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US20090293396A1 - Structural insulated panel for building construction - Google Patents

Structural insulated panel for building construction Download PDF

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Publication number
US20090293396A1
US20090293396A1 US12/470,573 US47057309A US2009293396A1 US 20090293396 A1 US20090293396 A1 US 20090293396A1 US 47057309 A US47057309 A US 47057309A US 2009293396 A1 US2009293396 A1 US 2009293396A1
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osb
structural
panel
panels
sip
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US12/470,573
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William H. Porter
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Individual
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Priority to US12/470,573 priority Critical patent/US20090293396A1/en
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/14—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E04C2/243—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 one at least of the material being insulating
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E04C2/246—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 combinations of materials fully covered by E04C2/16 and E04C2/20
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/61—Connections for building structures in general of slab-shaped building elements with each other
    • E04B1/6108—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
    • E04B1/612—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces
    • E04B1/6145—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with recesses in both frontal surfaces co-operating with an additional connecting element
    • E04B1/6162—Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by means between frontal surfaces with recesses in both frontal surfaces co-operating with an additional connecting element the connection made by an additional locking key

Definitions

  • the present invention relates to structural insulated panels such as for building exterior walls, and building structures using same.
  • Structural insulated panels have been around for a number of years. In the 1950's until about 1980, panels were made 4 feet wide and up to 12 feet long with commodity plywood and other materials. Some of these panels have finishes that were acceptable as exterior wall surfaces. The most common was a plywood pattern called reverse board and batten or sometimes T 1-11 ply. The inside of that was a material such as drywall or plywood. The center of these panels was plastic foam to complete a SIP panel.
  • One aspect of the present invention is a structural insulated panel made with a foam plastic core and oriented strand board attached on either side to form board faces.
  • the oriented strand board faces are capped with a structural paper that provides a finished surface.
  • the core, OSB and structural paper are all securely bonded together.
  • Another aspect of the present invention is a “frameless” building where exterior walls are constructed primarily using structural insulated panels.
  • a building wall in another aspect of the present invention, includes two structural insulated panels positioned in-plane and with end edges adjacent.
  • Each panel includes a foam core, an OSB facer on each side, and structural paper on each side.
  • Each panel also includes an end portion with OSB facer extending beyond an outer surface of the foam core to define a cavity and an insert positioned between the end portions and extending into the cavity.
  • the insert includes a foam core and OSB facer on each side, the OSB facer on the insert fitting inside the OSB facer on the panels; and fasteners fastening each panel to the insert.
  • FIG. 1 is a perspective view of a structural insulated panel (SIP) embodying the present invention.
  • FIGS. 2-4 are perspective, side, and front views of a partially constructed building.
  • FIG. 5 is a cross section taken along line V-V in FIG. 4 .
  • FIGS. 6-9 are cross-sectional views showing various joints in an exterior wall of the building, including FIG. 6 showing an exterior-wall-to-roof-beam joint, FIG. 7 showing an exterior-wall-to-floor joint, FIG. 8 showing a SIP-to-SIP joint, and FIG. 9 being an exploded view of FIG. 8 .
  • the illustrated structural insulated panel is large in size, such as 8 foot by 24 foot, and further incorporates outer layers forming high grade exterior and interior finishes as manufactured.
  • the large size reduces on-site construction costs, and the exterior and interior finishes reduce on-site finishing costs.
  • the present SIP panels reduce the overall cost of total building construction, so that the completed cost is less expensive than “stick” construction (e.g., wood stud framing for “framed” buildings having an on-site added outside such as vinyl siding and an on-site added inside such as drywall).
  • the present SIP panels also save up to 50% of the heating and cooling costs, as well as meet fire code regulations.
  • This invention applies a finish in the factory to these large SIP panels.
  • a combination of changed factors and upgrades of materials with the oriented strand board (OSB) and structural insulated paper makes for a panel finished inside and out.
  • OSB oriented strand board
  • structural paper is commercially available and can be used in the present SIP.
  • Some grades of structural paper have a tensile strength in a machine direction (parallel a longitudinal plane of the paper) of over 15,000 psi, which is up to about half a tensile strength of mild steel.
