COMPOSITION FOR STRUCTURAL INSULATED PANEL

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from a U.S. Provisional Patent Appl. No. 63/738,073, filed on Dec. 23, 2024, which is incorporated herein by reference in its entirety.

FIELD OF INVENTION

The present invention relates generally to prefabricated structural insulated panels (SIPs) used in construction, and more particularly to a composition for manufacturing structural insulated panels having enhanced sustainability and thermal performance.

BACKGROUND

Building construction is widely recognized as a labor-intensive and time-consuming process. A typical commercial, industrial, or residential building may require more than a year to complete. Traditional construction methods expose laborers to significant physical strain and elevated risks of injury or fatality. In addition, construction costs are often high, rendering housing financially inaccessible for a large segment of the population.

To address the drawbacks associated with conventional construction techniques, various alternative building systems have been developed. Among these, prefabricated panel systems, which are manufactured off-site and assembled on-site, have gained popularity for residential, industrial, and light commercial applications. Such prefabricated systems offer several advantages, including reduced construction time, lower labor requirements, cost efficiency, and improved performance characteristics such as water resistance, fire resistance, and structural strength.

Prefabricated building systems are generally classified into modular construction systems and panelized construction systems. In modular construction, entire building sections or modules are fabricated off-site and transported to the construction site for assembly. In contrast, panelized construction focuses on the fabrication of individual building components, such as wall panels and roof panels, which are subsequently transported and assembled at the site.

Structural insulated panels (SIPs) are a type of sandwich composite structure in which an insulating rigid core is disposed between two structural facing layers. The facing layers may be formed from materials such as sheet metal, fiber cement board, magnesium oxide (MgO) board, plywood, or oriented strand board (OSB). The insulating core may include expanded polystyrene (EPS), extruded polystyrene (XPS), polyisocyanurate foam, polyurethane foam, or composite honeycomb structures.

In recent years, there has been an increasing emphasis on sustainability and energy efficiency across multiple industries, including the construction sector. Accordingly, there is a growing demand for prefabricated building systems, and in particular structural insulated panels, that provide improved environmental sustainability, thermal insulation performance, and resource efficiency.

SUMMARY OF THE INVENTION

The following provides a simplified summary of one or more embodiments of the present invention to facilitate a basic understanding of its features and advantages. This summary is not an exhaustive overview of all contemplated embodiments and is not intended to identify essential elements or define the full scope of the invention. It merely introduces certain concepts that are described in greater detail in the subsequent sections.

The principal object of the present invention is to provide structural insulated panels that are environmentally friendly.

Another object of the present invention is to provide structural insulated panels that are cost-effective to manufacture and deploy.

Another object of the present invention is to provide structural insulated panels that enable accelerated construction, wherein a drying time cycle is reduced to a period of weeks.

Another object of the present invention is to provide structural insulated panels that are adapted for on-site assembly.

Another object of the present invention is to provide structural insulated panels that are prefabricated into sections in a factory environment, wherein the sections are transportable and assemblable on-site.

In one aspect, the present disclosure provides a prefabricated panelized building system and a method for manufacturing prefabricated panels for constructing residential, industrial, and commercial buildings. The disclosed method enables a significant reduction in labor and material costs by employing a refined manufacturing process that integrates continuous, high-performance thermal insulation between vertical structural members.

The present invention is directed to structural insulated panels (SIPs) and methods for manufacturing the same for use in the construction of residential, industrial, and commercial buildings. The disclosed panels provide a prefabricated, panelized construction solution that is environmentally sustainable, cost-effective, and less labor-intensive than conventional building systems.

In one aspect, the invention provides a structural insulated panel including a framework formed by a plurality of studs arranged between a top rail and a bottom rail, the studs defining a plurality of stud bays. An insulation composition is disposed within the stud bays and configured to set and dry. The insulation composition comprises one or more hemp-based components and a lime-based binder, forming a continuous insulation layer within the panel.

In certain embodiments, the insulation composition comprises hempcrete, which may further include water and plant-based fibrous reinforcements, such as bamboo fibers or bamboo stalk. The composition is introducible into the stud bays in a flowable form and allowed to set to form a load-supporting insulating material with reduced thermal bridging between adjacent studs.

In another aspect, the invention provides a method for manufacturing a structural insulated panel, including forming a stud framework, introducing the disclosed insulation composition into the stud bays, and allowing the composition to set and dry to form a continuous thermal barrier capable of supporting structural loads. The method enables rapid prefabrication of panels suitable for on-site assembly.

In certain embodiments, the disclosed panels may include metal studs, wooden studs, or combinations thereof, and may further include diagonal support for seismic or lateral reinforcement. The panels may also include cladding on one or both sides and may be configured to accommodate mechanical, electrical, and plumbing components.

