Framed Forming Panel System

Abstract

A framed forming panel system a plurality of lightweight framed foam panels secured to a plurality of load bearing members having a user defined spacing to form a panel wall; ceiling for floor with a fastening region lattice. Each lightweight framed form panel composed a channel formed in a frame to receive a lightweight panel of foam. Fixation of framed panels to load bearing members in opposition to one another allows the panel walls, ceiling or floor to function as a form to retain an insulative mass placed within the voids created by the opposing framed panels.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

[0001] Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

[0003] Not Applicable.

REFERENCE TO A SEQUENCE LISTING

[0004] Not Applicable.

BACKGROUND OF THE INVENTION

[0005] (1) Field of the Invention

[0006] The present invention relates to a framed forming panel system for use in the construction of permanent or temporary structures, buildings and houses. More specifically the present invention relates to wall, ceiling and floor structures incorporating a top plate, sole plate and a plurality of load bearing members and the methods of constructing the same.

[0007] (2) Background of the Invention

[0008] For over 75 years, permanent and temporary construction of walls, ceilings and floors incorporate a plurality of load bearing members, like studs, ceiling joists or floor joists, spaced between 16 to 24 inches apart and fixed at their ends to either: (i) a top plate and sole plate to form a wall; (ii) top plates to form a ceiling or floor or (iii) sole plates to form a floor. This traditional frame arrangement creates a basic structure upon which strips, panels or sheets of wood, metal or sheetrock are secured to create a wall, ceiling or floor. Windows, doors and other openings can be framed into the walls, ceilings and/or floors prior to placement of strips, panels or sheets of wood, metal or sheetrock across the frame structure. Because the traditional strips, panels or sheets of wood, metal or sheetrock have little insulative properties, insulation for temperature and/or sound must be placed in the voids between the plurality of load bearing members before the strips, panels or sheets are installed. Furthermore, these strips, panels and sheets, once fixed in place, are poor forms to hold or retain insulative materials that are poured into voids between the load bearing-members. The present invention overcomes these shortfalls by attaching rigid framed insulative panels to load bearing members, wherein the framed panels are used as a form for poured-in-place insulation.

[0009] Traditional construction methods for permanent or temporary structures require at least two workers to hang and secure the strips, panels or sheets to the load bearing members due to weight and size of the strip, panel or sheet itself. The present invention is lightweight and rigid and does not require the same number of workers or fasteners. Additionally, the attachment of an article, like a shelf, to the surface of a strip, panel or sheet requires careful alignment over a load bearing structure to ensure a secure attachment to the wall and to prevent tearout of any fasteners. The present invention overcomes this shortfall by incorporating a fastening lattice that is formed across the load bearing members as framed panels are fitted onto the load bearing members.

BRIEF SUMMARY OF THE INVENTION

[0010] The present invention is a framed forming panel system 10 including a plurality of lightweight framed foam panels 20 secured to a plurality of load bearing members 30 spaced between approximately 12 to approximately 48 inches apart to form a panel wall 60, panel ceiling 70 or panel floor 80 with at least one inner region 62, 72 or 82. Each lightweight framed foam panel 20 comprises a channel 222 formed in a frame 22 to receive a lightweight panel of foam 24. The lightweight foam panel 24 can be fixed into the channel 222 and to the lightweight frame 22 by frame fasteners 28 and/or adhesive 26. In a preferred embodiment, a plurality of interstitial frames 23 are fixed at user defined spacing inside frame 22 to increase the rigidity of framed panel 20.

