U.S. patent application number 12/205526 was filed with the patent office on 2009-03-05 for rigid wall panel system.
This patent application is currently assigned to GREENSTEEL TECHNOLOGY, INC.. Invention is credited to Steven Barton.
Application Number | 20090056255 12/205526 |
Document ID | / |
Family ID | 40405312 |
Filed Date | 2009-03-05 |
United States Patent
Application |
20090056255 |
Kind Code |
A1 |
Barton; Steven |
March 5, 2009 |
Rigid wall panel system
Abstract
The invention is a prefabricated rigid wall panel assembly
constructed of a plurality of C-shaped studs inserted into kerfs in
a foam block. The closed ends of the C-shaped studs and the foam
block form substantially planar longitudinal edges of the panel
assembly capable of abutting an adjacent panel assembly.
Optionally, a header and/or footer plate inserted is into a
transverse kerf such that the plate overlaps the ends of the studs,
and the header and/or footer plate and the foam block form a
substantially planar transverse edge of the panel assembly.
Adjacent panel assemblies are preferably secured to one another
using a clip, the shape of which depends on the angle at which the
panel assemblies abut. Each panel assembly may also have a wire
chase.
Inventors: |
Barton; Steven; (Bella
Vista, AR) |
Correspondence
Address: |
HENRY LAW FIRM
P.O. BOX 1105
FAYETTEVILLE
AR
72702
US
|
Assignee: |
GREENSTEEL TECHNOLOGY, INC.
Bentonville
AR
|
Family ID: |
40405312 |
Appl. No.: |
12/205526 |
Filed: |
September 5, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60967502 |
Sep 5, 2007 |
|
|
|
Current U.S.
Class: |
52/309.7 ;
52/270 |
Current CPC
Class: |
E04C 2/22 20130101; E04B
1/6116 20130101; E04B 2001/6195 20130101; E04C 2/205 20130101; E04B
1/14 20130101 |
Class at
Publication: |
52/309.7 ;
52/270 |
International
Class: |
E04C 1/00 20060101
E04C001/00 |
Claims
1. A rigid wall panel assembly comprising: a foam block having a
center, an exterior surface, and an interior surface; a plurality
of longitudinal kerfs spaced across the interior surface of the
foam block that do not puncture the exterior surface of the foam
block; and a plurality of C-shaped studs having an open edge and a
closed edge wherein a portion of the C-shaped studs are located
within the longitudinal kerfs, and wherein two of C-shaped studs
are oriented with respect to the foam block such that the open edge
of the two C-shaped studs are oriented towards the center of the
foam block, and wherein the closed edge of the two C-shaped studs
and the foam block form two substantially planar longitudinal edges
of the rigid wall panel assembly.
2. The rigid wall panel assembly of claim 1, further comprising: a
transverse kerf in the foam block; a U-shaped top/bottom plate
having an open edge and a closed edge, wherein a portion of the
U-shaped top/bottom plate is located within the transverse kerf,
and wherein the U-shaped top/bottom plate is oriented with respect
to the foam block such that the open edge of the U-shaped
top/bottom plate is directed towards the center of the foam block,
and wherein the closed edge of the U-shaped top/bottom plate and
the foam block form at least one substantially planar transverse
edge of the rigid wall panel assembly.
3. The rigid wall panel assembly of claim 1, further comprising one
or more wire chases within a recess between a wallboard mounted to
the studs and an interior surface of the foam block.
4. A wall, comprising a plurality of adjacent rigid wall panel
assemblies, each rigid wall panel assembly further comprising: a
foam block having a center, an exterior surface, and an interior
surface; a plurality of longitudinal kerfs spaced across the
interior surface of the foam block that do not puncture the
exterior surface of the foam block; and a plurality of C-shaped
studs having an open edge and a closed edge wherein a portion of
the C-shaped studs are located within the longitudinal kerfs, and
wherein two of C-shaped studs are oriented with respect to the foam
block such that the open edge of the two C-shaped studs are
oriented towards the center of the foam block, and wherein the
closed edge of the two C-shaped studs and the foam block form two
substantially planar longitudinal edges of the rigid wall panel
assembly.
