U.S. patent application number 10/366248 was filed with the patent office on 2003-08-14 for prefabricated wall panel.
Invention is credited to Egan, Patrick.
Application Number | 20030150183 10/366248 |
Document ID | / |
Family ID | 27663323 |
Filed Date | 2003-08-14 |
United States Patent
Application |
20030150183 |
Kind Code |
A1 |
Egan, Patrick |
August 14, 2003 |
Prefabricated wall panel
Abstract
A prefabricated wall panel and method are disclosed. A panel
including a sheet rock layer and a laminated in-situ foam layer
within a frame is attached to a pre-existing masonry wall, such as
a basement wall.
Inventors: |
Egan, Patrick;
(Indianapolis, IN) |
Correspondence
Address: |
Woodard, Emhardt, Naughton,
Moriarty and McNett LLP
Bank One Center/Tower
111 Monument Circle, Suite 3700
Indianapolis
IN
46204-5137
US
|
Family ID: |
27663323 |
Appl. No.: |
10/366248 |
Filed: |
February 13, 2002 |
Current U.S.
Class: |
52/506.05 ;
52/511 |
Current CPC
Class: |
E04C 2/26 20130101; E04C
2/386 20130101; E04B 1/7675 20130101 |
Class at
Publication: |
52/506.05 ;
52/511 |
International
Class: |
E04B 009/00; E04C
001/40 |
Claims
What is claimed is:
1. A prefabricated wall panel assembly for finishing an inside
surface of a pre-existing wall, comprising; a rectilinear panel of
sheet rock having an inside surface and an outside surface and a
perimeter edge around said surfaces; a rectilinear frame comprising
right and left vertical frame members, said frame being attached to
said panel on its outside surface prior to attachment to the wall;
and, a laminated rigid foam layer along said outside surface of
said sheet rock panel and located within said frame with said frame
being attachable to the wall.
2. The prefabricated wall panel assembly of claim 1 wherein said
rigid foam layer comprises an in situ foam that has been injected
and has been cured within said frame.
3. The prefabricated wall panel assembly of claim 2 wherein said
foam comprises rigid polyurethane foam.
4. The prefabricated wall panel assembly of claim 3 and further
comprising top and bottom horizontal frame members.
5. The prefabricated wall panel assembly of claim 4 wherein said
foam layer comprises an in situ foam that has been injected and has
been cured within said frame members.
6. The prefabricated wall panel assembly of claim 5 wherein said
frame is flush with said perimeter edge of said wall panel at least
along substantial portions of said vertical frame members.
7. The prefabricated wall panel assembly of claim 6 wherein said
frame is flush with said perimeter edge of said wall panel along
the entire perimeter edge.
8. The prefabricated wall panel assembly of claim 7 wherein said
frame is made elongated wooden boards having a cross-sectional
dimension of approximately 1.5 inches by 1.5 inches, and wherein
said sheet rock is at least 4 feet wide by 8 feet long, and wherein
the insulation R-value through said wall panel assembly is at least
10.
9. The prefabricated wall panel assembly of claim 8 wherein said
foam layer is substantially impervious to water and water
vapor.
10. The prefabricated wall panel assembly of claim 9 wherein said
wall panel has an overall thickness of less than 3 inches and is
substantially planer on both the inside and outside surfaces, and
wherein the overall panel thickness is within a tolerance of less
than 1/4 inch across the panel.
11. The prefabricated wall panel assembly of claim 1 wherein said
foam comprises rigid polyurethane foam.
12. The prefabricated wall panel assembly of claim 1 and further
comprising top and bottom horizontal frame members.
13. The prefabricated wall panel assembly of claim 12 wherein said
foam layer comprises an in situ foam that has been injected and has
been cured within said frame members.
14. The prefabricated wall panel assembly of claim 1 wherein said
frame is flush with said perimeter edge of said wall panel at least
along substantial portions of said vertical frame members.
15. The prefabricated wall panel assembly of claim 1 wherein said
frame is flush with said perimeter edge of said wall panel along
the entire perimeter edge.
16. The prefabricated wall panel assembly of claim 1 wherein said
frame is made elongated wooden boards having a cross-sectional
dimension of approximately 1.5 inches by 1.5 inches.
17. The prefabricated wall panel assembly of claim 1 wherein said
foam layer is substantially impervious to water and water
vapor.
