U.S. patent application number 09/964013 was filed with the patent office on 2003-03-27 for system and method for providing viewports in a closed wall fabrication process.
This patent application is currently assigned to The Dow Chemical company. Invention is credited to Harris, Ellen M., Plsek, William J..
Application Number | 20030056452 09/964013 |
Document ID | / |
Family ID | 25508025 |
Filed Date | 2003-03-27 |
United States Patent
Application |
20030056452 |
Kind Code |
A1 |
Plsek, William J. ; et
al. |
March 27, 2003 |
System and method for providing viewports in a closed wall
fabrication process
Abstract
The present invention provides one or more viewports formed at
predetermined locations that allow inspections of an inside member
of a closed wall system. The viewports can be disposed at
predetermined locations that do not significantly impair the
structural characteristics of the outward layers or inside members.
In at least one embodiment, the viewports are formed in one or more
outward layers during fabrication of a closed wall system.
Generally, the closed wall system can be mass-produced in a
manufacturing facility, although the closed wall system may be
assembled at the job site.
Inventors: |
Plsek, William J.;
(Friendswood, TX) ; Harris, Ellen M.; (Lake
Jackson, TX) |
Correspondence
Address: |
LOCKE LIDDELL & SAPP LLP
600 TRAVIS
3400 CHASE TOWER
HOUSTON
TX
77002-3095
US
|
Assignee: |
The Dow Chemical company
|
Family ID: |
25508025 |
Appl. No.: |
09/964013 |
Filed: |
September 26, 2001 |
Current U.S.
Class: |
52/220.8 ;
52/656.2; 52/745.09; 52/799.1 |
Current CPC
Class: |
E04B 1/14 20130101 |
Class at
Publication: |
52/220.8 ;
52/745.09; 52/656.2; 52/799.1 |
International
Class: |
E04C 002/52 |
Claims
What is claimed is:
1. An inspection system for a closed wall, comprising: a) a closed
wall, having at least one inside member disposed between at least
two outward layers of material; and b) at least one viewport formed
at a predetermined location in at least one of the two outward
layers during fabrication of the closed wall, the viewport location
being determined by a known or anticipated location of the inside
member in the closed wall.
2. The system of claim 1, wherein the viewport is positioned to
align with the inside member, so that the at least one inside
member is observable through the viewport when the viewport is
open.
3. The system of claim 1, wherein each of the two outward layers
comprises a viewport formed therein.
4. The system of claim 1, wherein at least one viewport is
open.
5. The system of claim 1, wherein at least one viewport is
closed.
6. The system of claim 5, wherein the outward layer having the
closed viewport comprises a location indicator of the closed
viewport.
7. The system of claim 5, wherein the closed viewport is formed in
the outward layer prior to coupling of the outward layer with the
inside member.
8. The system of claim 1, wherein the viewport is formed in the
outward layer after coupling of the outward layer with the inside
member.
9. The system of claim 1, further comprising a building having at
least a foundation and a roof associated with the closed wall
system.
10. The system of claim 1, wherein a first viewport in a first
outward layer is positioned to allow one or more first inside
members to be viewed and a second viewport in a second outward
layer is positioned to allow one or more second inside members to
be viewed.
11. The system of claim 1, wherein a first viewport in a first
outward layer is positioned to align with a second viewport in a
second outward layer with the inside member disposed between the
two outward layers.
12. A method of preparing an inspection system for a closed wall,
comprising: a) providing at least one inside member; b) coupling at
least one outward layer with the inside member; and c) forming at
least one viewport in at least one outward layer of material during
fabrication of the closed wall.
13. The method of claim 12, wherein the viewport is formed in the
outward layer after coupling of the outward layer with the inside
member.
14. The method of claim 12, wherein the viewport is formed in the
outward layer prior to coupling of the outward layer with the
inside member and wherein the outward layer is aligned with the
inside member so that the inside member is visible through one or
more viewports when the viewports are open.
15. The method of claim 12, wherein forming the viewport comprises
forming the viewport through the outward layer so that the viewport
is open.
