초록 ▼

A building module. The building module has a rigid inner construction panel defining a planar surface thereon; one or more rigid brackets each affixed by one or more mechanical fasteners to the planar surface of the inner construction panel; a rigid, closed-cell, spray foam or adhesive matrix contig

A building module. The building module has a rigid inner construction panel defining a planar surface thereon; one or more rigid brackets each affixed by one or more mechanical fasteners to the planar surface of the inner construction panel; a rigid, closed-cell, spray foam or adhesive matrix contiguous to and substantially covering the planar surface of the construction panel and filling and surrounding and/or embedding at least a major portion of the one or more brackets. Each of the one or more brackets bears a planar surface facing substantially away from the planar surface of the inner construction panel. The surface area of the planar surface of each of the one or more brackets is substantially smaller than the surface area of the planar surface of the construction panel to which it is affixed. There is also a method for making a building module, a method for constructing a building using the building module, and brackets useful in the building module.

대표청구항 ▼

1. A building module, comprising: an inner construction panel defining a planar surface thereon;one or more rigid brackets each affixed by one or more mechanical fasteners to the planar surface of the inner construction panel, wherein each of the one or more brackets bears a planar surface facing su

1. A building module, comprising: an inner construction panel defining a planar surface thereon;one or more rigid brackets each affixed by one or more mechanical fasteners to the planar surface of the inner construction panel, wherein each of the one or more brackets bears a planar surface facing substantially away from the planar surface of the inner construction panel, wherein the surface area of the planar surface of each of the one or more brackets is substantially smaller than the surface area of the planar surface of the inner construction panel to which the one or more brackets is affixed; anda rigid, closed-cell, spray polyurethane foam or adhesive matrix contiguous to and substantially covering the planar surface of the inner construction panel and filling to and surround and/or embed at least a major portion of the one or more brackets,wherein the one or more brackets includes first and second slidably coextensive unitary components,wherein the first unitary component includes a back panel,a bottom ledge, andfirst and second side panels,wherein the back panel intersects the first and second side panels at substantially right angles, wherein the first and second side panels intersect the bottom ledge at substantially right angles, wherein the first and second side panels each have an outer surfaces, wherein the first and second side panels each have a plurality of splines protruding at their outer surface extending generally from top to bottom, wherein the back panel is flush and contiguous with respect to the planar surface of the inner construction panel, wherein the back panel is affixed to the planar surface of the inner construction panel,wherein the second unitary component includes a face panel,third and fourth side panels, anda rim,wherein the face panel intersects the third and fourth side panels at substantially right angles, wherein the rim extends around the upper edges of the face panel and the third and fourth side panels, wherein the face panel bears the planar surface of each of the one or more brackets, wherein the third and fourth side panels each have an inner surface, wherein the third and fourth side panels each have a plurality of splines protruding at their inner surface extending generally from top to bottom, wherein the plurality of splines of the first and second side panels are slidably coextensive with the splines of the third and fourth side panels. 2. The module of claim 1, wherein the foam or adhesive matrix fills and surrounds and/or embeds about 60% to about 90% of the depth of the one or more brackets. 3. The module of claim 1, wherein the one or more mechanical fasteners is a selected from the group consisting of screws, bolts, and adhesives. 4. The module of claim 1, wherein the module is a wall unit. 5. The module of claim 1, wherein the module is a ceiling unit. 6. The module of claim 1, wherein the module is a roofing unit. 7. The module of claim 1, wherein the module is a flooring unit. 8. The module of claim 1, wherein the bracket is a plastic bracket. 9. The module of claim 1, wherein the bracket is a metal bracket. 10. The module of claim 1, wherein the bracket is adjustable to accommodate and plumb walls, level floors and ceilings, and slope roofs. 11. The module of claim 1, wherein the inner construction panel is of a material is selected from the group consisting of wood plank, glass, metals, plywood, oriented strand board, particle board, fiberboard, hardboard, gypsum board, masonry, brick, stucco and concrete. 12. The module of claim 1, further comprising an external construction panel affixed to the planar surface(s) of the one or more brackets. 13. The module of claim 12, wherein the foam or adhesive matrix and the planar surface of each of the one or more brackets define a ventilation air gap between the foam and an external panel. 14. The module of claim 1, wherein the surface area of the planar surface of each of the one or more brackets is about 4 square inches or more. 15. The module of claim 1, wherein the surface area of the planar surface of each of the one or more brackets is about 9 square inches or more. 16. The module of claim 1, wherein the surface area of the planar surface of each of the one or more brackets is about 9 square inches to about 25 square inches. 