Panelized structural wall, floor, and roof panel

1 . A panel system comprising:

a foundation floor panel comprising:

a bottom inner panel;

an insulation layer arranged below the bottom inner panel;

a bottom outer panel defining a foundation mount configured to interface with a foundation structure;

a first joist coupled to the bottom inner panel;

a second joist:

laterally offset from the first joist; and

coupled to the bottom inner panel;

a foundation mount blocking:

bridging the first joist and the second joist;

arranged over the foundation mount; and

transferring forces between the foundation structure, the bottom outer panel, the insulation layer, the bottom inner panel, the first joist and the second joist;

a flange:

coupled to the bottom inner panel;

extending upwardly from a second edge of the bottom inner panel; and

configured to fasten to a second floor panel via a series of clinch connections;

a sill plate:

coupled to and extending along a top edge of the first joist;

configured to support a wall panel; and

defining a vertical floor datum;

a tie down:

coupled to the first joist;

extending vertically through the sill plate; and

configured to fasten to the wall panel; and

a primary subfloor:

arranged over the first joist and the second joist opposite the bottom inner panel;

bridging the first and second joists; and

configured to support a finished flooring surface.

2 . The panel system of claim 1 :

further comprising a floating floor panel comprising:

a second bottom inner panel;

a second insulation layer arranged below the second bottom inner panel;

a second bottom outer panel;

a third joist coupled to the second bottom inner panel;

a fourth joist:

laterally offset from the third joist; and

coupled to the second bottom inner panel;

a second flange:

coupled to the second bottom inner panel;

extending upwardly from a third edge of the second bottom inner panel; and

configured to fasten to the foundation floor panel via the series of clinch connections;

a second primary subfloor:

arranged over the third joist and the fourth joist opposite the second bottom inner panel;

bridging the third joist and the fourth joist; and

configured to support the finished flooring surface; and

wherein the foundation floor panel and the floating floor panel are assemblable into a section of a floor via the series of clinch connections:

arranged along the flange of the foundation floor panel and the second flange of the floating floor panel; and

configured to form an interlock securing the flange of the foundation floor panel to the second flange of the floating floor panel.

3 . The panel system of claim 2 , further comprising a secondary subfloor panel:

bridging the second joist of the foundation floor panel and the third joist of the floor panel;

abutting the primary subfloor of the foundation floor panel and the second primary subfloor of the floating floor panel; and

configured to removably nest over the flange of the foundation floor panel and the second flange of the floating floor panel for installation of the series of clinch connections.

4 . The panel system of claim 2 , further comprising a moisture barrier flap:

arranged on the bottom outer panel of the first floor panel; and

configured to overlap a junction between the first floor panel and the second floor panel to prevent ingress of moisture.

5 . The panel system of claim 2 :

wherein the foundation floor panel further comprises a gasket relief:

extending along an edge of the foundation floor panel between the bottom inner panel and the bottom outer panel; and

further comprising a gasket:

located along the gasket relief; and

configured to compress between the gasket relief of foundation floor panel and a second edge of the floating floor panel during installation of the series of clinch connections.

6 . The panel system of claim 1 :

further comprising a prefinished outer footing panel:

bonded to:

an exterior surface the footer element of the wall panel; and

an exterior edge of a floor panel;

insulating a junction between the wall panel and the floor panel; and

defining a prefinished outer surface.

7 . The panel system of claim 1 :

wherein the foundation floor panel further comprises:

an exterior mounting boss extending along outside of first joist;

further comprising cantilevered deck structure comprising:

an upper mounting extrusion:

configured to couple to the exterior mounting boss;

a lower support:

arranged below the upper mounting extrusion; and

fastened to the foundation floor panel;

a vertical strut:

extending between the upper mounting extrusion and the lower support;

a horizontal surface:

extending from the upper mounting extrusion; and

supporting a deck surface.

8 . The panel system of claim 1 , further comprising a rim joist:

extending perpendicular to first joist and second joist;

coupled to:

the first joist via a first joist bracket;

the second joist via a second joist bracket; and

configured to support a wall panel arranged perpendicular to the first joist.

9 . The panel system of claim 1 :

wherein the first joist and the second joist comprise sheet steel;

wherein the sill plate comprises a fiberglass extrusion; and

wherein the insulation layer comprises closed cell foam.

10 . The panel system of claim 1 :

further comprising a wall panel comprising:

a left column element:

configured to carry vertical loads through a left side of the wall panel; and

a right column element:

configured to carry vertical loads through a right side of the wall panel;

a footer element:

extending between the left column element and the right column element; and

comprising a lower flange defining a lower vertical wall datum configured to seat on a vertical floor datum surface of a floor panel to vertically locate the wall panel relative to the floor panel;

an insulative element:

extending between the left column element, the right column element, and the footer element; and

wherein the first wall panel and the floor panel are assemblable via a series of fasteners configured to:

install within the first set of fastener bores and the second set of fastener bores; and

mate the lower vertical wall datum of the first wall to the vertical floor datum of the floor panel.

