Interlocking panel building system

Claim 2

A modular construction component comprising: (a) an insulating core; and (b) a pair of metal channels attached to the core wherein the metal channels are attached and glued on opposing sides of the core, each channel having opposing channel flanges extending toward an opposing side of the core wherein a first flange of each of the metal channels covers a portion of an edge of the core, and a second flange of each of the channels is imbedded in the core, said flanges thereby providing structural strength for the component and avoiding a thermal short between the channels.

Claim 3

The component of claim 1 further including inner and outer wooden skins, wherein the core and channels are fixedly sandwiched between the inner and outer skins in a manner allowing for modular interfitting of the component with a mating modular component.

Claim 4

The component of claim 2 wherein a portion of the core is recessed within the inner and outer skins and wherein a portion of the core extends beyond the inner and outer skins for modular interfitting of the component with a mating modular component.

Claim 5

A rectangular wall section having inner and outer wooden wall skins, the wall section further comprising: (a) an insulating rectangular wall core sandwiched between and glued to the wall skins, said wall core having a first exposed vertical edge extending beyond the skins; and (b) a pair of metal wall channels attached and glued to opposite exposed sides of the wall core, each channel having opposing channel flanges extending toward an opposing wooden wall skin, wherein a first flange of each wall channel covers a portion of a first edge of the core and a second flange of each wall channel is embedded in the wall core, and wherein a second vertical, wall core edge and a top and a bottom core portion have a recessed area within the wall skins.

Claim 6

A rectangular wall section having inner and outer wooden wall skins, the wall section further comprising: (a) an insulating rectangular wall core sandwiched between and glued to the wall skins, said wall core having a first exposed vertical edge extending beyond the skins; and (b) a pair of metal wall channels attached and glued to opposite exposed sides of the wall core, each channel having opposing channel flanges extending toward an opposing wooden wall skin, wherein a first flange of each wall channel covers a portion of a first edge of the core and a second flange of each wall channel is embedded in the wall core, and wherein a second vertical, wall core edge and a top and a bottom core portion have a recessed area within the wall skins.

Claim 7

A top plate and bottom plate adapted for interfitting within a top and bottom core portion recessed area of a wall section, each plate comprising: (a) an elongate rectangular insulating beam; and (b) a pair of metal plate channels attached and glued to two opposing edges of the insulating beam, each plate channel having opposing channel flanges extending toward an opposing edge of the beam.

Claim 8

A top plate and bottom plate adapted for interfitting within a top and bottom core portion recessed area of a wall section, each plate comprising: (a) an elongate rectangular insulating beam; and (b) a pair of metal plate channels attached and glued to two opposing edges of the insulating beam, each plate channel having opposing channel flanges extending toward an opposing edge of the beam.

Claim 9

A top header comprising: (a) inner and outer rectangular wooden top header skins; (b) a rectangular insulating top header core sandwiched and glued between a pair of opposing metal header channels and the inner and outer top header skins, and having a recessed area in a top portion of the top header, each header channel having opposing channel flanges extemding toward an opposing header skin; and (c) a wood plate adjacent to a bottom portion of the top header core.

Claim 10

A top header comprising: (a) inner and outer rectangular wooden top header skins; (b) a rectangular insulating top header core sandwiched and glued between a pair of opposing metal header channels and the inner and outer top header skins, and having a recessed area in a top portion of the top header, each header channel having opposing channel flanges extemding toward an opposing header skin; and (c) a wood plate adjacent to a bottom portion of the top header core.

Claim 11

A bottom header comprising: (a) inner and outer rectangular wooden bottom header skins; (b) a rectangular insulating bottom header core sandwiched and glued between a pair of opposing metal bottom header channels and the inner and outer bottom header skins, and having a recessed area in a bottom portion of the bottom header, each header channel having opposing channel flanges extending toward an opposing header skin; and (c) a wood plate adjacent to a top portion of the bottom header core.

Claim 12

A bottom header comprising: (a) inner and outer rectangular wooden bottom header skins; (b) a rectangular insulating bottom header core sandwiched and glued between a pair of opposing metal bottom header channels and the inner and outer bottom header skins, and having a recessed area in a bottom portion of the bottom header, each header channel having opposing channel flanges extending toward an opposing header skin; and (c) a wood plate adjacent to a top portion of the bottom header core.

Claim 13

A rectangular roof section comprising: (a) upper and lower rectangular wooden roof skins; (b) a rectangular insulating roof core sandwiched and glued between the roof skins, said roof core having a first exposed edge extending beyond the skins and a second opposite edge having a recessed area; and (c) a pair of opposing metal roof channels attached and glued on opposing sides of the roof core, each roof channel having opposing channel flanges extending toward an opposing roof skin, and wherein a first flange of each roof channel covers a portion of a first edge of the core and a second flange of each roof channel is embedded in the roof core, thereby permitting interfitting of the first edge within a recessed area of an adjacent roof section.