16. The method of claim 12, wherein forming the viewport comprises
forming at least one viewport through only a portion of a thickness
of the outward layer so that the viewport is closed.
17. The method of claim 16, further comprising indicating a
location of the closed viewport on an opposite surface of the
outward layer having the closed viewport.
18. The method of claim 12, further comprising forming a first
viewport in a first outward layer and a second viewport in a second
outward layer and aligning the first and second viewports during
fabrication of the closed wall system.
19. The method of claim 12, further comprising allowing one or more
first inside members to be viewed through at least a first viewport
and one or more second inside members to be viewed through at least
a second viewport.
20. The method of claim 12, further comprising assembling the
closed wall to at least a portion of a building structure and
assembling further building portions to the closed wall.
21. An inspection system for a closed wall, comprising: a) a closed
wall, having at least one inside member disposed between at least
two outward layers of material; and b) at least one viewport formed
at a predetermined location in at least one of the two outward
layers during fabrication of the closed wall, and prior to coupling
of the outward layer having the viewport with the inside member,
the viewport location being determined by a known or anticipated
location of the inside member in the closed wall.
Description
SPECIFICATION
[0001] 1. Field of the Invention
[0002] The invention relates to the building industry. More
specifically, the invention relates to an inspection system and
method for providing viewports in a closed wall.
[0003] 2. Background of the Invention
[0004] In conventional construction, walls are fabricated by
erecting on a foundation a structural frame that is usually formed
from timber. The frame is subsequently clad internally with a
suitable material, which is usually finished to conceal the joints
with a wall covering. An exterior wall is usually made from
concrete block, brick veneer, or a suitable cladding material that
is fastened to the timber frame. Common exterior cladding materials
include wood, fiber-reinforced cement, and aluminum.
[0005] Inspections are usually required throughout the
construction. For example, formal inspections are dictated by
governmental codes and regulations and or privately required
measures. A building inspector will inspect the quality of
materials, spacing, size, and placement of structural members, the
member's attachment to adjacent surfaces, such as the foundation
and roof, and other aspects, as is necessary. Similarly, an
inspection is typically required on electrical, plumbing, and other
services installed in the building. The inspections will typically
occur prior to enclosing the wall, ceiling, or other building
section, because the services or structural members are hidden
after such closure.
[0006] In recent years, the cost of building using conventional
materials has escalated rapidly. Further, new methods have been
sought to make the buildings more thermally efficient and faster to
construct. One technology is the use of composite panels, also
known as "closed wall systems" or simply "closed walls." Such
closed walls typically include one or more structural materials and
one or more, typically two, surface materials, also known as
"skins" that enclose the members therebetween. Some closed walls
include insulating board sandwiched or otherwise disposed between
the skins with or without structural or other members. Typically,
the closed walls are made in relatively large sections, such as
four feet by eight feet or larger. The closed walls can be brought
to the building site, set in place, and fastened to rapidly erect
walls or other portions of the building. Further, the materials
used in the closed walls can be made from non-conventional
materials and promote ecological conservation.
[0007] Despite such advantages, acceptance of the closed wall
technology has been slow. Current standards can dictate a formal
inspection, requiring visual inspection of the interior
construction. This need is problematical in closed wall systems.
For example, important features in a closed wall can no longer been
seen, once the panel is erected at the job site.
[0008] The ability of the inspectors, framers, builders,
superintendents, and other people to inspect the structural members
is believed to at least in part cause some hesitancy to its
widespread use. Presently, for an inspector or other interested
person to examine the wall panel in a system requires either that
one or both skins be removed. However, the skin removal adds time
and complexity to the construction process. Alternatively,
individuals can cut unnecessary and often ill-advised holes in the
closed wall searching for a particular structure that may lie
beneath the skin. Damage can be caused in attempting to find the
structure, so that the wall panel loses its structural integrity or
causes subsequent inspection failure on the building. Thus, the
process can actually add time and expense to an otherwise orderly
construction.
[0009] Thus, there remains a need for a closed wall system that can
readily allow inspection in a controlled and predetermined
manner.