Advantageously, the disclosed structural insulated panels combine sustainability, thermal insulation, and structural performance, while remaining compatible with existing building standards. The invention therefore provides an improved prefabricated building solution that addresses the limitations of traditional construction methods and conventional insulated panel systems.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying figures, which are incorporated herein, form part of the specification and illustrate embodiments of the present invention. Together with the description, the figures further explain the principles of the present invention and to enable a person skilled in the relevant arts to make and use the invention.

FIG. 1 illustrates a structural insulated panel fabricated using studs and the disclosed composition, further showing diagonal support configured for seismic bracing, according to an exemplary embodiment of the present invention.

FIG. 2 illustrates the structural insulated panel with an exposed interior region to show the arrangement of the studs, according to an exemplary embodiment of the present invention.

FIG. 3 illustrates the structural insulated panel with its individual components separated, according to an exemplary embodiment of the present invention.

FIG. 4 illustrates the structural insulated panel including wall cladding, according to an exemplary embodiment of the present invention.

FIG. 5 illustrates a top view of the structural insulated panel, according to an exemplary embodiment of the present invention.

FIG. 6 illustrates an elevation view of the structural insulated panel, according to an exemplary embodiment of the present invention.

FIG. 7 illustrates a perspective view of the structural insulated panel, according to an exemplary embodiment of the present invention.

FIG. 8 illustrates a building, made from the disclosed structural insulated panels.

FIG. 9 illustrates the sustainable development that can be achieved using the disclosed structural insulated panels.

FIG. 10 illustrates potential applications of Structural Insulated Panel system in a large-scale sustainable master-planned development.

FIG. 11 is an aerial view showing residential neighborhoods, civic core, industrial zones, and green corridors enabled by panelized (SHP) SIP construction.

FIG. 12 illustrates a rendering of a regional manufacturing facility producing bio-composite SHP structural panels for on-site and regional deployment.

FIG. 13 illustrates the application SIPs in data center adjacent to renewable energy infrastructure (solar, wind, geothermal).

FIG. 14 illustrates the application SIPs in micro data center adjacent to commercial and/or a residential single-family building.

FIG. 15 illustrates mixed-use center with walkable retail, culinary spaces, and community amenities constructed using the same panelized building system.

DETAILED DESCRIPTION

The subject matter of the present invention will now be described more fully with reference to the accompanying drawings, which form a part of this disclosure and illustrate specific exemplary embodiments. However, it should be understood that the subject matter may be embodied in various forms and is not limited to the specific embodiments set forth herein. Rather, these embodiments are provided by way of example to convey the scope of the invention. It is intended that the claims encompass a broad range of subject matter, including methods, devices, components, and systems. Accordingly, the following detailed description is not intended to be taken in a limiting sense.

As used herein, the term “exemplary” is intended to mean “serving as an example, instance, or illustration.” Any embodiment described as “exemplary” should not be construed as preferred or more advantageous over other embodiments. Similarly, the expression “embodiments of the present invention” does not imply that all embodiments must include all features, advantages, or modes of operation described.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Furthermore, the terms “comprises,” “comprising,” “includes,” and/or “including” specify the presence of stated features, integers, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The following detailed description sets forth the best currently contemplated modes for carrying out exemplary embodiments of the invention. This description is not intended to be limiting, but rather to illustrate the general principles of the invention. The claims of any issued patent will define the scope of the invention.

The present invention relates to structural insulated panels (SIPs) for use in the construction of residential, industrial, and commercial buildings. The disclosed prefabricated panels provide a sustainable construction solution that is environmentally friendly, economical, and less labor-intensive compared to conventional building techniques. The insulation characteristics of the prefabricated panels exhibit significantly improved thermal insulation performance. Further, the disclosed prefabricated panels are configured to comply with existing construction standards, including ASTM and Uniform Building Code (UBC) standards.

The disclosed prefabricated panels may incorporate recycled light-gauge metal studs and/or wooden studs, thereby enhancing the versatility and sustainability of the invention. A composition according to the present invention is introducible into cavities formed by the studs and allowed to set and dry to form the prefabricated panels. The resulting panels provide a continuous thermal and fire-resistant barrier while being capable of supporting structural loads.

The disclosed prefabricated panels are particularly advantageous due to the incorporation of recycled materials and organic fire-resistant insulation, thereby promoting environmental sustainability without compromising structural integrity. The composition is configured to set rapidly, enabling accelerated panel fabrication and assembly, while forming a continuous barrier that enhances thermal insulation and fire-resistance performance.

In certain embodiments, the disclosed prefabricated panels include a framework formed from recycled light-gauge metal studs and/or wooden studs arranged to define a plurality of stud bays. The composition of the present invention is disposed within the cavities of the plurality of stud bays and allowed to dry, thereby forming the structural insulated panel.

