U.S. patent application number 13/065386 was filed with the patent office on 2012-09-27 for frame unit and method.
Invention is credited to Marko Spiegel.
Application Number | 20120240501 13/065386 |
Document ID | / |
Family ID | 46846215 |
Filed Date | 2012-09-27 |
United States Patent
Application |
20120240501 |
Kind Code |
A1 |
Spiegel; Marko |
September 27, 2012 |
FRAME UNIT AND METHOD
Abstract
An insulated frame unit for enclosing a wall to provide a highly
insulated and airtight wall is provided. The frame unit includes a
panel that is formed from a rigid insulated composition such as an
expanded foam composition. The panels can be mounted to a wall
frame in rows and columns to enclose the wall, and may include
outwardly extending flanges that can cooperate with a flange of an
adjacent frame unit to provide a stud-receiving opening into which
a stud is inserted when mounting the frame units to the frame of
the building. The frame unit is mountable to the frame with the
interior side of the stud extending from the inner side of the
frame unit so that adequate space is provided between the inner
side of the frame unit and an interior finish member mounted to the
interior side of the studs.
Inventors: |
Spiegel; Marko; (LaFox,
IL) |
Family ID: |
46846215 |
Appl. No.: |
13/065386 |
Filed: |
March 21, 2011 |
Current U.S.
Class: |
52/309.4 ;
52/404.4; 52/741.4; 52/745.09 |
Current CPC
Class: |
E04B 1/6145 20130101;
E04B 1/24 20130101; E04B 1/26 20130101; E04B 2001/2481
20130101 |
Class at
Publication: |
52/309.4 ;
52/404.4; 52/745.09; 52/741.4 |
International
Class: |
E04B 1/74 20060101
E04B001/74; E04B 2/04 20060101 E04B002/04; E04B 1/66 20060101
E04B001/66; E04C 2/20 20060101 E04C002/20 |
Claims
1. An insulated frame unit for use in constructing an exterior wall
of a building that has an exterior finish member for the exterior
of the building and an interior finish member for the interior room
that is defined by the wall, the wall including a plurality of
spaced apart generally vertical studs, the studs having an exterior
side facing the exterior of the building and an opposed interior
side facing the interior room, and the studs having a generally
predetermined thickness, predetermined width, and spacing between
the studs of at least about 12 inches, the frame unit comprising: a
panel composed substantially of a rigid foam insulating material,
the panel having first and second generally opposed ends, and third
and fourth generally opposed ends, an inner side and an outer side;
and at least two stud-receiving openings in the inner side of the
panel, the stud-receiving openings generally parallel to each other
and extending between the first and second ends of the panel, the
stud-receiving openings having a width that is sufficient to allow
a stud to be mounted within the stud-receiving openings, and the
stud-receiving openings having a depth that is less than the
predetermined width of the stud, so that when the exterior side of
the stud has been fully inserted into the stud-receiving opening
the interior side of the stud is spaced away from the inner side of
the panel for providing a service chamber between the inner side of
the panel and an interior finish member secured to the interior
side of the studs, and whereby an exterior finish member can be
secured proximate to the outer side of the panel; and the third end
of the panel having a first flange and first recess, and the fourth
end of the panel having a second flange and a second recess whereby
the first flange of the panel of the insulated frame unit is
adaptable to be positioned in the second recess of a second
insulated frame unit substantially identical to the insulated frame
unit to thereby provide a stud-receiving channel.
2. The insulated frame unit of claim 1 further comprising the panel
including an exterior sheathing adhered to the outer side of the
panel for attaching an exterior finish member to the outer
sheathing.
3. The insulated frame unit of claim 2 further comprising the panel
including an interior sheathing adhered to the inner side of the
panel and extending between the stud-receiving openings, the
interior sheathing for securing to the studs to provide rigidity
when a wall is formed from one or more frame units.
4. The insulated frame unit of claim 1 further comprising the panel
including an interior sheathing adhered to the inner side of the
panel and extending between the stud-receiving openings, the
interior sheathing for securing to the studs to provide rigidity
when a wall is formed from one or more frame units.
5. The insulated frame unit of claim 1 further comprising the first
end, the second end, the third end and the fourth end of the panel
each having a flange and a recess to allow the panel to abut with
other substantially identical panels when one other panel is
positioned adjacent each of the second end, the third end and the
fourth end of the panel, the recess of the first end providing a
space for allowing a sill to be positioned therein with the flange
of the first end for extending below the sill along the exterior
side of a foundational wall.
6. The insulated frame unit of claim 5 further comprising the panel
including an exterior sheathing adhered to the outer side of the
panel for attaching an exterior finish member to the outer
sheathing.
7. An insulated frame unit for use in constructing an exterior wall
of a building that has an exterior of the building and an interior
room that is defined by the wall, the wall including a plurality of
spaced apart generally vertical studs, the studs having an exterior
side facing the exterior of the building and an opposed interior
side facing the interior room, and the studs having generally
predetermined thickness, predetermined width, and spacing between
the studs greater than about twelve inches, the frame unit
comprising: a panel composed substantially of a rigid insulating
material, the panel having a body with first and second generally
opposed ends, and third and fourth generally opposed ends, the
panel having an inner side and an outer side; at least first and
second stud-receiving openings in the inner side of the panel, the
first stud-receiving opening being a slot in the inner side of the
panel that is spaced from the third and fourth sides of the body of
the panel, the second stud-receiving opening being located along
the fourth end of the panel, the stud-receiving openings being
generally parallel to each other and extending between the first
and second ends of the panel, the stud-receiving openings having a
width that is sufficient to allow a stud to be mounted within the
stud-receiving openings, a first flange extending outwardly from
the third end of the body of the panel adjacent the inner side of
the panel, and a second flange extending outwardly from the fourth
end of the body of the panel adjacent the outer side of the panel,
the length of the second flange being greater than the length of
the first flange.
8. The insulated frame unit of claim 7 wherein the rigid insulating
material is rigid foam.
9. The frame unit of claim 7 wherein when the third side of the
panel of the frame unit is positioned adjacent the fourth side of a
second panel of a second frame unit that is substantially identical
to the frame unit, the first flange of the third side of the panel
is overlapped by the second flange of the fourth side of the second
panel of the second frame unit and with the first flange of the
panel positioned within the second stud-receiving opening of the
second panel of the second frame unit to form a first
stud-receiving channel adjacent the third end of the panel, and
when the fourth side of the panel is positioned adjacent the third
side of a third panel of a third frame unit that is substantially
identical to the frame unit, the second flange of the fourth side
of the panel overlaps the first flange of the third side of the
third panel of the third frame unit and with the first flange of
the third side of the third panel of the third frame unit
positioned within the second stud-receiving opening of the first
panel to form a second stud-receiving channel adjacent the fourth
end of the panel.
10. The insulated frame unit of claim 9 wherein the width of the
slot is approximately the predetermined thickness of the stud
positioned therein to a provide an interference fit between the
slot and the stud, and the width of each of the first and second
stud-receiving channels is approximately the predetermined
thickness of a stud received therein for providing an interference
fit.