[0011] In a preferred embodiment, the lightweight frame 22 and lightweight foam panel 24 are manufactured prior to the construction of the panel wall 60, panel ceiling 70 or panel floor 80. In a preferred embodiment, a lightweight framed foam panel 20 measuring about 11/2 inches by about 4 foot by about 8 foot panel is approximately fifty percent (50%) lighter than a 1/2 inch by 4 feet by 8 feet oriented strand board ("OSB") panel used in conventional wall, ceiling or floor construction. This reduction in weight makes it easier for workers to position, hold and secure the panel to load bearing members 30, like studs 32 or joists 34. Furthermore, the same lightweight framed foam panel 20 has a significantly greater insulation "R" factor than a similar sized OSB panel. Finally, because framed panels 20 are lightweight, fewer fasteners 90 are required to secure framed panels 20 to studs 32 or joists 34 than use in traditional installations of strips, panels or sheets of plywood or sheetrock. Furthermore, the present invention increases the insulative character of the wall, ceiling or floor over traditional construction methods and components. A further use of the panel system includes use as a form that is left in place to hold a predetermined quantity of mass, wherein the mass can be in the form of a sound proofing mass, thermal mass, ballistic mass or combination thereof of such masses to create a periphery body to protect an interior habitable space against noise, fires, hurricanes, tornadoes, floods and earthquakes depending upon the nature of the mass. In short, the present invention is a lighter panel construction system that is easier to use in the construction of a permanent or temporary wall, ceiling or floor, especially when an insulative mass 100 is poured into a wall, ceiling or floor. Other and further objects, benefits, and advantages of the instant invention have been described above, and further below.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0012] FIG. 1A depicts a cross sectional view of a foam panel 24, adhesive 26, frame fastener 28, and a frame 22 that makes up a portion of the framed forming panel system 10.

[0013] FIG. 1B is a cross sectional view of a foam panel 24, adhesive 26, frame fastener 28, and a frame 22 with a thicker spine 224 than side walls 226 that makes up a portion of the framed forming panel system 10.

[0014] FIG. 2 is an isometric view of a framed forming panel system 10 used to construct a wall depicting a plurality of framed panels 20 fixed to a plurality of structural members 30 secured at a user defined spacing 66 between a top plate 50 and a sole plate 40. Each framed panel 20 in FIG. 2 depicts interstitial frames 23 fixed at a user defined spacing inside frame 22.

[0015] FIG. 3 is an isometric view of a framed forming panel system 10 used to construct a portion of a ceiling depicting a plurality of framed panels 20 fixed to a plurality of joists 34 separated from each other by a user defined spacing 66.

[0016] FIG. 4 is an isometric view of a framed forming panel system 10 used to construct a portion of a floor depicting a plurality of framed panels 20 fixed to a plurality of joists 34 separated from each other by a user defined spacing 86. Each framed panel 20 in FIG. 4 depicts interstitial frames 23 fixed at user defined spacing inside frame 22.

[0017] FIG. 5 is a cross sectional plan view of a framed forming panel system 10 used to construct a wall 05, ceiling 07 and floor 09 depicting a plurality of framed panels 20.

[0018] FIG. 6 is a plan view of a wall 05 constructed with a framed forming panel system 10 depicting a fastening region lattice 228, load bearing members 30 and mass 100. Each framed panel 20 in FIG. 6 depicts interstitial frames 23 fixed at user defined spacing inside frame 22.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Referring to FIGS. 2, 3 and 4, the present invention is a framed forming panel system 10 including a plurality of load bearing members 30 fixed at a user defined spacing 66, 76 or 86 from each other and between either: (i) a top plate 50 and a sole plate 40 to form a wall frame 61; (ii) a pair of top plates 50 to form a ceiling frame 71; or (iii) a pair of sole plates 40 to form a floor frame 81. In a preferred embodiment, a plurality of framed panels 20 are fixed to both sides of a wall frame 61 by panel fasteners 90. See FIG. 2. In another embodiment, a plurality of framed panels 20 are fixed to one side of a wall frame 61 by panel fasteners 90. In another embodiment, a plurality of framed panels 20 are fixed to both sides of a ceiling frame 71 by panel fasteners 90. See FIG. 3. In another embodiment, a plurality of framed panels 20 are fixed to one side of a ceiling frame 71 by panel fasteners 90. In yet another preferred embodiment, a plurality of framed panels 20 are fixed to both sides of a floor frame 81 by panel fasteners 90. See FIG. 4. In yet another preferred embodiment, a plurality of framed panels 20 are fixed to one side of a floor frame 81 by panel fasteners 90. In each of the embodiments described above, the user defined spacing between load bearing members 30 can range between about ten inches (10'') to about forty-eight inches (48''). In a preferred embodiment of the framed forming panel system 10, stud spacing 66 is about sixteen inches (16'') to about forty eight inches (48'') on center for a wall frame 61. In a preferred embodiment of the framed forming panel system 10, joist spacing 76 is about ten inches (10'') to about forty-eight inches (48'') on center for a ceiling frame 71. In yet another preferred embodiment of the framed forming panel system 10, joist spacing 86 is about ten inches (10'') to about forty-eight inches (48'') on center for a floor frame 71.