5. The wall of claim 4, each rigid wall panel assembly further
comprising: a transverse kerf in the foam block; a U-shaped
top/bottom plate having an open edge and a closed edge, wherein a
portion of the U-shaped top/bottom plate is located within the
transverse kerf, and wherein the U-shaped top/bottom plate is
oriented with respect to the foam block such that the open edge of
the U-shaped top/bottom plate is directed towards the center of the
foam block, and wherein the closed edge of the U-shaped top/bottom
plate and the foam block form at least one substantially planar
transverse edge of the rigid wall panel assembly.
6. The wall of claim 4 wherein the longitudinal edges of adjacent
rigid wall panel assemblies abut along a plane.
7. The wall of claim 4 wherein the longitudinal edges of adjacent
rigid wall panel assemblies abut along a plane, further comprising
one or more parallel clips having tabs formed to engage the open
edge of two of the C-shaped studs forming the longitudinal edges of
adjacent rigid wall panel assemblies.
8. The wall of claim 4 wherein the longitudinal edges of adjacent
rigid wall panel assemblies abut along a line. The wall of claim 4
wherein the longitudinal edges of adjacent rigid wall panel
assemblies abut along a line, further comprising one or more angled
clips having tabs formed to engage the open edge of two of the
C-shaped studs forming the longitudinal edges of adjacent rigid
wall panel assemblies.
Description
CROSS REFERENCES
[0001] This application claims priority to U.S. Application Ser.
No. 60/967,502, filed Sep. 5, 2007.
GOVERNMENTAL RIGHTS
[0002] None.
BACKGROUND OF THE INVENTION
[0003] This invention relates to a preformed rigid wall panel
system that is durable and easy to manufacture, transport, and
install on-site.
[0004] Wall structures for buildings are generally manufactured on
either a wooden or metal skeletal system of spaced-apart vertical
studs bordered by a top plate and a bottom plate. Such wall
structures have historically been built on-site with workers
manually joining together the vertical studs and top and bottom
plates, then raising the wall structure into place and securing it
to the floor system of the building. A surface covering is then
applied over the frame section, such as gypsum board, drywall, or
plaster. Often, insulation is positioned between the vertical studs
prior to installation of the surface covering.
[0005] In recent years, manufacturers have begun preparing
prefabricated wall framing sections off-site and transporting them
to the construction location. Piecing the prefabricated wall
sections together is done using conventional methods. Specific to
the instant invention, prefabricated wall sections manufactured
with metal studs and plates are insulated with EPS foam. These wall
systems are intended for use in commercial construction, although
they can be used in residential construction as well. The known
wall systems are generally manufactured by spacing apart metal
studs and inserting foam insulation into the void between the stud
spacing. The foam is often attached to the metal studs using a
variety of conventional means, such as adhesives. Prefabricated
wall panels may also be attached to one another using conventional
means such as adhesives, bolts and flat plates, or tongue and
groove connectors. It is an object of the invention to provide a
foam wall panel system that is easy to transport and assemble and
that has integrated means for securing adjacent panels.
[0006] U.S. Pat. No. 6,167,624 (the "'624 patent"), issued to
Lanahan et al., discloses a prior art foam panel having embedded
metal studs. The lateral, vertical edges of the panel have a
tongue-and-groove connector formed into the foam block. Adjacent
panels are fitted together using the tongue-and-groove connectors.
The '624 patent is representative of the deficiencies in the prior
art, as no prior art wall panel known to the inventor has disclosed
a method of joining the vertical edges of adjacent wall panels
together using structural materials. Rather, prior art methods
utilized top and bottom plates overlapping the horizontal edges of
the panels to secure the panels together. This method presents
serious structural deficiencies insofar as the adjacent panels are
held together with foam, rather than stronger structural materials
such as metal. It is an object of the invention to provide a foam
wall panel in which vertical edges of adjacent panels are secured
using metal structural materials to provide the panel with
additional strength.
BRIEF SUMMARY OF THE INVENTION
[0007] The rigid wall panel of the instant invention is more rigid
than those produced in the prior art due to the spacing and
placement of the metal studs with respect to the foam block. The
instant invention utilizes a plurality of spaced-apart, C-shaped
studs that are inserted into a foam block. A C-shaped stud is also
provided at each end of each wall panel section so that when two
panels are joined together, two C-shaped studs abut to form a rigid
connection point. Optionally, the foam block may receive top and
bottom plates that communicate at three points of contact with each
stud forming the panel. Preferably, the panel may be secured
together using clips that engage with and are secured to each of
the abutted metal studs.