  • a strength of the structural paper adds significant beam strength to the SIP.
  • FIGS. 2-5 illustrate a “frameless” building construction made using the present SIPs in exterior walls.
  • FIGS. 6-9 which disclose various joint arrangement optimized for the particular SIPs. It is contemplated that door and window openings as well as other features (e.g., openings for electrical boxes, outlets, switches, utility runs, and the like) can be pre-cut into the SIPs to reduce on-site construction labor and for a more efficient on-site construction. ( FIGS.
  • 2-3 , 5 show a circular window, but it is contemplated that different window shapes, sizes, and types can be accommodated.
  • components can be added to the prefabricated SIPs, if desired and appropriate, such as final outer colors, windows, hardware, utilities, inter-connectable utility modules adapted to interconnect between SIP panels, etc.
  • the illustrated SIP panel ( FIG. 1 ) includes prime paint 1 (such as white acrylic), structural paper 2 (such as Kraft paper with urethane impreg), adhesive 3 (such as resorsinal or phenolic), oriented strand board (OSB) 4 , adhesive 5 (such as urethane), and foam core 6 (such as expanded polystyrene).
  • the OSB 4 is a facer for the foam core 6 .
  • a plurality of the SIP panel of FIG. 1 are used to construct the frameless building construction of FIGS. 2-5 .
  • the illustrated building of FIG. 2 includes four SIP panels for each half of the roof, three for each of the building sides, and three for the floor. However, it is contemplated that each roof portion, building side, and floor can be made of one, two, or more SIP panels.
  • the building ( FIG. 3 ) includes a supporting frame including stilts 10 with diagonal cross braces 11 , floor joists 12 , a window 13 in one end, and roof truss members 15 (see FIG. 5 ). Pre-manufactured and pre-cut SIP panels are used to form the floor, walls, and roof. The building can be designed with dimensions selected as desired.
  • the illustrated building ( FIG. 3 ) includes a supporting frame including stilts 10 with diagonal cross braces 11 , floor joists 12 , a window 13 in one end, and roof truss members 15 (see FIG. 5 ). Pre-manufactured and pre-cut SIP panels are used to form the floor, walls, and roof. The building can be designed with dimensions selected as desired.
  • the illustrated building ( FIG.
  • D 3 includes exemplary dimensions: D 1 of 24′, D 2 of 20′-61 ⁇ 8′′, D 3 of 16′, D 4 roof pitch of 12′′ run to 6′′ rise, D 5 floor height of 9′-83 ⁇ 8′′, D 6 under-floor-joist height of 8′, D 7 SIP width of 8′, D 8 floor-to-ceiling height of about 10′-93 ⁇ 8′′, D 9 peak ceiling height of 16′-93 ⁇ 4′′, and D 10 window diameter of 5′.
  • additional openings can be made, such as for doors, rectangular windows, channels for utility routing, and the like.
  • FIGS. 6-9 are cross-sectional views showing various joints in a building 20 including an outer wall SIP panel 21 and roof SIP panel 22 .
  • FIG. 6 shows an exterior-wall-to-roof-beam joint 23 .
  • a roof SIP panel 22 is secured to an outer wall SIP panel 21 as follows.
  • the outer wall SIP panel 21 includes a wood 2 ⁇ 4 topper 24 secured to the foam core 6 of the outer wall SIP panel 21 with a foam sealant 25 , and further secured by 8d nails 26 (or #14 11 ⁇ 2′′ staples) that extend through OSB 4 into sides of the topper 24 .
  • Beams of foam sealant 27 provide a continuous bead bond making a wood-to-wood (i.e., OSB to topper) connection.
  • a beveled (triangular) 2 ⁇ seat component 28 that provides a minimum bearing of 3 inches for the roof SIP panel 22 on the topper 24 and outer wall SIP panel 21 .
  • a screw 29 (such as #14 panel screw 11 ⁇ 2′′) longer than the roof SIP panel 21 is extended through the roof SIP panel 21 into the topper 24 .
  • the roof SIP panel 22 includes EPS foam core 6 and OSB 4 on both sides, but structural paper 2 only on the inside/lower surface facing the wall SIP panel 21 .
  • FIG. 7 shows an exterior-wall-to-floor joint 30 between an outside wall SIP panel 21 and a floor SIP panel 31 .
  • the outside wall SIP panel 21 includes EPS foam core 6 and OSB 4 on both sides as well as structural paper 2 on both sides of the wall SIP panel 22 .
  • a ledger board 32 e.g., 2 ⁇ 8 wood board
  • screws 29 such as #14 panel screw 11 ⁇ 2′′
  • a second board 33 fits against an end of the floor SIP panel 30 , and in particular fits between the OSB boards 4 and against the foam core 6 .
  • FIG. 8 shows a SIP-to-SIP joint 40
  • FIG. 9 is an exploded view of FIG. 8
  • the joint 40 includes opposing end portions 41 of SIP panel 21 (or of SIP panels 22 or 31 ) and an insert 42 .
  • the insert 42 includes a foam core 43 (similar to core 6 ) and OSB 44 (similar to OSB 4 ) adhered together.
  • a thickness of the insert 42 fits between and inside the OSB 4 of the end portions 41 of each SIP panel 21 .
  • Beads 45 - 47 are placed along an inside of the end portions 41 on the OSB 4 and the foam core 6 of each SIP panel 21 .
  • the end portions 41 are brought against the insert 42 , and 8d nails 48 (or #14 11 ⁇ 2′′ staples) are extended through OSB 4 into sides of the insert 42 .
  • the OSB 4 on each side of the SIP panels 21 abut (or are closely adjacent) in inline positions.
  • the illustrated insert 42 is about 31 ⁇ 4′′ long, such that about 15 ⁇ 8′′ of each end of the insert 42 fits into the mating cavity in the end portions 41 of the SIP panel 21 .