[0020] The cross section form of the load bearing members 30 can be square, rectangular or a generally "U" shape. See FIGS. 2, 3 and 4. It is contemplated that load bearing members 30 can be fixed to a sole plate 40 or top plate 50 as a single unit or as two units fixed to one another to form a load bearing member 30 with an I-beam or box-beam cross section to create a larger fastening surface to which a framed panel 20 can be affixed. See FIGS. 2, 3 and 4. The width of a load bearing member 30 ranges from about one and one-quarter inches (11/4) to about three inches (3'') to provide a fastening surface 36 of about 11/4 inches across the width of a load bearing member 30. Load bearing member 30 can be constructed of wood, steel, carbon fiber or a combination thereof. In a preferred embodiment, load bearing members 30 are wooden, galvanized steel or a combination of both.

[0021] A framed panel 20 of the framed forming panel system 10 includes a foam panel 24 fixed by frame fasteners 28 and/or adhesive 26 into a generally "U" shaped channel 222 formed in a frame 22 that surrounds the periphery of the foam panel 24. See FIGS. 1 through 6. Frame fasteners 28 can be screws, self tapping screws, rivets, arrow clips, canoe clip, Christmas tree clips, and/or key hole clips. In a preferred embodiment, frame fasteners 28 are self tapping screws. Adhesive 26 can be drying adhesives, pressure sensitive adhesives, contact adhesives, hot adhesives, multi-part reactive adhesives, one part reactive adhesives, natural adhesives, synthetic adhesives of a combination thereof. In a preferred embodiment, adhesive 26 is a two-part reactive elastomeric polyurethane froth adhesive.

[0022] A framed panel 20, as disclosed herein, has a significantly greater rigidity over that of an unframed foam panel 24 or even a traditional sized sheet of 1/4 or 1/2'' plywood. With the inclusion of interstitial frames 23 within frame 22 an enhanced embodiment of a framed panel 20 is able to provide even greater rigidity over an unframed foam panel 24 or traditional sized sheet of plywood. Without a frame 22 supporting its periphery, a foam panel 24 is susceptible to bending, flexing and breaking. An unframed foam panel 24 or even a traditional sized sheet of 1/4'' or 1/2'' plywood are not suitable for use as a form to support and contain a poured in insulative mass 100 because of its lack of rigidity and firmness as a construction material. By fixing a frame 22 to a periphery of a foam panel 24, a framed panel 20 is formed that protects against the tear out of panel fasteners 90 as well as protects against compression of foam panel 24 at its periphery. In short, a framed panel 20 of the present invention allows a foam panel 24 to be securely mounted to a plurality of load bearing members 30 to be used not only as insulation but as a durable wall covering or as a form to contain and hold an insulative mass 100. Furthermore, when a plurality of framed panels 20 are installed across a plurality of load bearing members 30, the frames 22 further provide a fastening region lattice 228 between load bearing members 30. See FIGS. 2, 3, 4 and 6. Such a fastening region lattice 228 provides additional locations to fasten or securely fix articles (such as shelves) to a wall 05, ceiling 07 or floor 09 between load bearing members 30. In a preferred embodiment, a plurality of interstitial frames 23 set at user defined spacing inside the frame 22 not only increase rigidity of the framed panel 20, but also increase the area of a fastening region lattice 228. Compare FIG. 3 with FIG. 4.