11. The insulated frame unit of claim 9 further comprising the
stud-receiving openings having a depth that is less than the
predetermined width of the stud, so that when the exterior side of
the stud has been fully inserted into the stud-receiving opening
the interior side of the stud is spaced away from the inner side of
the panel for providing a service chamber between the inner side of
the panel and an interior finish member when the interior finish
member is secured to the interior side of the studs.
12. The insulated frame unit of claim 11 further comprising a third
flange extending outwardly from the first end of the body of the
panel adjacent the outer side of the panel and a fourth flange
extending outwardly from the second end of the body adjacent the
inner side of the panel.
13. An exterior wall construction for a building comprising: a
frame having a plurality of spaced apart generally parallel studs,
the studs having an exterior side facing the exterior of the
building and an opposed interior side facing an interior of the
building, and the studs having a generally predetermined thickness,
predetermined width, and spacing between the studs of at least
about 12 inches; first and second insulated frame units, each
insulated frame unit comprising a panel composed substantially of
rigid insulating material, the panel having first and second
generally opposed ends, and third and fourth generally opposed
ends, an inner side and an outer side, the panel including a
stud-receiving opening in the inner side of the panel, the
stud-receiving opening having a stud positioned therein with the
interior side of the stud spaced inwardly from the inner side of
the panel, the first insulated frame unit positioned adjacent the
second insulated frame unit; an interior finish member secured to
the interior side of the stud, the interior finish member spaced
from the inner side of the panel to provide a service chamber
between the inner side of the panel and the interior finish member;
and each of the first and second insulated frame units having a
first flange extending outwardly from the third end of the panel
adjacent the inner side of the panel, and a second flange extending
outwardly from the fourth end of the panel adjacent the outer side
of the panel, the length of the second flange being greater than
the length of the first flange, the first insulated frame unit
positioned adjacent the second insulated frame unit so that the
third side of the panel of the first insulated frame unit is
adjacent the fourth side of the panel of the second insulated frame
unit, and the second flange of the second insulated frame unit
overlaps the first flange of the first insulated frame unit to
thereby provide the stud-receiving opening.
14. (canceled)
15. An exterior wall construction for a building comprising: a
frame having a plurality of spaced apart generally parallel studs,
the studs having an exterior side facing the exterior of the
building and an opposed interior side facing an interior of the
building, and the studs having a generally predetermined thickness,
predetermined width, and spacing between the studs of at least
about 12 inches; and first and second insulated frame units, each
of the insulated frame units comprising a panel composed
substantially of rigid insulating material, the panel having a body
with first and second generally opposed ends, and third and fourth
generally opposed ends, the panel having an inner side and an outer
side, a first flange extending outwardly from the third end of the
body of the panel adjacent the inner side of the panel, and a
second flange extending outwardly from the fourth end of the body
of the panel adjacent the outer side of the panel, the length of
the second flange being greater than the length of the first
flange, the first insulated frame unit positioned adjacent the
second insulated frame unit so that the third side of the panel of
the first insulated frame unit is adjacent the fourth side of the
panel of the second insulated frame unit, and the second flange of
the second insulated frame unit overlaps the first flange of the
first insulated frame unit to thereby provide a stud-receiving
opening, and the stud-receiving opening having a stud positioned
therein.
16. The exterior wall construction of claim 15 further comprising
the stud having an exterior side and an interior side, the exterior
side of the stud positioned in the stud-receiving opening and an
interior side of the stud spaced inwardly from the inner side of
the panel; and an interior finish member secured to the interior
side of the stud, the interior finish member spaced from the inner
side of the panel to provide a service chamber between the inner
side of the panel and the interior finish member.
17. A method of constructing an exterior wall of a building having
a frame having a plurality of spaced apart generally parallel
studs, the studs having an exterior side facing the exterior of the
building and an opposed interior side facing an interior of the
building, and the studs having a generally predetermined thickness,
predetermined width, and spacing between the studs of at least
about 12 inches comprising: providing a plurality of insulated
frame units, each insulated frame unit comprising a panel composed
substantially of rigid insulating material, the panel having first
and second generally opposed ends, and third and fourth generally
opposed ends, an inner side and an outer side, the panel including
a stud-receiving opening in the inner side of the panel, providing
a first flange extending outwardly from the third end of the panel
adjacent the inner side of the panel, and a second flange extending
outwardly from the fourth end panel adjacent the outer side of the
panel, the length of the second flange being greater than the
length of the first flange; installing the plurality of insulated
frame units onto the frame to enclose the frame by installing an
insulated frame unit onto the frame by positioning the exterior
side of the stud within the stud-receiving opening in the inner
side of the panel and with the interior side of the stud spaced
from the inner side of the panel; installing a first insulated
frame unit adjacent a second insulated frame unit so that the third
side of the panel of the first insulated frame unit is adjacent the
fourth side of the panel of the second frame unit and the second
flange of the panel of the second insulated frame unit overlaps the
first flange of the panel of the first insulating frame unit
whereby the overlapping of the second flange of the second
insulated frame unit with the first flange of the first frame unit
forms the stud-receiving opening; and installing an interior finish
member to the interior side of the stud with the interior finish
member spaced from the inner side of the panel to provide a service
chamber between the inner side of the panel and the interior finish
member.
18. (canceled)
19. A method of constructing an exterior wall of a building having
a frame having a plurality of spaced apart generally parallel
studs, the studs having an exterior side facing the exterior of the
building and an opposed interior side facing the interior of the
building, and the studs having a generally predetermined thickness,
predetermined width, and spacing between the studs of at least
about 12 inches comprising: providing a plurality of insulated
frame units, each insulated frame unit comprising a panel composed
substantially of rigid insulating material, the panel having a body
with first and second generally opposed ends, and third and fourth
generally opposed ends, the panel having an inner side and an outer
side, a first flange extending outwardly from the third end of the
body of the panel adjacent the inner side of the panel, and a
second flange extending outwardly from the fourth end of the body
of the panel adjacent the outer side of the panel, the length of
the second flange being greater than the length of the first
flange; positioning a first insulated frame unit adjacent a second
insulated frame unit so that the third side of the panel of the
first insulated frame unit is adjacent the fourth side of the panel
of the second frame unit and the second flange of the panel of the
second insulated frame unit overlaps the first flange of the panel
of the first insulating frame unit whereby the overlapping of the
second flange of the second insulated frame unit with the first
flange of the first frame unit forms a stud-receiving opening;
positioning a stud within the stud-receiving opening; and securing
at least one of the first and second insulated frame units to the
stud.
20. The method of claim 19 further comprising the stud having an
interior side and an exterior side, and installing the plurality of
insulated frame units onto the frame to enclose the frame by
installing the insulated frame unit onto the frame by positioning
the exterior side of the stud within the stud-receiving opening
with the interior side of the stud spaced from the inner side of
the panel; and installing an interior finish member to the interior
side of the stud with the interior finish member spaced from the
inner side of the panel to provide a service chamber between the
inner side of the panel and the interior finish member.