18. The prefabricated wall panel assembly of claim 1 wherein said
wall panel has an overall thickness of less than 3 inches and is
substantially planer on both the inside and outside surfaces, and
wherein the overall panel thickness is within a tolerance of less
than 1/4 inch across the panel.
19. A prefabricated wall panel for finishing an inside surface of a
pre-existing wall, consisting essentially of: a rectilinear panel
of sheet rock having an inside surface and an outside surface and a
perimeter edge around said surfaces; a rectilinear frame comprising
top and bottom horizontal frame members and right and left vertical
frame members, said frame being attached to said panel on its
outside surface prior to attachment to the wall; and, a laminated
rigid foam layer adhered directly to said outside surface of said
sheet rock panel and located within said frame with said frame
being attachable to the wall.
20. The prefabricated wall panel of claim 19 wherein said frame is
flush with said perimeter edge of said wall panel along the entire
perimeter edge.
21. The prefabricated wall panel of claim 20 wherein said foam
comprises rigid polyurethane foam.
22. The prefabricated wall panel assembly of claim 19 wherein said
foam layer is substantially impervious to water and water
vapor.
23. The prefabricated wall panel assembly of claim 20 wherein said
foam layer is substantially impervious to water and water
vapor.
24. A method for providing a finish wall panel on a pre-existing
wall, comprising the acts of: within a factory, providing a sheet
rock panel, a foamable media, and a frame member, and in-situ
foaming said foamable media directly on a surface of said sheet
rock and within said frame member; and, curing said foamable media
into a rigid, moisture impervious foam panel adhered directly to
said surface of said sheet rock.
25. The method of claim 24 and further including the acts of
aligning said frame member around and substantially flush with a
perimeter edge of said sheet rock before the act of curing said
foamable media.
26. The method of claim 25 and further comprising the acts of
transporting said panel to a job site, and attaching said panel to
a pre-existing wall.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to prefabricated wall panels,
and more specifically, prefabricated wall panels to be secured to
pre-existing walls.
[0002] There is a large need for finishing pre-existing, unfinished
walls, such as basement walls. Many basement walls get finished as
either a part of original construction or subsequent remodeling to
finish a basement. Typically one would place a vapor barrier
against the masonry surface, frame up a 2.times.4 wall composed of
a top plate and bottom plate and studs every 16" on center. One
would than fill fiberglass insulation batting between the studs
with it fastened to or held adjacent the studs. A second vapor
barrier may then be installed over the studs. Finally sheet rock is
fastened to the studs to form a finished surface. Each step in the
above finishing process requires significant amount of labor.
[0003] The present invention improves on this assembly and method.
It simplifies the construction process, provides an improved
product, is simple, and lends itself well to warehousing, transport
and handling prior to its job site installation.
SUMMARY OF THE INVENTION
[0004] The invention is set forth in the claims below, and the
following is not in any way to limit, define or otherwise establish
the scope of legal protection. In general terms, the present
invention relates to a prefabricated wall panel assembly for
finishing an inset surface pre-existing wall. The wall panel
preferably includes a rectilinear panel of sheet rock, and also
preferably includes a rigid foam layer laminated to the sheet
rock.
[0005] One object of the present invention is an improved
prefabricated wall panel. This and other objects may be discerned
from the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of the backside of a panel
according to one version of the present invention.
[0007] FIG. 2 is a rear elevation view of the panel of FIG. 1.
[0008] FIG. 3 is a side elevation view of the panel of FIG. 1. Note
that in the preferred version, each side view is a mirror image of
the other.
[0009] FIG. 4 is a top plan view of the panel of FIG. 1. Note that
in the preferred version, the bottom view is a mere image of the
top view.
[0010] FIG. 5 is a front elevation view of the wall panel of FIG.
1.
[0011] FIG. 6 is a top cut-away sectional view of portions of two
wall panels according to one version of the present invention
attached to a wall structure W.
[0012] FIG. 7 is a flow chart of a method according to one version
of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] For the purposes of promoting an understanding of the
principles of the invention, reference will now be made to the
embodiments illustrated in the drawings and specific language will
be used to describe the same. It will nevertheless be understood
that no limitation of the scope of the invention is thereby
intended, and alterations and modifications in the illustrated
device and method and further applications of the principles of the
invention as illustrated therein, are herein contemplated as would
normally occur to one skilled in the art to which the invention
relates.