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Building Environments (AREA)
  • Load-Bearing And Curtain Walls (AREA)

Abstract

A structural insulated panel (SIP), such as 8 foot×24 foot, is made with a foam plastic core, oriented strand board on each face, and structural paper on either side of that, all bonded together. The oriented strand board capped with structural paper provides a particularly strong wall structure. Also, the structural paper provides a finished surface as manufactured. SIP-to-SIP joints are created using an insert sandwiched between end portions of in-line-joined SIP panels.

Description

    CROSS REFERENCE TO RELATED APPLICATION
  • This application claims benefit under 35 U.S.C. §119(e) of provisional application Ser. No. 61/056,217, filed May 27, 2008, entitled STRUCTURAL INSULATED PANEL FOR BUILDING CONSTRUCTION, the entire contents of which are incorporated herein in its entirety.
    • BACKGROUND
  • The present invention relates to structural insulated panels such as for building exterior walls, and building structures using same.
  • Structural insulated panels (SIPS) have been around for a number of years. In the 1950's until about 1980, panels were made 4 feet wide and up to 12 feet long with commodity plywood and other materials. Some of these panels have finishes that were acceptable as exterior wall surfaces. The most common was a plywood pattern called reverse board and batten or sometimes T 1-11 ply. The inside of that was a material such as drywall or plywood. The center of these panels was plastic foam to complete a SIP panel.
  • The SIP panels discussed above were largely superseded when oriented strand board (OSB) became available in 8 foot by 24 foot sheets. The 4 foot wide panels were too costly and inefficient to install when one big panel could replace six small 4-foot-wide panels. However, a problem with this big 8 foot by 24 foot panel was that it did not have a finished surface on the inside nor outside, since OSB does not provide it. Thus, the big panels were usually covered with drywall on the inside and covered with exterior siding on the outside. Unfortunately, this process of covering inside and outside surfaces after building/wall construction is very expensive and made construction with SIPs more expensive than conventional “stick” construction. Even though SIP construction could save 30% to 50% of the heat loss, there has been continued resistance to use the SIP systems because of costs of material versus “stick” construction.
    • SUMMARY OF THE PRESENT INVENTION
  • One aspect of the present invention is a structural insulated panel made with a foam plastic core and oriented strand board attached on either side to form board faces. The oriented strand board faces are capped with a structural paper that provides a finished surface. The core, OSB and structural paper are all securely bonded together.
  • Another aspect of the present invention is a “frameless” building where exterior walls are constructed primarily using structural insulated panels.
  • In another aspect of the present invention, a building wall includes two structural insulated panels positioned in-plane and with end edges adjacent. Each panel includes a foam core, an OSB facer on each side, and structural paper on each side. Each panel also includes an end portion with OSB facer extending beyond an outer surface of the foam core to define a cavity and an insert positioned between the end portions and extending into the cavity. The insert includes a foam core and OSB facer on each side, the OSB facer on the insert fitting inside the OSB facer on the panels; and fasteners fastening each panel to the insert.
  • These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.
    • BRIEF DESCRIPTION OF DRAWINGS
  • FIG. 1 is a perspective view of a structural insulated panel (SIP) embodying the present invention.
  • FIGS. 2-4 are perspective, side, and front views of a partially constructed building.
  • FIG. 5 is a cross section taken along line V-V in FIG. 4.
  • FIGS. 6-9 are cross-sectional views showing various joints in an exterior wall of the building, including FIG. 6 showing an exterior-wall-to-roof-beam joint, FIG. 7 showing an exterior-wall-to-floor joint, FIG. 8 showing a SIP-to-SIP joint, and FIG. 9 being an exploded view of FIG. 8.
    •  DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