[0008] These and other advantages provided by the invention will
become apparent from the following detailed description which, when
viewed in light of the accompanying drawings, disclose the
embodiments of the invention.
BRIEF DESCRIPTION OF TIE DRAWINGS
[0009] FIG. 1 is a perspective view of the rigid wall panel
assembly.
[0010] FIG. 2 is a top view of the rigid wall panel assembly.
[0011] FIG. 3a is a perspective view of a foam block utilized in
the rigid wall panel assembly.
[0012] FIG. 3b is a perspective view of a stud utilized in the
rigid wall panel assembly.
[0013] FIG. 4 is a perspective view showing the installation of a
stud into a foam block.
[0014] FIG. 5a is a perspective view showing the installation of a
top/bottom plate on the rigid wall panel assembly.
[0015] FIG. 5b is a perspective view of a top/bottom plate once
installed on the rigid wall panel assembly.
[0016] FIG. 6 is a perspective view of two parallel rigid wall
panel assemblies abutted together at the longitudinal edges of the
rigid wall panel assemblies.
[0017] FIG. 7 is a top view of a clip connecting together two
parallel rigid wall panel assemblies.
[0018] FIG. 8 is a perspective view of two angled rigid wall panel
assemblies abutted together at the longitudinal edges of the rigid
wall panel assemblies.
[0019] FIG. 9 is a top view of a clip connecting together two
angled rigid wall panel assemblies.
Listing of Components
[0020] 101--rigid wall panel assembly
[0021] 103--C-shaped studs
[0022] 105--foam block
[0023] 107--longitudinal edge
[0024] 109--longitudinal kerfs
[0025] 111--exterior surface
[0026] 113--interior surface
[0027] 115--recess
[0028] 117--wallboard
[0029] 119--transverse kerfs
[0030] 121--top/bottom plate
[0031] 122--transverse edges
[0032] 123--first lip
[0033] 125--second lip
[0034] 127--points of contact
[0035] 129--parallel clip
[0036] 131--tabs
[0037] 133--angled clip
DETAILED DESCRIPTION OF THE INVENTION
[0038] The instant invention is drawn to a rigid wall panel
assembly for use in residential and commercial construction.
[0039] Referring to FIGS. 1 and 2, the rigid wall panel assembly
101 of the instant invention is formed by spacing apart a plurality
of C-shaped studs 103, preferably metal, wherein a sufficient
number of C-shaped studs 103 are used to provide the desired length
for rigid wall panel assembly 101. While the dimensions of the
C-shaped studs 103 can be varied greatly, it is preferable that
each C-shaped stud 103 is approximately five and one-half (51/2)
inches in width. The spacing between C-shaped studs 103 will
largely be determined by building codes and construction
requirements for the location where rigid wall panel assembly 101
will be utilized. The C-shaped studs 103 are inserted into a foam
block 105, preferably made of EPS foam, which allows C-shaped studs
103 to maintain the desired spacing. Each rigid wall panel assembly
101 has a C-shaped stud 103 at each longitudinal edge 107,
preferably such that the open edges of C-shaped studs 103 point
toward the center of foam block 105 and the closed edges of
C-shaped studs 103 are flush with longitudinal edge 107.
[0040] The method of constructing rigid wall panel assembly 101 is
shown in more detail in FIGS. 3a, 3b, and 4. Foam block 105 has a
plurality of longitudinal kerfs 109, which are preferably evenly
spaced across the transverse axis of foam block 105. Longitudinal
kerfs 109 preferably run along the weight-bearing axis of rigid
wall panel assembly 101, which typically lies in the vertical plane
for standard wall installations. However, rigid wall panel assembly
101 may be used in other applications, such as roof framing, in
which case longitudinal kerfs will not be in the vertical plane.
Longitudinal kerfs 109 have a cross-section that is substantially
identical to a predetermined portion of the cross section of
C-shaped studs 103; however, in order for the closed edge of
C-shaped studs 103 to be flush with both longitudinal edges 107,
the longitudinal kerfs 109 at the two longitudinal edges 107 must
be mirror images of each other. Foam block 105 and C-shaped studs
103 form longitudinal edges 107 such that longitudinal edges are
substantially planar. To assemble rigid wall panel assembly 101,
C-shaped studs 103 are inserted into longitudinal kerfs 109, either
manually or by using machinery such as that disclosed in
commonly-owned U.S. application Ser. No. 12/218,678.