[0014] Wall panel 10 is the preferred version of the present
invention. Preferably, it is a flat, rectilinear sheet
prefabricated to have a sheet of drywall, also called sheet rock
(typically gypsum based) laminated in the factory to a backing
material of rigid, thermal-insulating structural foam that is
substantially impervious to moisture. The sheet rock 40, is of a
standard type, typically in standard dimensions (for example, 4
ft..times.8 ft., 4 ft..times.10 ft., 54".times.12 ft., or
otherwise). Sheet rock 40 likewise typically has standard thickness
of 1/4", 1/2", 5/8" or otherwise.
[0015] Laminated on the back surface of sheet rock 40 is foam panel
30. In the preferred embodiment, foam panel is fabricated in the
factory to be laminated on the sheet rock 40 directly to the sheet
rock without intervening layers. More preferably, the composition
of the in-situ foam making up foam layer 30 is self-adhering to
sheet rock panel 40. A preferred example of such foam is in-situ
foaming of polyurethane foam directly on to the back of the sheet
rock. Polyurethane foam has advantageous characteristics in that it
is structurally rigid, and thereby protects and enhances the
overall strength of panel assembly 10. Additionally, it is
impervious, or at least substantially impervious, to moisture, such
as water and/or water vapor, and therefore acts not only as an
insulation member with good R-value characteristics, (e.g. R value
of at least 10 or more, and about 14 for a 2 inch thick panel) but
also acts as a moisture barrier. The thickness of foam layer 30 may
vary. Accordingly, foam layer thickness T2 will rarely exceed three
(3) inches, and ordinarily will be two (2) inches or less in
thickness. The preferred thickness T2 is the same as the thickness
of frame 50, typically 11/2" inches thick. Thus, for example, the
overall thickness T1 of panel 10 is typically 2 inches.
[0016] Moreover, the back, outside surface 32 of the foam layer, as
compared to the front, inside surface 42 of the sheet rock, are
highly parallel and planer. Preferably, this attribute leads to
uniform overall panel 10 thickness T-1 (see FIG. 4) that does not
vary in thickness beyond a tolerance of approximately 1/4", and
more preferably, about 1/8", and more preferably, a thickness
tolerance of about {fraction (1/16)}" or less. This thickness
tolerance is achieved by careful manufacturing and the
prefabrication of the panel assembly 10 in a factory.
[0017] Wall panel 10 also preferably has a high degree planer
tolerance. Typically, the tolerances of wall panel 10 are held to
planer tolerance the same as the sheet rock used as a component in
the present invention. Preferably, such planar tolerances are less
than 1/4 inch across the panel in a fully supported horizontal
mode.
[0018] Preferably, panel 10 also includes a frame 50 around
portions, and preferably all of the perimeter edge 22 of the panel.
Preferably, the frame is made from wood attached to sheet rock 40,
foam panel 30 and/or both. Typically, the frame is made of 11/2"
.times.11/2" cross-section wood members running along the
respective lengths and widths of the panels. For example, in the
illustrated version, frame members 53 and 55 comprise the vertical
portions of the frame along the side edges of the panel, whereas
frame members 52 and 54 are along the top and bottom, respectively,
of the panel member (see FIG. 2). The frame could be made of metal,
plastic or other material as well.
[0019] Collectively, the frame 50 and foam 30 make up the backing
to the sheet rock 40. The backing, and more typically, the frame
50, are deliberately aligned to be flush with all, or substantially
all, of the perimeter edge of the sheet rock which corresponds to
perimeter edge 22 of the panel. In this way, the backing, such as
the frame, provide support and protection for the edges of the
sheet rock. This reduces or eliminates marring or breakage of the
edges of the sheet rock during transportation, shipping and
handling. The backing may optionally be provided with a tongue and
groove mechanism, typically on the vertical side edges to
facilitate engagements and interlocking. This may include a tongue
and groove or other inter-digitating surfaces on the frame members
55 and 53. It may also include staggering frame members 53 and 55
corresponding to mount inward and outward, respectively, of the
perimeter so that in the final assembled form, adjacent sheet rock
may overlap a laterally projecting frame member of an adjacent
panel in whole or in part. While this optional approach may be
used, it is not preferred in that it provides less perimeter
protection for the edge of the sheet rock that extends proud of the
frame member or the backing member. Also, some or all of the frame
members 51-54 may be omitted or have gaps according to design
considerations. For example, one design would be to omit the wooden
frame members 52 and 54 on the top and bottom edges, leaving only
side frame members for attachment to the wall structure, adjacent
panel members or both. Similarly, while not preferred, the foam
core panel may be made in-situ on the sheet rock in a mold without
any frame members. However, in the preferred version, during the
fabrication process in the factory, the frame members effectively
function as part of the mold to contain the in-situ form making
foam panel 30. Moreover, by having the frame members in place prior
to in-situ molding, foam such as polyurethane foam will expand
against and bind to the frame member adding to the overall
structural strength and homogeneity of the panel.