11 . The panel system of claim 10 :

further comprising a roof panel comprising:

an inner panel:

defining a first inner panel edge configured to rest on the top plate of first wall panel;

an insulation layer extending above the inner panel;

a moisture barrier:

arranged above the insulation layer; and

extending across an exterior surface of the roof panel;

a first joist:

coupled to and extending below the inner panel; and

offset from a first edge of the inner panel;

a second joist:

coupled to and extending below the inner panel;

laterally offset from the first joist; and

offset from a second edge of inner panel opposite the first edge of the inner panel;

a ceiling surface:

coupled to a first lower surface of the first joist and a second lower surface of the second joist;

wherein the roof panel is assemblable to the wall panel via a joist bracket:

defining a first surface coupled to the first joist via a first series of fasteners; and

defining a second surface coupled to the header of the first wall panel via a second series of fasteners.

12 . The panel system of claim 1 :

further comprising a wall panel, in a set of wall panels, comprising:

a left column element:

configured to carry vertical loads through a left side of the wall panel; and

defining a left gasket relief extending vertically along the left column element;

a right column element:

configured to carry vertical loads through a right side of the wall panel;

a footer element:

extending between the left column element and the right column element; and

defining a lower vertical wall datum configured to seat on a vertical floor datum surface of a floor panel to vertically locate the wall panel relative to the floor panel;

a header element:

extending between the left column element and the right column element above the footer element;

an insulative element:

extending between the left column element, the right column element, the header element, and the footer element;

a lower flange extending rearward from the footer element defining:

a lower vertical wall datum configured to seat against a floor datum of the floor panel to locate the wall panel relative to the floor panel; and

a tie down bore;

wherein the tie down of the floor panel installs within the tie down bore of the wall panel to mate the lower vertical wall datum of the wall panel to the vertical floor datum of the foundation floor panel.

13 . The panel system of claim 1 :

wherein the foundation mount of the foundation floor panel comprises:

a thrust plate arranged on the bottom outer panel configured to:

mate with a thrust bearing of a pier foundation; and

transfer a vertical load of the structure onto a foundation pier via the thrust bearing;

further comprising a foundation pier comprising:

a first pier:

configured to support a bottom surface of a structure; and

comprising:

a distal end configured to install below a terrestrial frost line; and

a proximal end configured to extend above the terrestrial frost line;

a collar:

arranged on the proximal end of the first pier;

defining a first cable guide extending along a first horizonal axis; and

defining a second cable guide extending along a second horizonal axis orthogonal to the first horizontal axis;

the thrust bearing arranged on the collar opposite the first pier;

a first cable:

defining a first end coupled to the bottom surface of the structure;

extending along the first horizonal axis;

passing through the first cable guide; and

defining a second end opposite the first end;

a second cable:

defining a third end coupled to the bottom surface of the structure;

extending along the second horizonal axis;

passing through the second cable guide; and

defining a fourth end opposite the third end;

a first spring assembly:

coupled to the bottom surface of the structure and to the second end of the first cable; and

configured to tension the first cable along the first horizontal axis to resist motion of the structure along the second horizontal axis; and

a second spring assembly:

coupled to the bottom surface of the structure and to the fourth end of the second cable; and

configured to tension the second cable along the second horizontal axis to resist motion of the structure along the first horizontal axis.

14 . A panel system comprising:

a roof panel comprising:

an inner panel:

defining a first inner panel edge configured to rest on a top plate of first wall panel;

an insulation layer extending above the inner panel;

a moisture barrier:

arranged above the insulation layer; and

extending across an exterior surface of the roof panel;

a first joist:

coupled to and extending below the inner panel; and

offset from a first edge of the inner panel;

a second joist:

coupled to and extending below the inner panel;

laterally offset from the first joist; and

offset from a second edge of inner panel opposite the first edge of the inner panel;

a flange:

coupled to the inner panel;

extending upwardly from the second edge of the inner panel; and

configured to fasten to a second roof panel via a series of clinch connections; and

a gutter mount:

extending outwardly from the first edge of the roof panel; and

configured to locate a gutter over the top plate of the first wall panel.

