US 9,212,485 B2 · Modular building panel

Abstract

An improved modular building panel and system for building construction is disclosed. The improved modular building panel comprises a novel honeycomb or lattice core comprising multiple layers of corrugated, preferably metal, components mechanically connected by any means known in the art, but which may be chemical bonding. External cladding layers comprising a novel cement mix comprising, in a preferred embodiment, Portland cement, silica sand, perlite, glass beads, and water, in combination with the honeycomb structure, provide a lightweight, highly durable, low-cost, projectile resistant, highly insulating, water, mold and mildew resistant, wind resistant novel modular wall system which is adapted for use in commercial, residential, and other construction and which provides superior security to the user. The modular building panel and system of the invention may be utilized for walls, roofs, floors, bridges, or other structures.

An improved modular wall system, comprising:

an inner panel having an interior side, exterior side, top edge, bottom edge, and right side edge;
an outer panel having an interior side, exterior side, top edge, bottom edge, and right side edge;
a first corrugated panel having a top and a bottom;
a second corrugated panel having a top and a bottom;
a third corrugated panel having a top and a bottom;
a fourth corrugated panel having a top and a bottom;
wherein said first corrugated panel and said second corrugated panel are attached by a first attachment means selected from the group consisting of chemical bonding, threaded fasteners, rivets and welding to form a first honeycomb structure having a first side and a second side, and wherein said third corrugated panel and said fourth corrugated panel are attached by a second attachment means selected from the group consisting of chemical bonding, threaded fasteners, rivets and welding to form a second honeycomb structure having a first side and a second side, said first honeycomb structure and said second honeycomb structure comprising a plurality of interstitial spaces;
a horizontal corrugated panel having a posterior side and an anterior side;
a thermal break panel having a first side and a second side;
a first top plate having a thickness and a second top plate having an upper surface;
a male snap channel having a chevron channel and a female snap channel having a chevron channel adapted to provide a spring loaded retaining fit with said male snap channel chevron channel,
a first support channel and a second support channel;
a bottom channel;
an exterior panel mounting strip and a plurality of exterior panel mounting clips attached to said interior side of said exterior panel;
and
a plurality of interior panel mounting brackets attached to said posterior side of said horizontal corrugated panel, said interior panel mounting brackets adapted to receive a plurality of exterior panel mounting clips attached to said interior side of said interior panel,
wherein said first honeycomb structure first side is attached to said thermal break panel first side, and wherein said second honeycomb structure is attached to said thermal break panel second side by said first attachment means;
and
wherein said second honeycomb structure second side is attached to said horizontal corrugated panel anterior side by said first attachment means;
and
wherein said first top plate is attached to said inner surface of said interior panel at said top of said interior panel by said first attachment means such that said upper surface of said first top plate is substantially flush with said top of said interior panel;
and
wherein said second top plate is attached to said inner surface of said exterior panel at said top of said exterior panel by said first attachment means such that said upper surface of said second top plate is spaced below said top of said interior panel said thickness of said first top plate, and wherein said first top plate and said second top plate are attached by a plurality of sheet metal screws;
and
wherein said bottom plate is disposed between and attached to said inner surface of said exterior panel and said inner surface of said interior panel by said first attachment means, such that the bottom surface of said bottom plate forms a substantially flush closure to said modular building panel;
and
wherein said male snap channel is disposed between and attached to said interior panel interior surface and said exterior panel interior surface by said first attachments means;
and
wherein said female snap channel is disposed between and attached to said interior panel interior surface and said exterior panel interior surface by said first attachments means;
and
wherein said exterior panel mounting strip is attached to said second side of said first honeycomb structure running in a transverse direction the corrugations of said first and second corrugated panel, and adapted to receive said exterior panel mounting clips in a sliding engagement such that when said exterior panel mounting clips are engaged with said exterior panel mounting strip, said exterior panel is held in place and forms the exterior surface of the modular building panel;
and
wherein said plurality of interior panel mounting brackets are adapted to receive said plurality of interior panel mounting clips in a sliding engagement such that when said interior panel mounting clips are engaged with said interior panel mounting brackets, said interior panel is held in place and forms the interior surface of the modular building panel.

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Modular building panel

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Modular building panel

Life of this patent

Abstract

Claims18