SUMMARY OF THE INVENTION
[0010] The present invention provides one or more viewports formed
at predetermined locations that allow a person performing an
inspection to view an inside member of a closed wall system. The
viewports can be disposed at predetermined locations that do not
significantly impair the structural characteristics of the outward
layers or inside members. In at least one embodiment, the viewports
are formed in one or more outward layers during fabrication of a
closed wall system. Generally, the closed wall system can be
mass-produced in a manufacturing facility, although the closed wall
system may be fabricated at the job site.
[0011] In one embodiment, the invention provides an inspection
system for a closed wall, comprising a closed wall having at least
one inside member disposed between at least two outward layers of
material and at least one viewport formed at a predetermined
position in at least one of the two outward layers during
fabrication of the closed wall.
[0012] Further, the invention provides a method of preparing an
inspection system for a closed wall, comprising providing at least
one inside member, forming at least one viewport in at least one
outward layer of material, and enclosing the inside member between
the outward layer having the viewport and a second outward
layer.
[0013] The invention also provides an inspection system for a
closed wall, comprising a closed wall having at least one inside
member disposed between at least two outward layers of material,
and at least one viewport formed at a predetermined location in at
least one of two outward layers during fabrication of the closed
wall and prior to covering of the outward layer having a viewport
with the inside member, the location being determined by a known or
anticipated location of the inside member in the closed wall.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] A more particular description of the invention, briefly
summarized above, may be had by reference to the embodiments
thereof that are illustrated in the appended drawings and described
herein. However, it is to be noted that the appended drawings
illustrate only some embodiments of the invention. Therefore, the
drawings are therefore not to be considered limiting of its scope,
for the invention may admit to other equally effective
embodiments.
[0015] FIG. 1 is a perspective schematic view of a building having
a closed wall.
[0016] FIG. 2 is a perspective schematic view of a closed wall with
an open viewport.
[0017] FIG. 3 is a cross-sectional schematic view of a closed wall
with a closed viewport.
[0018] FIG. 4 is a cross-sectional schematic view of a closed wall
with another closed viewport.
[0019] FIG. 5 is a cross-sectional schematic view of a closed wall
with another closed viewport.
DETAILED DESCRIPTION OF THE INVENTION
[0020] FIG. 1 is a perspective schematic view of a building having
a closed wall. A building 10 is representative of any building upon
which a closed wall may be installed. Building 10 can include
residential, commercial, industrial, and other types of structures.
The building can include any shape that can be constructed such as
rectangular, square, multi-story, single-story, geodesic, or any
other shape in which a building may be made. Generally, a building
will include a foundation 12, walls 14, and roof 16.
[0021] The foundation 12 can be any typical foundation, such as but
not limited to, a slab, wood, beam, steel, raised platform, and
other types of underlying supports. Further, the foundation can be
the upper level of a lower story in a multi-story building.
Generally, one or more walls 14 form a supporting surface between
the foundation and a roof. The term "wall," "walls," and like terms
are used broadly herein and can include exterior or interior walls
that may be vertical, horizontal, or at angles to the foundation,
as is appropriate to the particular building design.
[0022] The roof 16 is shown to be an angled roof as would generally
exist in many buildings. However, it is to be understood that the
roof can have any shape as is appropriate, including a flat roof
found in many buildings. Further, the building 10 can have one or
more doors 18 and one or more windows 20. An exterior 22 of the
building 10 generally includes an exterior medium such as brick,
stone, metal, wood, fiberglass, composites, and other materials to
protect from weather, theft, and other aspects known to those with
ordinary skill in the art.
[0023] A closed wall, shown in more detail in FIG. 2, can be
installed inwardly of the building exterior 22. The closed wall
generally is a composite wall containing a first outward layer 24
and a second outward layer 26 with one or more inside members
enclosed or otherwise disposed therebetween. One or more of the
outward layers 24, 26 can include a variety of structural or
nonstructural material. For example, the outward layers can include
materials made from sheetrock, plywood, particle board, oriented
strand board (OSB), laminates, fiberboard, insulation boards and
other insulating materials, films, plastics, metals, and other
building materials. The second outward layer can be made of similar
materials.