15 . The panel system of claim 14 :

further comprising a second roof panel comprising:

a second inner panel:

defining a second inner panel edge configured to rest on a top plate of a wall panel;

a second insulation layer extending above the inner panel;

a second moisture barrier:

arranged above the second insulation layer; and

extending across a second exterior surface of the second roof panel;

a third joist:

coupled to and extending below the second inner panel; and

offset from a second inner panel edge of the second inner panel;

a fourth joist:

coupled to and extending below the second inner panel;

laterally offset from the third joist; and

offset from a third edge of inner panel opposite the second inner panel edge;

a second flange:

coupled to the second inner panel;

extending the second inner panel edge; and

configured to fasten to the first roof panel via a series of clinch connections; and

a second gutter mount:

extending outwardly from an outer panel edge of the roof panel; and

cooperating with the gutter mount to support a gutter at a target angle for water flow,

wherein the roof panel and the second roof panel are assemblable into planar horizontal non-sloped roof surface via the series of clinch connections:

arranged along the flange of the roof panel and the second flange of the second roof panel; and

configured to form an interlock securing the flange to the second flange.

16 . The panel system of claim 15 , further comprising a moisture barrier flap configured to overlap a junction between the roof panel and the second roof panel to prevent ingress of moisture.

17 . The panel system of claim 15 :

wherein the roof panel further comprises a gasket relief:

extending along an edge of the roof panel; and

further comprising a gasket:

located along the gasket relief; and

configured to compress between the gasket relief of the roof panel and the second edge a second roof during installation of the series of clinch connections.

18 . The panel system of claim 14 , wherein the roof panel further comprises a blocking:

extending between the first joist and the second joist; and

configured to prevent rolling of the first joist and the second joist.

19 . The panel system of claim 14 :

further comprising a prefinished outer panel:

bonded to:

an exterior surface the header element of the wall panel; and

an exterior edge of a roof panel;

insulating a junction between the wall panel and the roof panel; and

defining a prefinished outer surface.

20 . A structure comprising:

a floor panel comprising:

a bottom inner panel;

an insulation layer arranged below the bottom inner panel;

a bottom outer panel defining a foundation mount configured to interface with a foundation structure;

a first joist coupled to the bottom inner panel;

a second joist:

laterally offset from the first joist; and

coupled to the bottom inner panel;

a flange:

coupled to the bottom inner panel;

extending upwardly from a second edge of the bottom inner panel; and

configured to fasten to a second floor panel via a series of clinch connections;

a sill plate:

coupled to and extending along a top edge of the first joist;

configured to support a wall panel; and

defining a vertical wall panel datum;

a tie down:

coupled to the first joist;

extending vertically through the sill plate; and

configured to fasten to the wall panel; and

a primary subfloor:

arranged over the first joist and the second joist opposite the bottom inner panel;

bridging the first and second joists; and

configured to support a finished flooring surface; and

a wall panel, in a set of wall panels, comprising:

a left column element:

configured to carry vertical loads through a left side of the wall panel; and

defining a left gasket relief extending vertically along the left column element;

a right column element:

configured to carry vertical loads through a right side of the wall panel;

a footer element:

extending between the left column element and the right column element; and

defining a lower vertical wall datum configured to seat on a vertical floor datum surface of a floor panel to vertically locate the wall panel relative to the floor panel;

a header element:

extending between the left column element and the right column element above the footer element;

an insulative element:

extending between the left column element, the right column element, the header element, and the footer element;

a left clinch flange:

extending rearward from the left column element opposite the exterior façade panel;

laterally offset from the left gasket relief;

configured to mate to a second right clinch flange of a second wall panel installed adjacent the wall panel, via a series of clinch connections; and

defining a left lateral wall datum configured to laterally locate the first wall panel relative to the second wall panel; and

a left return flange:

configured to stiffen the left clinch flange; and

extending laterally from the left clinch flange opposite the second wall panel; and

a roof panel comprising:

an inner panel:

defining a first inner panel edge configured to rest on the top plate of first wall panel;

a moisture barrier:

extending across an exterior surface of the roof panel;

a first joist:

coupled to and extending below the inner panel; and

offset from a first edge of the inner panel;

a second joist:

coupled to and extending below the inner panel;

laterally offset from the first joist; and

offset from a second edge of inner panel opposite the first edge of the inner panel;

a flange:

coupled to the inner panel;

extending upwardly from the second edge of the inner panel; and

configured to fasten to a second roof panel via a series of clinch connections;

wherein wall panel and the roof panel are assemblable via a joist bracket:

defining a first surface coupled to the first joist via a first series of fasteners; and

defining a second surface coupled to the header of the first wall panel via a second series of fasteners; and

wherein the first wall panel and the floor panel are assemblable via a series of fasteners configured to:

install within the first set of fastener bores and the second set of fastener bores; and

mate the lower vertical wall datum of the first wall to the vertical floor datum of the floor panel.