  • The illustrated structural insulated panel (SIP panel) is large in size, such as 8 foot by 24 foot, and further incorporates outer layers forming high grade exterior and interior finishes as manufactured. The large size reduces on-site construction costs, and the exterior and interior finishes reduce on-site finishing costs. As a result, the present SIP panels reduce the overall cost of total building construction, so that the completed cost is less expensive than “stick” construction (e.g., wood stud framing for “framed” buildings having an on-site added outside such as vinyl siding and an on-site added inside such as drywall). The present SIP panels also save up to 50% of the heating and cooling costs, as well as meet fire code regulations.
  • This invention applies a finish in the factory to these large SIP panels. A combination of changed factors and upgrades of materials with the oriented strand board (OSB) and structural insulated paper makes for a panel finished inside and out.
      • 1. The OSB supplied is a higher grade that has minimum edge swell so that it is more suitable for exteriors, and its thickness is selected for functional requirements of the application of use. For example, the OSB thickness can be ¼″ to ¾″, or more typically about ⅜″ to ½″.
      • 2. The OSB is treated and has a high degree of fire resistance for the inside to help meet building fire codes.
      • 3. A structural paper (Kraft) with a polyurethane impregnation is used to face the OSB. Urethane impregnation of the Kraft paper is usually from 20% to 35%.
      • 4. A waterproof adhesive is used to apply the structural paper to the OSB. The adhesive is of a fire-resistant type to help meet building codes. The adhesive penetrates well into the OSB to prevent delaminations.
      • 5. A prime coat of white paint is applied to the structural paper to make panel more weather-resistant on the outside and ready for a finish coat on the inside by the owner in the field.
      • 6. The outer and inner faces of prime paint, structural paper and OSB are laminated to both sides of the plastic foam. (Alternatively, one or both of the prime paint and the structural paper can be left off one side.)
      • 7. The foam is usually an Expanded Polystyrene, Extruded Polystyrene or Urethane foam plastic. The foam acts as an insulator and as part of the structure. It can have whatever foam weight and additives that are appropriate for a particular application. It is contemplated that expanded foam having a weight of about 0.8 to 2 pounds per cubic foot, or more preferably about 1 pound per cubic foot will work well in many applications.
      • 8. The application of the paper to the OSB must be done with heat and pressure for good bonding. The system can be either accomplished with a flat bed press or a roller press where the heat is transferred through the paper very rapidly since it is very thin. Thickness of the paper is typically 0.011 inches to 0.022 inches.
      • 9. The SIP panels can be cut on-site or pre-cut at the factory.
  • By way of example, structural paper is commercially available and can be used in the present SIP. Some grades of structural paper have a tensile strength in a machine direction (parallel a longitudinal plane of the paper) of over 15,000 psi, which is up to about half a tensile strength of mild steel. When adhered to outside and inside surfaces of an SIP arrangement, a strength of the structural paper adds significant beam strength to the SIP.
  • FIGS. 2-5 illustrate a “frameless” building construction made using the present SIPs in exterior walls. Note FIGS. 6-9 which disclose various joint arrangement optimized for the particular SIPs. It is contemplated that door and window openings as well as other features (e.g., openings for electrical boxes, outlets, switches, utility runs, and the like) can be pre-cut into the SIPs to reduce on-site construction labor and for a more efficient on-site construction. (FIGS. 2-3, 5 show a circular window, but it is contemplated that different window shapes, sizes, and types can be accommodated.) Also, components can be added to the prefabricated SIPs, if desired and appropriate, such as final outer colors, windows, hardware, utilities, inter-connectable utility modules adapted to interconnect between SIP panels, etc.