[0023] The rigidity of a framed panel 20 is determined largely by the gauge of frame 22, depth of channel 222 and thickness of foam panel 24. A lighter gauge frame 22 will not be as rigid as a heavier gauge frame 22. It is contemplated that the gauge of a frame 22 can range between approximately twenty six (26) gauge to approximately twelve (12) gauge. In a preferred embodiment, frame 22 has a uniform gauge. See FIG. 1A. In another embodiment, frame 22 has a spine 224 with a gauge that is different than the opposing channel walls 226. In a preferred embodiment, spine 224 has a gauge that is thicker than the opposing channel walls. See FIG. 1B. The depth of a frame channel 222 can also affect the rigidity of a foam panel 24. The rigidity of framed panel 20 with a deep channel 222 is greater than a framed panel 20 with a shallow channel 222. It is contemplated that a frame 22 can be constructed from metal, plastic, carbon fiber or a combination thereof. In a preferred embodiment, channel 222 is a generally "U" shaped channel 222 of approximately one inch (1'') depth and approximately one and one half inch (11/2'') width formed in an approximately sixteen (16) to approximately twenty (20) gauge galvanized metal frame 22. In another preferred embodiment, channel 222 is a generally "U" shaped channel 222 of approximately one inch (1'') depth and approximately one and one half inch (11/2'') width formed in an approximately sixteen (16) to twenty (20) gauge plastic frame 22.

[0024] It is contemplated that foam panel 24 is constructed from rigid cellular polystyrene. In a preferred embodiment, foam panel 24 is constructed from rigid cellular polystyrene thermal insulation that meets or exceeds ASTM C578 standards. In a preferred embodiment, a single sheet of foam panel 24 fits within a channel 222 formed in frame 22. In another embodiment, more than one sheet of foam panel 24 is installed within channel 222 formed in frame 22. It is contemplated that a covering 242, such as a metal foil, a plastic sheet, and/or a paper sheet may be affixed to at least one surface of foam panel 24 for enhanced thermal insulation, panel stability and/or panel durability.

[0025] In a preferred embodiment, a plurality of load bearing members 30 are studs 32 aligned to form a generally vertical planar wall frame 61 with an inner wall region 62 and an outer wall region 64. See FIG. 2. A series of framed panels 20 are butted up against one another and affixed to a plurality of studs 32 by panel fasteners 90 to form a panel wall 60 with a fastening region lattice 228. In another preferred embodiment, framed panels 20 are affixed to both sides of a plurality of load bearing members 30 to form voids 68 in panel wall 60. See FIG. 2. It is contemplated that the length, width and thickness of a framed panel 20 would be similar to the dimensions of conventional plywood panels or sheetrock panels used to cover a plurality of studs 32 with a user defined stud spacing 66. In a preferred embodiment, framed panel 20 is about four feet (4') wide, about eight feet (8') long and about one and one half inches (11/2'') thick. In another preferred embodiment, framed panel 20 is about two feet (2') wide, about eight feet (8') long and about two inches (2'') thick. In either preferred embodiment described above, framed panels 20 are stacked on top of each other to cover an eight foot (8') tall wall.

[0026] In a preferred embodiment, a plurality of load bearing members 30 are joists 34 aligned to form a generally horizontal planar ceiling frame 71 with an inner ceiling region 72 and an outer ceiling region 74. See FIG. 3. A series of framed panels 20 are butted up against one another and affixed to the plurality of joists 34 by panel fasteners 90 to form a panel ceiling 70 and a fastening region lattice 228. In another preferred embodiment, framed panels 20 are affixed to both sides of a plurality of load bearing members 30 to form voids 78 in panel ceiling 70. See FIG. 3. It is contemplated that the length, width and thickness of a framed panel 20 would be similar to the dimensions of conventional panels used to cover a plurality of joists 34 with a user defined joist spacing 76. In a preferred embodiment, framed panel 20 is about two feet (2') wide, about eight feet (8') long and ranges between about one and one half inches (11/2'') to about two and one half inches (21/4'') inches thick.

[0027] In a preferred embodiment, a plurality of load bearing members 30 are joists 34 aligned to form a generally horizontal planar floor frame 81 with an inner floor region 82 and an outer floor region 84. See FIG. 4. A series of framed panels 20 are butted up against one another and affixed to the plurality of joists 32 by panel fasteners 90 to form a panel floor 80 and a fastening region lattice 228. In another preferred embodiment, framed panels 20 are affixed to both sides of a plurality of load bearing members 30 to form voids 88 in panel floor 80. See FIG. 4. It is contemplated that the length, width and thickness of a framed panel 20 would be similar to the dimensions of conventional panels used to cover a plurality of studs 32 with a user defined joist spacing 86. In a preferred embodiment, framed panel 20 is about two feet (2') wide, about eight feet (8') long and ranges between about one and one half inches (11/2'') to about two and one half inches (21/2'') thick.