Description
FIELD OF THE INVENTION
[0001] This invention relates to a building product and method for
constructing a wall of a building.
BACKGROUND OF THE INVENTION
[0002] A need exists for an improved building product and method
for constructing an efficiently insulated and airtight wall for a
building.
SUMMARY OF THE INVENTION
[0003] In accordance with the present invention an insulated frame
unit is provided for use in constructing an exterior wall of a
building that has an exterior finish member for the exterior of the
building and an interior finish member for the interior room that
is defined by the wall. The wall includes a plurality of spaced
apart generally vertical studs, the studs having an exterior side
facing the exterior of the building and an opposed interior side
facing the interior room. The studs have a generally predetermined
thickness, predetermined width, and spacing between the studs of at
least about 12 inches. The frame unit comprises a panel composed
substantially of a rigid insulating material, and the panel has
first and second generally opposed ends, and third and fourth
generally opposed ends, an inner side and an outer side. The panel
also includes at least two stud-receiving openings in the inner
side of the panel. The stud-receiving openings are generally
parallel to each other and extend between the first and second ends
of the panel. The stud-receiving openings have a width that is
sufficient to allow a stud to be mounted within the stud-receiving
openings. The stud-receiving openings have a depth that is less
than the predetermined width of the stud, so that when the exterior
side of the stud has been fully inserted into the stud-receiving
opening, the interior side of the stud is spaced away from the
inner side of the panel to provide a service chamber between the
inner side of the panel and an interior finish member secured to
the interior side of the studs. An exterior finish member can be
secured proximate to the outer side of the panel.
[0004] In accordance with another aspect of the present invention
an insulated frame unit for use in constructing an exterior wall of
a building that has an exterior of the building and an interior
room that is defined by the wall is provided. The wall includes a
plurality of spaced apart generally vertical studs. The studs have
an exterior side facing the exterior of the building and an opposed
interior side facing the interior room. The studs having generally
predetermined thickness, predetermined width, and spacing between
the studs greater than about twelve inches. The frame unit
comprises a panel composed substantially of a rigid insulating
material. The panel has a body with first and second generally
opposed ends, and third and fourth generally opposed ends, and the
panel has an inner side and an outer side. The panel has at least
first and second stud-receiving openings in the inner side of the
panel. The first stud-receiving opening is a slot in the inner side
of the panel that is spaced from the third and fourth sides of the
body of the panel. The second stud-receiving opening is located
along the fourth end of the panel. The stud-receiving openings are
generally parallel to each other and extend between the first and
second ends of the panel. The stud-receiving openings have a width
that is sufficient to allow a stud to be mounted within the
stud-receiving openings. The panel has a first flange extending
outwardly from the third end of the body of the panel adjacent the
inner side of the panel, and a second flange extending outwardly
from the fourth end of the body of the panel adjacent the outer
side of the panel. The length of the second flange is greater than
the length of the first flange.
[0005] In accordance with a further aspect of the invention an
exterior wall construction for a building is provided. The exterior
wall construction comprises a frame having a plurality of spaced
apart generally parallel studs. The studs have an exterior side
facing the exterior of the building and an opposed interior side
facing the interior of the building. The studs have a generally
predetermined thickness, predetermined width, and spacing between
the studs of at least about 12 inches. The construction has a first
and a second insulated frame unit. Each insulated frame unit
comprises a panel composed substantially of rigid insulating
material. The panel has first and second generally opposed ends,
and third and fourth generally opposed ends, an inner side and an
outer side. The panel includes a stud-receiving opening in the
inner side of the panel. The stud-receiving opening has a stud
positioned therein with the interior side of the stud spaced
inwardly from the inner side of the panel. The first insulated
frame unit is positioned adjacent the second insulated frame unit.
An interior finish member is secured to the interior side of the
stud. The interior finish member is spaced from the inner side of
the panel to provide a service chamber between the inner side of
the panel and the interior finish member.
[0006] In accordance with a further aspect of the invention an
exterior wall construction for a building is provided. The exterior
wall construction comprises a frame having a plurality of spaced
apart generally parallel studs. The studs have an exterior side
facing the exterior of the building and an opposed interior side
facing an interior of the building, and the studs have a generally
predetermined thickness, predetermined width, and spacing between
the studs of at least about 12 inches. The wall construction
includes a first and a second insulated frame units. Each of the
insulated frame units comprises a panel composed substantially of
rigid insulating material. The panel has a body with first and
second generally opposed ends, and third and fourth generally
opposed ends. The panel has an inner side and an outer side, a
first flange extending outwardly from the third end of the body of
the panel adjacent the inner side of the panel, and a second flange
extending outwardly from the fourth end of the body of the panel
adjacent the outer side of the panel. The length of the second
flange is greater than the length of the first flange. The first
insulated frame unit is positioned adjacent the second insulated
frame unit so that the third side of the panel of the first
insulated frame unit is adjacent the fourth side of the panel of
the second insulated frame unit. The second flange of the second
insulated frame unit overlaps the first flange of the first
insulated frame unit to thereby provide a stud-receiving opening.
The stud-receiving opening has a stud positioned therein.
[0007] In accordance with a still another aspect of the invention a
method of constructing an exterior wall of a building having a
frame is provided. The frame has a plurality of spaced apart
generally parallel studs, the studs having an exterior side facing
the exterior of the building and an opposed interior side facing an
interior of the building. The studs have a generally predetermined
thickness, predetermined width, and spacing between the studs of at
least about 12 inches. The method comprises providing a plurality
of insulated frame units. Each of the insulated frame units
comprises a panel composed substantially of rigid insulating
material. The panel has first and second generally opposed ends,
and third and fourth generally opposed ends, an inner side and an
outer side. The panel includes a stud-receiving opening in the
inner side of the panel. The method includes installing the
plurality of insulated frame units onto the frame to enclose the
frame. The frame units are installed by installing an insulated
frame unit onto the frame by positioning the exterior side of the
stud within the stud-receiving opening in the inner side of the
panel and with the interior side of the stud spaced from the inner
side of the panel. An interior finish member is installed to the
interior side of the stud with the interior finish member spaced
from the inner side of the panel to provide a service chamber
between the inner side of the panel and the interior finish
member.