[0024] The term "inside member" is intended to include any
member(s) or feature(s) that can be disposed or formed at least
partially between the first and second outward layers 24, 26. For
example, some inside members can be studs, insulation, headers,
elements of the plumbing or electrical systems, such as pipes,
vents, conduits, wires, and rigid and flexible insulation, or other
elements as can exist between the two outward members in a
building. Further, the inside members can include openings, such as
holes of various sizes and shapes, access ports, and other void
areas. In at least one embodiment, a standard closed wall thickness
can be formed from about {fraction (7/16)} inch thick outward
layers and each about 31/2 inches thick inside members, although
the thicknesses can vary depending on the building and materials
used. Insulative, plumbing, electrical, and other elements can be
installed therein.
[0025] One exemplary embodiment of various inside members that can
generally be included in a closed wall is shown in the exemplary
embodiment of FIG. 1. Full-length studs 28, generally known as
kings studs, are used to support the wall along its length. Shorter
studs 30, known as Jack studs, can be used to support headers 32
that can span distances laterally between king studs 28. Insulation
29 can be placed between one or more of the studs and throughout
the building structure. Shorter supports 34 may be used to support
other headers 36 below building structures, such as the window 20.
A structure supporting the roof 16, generally termed herein upper
structure 38 can include joists, rafters, braces, and other
supports. Further, the upper structure 38 can include girders,
beams, and other supports for multi-story building structures.
[0026] In at least one embodiment, one or more of the outward
layers can be laminated or otherwise coupled to the inside member,
such as a insulation foam core, during the fabrication process.
Alternatively, the outward members can be provided and the foam
core or other inside member can be formed between the outward
layers.
[0027] Other inside members disposed between the outward layers 24,
26 can include elements of the plumbing system 40, such as pipes,
vents, drains, and other plumbing elements. Similarly, the inside
members disposed in the space between the outward layers 24, 26 can
include elements of an electrical system. Such elements can include
conduits, wires, boxes, switches, and other typical electrical
elements.
[0028] An interior 44 is formed inward of the closed wall. As
described above, generally an inspector can inspect the structure
from the interior 44 of a typical construction and determine that
the various members are satisfactory. With the closed wall system,
the inside elements described above are not visible and not subject
to ready inspection to determine the sufficiency, quality, and
presence of the inside member(s). The term "inspector" is used
broadly herein as intended to include any person or device that
views, determines, ascertains, measures, examines, or otherwise
inspects one or more items of interest. The viewports of the
present invention, shown in FIG. 2, provide an ability to readily
inspect interior portions of the closed wall.
[0029] FIG. 2 is a perspective schematic view of a closed wall with
an open viewport. The closed wall 50 generally includes a first
outward layer 24 and a second outward layer 26. The inside member
51 can include one or more elements such as studs 52, 58, and 60
and other structural elements, and insulation member 54. The
insulation member 54 can include any insulation material generally
used in closed wall systems, including relatively rigid foam cores,
polyurethane, polystyrene, EPS, XPS, and polyisocyanurate, more
flexible materials, such as fiberglass batting, or other materials
known to those with ordinary skill in the art. Further, the inside
member(s) 51 can include plumbing elements 56, such as pipes and
other elements described above, and electrical element(s) 57 such
as an electrical wire, conduit, and other general electrical
elements, as well as features, such as openings through which the
plumbing, electrical and other elements can be disposed or accessed
in the closed wall. Other systems can be included within the gamut
of inside member(s) 51, as would generally be found in a building
structure.
[0030] The present invention allows an inspection of the inside
members in a predetermined and controlled manner. The inspection
system of the present invention includes one or more viewports 62
formed at predetermined locations in one or more of the outward
layers 24, 26. The predetermined locations of the viewports can be
determined by the known or anticipated locations of the inside
member(s) to be inspected. In at least one embodiment, the
viewport(s) 62 can be formed through the thickness of the outward
layer(s). If desired, the viewport can be resealed upon completion
of the inspection by a suitable insert, plug, or fill material.