Claim 14

A rectangular roof section comprising: (a) upper and lower rectangular wooden roof skins; (b) a rectangular insulating roof core sandwiched and glued between the roof skins, said roof core having a first exposed edge extending beyond the skins and a second opposite edge having a recessed area; and (c) a pair of opposing metal roof channels attached and glued on opposing sides of the roof core, each roof channel having opposing channel flanges extending toward an opposing roof skin, and wherein a first flange of each roof channel covers a portion of a first edge of the core and a second flange of each roof channel is embedded in the roof core, thereby permitting interfitting of the first edge within a recessed area of an adjacent roof section.

Claim 15

A modular construction system comprising: (a) a rectangular wall section having inner and outer wooden wall skins, the wall section further comprising: (i) an expanded polystyrene rectangular wall core sandwiched between and glued to the wall skins, said wall core having a first exposed vertical edge extending beyond the skins; (ii) a pair of metal wall channels attached and glued to opposite exposed sides of the wall core, each wall channel having opposing channel flanges extending toward an opposing wall skin, wherein a first flange of each wall channel covers a portion of a first edge of the core and a second flange of each wall channel is embedded in the wall core, and wherein a second vertical wall core edge and a top and a bottom core portion have a recessed area within the wall skins; (b) top plate and bottom plate each comprising: (i) an elongate rectangular expanded polystyrene beam; (ii) a pair of metal plate channels attached and glued to two opposing edges of the beam, each plate channel having opposing channel flanges extending toward an opposing edge of the beam, wherein the top and bottom plates interfit within the top and bottom core portion recessed areas of the wall section; (c) a top header comprising: (i) inner and outer rectangular wooden top header skins; (ii) a rectangular expanded polystyrene top header panel sandwiched and glued between a pair of opposing metal header channels and the inner and outer top header skins, each header channel having opposing channel flanges extending toward an opposing top header skin and the top header having a recessed area in a top portion of the top header panel; (iii) a wood plate adjacent to a bottom portion of the top header panel; (d) a bottom header comprising: (i) inner and outer rectangular wooden bottom header skins; (ii) a rectangular expanded polystyrene bottom header panel sandwiched and glued between a pair of opposing metal bottom header channels and the inner and outer bottom header skins, the bottom header channels having opposing channel flanges extending toward an opposing bottom header skin, and the bottom header having a recessed area in a bottom portion of the bottom header panel; (iii) a wood plate adjacent to a top portion of the bottom header panel; (e) a rectangular roof section comprising: (i) upper and lower rectangular wooden roof skins; (ii) a rectangular expanded polystyrene roof core sandwiched and glued between the roof skins, said roof core having a first exposed edge extending beyond the roof skins and a second opposite edge having a recessed area; (iii) a pair of opposing metal roof channels attached and glued on opposing exposed sides of the roof core, each roof channel having opposing channel flanges extending toward an opposing roof skin, and wherein a first flange of each roof channel covers a portion of a first edge of the core and a second flange of each roof channel is embedded in the roof core, thereby permitting interfitting of the exposed edge within a recessed area of an adjacent roof section; (f) a structural beam comprising: (i) inner and outer oriented strand board beam skins; and (ii) a rectangular expanded polystyrene beam core sandwiched and glued between a pair of opposing metal beam channels and the inner and outer beam skins, each beam channel having opposing channel flanges extending toward an opposing beam skin, and each beam having a wooden upper top and bottom plate adjacent to the core.