[0008] In accordance with still another aspect of the invention a
method of constructing an exterior wall of a building having a
frame is provided. The frame has a plurality of spaced apart
generally parallel studs. The studs have an exterior side facing
the exterior of the building and an opposed interior side facing
the interior of the building. The studs have a generally
predetermined thickness, predetermined width, and spacing between
the studs of at least about 12 inches. The method comprises
providing a plurality of insulated frame units. Each of the
insulated frame units comprises a panel composed substantially of
rigid insulating material. The panel has a body with first and
second generally opposed ends, and third and fourth generally
opposed ends. The panel has an inner side and an outer side, a
first flange extending outwardly from the third end of the body of
the panel adjacent the inner side of the panel, and a second flange
extending outwardly from the fourth end of the body of the panel
adjacent the outer side of the panel. The length of the second
flange is greater than the length of the first flange. The method
includes positioning a first insulated frame unit adjacent a second
insulated frame unit so that the third side of panel of the first
insulated frame unit is adjacent the fourth side of the panel of
the second frame unit. The second flange of the panel of the second
insulated frame unit overlaps the first flange of the panel of the
first insulating frame unit. The overlapping of the second flange
of the second insulated frame unit with the first flange of the
first frame unit forms a stud-receiving opening. A stud is
positioned within the stud-receiving opening. At least one of the
first and second insulated frame units is secured to the stud.
[0009] In accordance with another aspect of the invention an
insulated frame unit is provided that can be used to construct an
exterior wall that provides a high level of insulation and
airtightness.
[0010] In accordance with another aspect of the invention an
insulated frame unit is provided that has a design that is easily
scalable to provide insulating properties for various different
climate zones.
[0011] Other advantages and features of the invention will become
apparent from the following description and from reference to the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view an interior side of a building
illustrating a wall construction in accordance with the present
invention;
[0013] FIG. 2 is a perspective view an exterior side of a building
illustrating a wall construction in accordance with the present
invention;
[0014] FIG. 3 is a perspective view of the inner side of a frame
unit in accordance with the present invention;
[0015] FIG. 4 is a perspective view of the outer side of a frame
unit in accordance with the present invention;
[0016] FIG. 5 is a fragmentary top sectional view of three frame
units positioned side by side in a row;
[0017] FIG. 6 is a fragmentary top sectional view of another
embodiment of three frame units positioned in a corner of a
building;
[0018] FIG. 7 is a fragmentary top sectional view of another
embodiment of three frame units positioned in a corner of a
building;
[0019] FIG. 8 is a fragmentary top sectional view of another
embodiment of three frame units positioned side by side in a row
using steel studs to mount the frame units;
[0020] FIG. 9 is a fragmentary top perspective view of another
embodiment of a frame unit using a stud form of engineered lumber
to mount the frame unit; and
[0021] FIG. 10 is a fragmentary perspective view illustrating
another embodiment of frame units positioned side by side in a
row.
DETAILED DESCRIPTION
[0022] While this invention is susceptible of embodiment in many
different forms, there are shown in the drawings and described in
detail herein, several specific embodiments with the understanding
that the present disclosure is to be considered as exemplifications
of the principles of the invention and is not intended to limit the
invention to the embodiments illustrated.
[0023] The present invention relates to the construction of a
building that has superior insulating and air infiltration
reduction properties. These objectives are achieved while at the
same time also achieving reduced onsite construction costs and
construction times. Moreover, the utilization of the building
products and methods of the present invention can be used in
concert with building framing methods that are already familiar to
tradesmen, such as, for example, a platform framing process.
[0024] Referring to FIGS. 1 and 2, building 10 is shown with a
building shell frame 12 constructed of wood framing. The frame 12
of building 10 has exterior walls 14 that include wood studs 18. A
plurality of insulated frame units 20 of the present invention are
shown installed on studs 18 of exterior walls 14 to thereby enclose
and insulate exterior walls 14. Frame units 20 can be mass produced
offsite to reduce labor costs, and then shipped to the construction
site. At the construction site, frame units 20 can be installed to
form walls 14 with reduced labor costs and construction times.
Importantly, frame units 20 are designed to form a highly insulated
building wall 14 while using a single relatively thick continuous
insulation layer of a rigid material, for example, expanded
polystyrene foam with a thickness of about 5-8 inches or greater.
This approach is in contrast to attempting to increase the
insulating efficiency of a wall design that has an interior layer
of insulation, by adding an additional and separate exterior layer
of insulation. A wall construction using separate exterior and
interior insulation layers has an increased risk of experiencing
problems related to vapor condensation. Vapor condensation that
occurs between the insulating layers can lead to premature building
decay, possible mold formation and the deterioration of the
insulation layers. Frame units 20 of the present invention achieve
a high level of insulating efficiencies while avoiding the
aforementioned condensation related problems. Also, by using a
single relatively thick layer of insulation, the cost of installing
separate inside and outside insulation layers is avoided.
[0025] It is additionally noted that frame units 20 can be
manufactured to have different thicknesses for the insulating layer
of a panel 68 that is included in frame units 20. This allows frame
units 20 to be easily scaled to appropriately meet the varying
insulating requirements for buildings constructed in different
climate zones. Importantly, by interlocking the insulating panel 68
with studs 18 and frame 12, a thick layer of insulation can be
attached to thereby construct highly insulated building walls. It
is further noted that the rigid insulating material of panel 68 of
frame units 20 preferably straddles the vertical plane of the
foundation wall 26. Thus, the use of a relatively thick layer of
the rigid insulating material need not unduly reduce interior room
space or unduly impact the aesthetic appearance of the exterior of
the building. It is further noted that frame units 20 may
optionally include an exterior sheathing 22 and/or an interior
sheathing 24. Optional exterior sheathing 22 is useful for
attaching certain types of an exterior finishing member 28, such
as, for example, wood siding. Optional interior sheathing 24 can be
secured to studs 18, such as by brackets 30 to thereby increase
building rigidity against shear force and also to provide a fire
barrier. Additionally, or alternatively, a protective fire
retardant can optionally be applied to panel 68. Sheathing 22, 24
may be any suitable material, for example OSB board or plywood.
Sheathing 22, 24 typically is secured to panel 68 by adhesive.
[0026] Importantly, frame units 20 are configured for mounting to
frame 12 of building 10 in a manner that provides a service chamber
32 for installing electrical boxes, electrical switches, wiring and
the like. Chamber 32 is located between frame member 20 and an
interior finish member 38 attached to stud 18. Interior finish
member 38 may be any customary interior finish member such as, for
example, dry wall, paneling or plaster. Chamber 32 preferably has a
depth that provides sufficient space for the installation of
electrical outlet boxes and electrical switch boxes, and to provide
adequate space for installing conduit, wiring, cable, plumbing and
other such utility services. Typically, chamber 32 is preferably
sized to provide at least about a 2 inch space between frame units
20 and interior finish member 38. For most residential building
construction, chamber 32 preferably has a space of about 2 to about
3 inches.