[0041] Longitudinal kerfs 109 are shaped such that a portion of
C-shaped studs 103 are recessed within foam block 105 so that a
predetermined width of foam, typically 1.5 inches according to many
local building codes, remains between C-shaped studs 103 and the
exterior surface 111 of foam block 105. Also preferably, C-shaped
studs 103 also protrude from the interior surface 113 of foam block
105 to allow wire chases or other necessary materials to be
installed in the recess 115 between interior surface 113 of foam
block 105 and wallboard 117 that is mounted to rigid wall panel
assembly 101.
[0042] Optionally, as shown in FIGS. 5a and 5b, foam block 105 may
have one or more transverse kerfs 119 for receiving a top/bottom
plate 121. Together, foam block 105 and each top/bottom plate 121
form a substantially planar transverse edge 122. Top/bottom plate
121 is generally U-shaped, and the open edge of top/bottom plate
121 points toward the center of rigid wall panel assembly 101.
Transverse kerfs 119 receive a first lip 123 of the open edge of
top/bottom plate 121, and a second lip 125 of the open edge of
top/bottom plate 121 abuts the portion of C-shaped stud 103
protruding from foam block 105. Top/bottom plates 121 may be
secured to C-shaped studs 103 by various methods, including rivets,
self-tapping screws, or other methods known in the art. Thus
configured, each top/bottom plate 121 provides three points of
contact 127 with each C-shaped stud 103, which allows rigid foam
panel assembly 101 to be much stronger than prefabricated panels of
the prior art. Furthermore, such strength does not sacrifice
insulation capabilities of rigid wall panel assembly 101, as
transverse kerf 119 is cut such that foam block 105 is flush with
the closed edge of top/bottom plate 121.
[0043] Depending on the height and width of rigid wall panel
assembly 101, longitudinal kerfs 109 may be shorter than, the same
length as, or longer than transverse kerfs 119. Persons having
ordinary skill in the art will recognize that the terms
longitudinal and transverse are used for the convenience of the
reader and are not intended as a functional limitation of the
dimensions of the rigid wall panel assembly 101 disclosed
herein.
[0044] As shown in FIGS. 6 and 7, a plurality of rigid wall panel
assemblies 101 may be placed parallel to one another such that
longitudinal edges 107 (and corresponding C-shaped studs 103) of
adjacent rigid wall panel assemblies 101 abut along a plane.
C-shaped studs 103 forming longitudinal edges 107 may then be
fastened together using conventional fastening means. Optionally,
however, one or more parallel clips 129 may be used to secure
adjacent C-shaped studs 103. The cross-section of parallel clip 129
is generally C-shaped and includes one or more tabs 131. Tabs 131
allow one longitudinal side of parallel clip 129 to be fitted over
C-shaped stud 103 such that parallel clip 129 can then be rotated
into place (as seen in FIG. 7). Tabs 131 are then formed so as to
overlap the open edge of C-shaped stud 103 to secure parallel clip
129 to C-shaped stud 103.
[0045] As shown in FIGS. 6 and 7, a plurality of rigid wall panel
assemblies 101 may be placed adjacent to one another at a
predetermined angle such that C-shaped studs 103 corresponding to
longitudinal edges 107 of adjacent rigid wall panel assemblies 101
abut along a line. The predetermined angle shown in FIGS. 6 and 7
is a perpendicular angle, although the invention is not limited to
any particular angle. Due to the minimal amount of communication
between adjacent C-shaped studs 103 forming longitudinal edges 107,
conventional fastening means are not well suited to fastening
together adjacent rigid wall panel assemblies abutting at an angle.
However, one or more angled clips 133 may be used to secure
adjacent C-shaped studs 103. The cross-section of angled clip 133
is generally W-shaped and includes one or more tabs 131. Tabs 131
allow one longitudinal side of angled clip 133 to be fitted over
C-shaped stud 103 such that angled clip 133 can then be rotated
into place (as seen in FIG. 9). Tabs 131 are then formed so as to
overlap the open edge of C-shaped stud 103 to secure angled clip
133 to C-shaped stud 103.
[0046] While the inventors have described above what they believe
to be the preferred embodiments of the invention, persons having
ordinary skill in the art will recognize that other and additional
changes may be made in conformance with the spirit of the invention
and the inventors intend to claim all such changes as may fall
within the scope of the invention.
* * * * *