Claim 16

A modular construction system comprising: (a) a rectangular wall section having inner and outer wooden wall skins, the wall section further comprising: (i) an expanded polystyrene rectangular wall core sandwiched between and glued to the wall skins, said wall core having a first exposed vertical edge extending beyond the skins; (ii) a pair of metal wall channels attached and glued to opposite exposed sides of the wall core, each wall channel having opposing channel flanges extending toward an opposing wall skin, wherein a first flange of each wall channel covers a portion of a first edge of the core and a second flange of each wall channel is embedded in the wall core, and wherein a second vertical wall core edge and a top and a bottom core portion have a recessed area within the wall skins; (b) top plate and bottom plate each comprising: (i) an elongate rectangular expanded polystyrene beam; (ii) a pair of metal plate channels attached and glued to two opposing edges of the beam, each plate channel having opposing channel flanges extending toward an opposing edge of the beam, wherein the top and bottom plates interfit within the top and bottom core portion recessed areas of the wall section; (c) a top header comprising: (i) inner and outer rectangular wooden top header skins; (ii) a rectangular expanded polystyrene top header panel sandwiched and glued between a pair of opposing metal header channels and the inner and outer top header skins, each header channel having opposing channel flanges extending toward an opposing top header skin and the top header having a recessed area in a top portion of the top header panel; (iii) a wood plate adjacent to a bottom portion of the top header panel; (d) a bottom header comprising: (i) inner and outer rectangular wooden bottom header skins; (ii) a rectangular expanded polystyrene bottom header panel sandwiched and glued between a pair of opposing metal bottom header channels and the inner and outer bottom header skins, the bottom header channels having opposing channel flanges extending toward an opposing bottom header skin, and the bottom header having a recessed area in a bottom portion of the bottom header panel; (iii) a wood plate adjacent to a top portion of the bottom header panel; (e) a rectangular roof section comprising: (i) upper and lower rectangular wooden roof skins; (ii) a rectangular expanded polystyrene roof core sandwiched and glued between the roof skins, said roof core having a first exposed edge extending beyond the roof skins and a second opposite edge having a recessed area; (iii) a pair of opposing metal roof channels attached and glued on opposing exposed sides of the roof core, each roof channel having opposing channel flanges extending toward an opposing roof skin, and wherein a first flange of each roof channel covers a portion of a first edge of the core and a second flange of each roof channel is embedded in the roof core, thereby permitting interfitting of the exposed edge within a recessed area of an adjacent roof section; (f) a structural beam comprising: (i) inner and outer oriented strand board beam skins; and (ii) a rectangular expanded polystyrene beam core sandwiched and glued between a pair of opposing metal beam channels and the inner and outer beam skins, each beam channel having opposing channel flanges extending toward an opposing beam skin, and each beam having a wooden upper top and bottom plate adjacent to the core.

Claim 17

The construction system as recited in claim 9 wherein the wall skin and top and bottom header skins are oriented strand board (OSB) of about 3/8 to 1-inch thickness.

Claim 18

The construction system as recited in claim 10 wherein the wall skin OSB is a four-foot-by-foot sheet.

Claim 19

The construction system as recited in claim 9 wherein the metal wall channels, plate channels, and header channels are formed from galvanized steel from about 0.03 to 0.06-inch thickness.

Claim 20

The construction system as recited in claim 9 wherein the expanded polystyrene has a thermal conductivity K factor of about 0.2 Btu/hour.square foot.degree F.inch and a density in the range of 1-2 pounds per cubic foot.

Claim 21

A corner post adapted for interfitting with an adjacent modular wall section and header section, the post comprising: (a) an insulating core having an interior and exterior 90° angle surface; (b) an outer metal channel-shaped section angled at 90° and glued to an outer surface of the core, the outer section having flanges extending toward the interior surface of the core; (c) an inner metal channel-shaped section angled at 90° and glued to an inner surface of the inner core, the inner section having flanges extending toward the exterior surface of the core; and (d) a pair of wooden skins attached to an outer surface of the metal channel-shaped sections.

Claim 22

A corner post adapted for interfitting with an adjacent modular wall section and header section, the post comprising: (a) an insulating core having an interior and exterior 90° angle surface; (b) an outer metal channel-shaped section angled at 90° and glued to an outer surface of the core, the outer section having flanges extending toward the interior surface of the core; (c) an inner metal channel-shaped section angled at 90° and glued to an inner surface of the inner core, the inner section having flanges extending toward the exterior surface of the core; and (d) a pair of wooden skins attached to an outer surface of the metal channel-shaped sections.

Claim 23

A corner post adapted for interfitting with an adjacent modular wall section and header section, the post comprising: (a) an insulating core having an interior and exterior 45° angle surface; (b) an outer metal channel-shaped section angled at 45° and glued to an outer surface of the core, the outer section having flanges extending toward the interior surface of the core; (c) an inner metal channel-shaped section angled at 45° and glued to an inner surface of the core, the inner section having flanges extending toward the exterior surface of the core; (d) a pair of wooden skins attached to an outer surface of the metal channel-shape sections; and (e) a pair of wooden skins attached to an inner surface of the metal channel-shaped sections.

Claim 24

A corner post adapted for interfitting with an adjacent modular wall section and header section, the post comprising: (a) an insulating core having an interior and exterior 45° angle surface; (b) an outer metal channel-shaped section angled at 45° and glued to an outer surface of the core, the outer section having flanges extending toward the interior surface of the core; (c) an inner metal channel-shaped section angled at 45° and glued to an inner surface of the core, the inner section having flanges extending toward the exterior surface of the core; (d) a pair of wooden skins attached to an outer surface of the metal channel-shape sections; and (e) a pair of wooden skins attached to an inner surface of the metal channel-shaped sections.