  • The illustrated SIP panel (FIG. 1) includes prime paint 1 (such as white acrylic), structural paper 2 (such as Kraft paper with urethane impreg), adhesive 3 (such as resorsinal or phenolic), oriented strand board (OSB) 4, adhesive 5 (such as urethane), and foam core 6 (such as expanded polystyrene). The OSB 4 is a facer for the foam core 6. A plurality of the SIP panel of FIG. 1 are used to construct the frameless building construction of FIGS. 2-5. The illustrated building of FIG. 2 includes four SIP panels for each half of the roof, three for each of the building sides, and three for the floor. However, it is contemplated that each roof portion, building side, and floor can be made of one, two, or more SIP panels.
  • The building (FIG. 3) includes a supporting frame including stilts 10 with diagonal cross braces 11, floor joists 12, a window 13 in one end, and roof truss members 15 (see FIG. 5). Pre-manufactured and pre-cut SIP panels are used to form the floor, walls, and roof. The building can be designed with dimensions selected as desired. The illustrated building (FIG. 3) includes exemplary dimensions: D1 of 24′, D2 of 20′-6⅛″, D3 of 16′, D4 roof pitch of 12″ run to 6″ rise, D5 floor height of 9′-8⅜″, D6 under-floor-joist height of 8′, D7 SIP width of 8′, D8 floor-to-ceiling height of about 10′-9⅜″, D9 peak ceiling height of 16′-9¾″, and D10 window diameter of 5′. Notably, in addition to the window 13, additional openings can be made, such as for doors, rectangular windows, channels for utility routing, and the like.
  • FIGS. 6-9 are cross-sectional views showing various joints in a building 20 including an outer wall SIP panel 21 and roof SIP panel 22. Specifically, FIG. 6 shows an exterior-wall-to-roof-beam joint 23. A roof SIP panel 22 is secured to an outer wall SIP panel 21 as follows. The outer wall SIP panel 21 includes a wood 2×4 topper 24 secured to the foam core 6 of the outer wall SIP panel 21 with a foam sealant 25, and further secured by 8d nails 26 (or #14 1½″ staples) that extend through OSB 4 into sides of the topper 24. Beams of foam sealant 27 provide a continuous bead bond making a wood-to-wood (i.e., OSB to topper) connection. A beveled (triangular) 2× seat component 28 that provides a minimum bearing of 3 inches for the roof SIP panel 22 on the topper 24 and outer wall SIP panel 21. A screw 29 (such as #14 panel screw 1½″) longer than the roof SIP panel 21 is extended through the roof SIP panel 21 into the topper 24. The roof SIP panel 22 includes EPS foam core 6 and OSB 4 on both sides, but structural paper 2 only on the inside/lower surface facing the wall SIP panel 21.
  • FIG. 7 shows an exterior-wall-to-floor joint 30 between an outside wall SIP panel 21 and a floor SIP panel 31. The outside wall SIP panel 21 includes EPS foam core 6 and OSB 4 on both sides as well as structural paper 2 on both sides of the wall SIP panel 22. A ledger board 32 (e.g., 2×8 wood board) is attached to the outer wall SIP panel 21 by using screws 29 (such as #14 panel screw 1½″) longer than the outer wall SIP panel 21 extended through the outer wall SIP panel 21 into the ledger board 32. A second board 33 fits against an end of the floor SIP panel 30, and in particular fits between the OSB boards 4 and against the foam core 6. Several 8d nails 34 (or #14 1½″ staples at 6″ O.C. typical) extend through the OSB boards 4 into the second board 33. Additional screws 29 (such as #14 panel screw 1½″) longer than the outer wall SIP panel 22 are extended through the outer wall SIP panel 22 into the second board 33. Adhesive and/or sealant can be used as desired.
  • FIG. 8 shows a SIP-to-SIP joint 40, and FIG. 9 is an exploded view of FIG. 8. The joint 40 includes opposing end portions 41 of SIP panel 21 (or of SIP panels 22 or 31) and an insert 42. The insert 42 includes a foam core 43 (similar to core 6) and OSB 44 (similar to OSB 4) adhered together. A thickness of the insert 42 fits between and inside the OSB 4 of the end portions 41 of each SIP panel 21. Beads 45-47 are placed along an inside of the end portions 41 on the OSB 4 and the foam core 6 of each SIP panel 21. The end portions 41 are brought against the insert 42, and 8d nails 48 (or #14 1½″ staples) are extended through OSB 4 into sides of the insert 42. The OSB 4 on each side of the SIP panels 21 abut (or are closely adjacent) in inline positions. The illustrated insert 42 is about 3¼″ long, such that about 1⅝″ of each end of the insert 42 fits into the mating cavity in the end portions 41 of the SIP panel 21.
  • It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