[0031] In at least one embodiment, the viewports 62 can be spaced
at predetermined intervals to account for general spacing of
structural members, requested spacing by an inspector or architect,
or some other requirements. The viewports 62 can be spaced in line
or staggered at some predetermined configuration. If the viewports
are in a vertical closed wall, then it may be advantageous to have
the viewports at some position that would readily facilitate
viewing through the viewports, such as an average eye-level
height.
[0032] The predetermined viewport positions can advantageously be
at junctions where such positions have minimal, if any, structural,
visual, insulative, or other effect upon the associated outward
layer. The viewports can be made at specifically selected strategic
locations to view one or more inside members, such as junctions
between studs and headers, junctions having multiple inside
members, angles or bends in piping that may need inspection for
leaks, and other locations based on selected criteria as may be
appropriate in general or for job-specific closed walls.
Alternatively, the viewports can be made at predetermined positions
that are uniformly spaced in the closed walls. Further, the
viewports can be a standard size or may vary in shape and size
depending on the location and size of the inside member(s) to be
viewed, such as viewport 62'. Some viewports can be at least
partially closed, such as viewport 62", including viewports
described in FIGS. 3-5. In at least one embodiment, the viewport
can be covered by a transparent or translucent material so that the
inside member is still viewable, and thus still considered an open
viewport herein.
[0033] The viewports can be formed after coupling the inside
member(s) with the outer layer(s). Viewports can also be formed
prior to coupling the outward layer(s) with the inside member.
Generally, the outward layers are coupled to insulative or
structural members. The viewports can be formed in the outward
layers after or prior to such coupling. The term "coupling" is used
broadly herein and is intended to include any method of securing,
binding, bonding, fastening, attaching, joining, inserting therein,
forming thereon or therein, or otherwise associating one or more of
the layers and members together. Generally, the inside members are
not otherwise visible from the external faces of the outward layers
after assembly of the wall into the building structure and
sometimes after fabrication of the closed wall itself.
[0034] Further, the viewports can be formed on both outward layers.
For example, the viewports can be formed in the outward layer 24,
so that inspections can be made of the closed wall attachment to
the foundation or adjacent structure. Other viewports can be formed
in outward layer 26, so that inspections of plumbing, electrical,
framing members, such as pipes, wiring, conduit, studs and headers,
and other inside members may be made even after the exterior 22 of
the building is installed.
[0035] The viewport can be created consistently in predetermined
positions in a manufacturing environment. Alternatively, the
viewport can be formed in the outward layers at other stages of the
overall fabrication process of the closed wall. In some
embodiments, the one or more of the outer layers may be coupled
with the inside member at the job site. The viewports can be formed
at a job site in the closed walls at predetermined positions.
[0036] The viewports can be produced in any manner known to those
with ordinary skill in the art including, but not limited to,
manually, power-assisted such as with electrical and pneumatic
tools, semi-automatically with an operator directing the formation
of the viewport, or in an automatic, integrated system as part of
the outward layer manufacturing process. Such an automatic
integrated system can include, for example, mixers, presses, ovens,
conveyors, punches, and other equipment, as would be apparent to
those with ordinary skill in the art, given the understanding
provided by the description of the invention contained herein.
[0037] In one embodiment, a viewport can be formed in the first
outward layer to align with any inside member 51 disposed between
the outward layers 24, 26, such that the inside member can be
viewed either directly or at some angle through a viewport.
Further, a viewport can be formed in the other outward layer and
can be aligned with a viewport in the first outward layer so that
by looking through one viewport the other viewport can be seen.
This positioning may facilitate ready inspection of these inside
members. The viewport can be plugged or otherwise closed after
inspection to facilitate thermal insulative properties, air flow,
privacy, and other aspects.
[0038] FIG. 3 is a cross-sectional schematic view of a closed wall
with a closed viewport. In this embodiment, a viewport 65 does not
extend through the thickness of the corresponding outward layer and
is closed. A closed viewport 65 can be formed through a portion of
the corresponding outward layer, generally leaving a relatively
thin portion 66 of the corresponding outward layer. In one
embodiment, the closed viewport 65 can be formed on an inside
surface of the outer layer, so that the viewport is substantially
hidden from the outside. Alternatively, the viewport can be formed
on an outside surface of the outer layer, as described in FIG.