[0028] An insulative mass 100 of the framed forming panel system 10 can be acoustic, thermal and/or ballistic. A user's selection of an insulative mass 100 is, in part, determined by the depth of load bearing members 30 as well as the type of insulation required, sound, thermal, ballistic or a combination thereof. Insulative mass 100 is placed in voids 68, 78 and 88 between opposing framed panels 20. See FIG. 6. It is contemplated that insulative mass 100 can be air, paper fiberglass, mineral wool, rock wool, slag wool, plastic, natural fibers, polystyrene foam, polyisocyanurate foam, polyurethane foam, open cell foam, closed cell foam, rubber, sponged melamine, vermiculite, perlite, dirt, asphalt, concrete, cement and/or any combination thereof. It is further contemplated that such insulative mass 100 can be in the form of blankets, rolls, pellets, boards, blocks, liquids that solidify after being poured-in-place or a combination thereof to be placed in voids 68, 78 or 88.

[0029] It is further contemplated that a framed forming panel system 10 as described herein could be used in conjunction with traditionally constructed structures to reduce construction costs or make repairs to existing traditionally constructed structures after fire, flooding or other damage. It is further contemplated that a framed forming panel system 10 as described herein can be used to construct temporary housing 100 with at least a panel floor 80, a panel ceiling 70 or a combination of both. See FIG. 5. Outer wall regions 64 would be covered with a flexible material 102 temporarily fastened to a plurality of studs 32 by refastenable fasteners 92 like ties, hook and loop, buttons, snaps or a combination thereof.

[0030] In a preferred embodiment, an insulative mass 100 is formed about the periphery of a habitable space 03 by using a framed forming panel system 10 wherein the walls 05 of a habitable space 03 are constructed from a plurality of load bearing members 30, namely studs 32, fixed between a sole plate 40 and a top plate 50 at a user defined stud spacing 66 to form a wall frame 61 with an inner wall region 62 and an outer wall region 64. A plurality of framed panels 20 are fastened to said plurality of studs 32 to cover said inner and outer wall regions 62 and 64 to form a plurality of voids 68 in said wall frame 61. A user defined amount of insulative mass 100 is placed in said plurality of voids 68 and held in place by the plurality of framed panels 24 attached to the plurality of studs 32 to insulate, along the periphery, the habitable space 03.

[0031] In another embodiment, an insulative mass 100 is formed about the ceiling 07 of a habitable space 03 by using a framed forming panel system 10 wherein the ceiling 07 of a habitable space 03 is constructed from a plurality of load bearing members 30, namely joists 34, fixed between 2 pairs of opposing top plates 50 at a user defined joist spacing 76 to form a ceiling frame 71 with an inner ceiling region 72 and an outer ceiling region 74. A plurality of framed panels 20 are fastened to said plurality of joists 34 to cover said inner and outer ceiling regions 72 and 74 to form a plurality of voids 78 in said ceiling frame 71. A user defined amount of insulative mass 100 is placed in said plurality of voids 78 and held in place by the plurality of framed panels 24 attached to the plurality of joists 34 to insulate the ceiling 07 of habitable space 03.

[0032] In another embodiment, an insulative mass 100 is formed about the floor 09 of a habitable space 03 by using a framed forming panel system 10 wherein the floor 09 of a habitable space 03 is constructed from a plurality of load bearing members 30, namely joists 34, fixed between 2 pairs of opposing sole plates 40 at a user defined joist spacing 86 to form a floor frame 81 with an inner floor region 82 and an outer floor region 84. A plurality of framed panels 20 are fastened to said plurality of joists 34 to cover said inner and outer floor regions 82 and 84 to form a plurality of voids 88 in said floor frame 81. A user defined amount of insulative mass 100 is placed in said plurality of voids 88 and held in place by the plurality of framed panels 24 attached to the plurality of joists 34 to insulate the floor 09 of habitable space 03.