Claims (11)

1. A structural insulated panel comprising:
a foam plastic core and oriented strand board (OSB) attached on either side of the core to form board faces, the board faces being capped with a structural paper that provides a finished surface; the core, OSB and structural paper all being securely bonded together.
2. The structural insulated panel defined in claim 1, wherein a prime paint is applied to the outer face of the structural paper.
3. The structural insulated panel defined in claim 1, wherein the adhesive used to bond the paper to the OSB is waterproof and adds to the fire resistance.
4. The structural insulated panel defined in claim 1, wherein the plastic foam core is one of Expanded Polystyrene, Extruded Polystyrene, or Urethane.
5. The structural insulated panel defined in claim 1, wherein the OSB has added chemicals to reduce the edge swell and increase the fire resistance.
6. The structural insulated panel defined in claim 5, wherein the OSB is at least about 2½ inch thick to provide good fire resistance.
7. The structural insulated panel defined in claim 1, where the panel size is very large, such as 8 foot by 24 foot, to eliminate the need for many small panels with numerous junctures.
8. A building comprising a plurality of the structural insulated panels defined in claim 7, the plurality of panels being attached together to form walls without wood framing, whereby the interconnected arrangement of large panels speeds erection of the building, improves building structure, and reduces energy loss through the building walls once constructed.
9. The structural insulated panel defined in claim 1, where a panel substantially forms a structural wall or roof of a building.
10. A building wall comprising:
two structural insulated panels positioned in-plane and end edges adjacent; each panel including a foam core, an OSB facer on each side, and structural paper on each side; each panel including an end portion with the OSB facer extending beyond an outer surface of the foam core to define a cavity; and
an insert positioned between the end portions and extending into the cavity; the insert including a foam core and OSB facer on each side, the OSB facer on the insert fitting inside the OSB facer on the panels; and
fasteners fastening each panel to the insert.
11. The building wall defined in claim 10, wherein the fasteners include shafts that extend through at least one of the OSB facers on the insert and through an adjacent one of the OSB facers on the panels.
US12/470,573 2008-05-27 2009-05-22 Structural insulated panel for building construction Abandoned US20090293396A1 (en)