[0027] In one aspect of the invention, studs 18 are conventional
wood lumber, such as for example 2.times.4, 2.times.6 or 2.times.8
wood studs, although the present invention may be also practiced
with other stud sizes. Larger studs, 2.times.10 or 2.times.12
studs, for example, may be used when scaling frame units 20 for
climate zones requiring higher insulating properties. By way of
reference, 2.times.4, 2.times.6 and 2.times.8 studs typically have
a nominal thickness of about 11/2 inches. 2.times.4, 2.times.6 and
2.times.8 studs have typical nominal width dimensions of about 31/2
inches, 51/2 inches and 71/4 inches, respectively. One typical
height, or length, for a stud is 8 feet. Typically, this height is
used for interior rooms 40 that have a ceiling height of about
eight feet. Nine foot long, or longer, studs can be used when
higher ceiling heights are desired. Frame units 20 of the present
invention are easily adaptable for use with studs 18 of other
heights, widths or thicknesses. The framing for walls 14 typically
includes a horizontal sole plate, or sill, 42 that is secured to a
floor 44 of building 10. As best seen in FIG. 1, a bottom end 48 of
stud 18 is secured to a sill 42 while a top end 50 of stud 18 is
secured to a horizontal top plate 52. Customarily, studs 18 are
secured in place by nailing to sill 42 and top plate 52. Studs 18
are typically laid out with a predetermined spacing therebetween of
at least about 12 inches, for example, a stud spacing of about 16
inches on center, or about 24 inches on center. For the exemplary
wood framing illustrated in FIG. 1, studs 18 2.times.6's are laid
out with a spacing of 24 inches between the centerlines of studs
18. The height of exemplary studs 18 as shown in FIG. 1 is
approximately 9 feet.
[0028] Referring to FIGS. 1 and 4, exemplary frame units 20 have a
height 54 for outer side 76 of panel 68 that is 4 feet, and a width
56 that is also 4 feet. It is noted the width 55 along the inner
side 74 of panel 68 is smaller than width 56. Typically, width 56
will be greater than width 55 by an amount equal to the thickness
of one stud 18, i.e., two times one-half the thickness of studs 18.
The height of the inner side 74, like outer side 76, is 4 feet for
exemplary frame unit 20. Such a size for frame units 20 allows for
relatively easy handling of frame unit 20 during installation of
frame units 20 to form walls 14. It being understood, however, that
frame units 20 may be formed with various other dimensions,
including, for example, 4 feet by 8 feet, or 8 feet by 4 feet.
Also, for a room that has a ceiling height of 9 feet, for example,
a 4-foot high frame unit 20 may be vertically stacked with a 5-foot
high frame unit 20. Alternatively, if desired, two or more frame
units 20 of various heights can be vertically stacked to the
ceiling height of the room. As can be appreciated by viewing FIG.
1, interior room 40 has a ceiling height that exceeds 8 feet. The
frame of exterior wall 14 is enclosed by vertically stacking a
4-foot high bottom frame unit 60, a 4 foot high second frame unit
62 and a third 1-foot high frame unit 64 positioned above frame
unit 62 for the nine-foot ceiling height of room 40. Alternatively,
as can be appreciated by viewing FIG. 2, exterior wall 14 may be
constructed by primarily using 4-foot high panels. In this
instance, frame units 20 would need modification to be adapted, for
example, for fitting the framing configuration adjacent the first
and second stories of build 10. As discussed later in detail,
typically, frame units 20 are separately installed one at a time at
the construction site. Alternatively, frame units 20 could be
assembled to form a whole wall, or a section of a wall, that is
then shipped to the building construction site and used to
construct walls 14 and building 10.
[0029] As best seen in FIGS. 3-5, the frame unit 20 includes a
rigid insulating panel 68. Panel 68 may be formed from any suitable
rigid insulating material. For example, panel 68 may be formed of a
composition of foam, such as expanded polystyrene foam. Expanded
polystyrene has an R value of approximately 4.6 per inch of
thickness and has additional desirable structural strength
properties. Thus, the thickness 66 of panel 68 can be readily
scaled to provide walls 14 with R values on the order of 20, 30,
40, 60 or greater as required for the climate zone in which
building 10 is located. Panel 68 can be formed by any suitable
method. For example, panel 68 may be molded, or may be cut from a
larger block of rigid insulating material to form panel 68 of a
desired size and configuration. Panel 68 has a body 70 with
typically a generally flat inner side 74, and typically a generally
flat outer side 76. When viewed from inner side 74, body 70 has a
left side end 80 and an opposite right side end 82. Body 70 of
panel 68 of frame unit 20 also has a top end 84 and an opposite
bottom end 86. A recess 90 in outer side 76 extends along left side
end 80 to form an inner left flange 92 at left side end 80.
Similarly, a recess 94 in inner side 74 along right side end 82
forms an outer right flange 96 at right side end 82 of panel 68 of
frame unit 20. As best seen by viewing FIGS. 3 and 4, a recess 100
in outer side 76 extends along top end 84 to form an inner top
flange 102 at top end 84. Similarly, a recess 104 in inner side 74
along bottom end 86 of panel 68 of frame unit 20 forms outer bottom
flange 106 at bottom end 86 of panel 68. As will be discussed below
in detail, outwardly extending flanges 92, 96, 102 and 106 of one
frame unit 20 are used to respectively overlap with an adjacent
flange 96, 92, 106 or 102 on a panel 68 of an adjacently positioned
frame unit 20. Panel 68 also may include a seal recess 111 and a
seal recess 113. When panels 68 are positioned side by side,
recesses 111, 113 cooperate to form a channel 117 into which an
elastic seal member 115 is held to extend from top end 84 to bottom
end 86 of panels 68. To alternatively inhibit airflow through the
junction of side by side panels 68, the channel formed by recesses
111, 113 may be injected on site with a sealing compound after
panels 68 are positioned side by side.
[0030] Multiple frame units 20 may be horizontally installed side
by side to form a row of frame units 20. As will be discussed in
detail below, when frame units 20 are positioned in a row, inner
left flanges 92 and outer right side flanges 96 are provided with
lengths that allow them to cooperate with an adjacent frame unit 20
to form a space into which stud 18 may be received. Multiple frame
units 20 may also be vertically stacked in a column. When stacked
in a column, bottom flange 106 of an upper frame unit 20 overlaps
with top flange 102 of the adjacent lower framed unit 20. Thus,
columns and rows of frame units 20 can be installed so that frame
units 20 abut, overlap and interlock with each other to thereby
enclose a framed exterior wall 14 to provide a highly insulated and
airtight wall. It is also noted that when a frame member 20 is
positioned adjacent sill 42, such as those indicated as frame units
110 and 112 in FIG. 1, bottom outer flange 106 overhangs sill 42.
Preferably, bottom outer flange 106 extends in close engagement
along outer edge 116 of sill 42, and in close engagement along the
outer surface 118 of foundation wall 120 supported on footing 121.
This provides a highly insulated and airtight wall 14 adjacent the
bottom area 122 of wall 14. It is also noted that building 12 may
include a separate additional foam insulation member 124 that abuts
against the bottom 108 of flange 106 and extends downward along
outer surface 118 of foundation wall 120. As shown in FIG. 1, an
additional foam insulating member 125 is provided to insulate the
bottom 127 of exemplary concrete slab floor 44. The grade of the
building site is indicated at 129.