4.
[0039] The thin portion 66 can be removed if desired at a later
time to allow an inspection of the inside member 51. For example,
the thin portion 66 can be removed mechanically with a hammer or
screwdriver, chisel, or automatically with power tools, such as a
router, or other devices as could be used in a typical construction
job site. Further, the viewport can have a weakened portion 70
about its periphery or another portion of the viewport to
facilitate removal of at least part of the thin portion 66. The
weakened portion 70 can be formed, for example, by perforating, die
cutting, and other methods of weakening a material to facilitate
later removal as is known in the art. The weakened portion 70 can
extend fully through the thickness of the thin member and/or outer
layer or partially therethrough.
[0040] An indicator 66 can be placed on an opposite surface from
the closed viewport 65 to indicate a location of the viewport 65
when the viewport 65 is hidden from external view. In at least one
embodiment, the indicator 66 can be formed about the periphery or
another portion of the viewport and include the weakened portion
70. The indicator can also include a marking, indention,
protrusion, or other element that would indicate the presence of a
viewport. Thus, numerous viewports 65 on the material layer can be
formed in one or more of the outward layers, but hidden from
external view and accessed at discretionary times and places.
[0041] If the viewport 65 is opened, the opening can be closed if
desired subsequent to the inspection by inserting plugs, fill
material, or other elements that restrict the sight, air flow,
noise, and disadvantageous conditions. Alternatively, the thin
portion 66 can be replaced with a translucent or transparent
member, so that the closed viewport 65 can function as an open
viewport, in that the inside member 51 can be viewed through the
viewport.
[0042] FIG. 4 is a cross-sectional schematic view of a closed wall
with another embodiment of the closed viewport. The embodiment is
similar to the embodiment described in reference to FIG. 3. The
viewport 65 is formed toward the outer surface of the outward
layer(s) 24, 26 and the thin section 66 is formed inwardly from the
outer surface. In this and other embodiments described herein, a
weakened portion 70 can be formed in the thin section and/or
outward layer to facilitate removal of at least part of the thin
section by perforating, die cutting, or by other methods of at
least partially weakening materials to facilitate later removal, as
is known in the art.
[0043] FIG. 5 is a cross-sectional schematic view of a closed wall
with another embodiment of the closed viewport. In some
embodiments, the closed viewports 65 may be formed without the thin
member, for example, by using a weakened portion 70. The weakened
portion 70 can define the periphery of the viewport in the outer
layer, so that if the weakened portion is removed, the viewport is
at least partially open. The weakened portion can extend partially
or fully through the thickness of the outer layer.
[0044] While the foregoing is directed to various embodiments of
the present invention, other and further embodiments can be devised
without departing from the basic scope thereof. For example, the
various methods and embodiments of the invention can be included in
combination with each other to produce variations of the disclosed
methods and embodiments. Discussion of singular elements can
include plural elements and vice-versa. Also, any directions shown
or described such as "top," "bottom," "left," "right," "upper,"
"lower," and other directions and orientations are described herein
for clarity in reference to the figures and are not to be limiting
of the actual device or system or use of the device or system. The
device or system can be used in a number of directions and
orientations. Further, the order of steps can occur in a variety of
sequences unless otherwise specifically limited. The various steps
described herein can be combined with other steps, interlineated
with the stated steps, and/or split into multiple steps.
Additionally, the headings herein are for the convenience of the
reader and are not intended to limit the scope of the
invention.
[0045] Further, any references mentioned in the application for
this patent as well as all references listed in the information
disclosure originally filed with the application are hereby
incorporated by reference in their entirety to the extent such may
be deemed essential to support the enabling of the invention(s).
However, to the extent statements might be considered inconsistent
with the patenting of the invention(s), such statements are
expressly not meant to be considered as made by the Applicants.
* * * * *