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Publication number Priority date Publication date Assignee Title
US20090320387A1 (en) * 2008-06-27 2009-12-31 Innovida Factories, Ltd. Sandwich panel ground anchor and ground preparation for sandwich panel structures
US20100005732A1 (en) * 2008-07-10 2010-01-14 Innovida Holdings, Inc. Building roof structure having a round corner
US20110209734A1 (en) * 2010-03-01 2011-09-01 Hunter's Comfort, LLC Insulated sport/utility shelter
US8875475B2 (en) 2013-03-14 2014-11-04 Millport Associates S.A. Multiple panel beams and methods
US20140352232A1 (en) * 2012-01-23 2014-12-04 Inter Hospitality Holding B.V. Method and system for construction of a building
FR3028273A1 (en) * 2014-11-06 2016-05-13 Eccologis NEW INSULATING BONDING ELEMENT BETWEEN COMPOSITE PANELS FOR THE BUILDING, NEW ADAPTED PANELS AND METHOD OF CONSTRUCTING WALLS
US9631359B2 (en) 2012-01-23 2017-04-25 Vastint Hospitality B.V. Prefabricated module for a building
CN106703218A (en) * 2016-12-30 2017-05-24 李玉金 Assembly type energy-saving house profile
EP3239423A1 (en) * 2016-04-29 2017-11-01 Zenergy AB Fire resistant construction panel element system
US9920517B2 (en) 2016-08-17 2018-03-20 Pratt Corrugated Holdings, Inc. Insulation batt
US20190210317A1 (en) * 2010-08-24 2019-07-11 James Walker Frameless construction using single and double plenum panels
USD867616S1 (en) 2013-07-22 2019-11-19 Vastint Hospitality B.V. Prefabricated module
US10500772B2 (en) 2016-09-01 2019-12-10 Bryan Scott Mello Expanded foam-filled building panel
US10875218B2 (en) 2016-09-01 2020-12-29 Bryan Scott Mello Method and apparatus for manufacturing building panels
US11808029B2 (en) * 2018-02-12 2023-11-07 Megawall Australia Pty Ltd Relating to connection of structural components to panels
EP4372173A3 (en) * 2022-11-16 2024-08-28 MB "Geoideja" An optimal construction system for buildings and a method of using three elements and their components
US20250146276A1 (en) * 2023-11-08 2025-05-08 Dieter Roland Krohmer Structural Composite Wall and Building System

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US6240704B1 (en) * 1998-10-20 2001-06-05 William H. Porter Building panels with plastic impregnated paper
US6523324B1 (en) * 1998-10-20 2003-02-25 William H. Porter Building panels with plastic impregnated paper
US6408594B1 (en) * 1999-06-16 2002-06-25 William H. Porter Reinforced structural insulated panels with plastic impregnated paper facings
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US20040040244A1 (en) * 2002-08-28 2004-03-04 Charles Baker Structure and method for interconnecting construction units made from composite materials
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US20060053739A1 (en) * 2004-09-10 2006-03-16 Jaffee Alan M Methods of providing water protection to floor structures and floor structures formed by the same
US7516592B1 (en) * 2005-03-31 2009-04-14 Pratt James M Foundation crack sealer and method of use