[0031] In one embodiment of the invention, certain frame units 20
may be considered as a standard type or typical frame unit 20. A
standard type frame unit 20 has a basic size and configuration that
typically allows it be used to enclose a majority of wall 14 of the
building 12. Non-standard frame units 134 are those frame units 20
that need to be used to enclose an area of the framed wall 14 where
a standard frame unit 20 would be too large or too small to fit the
desired space. Non-standard frame unit 20 also typically would be
used in certain areas of a framed wall 14, such as, for example,
exemplary non-standard frame units 142 used adjacent a window
opening 140 location, adjacent a corner 144 of an interior room 40,
adjacent a doorway, or at other locations where a full-sized
standard size framing unit 20 would not fit, or otherwise require
modification to fit building frame 12. Often, non-standard frame
units 134 may be formed simply by trimming down a standard frame
unit 20 to a required size. In some instances, a standard frame
unit 20 may even be trimmed to a width wherein only one of stud
receiving openings 148, 150 or 152 remains on the trimmed down
frame unit 20. Such as, for example, a non-standard frame unit
having only stud-receiving slot 154 for mounting to one of studs
18, which might be used, for example, for enclosing a relatively
narrow area of wall 14. In other instances, a non standard frame
unit 134 may have a somewhat modified configuration from that of a
standard frame unit 20, such as frame units 142 adapted for use at
corner 144, as explained later in greater detail.
[0032] FIG. 5 is provided to illustrate cooperation of standard
frame units 20 when mounted horizontally side-by-side in a row for
enclosing a portion 126 of wall 14 of building 12. For purposes of
aiding in the description, the row of horizontally mounted
identical frame units 20 have been additionally numbered as a left
frame unit 128, a center frame unit 130 and right frame unit 132.
For clarity, one stud 18 and interior finish member 38 have been
omitted. In FIG. 5 there can be seen three stud-receiving openings
148, 150, 152 for receiving studs 18 used to frame wall 14.
Stud-receiving opening 150 may be provided as a slot 154, while
stud-receiving openings 148 and 152 are provided as stud-receiving
channels 158 and 160, respectively. Stud-receiving channel 158 is
formed by the cooperation of flanges 92 and 96 at the left side of
center frame unit 130. Stud-receiving channel 160 is formed by the
cooperation of flanges 92 and 96 at the right side of center frame
unit 130. Typically, stud-receiving openings 148, 150 and 152 are
all generally vertical and substantially parallel to each
other.
[0033] In exemplary frame unit 20 shown in FIG. 5, panel 68 has a
single slot 154 centrally located along width 55 of inner side 74
of panel 68. Thus, when a panel with a width 56 of 4 feet is used
in conjunction with studs 18 framed at 24 inches on center,
stud-receiving channel 158, slot 154 and stud-receiving channel 160
will respectively be aligned for mounting engagement with three
studs 18. Two of those three studs 18 are shown as studs 170 and
172. A stud 18 which is inserted into left stud-receiving opening
148 is omitted for clarity. It is understood, however, that if
panel 68 is wider than four feet, if necessary, such wider panel
would be formed to have enough additional slots 154 to cooperate
with any the additional studs 18 to which such wider panel 68 is
intended to be mounted. For example, for a frame unit 20 that is
eight feet wide, panel 68 might be mounted on a row of 5 spaced
apart studs 18 that are framed on 24 inch centers to span eight
feet. Thus, such wider panel 68 of wider frame unit 20 would be
provided with three stud-receiving slots 154. The three
stud-receiving slots 154 would be aligned for insertion on the
three interior studs 18 of the row of five studs 18. The
stud-receiving channels 158 and 160 would be positioned for
alignment with the end studs 18 of the row of five studs 18.
Stud-receiving channels 158 and 160 would be formed as described
previously, i.e. by flanges 92 and 96 of panel 68 and their
respective cooperation with flanges 96 and 92 of panels 68 of the
adjacent frame units 20 that are placed side by side with the wider
frame unit 20. A 4-foot wide panel 68 may also have more than one
slot 154 in certain other framing applications, such as where studs
are framed in on 16-inch centers. For example, a 4-foot wide panel
for mounting on studs 18 framed at 16-inch centers would have two
slots 154 for mounting on the interior 2 studs of the row of 4
studs spanning 48 inches.
[0034] It is noted that stud-receiving openings 148, 150, 152 have
widths 178, 180 and 182, respectively, which are sized to at least
allow the nominal thickness 176 of the stud 18 be received therein.
For example, when studs 18 have a nominal thickness 176 of 11/2
inches, the widths of stud-receiving openings 148, 150, and 152 are
at least about 11/2 inches or greater. Preferably, widths 178, 180
and 182 are about 11/2 inches. A 11/2 inch width for stud-receiving
openings 148, 150, 152 provides a surface contact with stud 18 to
provide an airtight fit. In the case of slot 154, the 11/2 inch
width can provide an interference fit between slot 154 and stud 18
inserted therein. This interference fit helps hold a frame unit 20
in place at stud 18 by friction during the process of installing
frame units 20 onto the studs 18 to enclose exterior walls 14.
[0035] In now describing stud-receiving channels 158 and 160 in
greater detail, it is first noted that stud-receiving channels 158
and 160 are typically substantially identical to each other and are
formed in the same manner. Formation of channels 158, 160 occurs
when outer flange 96 is positioned to overlap with inner flange 92.
As indicated in FIG. 4, outer flange 96 has a length 186 that is
greater than the length 188 of inner flange 92. Length 186 of outer
flange 96 may be, for example, about 4 inches. The length 188 may
be, for example, about 21/2 inches. Such dimensioning would result
in a width of about 11/2 inches for stud-receiving channels 158,
160. Stated another way, the difference in lengths of the flanges
96 and 92 at the junction 192 between panels 68 of frame units 128
and 130, is the width 178 of stud-receiving opening 148. Likewise,
the difference in lengths of the flanges 96 and 92 is the width 182
of stud-receiving opening 152 at the junction 194 between panels 68
of frame units 130 and 132. The difference in lengths of flanges 96
and 92 may be substantially the same as predetermined width 176 of
stud 18 that is to be mounted in stud-receiving channel 158 or 160,
to thereby provide an air-tight fit against stud 18. For some
framing applications, it may be advantageous to form the length of
flanges 92 and 96 so as to yield different widths for channels 158,
160.
[0036] Thus, stud-receiving channel 158 is defined by edge 198 of
recess 94, edge 200 of left inner flange 92, and a surface 202 of
right outer flange 96. It also noted that junction 192 and junction
194 between abutted frame units 128 and 130, and 130 and 132,
respectively, do not directly transverse in a straight line from
outer side 76 to inner side 74 of panels 68. Instead, junctions 192
and 194 follow a stepped path having a leg 206 and a leg 208. These
stepped junctions 192 and 194 provide a number of advantages.