[0020] FIG. 6 illustrates a top partial cut-away view of two panels
attached to a pre-existing wall member W. Typically, wall member W
is a basement wall, such as a poured concrete wall, cinder block or
other masonry wall. Preferably, the framing structure such as
wooden furring strips 60 is attached to or adjacent to wall 60
using any of a variety of known techniques, including adhesives,
fasteners, header and footer joists or the like. Alternatively, the
present invention may be used without a frame member 60 with panels
of the present invention being secured directly to the masonry wall
W. As shown, the two wall panels corresponding to the "A" and "B"
suffix of the corresponding previously described reference
characters is shown. For example, wall panel with sheet rock 40A is
substantially adjacent to sheet rock 40B. Sheet rock 40A is secured
directly to foam layer 30A and vertical frame member 53A.
Similarly, sheet rock 40B is secured to in-situ foam panel 30B from
the factory as well as vertical frame member 55B. The wall panels
may be attached to the pre-existing wall member W in any number of
ways, including mechanical fasteners, hangers, adhesives and/or
such as nails, screws, staples or otherwise such as shown with
fastener 73A and 73B. Optionally, pre-drilled holes and/or indicia
markings may be provided in corresponding heights or locations to
facilitate fastener installation, although this is not preferred.
In the final assembly, the adjacent sheet rock panels 40A and 40B
include `mud`, namely plaster or other joint filler material used
in the drywall trade. This may be done without tape, or with tape
as is known utilizing sheet rock with preformed recesses to
accommodate joint tape and mud. Thereafter, it is sanded and
finished with paint or otherwise.
[0021] As shown in FIG. 7, the present invention improves
efficiency and simplicity of finishing pre-existing walls such as
basements. FIG. 7 shows a variety of acts used in the method
according to the present invention. Initially, within a factory 85
under factory conditions with precision tolerances as previously
described, one begins by the act of providing sheet rock 81 and the
act of providing frame or framing material 82 and providing foam
83. Preferably, the foam as is previously described, beginning in a
liquid and/or foamable mode in foamed in-situ adjacent to sheet
rock, and preferably within the frame which is also adjacent to
sheet rock. It is injected in the space behind the sheet rock,
typically in openings in the frame. This in-situ foaming acts to
attach the backing, namely the foam and optionally the frame to the
sheet rock in act 84. This is typically done in a press or other
molding operation to maintain the back surface 32 of the foam panel
substantially planer and parallel to the front surface 42 of the
sheet rock as previously described. Typically, a mold release is
used to allow the molding surface forming surface 32 to disengage
from the otherwise adhesive nature of the in-situ foam, such as
polyurethane foam. Preferably, such mold release comprises a thin
film, such as a polymer film, immediately in contact with layer 30.
Such film may be removed at the factory, may be removed at the job
site, or optionally, may be left in place as a part of panel 30
during final installation to adjacent wall W. In any event, the
finished panel assembly is transported from the factory to the job
site. This may be done directly or indirectly, such as transporting
it to home improvement warehouses, lumber yards and the like for
purchase at the retail level by a home "do it yourselfer".
Conversely, it may be shipped directly to a job site depending on
business considerations, all within the scope of act 86.
Thereafter, several panels according to the present invention are
attached to pre-existing walls in act 87, such as for example, in
the assembly of FIG. 6. Thereafter, final finishing of mudding the
joints in act 88 is performed, corresponding to the plastered joint
44 (see 66 as previously described). This may include joint tape as
well as the joint compound. Final finishing, such as paint,
wallpaper or the like may thereafter be applied to the inside
finished surface of the wall.
[0022] While the invention has been illustrated and described in
detail in the drawings and foregoing description, the same is to be
considered as illustrative and not restrictive in character, it
being understood that only the preferred embodiment have been shown
and described and that all changes and modifications that come
within the spirit of the invention are desired to be protected. The
articles "a", "an", "said" and "the" are not limited to a singular
element, and include one or more such element.
* * * * *