17. A method for constructing a building, comprising: joining a plurality of the building modules of claim 1. 18. The module of claim 1, wherein the module includes the rigid, closed-cell, spray polyurethane foam. 19. A method for making a building module, comprising: (a) affixing one or more rigid brackets to a planar surface of an rigid inner construction panel by one or more mechanical fasteners, wherein the one or more brackets each bears a planar surface facing substantially away from the planar surface of the inner construction panel, wherein the surface area of the planar surface of the one or more brackets is substantially smaller than the surface area of the planar surface of the inner construction panel to which it is affixed; and(b) applying a rigid, closed-cell, spray polyurethane foam or adhesive contiguous to substantially cover the planar surface of the inner construction panel and fill and surround and/or embed at least a major portion of the one or more brackets,wherein the one or more brackets includes first and second slidably coextensive unitary components,wherein the first unitary component includes a back panel,a bottom ledge, andfirst and second side panels,wherein the back panel intersects the first and second side panels at substantially right angles, wherein the first and second side panels intersect the bottom ledge at substantially right angles, wherein the first and second side panels each have an outer surfaces, wherein the first and second side panels each have a plurality of splines protruding at their outer surface extending generally from top to bottom, wherein the back panel is flush and contiguous with respect to the planar surface of the inner construction panel, wherein the back panel is affixed to the planar surface of the inner construction panel,wherein the second unitary component includes a face panel,third and fourth side panels, anda rim,wherein the face panel intersects the third and fourth side panels at substantially right angles, wherein the rim extends around the upper edges of the face panel and the third and fourth side panels, wherein the face panel bears the planar surface of each of the one or more brackets, wherein the third and fourth side panels each have an inner surface, wherein the third and fourth side panels each have a plurality of splines protruding at their inner surface extending generally from top to bottom, wherein the plurality of splines of the first and second side panels are slidably coextensive with the splines of the third and fourth side panels. 20. The method of claim 19, wherein surface area of the planar surface of each of the one or more brackets is about 9 square inches to about 25 square inches. 21. The method of claim 19, wherein the method applies the rigid, closed-cell, spray polyurethane foam. 22. A bracket, comprising: first and second slidably coextensive unitary components, wherein the first unitary component includes a back panel,a bottom ledge, andfirst and second side panels,wherein the back panel intersects the first and second side panels at substantially right angles, wherein the first and second side panels intersect the bottom ledge at substantially right angles, wherein the first and second side panels each have an outer surfaces, wherein the first and second side panels each have a plurality of splines protruding at their outer surface extending generally from top to bottom, wherein the back panel is flush and contiguous with respect to the planar surface of the inner construction panel, wherein the back panel is affixed to the planar surface of the inner construction panel,wherein the second unitary component includes a face panel,third and fourth side panels, anda rim,wherein the face panel intersects the third and fourth side panels at substantially right angles, wherein the rim extends around the upper edges of the face panel and the third and fourth side panels, wherein the face panel bears the planar surface of each of the one or more brackets, wherein the third and fourth side panels each have an inner surface, wherein the third and fourth side panels each have a plurality of splines protruding at their inner surface extending generally from top to bottom, wherein the plurality of splines of the first and second side panels are slidably coextensive with the splines of the third and fourth side panels. 23. A building module, comprising: an inner construction panel defining a planar surface thereon,one or more rigid brackets each affixed by one or more mechanical fasteners to the planar surface of the construction panel, wherein each of the one or more brackets bears a planar surface facing substantially away from the planar surface of the construction panel, wherein the surface area of the planar surface of each of the one or more brackets is substantially smaller than the surface area of the planar surface of the construction panel to which the one or more brackets is affixed; andan exterior panel affixed to the planar surface of each of the one or more brackets,wherein the one or more brackets is substantially free of a rigid structural foam or an adhesive matrix, wherein the one or more brackets is a plurality of the bracket set forth in claim 22. 24. The bracket of claim 22, wherein surface area of the planar surface of each of the one or more brackets is about 9 square inches to about 25 square inches. 25. The module of claim 23, wherein surface area of the planar surface of each of the one or more brackets is about 9 square inches to about 25 square inches.