The compositions according to the present invention comprise environmentally sustainable materials. The ingredients of the disclosed composition include renewable and non-toxic components that meet or exceed industry-standard fire-resistance ratings. The composition is configured to set within a stud bay, thereby forming continuous insulation between adjacent studs within each stud bay. The resulting panel provides continuous thermal insulation across the panel with minimal thermal bridging. The disclosed panel further exhibits load-bearing properties sufficient to meet structural performance requirements without compromising insulation performance.

In certain embodiments, the disclosed composition includes hemp pulp, hemp stalk, bamboo stalk, and lime powder. These components may be mixed with water to form a slurry, which can be poured into a mold or stud cavity and allowed to set to form the disclosed panel or panel block.

In certain exemplary implementations, the composition may include approximately 30.67 cubic feet (300 lbs.) of hemp pulp, 30.67 cubic feet (480 lbs.) of lime, 30.67 cubic feet (5 lbs.) of bamboo, and 30.67 cubic feet (20 lbs.) of hemp stalk. The disclosed quantities are illustrative and non-limiting, and variations in proportions are within the scope of the present invention.

The panel may further include cladding on one or both sides. The cladding may be formed from organic and sustainable materials, including but not limited to hemp-lime concrete, corkboard, or similar materials. In certain embodiments, the same or similar material may be applied around openings such as doors and windows to enhance insulation performance and reduce or eliminate the use of gypsum drywall.

The panel may further include provisions for mechanical, electrical, and plumbing (MEP) conduits. Such conduits may be routed through interior wall-mounted clamps, manifolds, or channels, and may be enclosed by decorative or protective panels, including custom wainscoting panels.

In certain embodiments, metal studs used in the panel framework may be primed or coated with an anti-rust coating, although such treatment is optional. Any anti-corrosion coating known in the art and suitable for metal studs is considered to be within the scope of the present invention.

In certain implementations, the cladding may be formed by spraying the coating materials, wherein multiple layers may be deposited. Suitable materials, such as colors and clays may be added for imparting designs, colors, and patterns on the panel.

FIGS. 1, 2, and 3 illustrate wall panels 100 formed in accordance with an exemplary embodiment of the present invention. As shown, the panel 100 includes a plurality of studs 110 arranged between a top rail 120 and a bottom rail 130, thereby forming a structural frame. Diagonal supports 140 may be incorporated to provide additional structural reinforcement, including seismic resistance. A window opening 150 is formed within the panel 100. The panel further includes an infill material 160 comprising the disclosed composition or a composite material. While FIG. 1 illustrates a completed panel, FIG. 2 illustrates an exposed region to show the internal stud arrangement 210. FIG. 4 illustrates a wall assembly 400 including cladding 170 disposed on an exterior side of the panel 100, wherein cladding may be applied to one or both sides of the panel.

FIG. 5 illustrates a top view of the wall assembly 400 showing cladding 170 disposed on both sides of the panel 100. FIG. 6 illustrates an elevation view further showing a steel track or wooden plate 410 associated with the panel assembly.

The disclosed panels exhibit fire-resistant properties, rodent deterrence, carbon absorption capability, and resistance to mold and mildew. The panels further demonstrate enhanced thermal insulation performance. By way of example, insulation performance was evaluated for panels of varying thicknesses, yielding approximate R-values of R-30 for 12-inch panels, R-40 for 16-inch panels, and R-50 for 20-inch panels. Panels having heights of 8 feet, 10 feet, and 12 feet were also fabricated and evaluated for structural strength and durability, and were found to comply with applicable construction standards.

Hemp pulp is known in the art and is derived from fibers of the industrial hemp plant (Cannabis sativa L.). In certain embodiments, the hemp pulp may be obtained from the hemp stalk, including long bast fibers (outer bark fibers) and/or shorter hurd fibers (woody inner core). In some cases, recycled or waste hemp materials, such as stem fibers or reclaimed hemp rope, may be utilized.

Hemp stalk refers to the main stem of the industrial hemp plant (Cannabis sativa L.), which is cultivated for industrial and consumable purposes and contains low tetrahydrocannabinol (THC) content, typically less than 0.3% by weight. Hemp stalks include two primary fiber types: bast fibers forming an outer layer, and hurd (shive) fibers forming an inner core.

Hempcrete is a bio-composite material formed from hemp shives (the woody inner core of the hemp plant) combined with a lime-based binder. In certain embodiments, hempcrete combined with bamboo fibers forms a composite material exhibiting enhanced reinforcement, tensile strength, and flexural performance. The combination of bamboo's structural strength with the insulating and low-carbon properties of hemp-based composites provides a highly advantageous solution for sustainable construction applications.

In certain implementations, the studs and diagnose supports, when made from metals, may preferably have a coating of anti-rust primer.

While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above-described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention as claimed.