First, each stepped junction 192, 194 provides increased surface
area for sealing contact along the junctions 192, 194. Secondly,
the stepped junctions avoid a direct pathway from outer side 76 and
inner side 74. This resists air infiltration directly along
junctions 192, 194, such as may otherwise occur during periods of
strong winds. It is additionally noted that the increased sealing
surface area provided by stepped junctions 192 and 194, and their
indirect paths, also reduces the loss of conditioned air from
interior room 40 to the outside of walls 14. The same advantages
are provided by a stepped junction 196, formed when outer bottom
flange 106 of one frame unit 20, overlaps inner top flange 102 of
another frame unit 20, such as when vertically stacking frame units
20, as shown in FIG. 1.
[0037] The depth 175 of the stud-receiving openings 148, 150, and
152, is another important aspect of the present invention. This is
because the depth 175 of stud-receiving openings 148, 150 and 152,
along with the width of stud 18 are the factors that determine the
depth of service chamber 32. More specifically, depth 175 is the
distance that stud 18 is inserted into stud-receiving openings 148,
150, 152, when stud 18 has been fully inserted therein to mount
frame unit 20 to stud 18. In the configuration shown for
stud-receiving openings 148, 150, 152, when stud 18 is fully
inserted, the exterior side 216 of stud 18 abuts against a
respective back side 218, 220, or 222 of stud-receiving channel
158, slot 154 and stud-receiving channel 160. Thus, depth 175 of
stud-receiving openings 148, 150, 152 will be the distance from
back side 218, 220, and 222 and the inner side 226 of frame unit
20. The inner side of frame unit 20 will be the inner side 228 of
inner sheathing 24, when optional inner sheathing 24 is used.
Preferably, interior sheathing 24 is provided for frame unit 20,
and interior sheathing 24 is secured to studs 18 with brackets 30
to provide rigidity for the wall. As stated, depth 175 of
stud-receiving opening 148, 150, and 152 is important to provide an
adequate depth 234 (indicated in FIG. 7) for service chamber 32
between the inner side of frame member 20 and interior finish
member 38. Interior finish member 38 may be any desired member,
typically for example, drywall, plaster or wall paneling. The depth
234 for service chamber 32, generally will at least suffice to
allow space for electrical boxes, such as for electrical outlets
31, light switches 33 and for meeting the depth requirements for
providing other utility type services. The fact that frame unit 20
is interlocked and secured to the building frame allows rigid panel
68 to extend outwardly from the general vertical plane of outer
surface 118 of outer foundational wall 120, which aids in allowing
an adequate depth to be provided for service chamber 32. With the
high R values provided with the frame members 20 and method of the
present invention, it is not necessary to fill service chamber 32
with additional insulating materials. Therefore, such additional
insulation need not be present where it would compete for space
that is required by electrical outlet boxes 31, electrical light
switch boxes 33, conduits 35, wiring, plumbing and other services.
Instead, when exterior side 216 of stud 18 is fully inserted into
stud-receiving opening 148, 150, or 152 the interior side 238 of
stud 18 will extend spaced away from the inner surface of frame
unit 20 a distance 240 and allow a generally unencumbered service
chamber 32 to be provided. Distance 240 will be the width 242 of
stud 18 less the depth 175 of the stud-receiving opening 148, 150,
or 152 into which stud 18 is inserted. For example, a 2.times.6
stud 18 having a nominal width of 51/2 inches, inserted into a
stud-receiving opening 148 having a depth 175 of three inches will
result in the interior side of stud 18 extending a distance 240 of
21/2 inches away from inner side 226 of frame unit 20. This
provides a service chamber 32 between inner side 226 and interior
finish member 38 that has a depth 234 of 21/2 inches (reference 234
being shown in FIG. 7 which is illustrated with an interior finish
member 38).
[0038] FIG. 9 shows an alternative embodiment for insulated frame
unit 20. Insulated frame unit 244 can be used with a stud 246. Stud
246 has a configuration that is typical for studs formed from
engineered lumber. Stud 246 has a wood back cap 248 and a wood
front cap 250 that are glued to wood plate 252. Stud 246 of
engineered lumber can provide increased strength with less
shrinkage of stud 246. Thus, less settling of building 10 takes
place due to a later shrinkage of studs 246. A generally T-shaped
stud-receiving opening 254 is provided in panel 256 of frame unit
244. Stud-receiving opening 254 typically extends from top end 260
of panel 256 to bottom end 261 of panel 256. Panel 256 is formed of
the same rigid insulating composition of panel 68 of frame unit 20.
Stud-receiving opening 254 is sized with a width 258 that is
sufficient to allow stud 246 to be inserted from the top end 260 of
panel 256. After stud 246 is inserted into the stud-receiving
opening 254, frame unit 244 is positioned between sill 42 and top
plate 52 of the building frame and secured in place. Thus, when the
exterior side 262 of stud 246 is fully positioned in stud-receiving
opening 254, the interior side 264 of stud 246 extends inwardly
from the inner side 268 of frame unit 244 at interior sheathing
270. This provides an adequate space for service chamber 272
located between interior sheathing 270 and drywall interior finish
member 274 (only partially shown for clarity) secured to interior
side 264 of stud 246. Holes 276 in stud 246 are provided for
conduits, wires and other utilities as needed.
[0039] FIG. 8 illustrates another embodiment of the invention
wherein insulated frame units 278 utilize steel studs 280, 282,
284. Exemplary frame units 288, 290, 292 are similar to frame units
20, except that frame units 288, 290 and 292 are configured to be
used with steel studs 280, 282, 284. Frame unit 290 has a
stud-receiving opening 296 that extends from top to bottom of inner
side 298 of panel 286 of frame unit 290. Panel 286 is formed of the
same rigid insulating composition of panel 68 of frame unit 20.
Steel stud 282 is inserted to extend the height of inner side 298
of panel 286. Steel stud 282 has an exterior side 294 and an
interior side 295 that is connected to exterior side 294 by side
299 of steel stud 282. Thus, when stud 282 has been inserted into
stud-receiving opening 296, interior side 295 is spaced from inner
side 298 of panel 286 of frame unit 290. Another steel stud 280 is
inserted into a stud-receiving recess 302 formed in a left inner
flange 304 of panel 286 of frame unit 290 to thereby mount steel
stud 280 to frame unit 290. Thus, when an interior finish member
291, such as drywall, is mounted onto the interior side 295 of each
of studs 280, 282, 284, an interior service chamber 300 is provided
between interior finish member 291 and the inner side 298 of panel
286 of frame units 288, 290 and 292.
[0040] FIG. 10 illustrates an alternative insulated frame unit 308.
