opposed surfaces of a plastic foam core. One of the outer facings is of a gypsum or cementous composite for use on the panel's inner surface, while the other outer facing is of oriented strand board (OSB) or other conventional building material which forms the panel's outer surface. Disposed between and laminated to the inner surface of the gypsum or cementous composite facing and the plastic foam core by a conventional bonding agent is a sheet of paper impregnated with urethane or polyisocyanurate plastic. The impregnated sheet of paper serves as a vapor barrier near the panel's inner surface to prevent moisture from permeating from the warm interior of the structure through the plastic foam insulation to the outside. The plastic impregnated sheet of paper bonded to the foam core and the panel's inner facing also substantially increases the tensile strength of the panel to withstand large transverse loads.