Cited By (28)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090320387A1 (en) * 2008-06-27 2009-12-31 Innovida Factories, Ltd. Sandwich panel ground anchor and ground preparation for sandwich panel structures
US8733033B2 (en) * 2008-06-27 2014-05-27 Millport Associates, SA Sandwich panel ground anchor and ground preparation for sandwich panel structures
US20100005732A1 (en) * 2008-07-10 2010-01-14 Innovida Holdings, Inc. Building roof structure having a round corner
US8782991B2 (en) 2008-07-10 2014-07-22 Millport Associates S.A. Building roof structure having a round corner
US20110209734A1 (en) * 2010-03-01 2011-09-01 Hunter's Comfort, LLC Insulated sport/utility shelter
US8517038B2 (en) * 2010-03-01 2013-08-27 Hunter's Comfort, LLC Insulated sport/utility shelter
US11492796B2 (en) * 2010-08-24 2022-11-08 Innovative Structural Building Products, Llc Frameless construction method using single and double plenum panels
US10822790B2 (en) * 2010-08-24 2020-11-03 Innovative Structural Building Products, Llc Frameless construction using single and double plenum panels
US20190210317A1 (en) * 2010-08-24 2019-07-11 James Walker Frameless construction using single and double plenum panels
US20140352232A1 (en) * 2012-01-23 2014-12-04 Inter Hospitality Holding B.V. Method and system for construction of a building
US9556632B2 (en) * 2012-01-23 2017-01-31 Vastint Hospitality B.V. Method and system for construction of a building
US9631359B2 (en) 2012-01-23 2017-04-25 Vastint Hospitality B.V. Prefabricated module for a building
US8875475B2 (en) 2013-03-14 2014-11-04 Millport Associates S.A. Multiple panel beams and methods
USD867616S1 (en) 2013-07-22 2019-11-19 Vastint Hospitality B.V. Prefabricated module
FR3028273A1 (en) * 2014-11-06 2016-05-13 Eccologis NEW INSULATING BONDING ELEMENT BETWEEN COMPOSITE PANELS FOR THE BUILDING, NEW ADAPTED PANELS AND METHOD OF CONSTRUCTING WALLS
WO2016071747A3 (en) * 2014-11-06 2016-08-11 Eccologis New insulating connecting element between composite building panels, new matching panels and method for building walls
EP3239423A1 (en) * 2016-04-29 2017-11-01 Zenergy AB Fire resistant construction panel element system
US9920517B2 (en) 2016-08-17 2018-03-20 Pratt Corrugated Holdings, Inc. Insulation batt
US10435884B2 (en) 2016-08-17 2019-10-08 Pratt Corrugated Holdings, Inc. Insulation batt
US10400443B2 (en) 2016-08-17 2019-09-03 Pratt Corrugated Holdings, Inc. Insulation batt
US10619346B2 (en) 2016-08-17 2020-04-14 Pratt Corrugated Holdings, Inc. Insulation batt
US10138628B2 (en) 2016-08-17 2018-11-27 Pratt Corrugated Holdings, Inc. Insulation batt
US10500772B2 (en) 2016-09-01 2019-12-10 Bryan Scott Mello Expanded foam-filled building panel
US10875218B2 (en) 2016-09-01 2020-12-29 Bryan Scott Mello Method and apparatus for manufacturing building panels
CN106703218A (en) * 2016-12-30 2017-05-24 李玉金 Assembly type energy-saving house profile
US11808029B2 (en) * 2018-02-12 2023-11-07 Megawall Australia Pty Ltd Relating to connection of structural components to panels
EP4372173A3 (en) * 2022-11-16 2024-08-28 MB "Geoideja" An optimal construction system for buildings and a method of using three elements and their components
US20250146276A1 (en) * 2023-11-08 2025-05-08 Dieter Roland Krohmer Structural Composite Wall and Building System

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