Frame units 308 each have a panel 310 formed from a rigid insulated
material of a composition as described previously regarding panel
68 of frame unit 20. Panel 310 has body 312 with a left
stud-receiving recess opening 314, a right stud-receiving recess
opening 318, and a stud-receiving opening 320. Stud-receiving
opening 320 may be a slot 322 that is centrally located along an
inner side 348 of panel 310. Slot 322, left stud-receiving recess
314 and right stud-receiving recesses 318 extend from a top end 324
to a bottom end 326 of body 312 of panel 310. When frame units 308
are positioned side by side in a row, junctions 328, 330 and 332
occur along adjacent panels 310. At each of junctions 328, 330 and
332, left stud-receiving recess 314 cooperates with an adjacent
right stud-receiving recess 318, to provide stud-receiving openings
336 in the form of a stud-receiving channel 335. Stud-receiving
channels 335 and slots 322 allow frame units 308 to be mounted to
studs 338 to enclose an exterior wall 340 of a building.
[0041] When the exterior side 342 of stud 338 is fully inserted
into one of stud-receiving openings 320, 336, the interior side 346
of stud 338 extends inwardly from inner side 348 of frame units
308. Thus, as previously described, a service chamber 350 is
provided between interior finish member 352 and inner side 348
panel of frame unit 308. Frame units 308 are secured to studs 338
such as by brackets 30 (not shown in FIG. 10) as previously
described. Frame units 308 may optionally include interior
sheathing 24 and/or exterior sheathing 22 (also not shown in FIG.
10) as previously described. Any or all of ends 381, 383, 385 or
387 of frame units 308 may include tongue and grooves for providing
airtight junction when frame units are positioned adjacent each
other. Alternatively, ends 381, 383, 385 and 387 may include
flanges as described previously in regard to frame unit 20.
[0042] FIG. 6 and FIG. 7 illustrate exemplary frame units 358, 360
and 380 that can be used for enclosing the corner of an exterior
wall. Referring to FIG. 7, non-standard corner frame units 358 and
360 are substantially the same as standard frame unit 20. When
viewed from a perspective of the interior of the room 362, it is
noted that left outer flange 364 of non-standard frame unit 358 is
longer than outer flange 96 of standard frame unit 20. The
additional length of left outer flange 364 compensates for an
additional stud 368 placed at the corner 370 of walls 372 and 374.
Also, recess 376 on frame unit 360 for seal member 115 is located
for a right angle junction of frame members 358 and 360. It is also
noted that for enclosing some configurations of a building frame,
such as at corner 370, it may be advantageous to configure a
non-standard frame unit, such as frame unit 358, to have two outer
flanges 364 and 366. FIG. 6 shows a corner 378 enclosed with a
corner frame unit 380 that has an inner corner recess 382
configured for receiving corner support member 384. Corner support
member 384 is formed of a plurality of studs 386 for additional
corner load bearing. Seal members 115 are provided at the junctions
388 and 390 between corner frame unit 380 and frame units 392 and
394, respectively. Studs 386, forming corner support member 384 may
also include an additional insulating member 396 for additional
insulation. Panels 391, 393 and 395 are formed of the same rigid
insulating composition as described for panel 68 of frame unit
20.
[0043] Referring to the figures generally and in particular FIGS. 1
and 2, it can be appreciated that once framed wall 14 of building
10 has been constructed, frame units 20 can be installed to enclose
wall 14. To avoid confusion, as shown in FIGS. 1 and 2, for
descriptive purposes certain studs 18 and other frame elements were
omitted in places. Generally, frame units 20 will be installed to a
wall 14 only after the frame of wall 14 has been fully completed.
In a typical installation process, a workman conducting the
installation is positioned on the exterior of building 10. A supply
of frame units 20 to be mounted to wall 14 is also positioned on
the exterior of building 10. This is because frame units 20 will be
installed face first onto the exterior side of framed wall 14.
Stated another way, inner side 226 of frame unit 20 is installed by
inward movement toward exterior side 216 of studs 18 of framed wall
14. As mentioned previously, the inner side of frame unit 20 will
be the inner side 74 of panel 68 when optional interior sheathing
24 is not included for frame unit 20. When interior sheathing 24,
is included, the inner side 226 of frame unit 20 will be the inner
side 228 of interior sheathing 24. Stud-receiving openings 150 and
152 are aligned with the respective studs 18 that are to be
received into stud-receiving openings 150 and 152. Thereafter, the
workman pushes against the outer side 76 of panel 68, or against
exterior sheathing 22, if optional exterior sheathing 22 is
included on frame unit 20. The inward pushing motion moves frame
unit 20 inwardly until continued forward movement is prevented when
studs 18 are fully inserted within stud-receiving openings 150 and
152. Typically, this occurs when exterior sides 216 of studs 18
respectively engage back sides 220 and 222 of stud-receiving
openings 150 and 152. Once so engaged, a third stud 18 is locate
proximate to, if not in contact with, edge 200 of left inner flange
92. It is again noted that when a frame unit 20 is installed on a
bottom row, preferably bottom outer flange 106 of frame unit 20
extends in close engagement along outer edge 116 of sill 42, and in
close engagement along the outer surface 118 of foundation wall
120. This provides a highly insulated and airtight wall 14 adjacent
the bottom end 122 of wall 14.
[0044] In a like manner, additional frame units 20 are installed in
the bottom row to enclose the bottom area of exterior wall 14 of
building 10. As described above the, inner flange 92 is located on
the left side of frame unit 20. Thus, it will appreciated that it
will be advantageous to install a row of frame units 20 working
from left to right from a perspective from the outside of the
building 10. However, it is understood that the invention is not to
be limited to inner flange 92 being located on the left side of
frame 20 and outer flange 96 being located at the right side of
frame unit 20. Frame units 20 can be formed with a reverse
orientation, i.e. with inner flange 92 being formed on the right
side end of frame unit 20, and with outer flange 96 being formed on
the left side end of frame 20.
[0045] From time to time, a workman from the inside of building 10
will secure frame units 20 to studs 18 by installing brackets 30,
such as by fastening bracket 30 with a fastener to stud 18. Bracket
30 is also fastened to frame unit 20, such as at interior sheathing
24. After one or more frame units 20 are installed in a bottom row,
additional frame units may be stacked vertically upward in a
column. Stacking a frame unit 20 on top of a lower installed frame
unit 20 is accomplished in similar manner to forming a row. One
difference is that outer bottom end flange 106 of frame unit 20
overhangs and engages inner top end flange 102 of frame unit 20 of
the lower frame unit 20, rather that sill 42.
[0046] Non-standard frame units 134 are used in corners 144, around
window opening 140, door openings and where otherwise required to
finish enclosing wall 14. Interior finish member 38 is installed to
studs 18. As previously described, interior finish member 38 is
spaced from the inner side 226 of frame member 20 to provide
service chamber 32. An exterior finishing member 28 is applied the
outer side 76 of panel 68 of frame unit 20. Typically, if wood
siding is the facade, frame unit 20 will include outer sheathing
22. Certain other types of facade, such as synthetic stucco, may be
applied directly to outer side 76 of panel 68 without using outer
sheathing 22.
[0047] While the invention has been described with respect to
certain preferred embodiments, it is to be understood that the
invention is capable of numerous changes, modifications, and
rearrangements without departing from the scope or spirit of the
invention as defined in the claims.
* * * * *