[0033] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the claims set forth below.

Claims

1. A framed forming panel system comprising a plurality of studs fixed between a top plate and a sole plate with a user defined spacing between each of said studs to form a wall frame having an inner wall region and an outer wall region; and a first plurality of framed panels fixed to said plurality of studs by a first plurality of panel fasteners to form a fastening region lattice across at least a portion of said wall frame, wherein each of said framed panels comprises a channel formed in a frame of sufficient dimensions to receive and hold a periphery of a foam panel.

2. The framed forming panel system as claimed in claim 1, wherein said plurality of studs each have a "U" shaped cross section.

3. The framed forming panel system as claimed in claim 1, wherein at least one void is formed in said wall frame by fixing in opposition to said first plurality of framed panels, a second plurality of framed panels fixed to said plurality of studs by a second plurality of fasteners.

4. The framed forming panel system as claimed in claim 3, wherein said at least one void is at least partially filled with an insulator from the group comprising of air, paper fiberglass, mineral wool, rock wool, slag wool, plastic, natural fibers, polystyrene foam, polyisocyanurate foam, polyurethane foam, open cell foam, closed cell foam, rubber, sponged melamine, vermiculite, perlite, dirt, asphalt, concrete, cement and/or any combination thereof.

5. The framed forming panel system as claimed in claim 1, wherein said plurality of panel fasteners are releasable.

6. The framed forming panel system as claimed in claim 1, wherein at least one interstitial member is fixed in said frame.

7. A framed forming panel system comprising a plurality of joists fixed between a first top plate and a second top plate with a user defined spacing between each of said joists to form a ceiling frame having an inner ceiling region and an outer ceiling region; and a first plurality of framed panels fixed to said plurality of joists by a first plurality of panel fasteners to form a fastening region lattice across at least a portion of said ceiling frame; wherein each of said framed panels comprises a channel formed in a frame of sufficient dimensions to receive and hold a periphery of a foam panel.

8. The framed forming panel system as claimed in claim 7, wherein said plurality of joists each have a "U" shaped cross section.

9. The framed forming panel system as claimed in claim 7, wherein at least one void is formed in said ceiling frame by fixing in opposition to said first plurality of framed panels, a second plurality of framed panels fixed to said plurality of joists by a second plurality of fasteners.

10. The framed forming panel system as claimed in claim 9, wherein said at least one void is at least partially filled with an insulator from the group comprising of air, paper fiberglass, mineral wool, rock wool, slag wool, plastic, natural fibers, polystyrene foam, polyisocyanurate foam, polyurethane foam, open cell foam, closed cell foam, rubber, sponged melamine, vermiculite, perlite, dirt, asphalt, concrete, cement and/or any combination thereof.

11. The panel system as claimed in claim 7, wherein said plurality of panel fasteners are releasable.

12. The frame forming panel system as claimed in claim 7, wherein at least one interstitial member is fixed in said frame.

13. A framed forming panel system comprising a plurality of joists fixed between a first sole plate and a second sole plate with a user defined spacing between each of said joists to form a floor frame having an inner floor region and an outer floor region; and a first plurality of framed panels fixed to said plurality of joists by a first plurality of panel fasteners to form a fastening region lattice across at least a portion of said floor frame; wherein each of said framed panels comprises a channel formed in a frame of sufficient dimensions to receive and hold a periphery of a foam panel.

14. The framed forming panel system as claimed in claim 13, wherein said plurality of joists each have a "U" shaped cross section.

15. The panel system as claimed in claim 13, wherein at least one void is formed in said floor frame by fixing in opposition to said first plurality of framed panels, a second plurality of framed panels fixed to said plurality of joists by a second plurality of fasteners.

16. The panel system as claimed in claim 15, wherein said at least one void is at least partially filled with an insulator from the group comprising of air, paper fiberglass, mineral wool, rock wool, slag wool, plastic, natural fibers, polystyrene foam, polyisocyanurate foam, polyurethane foam, open cell foam, closed cell foam, rubber, sponged melamine, vermiculite, perlite, dirt, asphalt, concrete, cement and/or any combination thereof.

17. The panel system as claimed in claim 13, wherein said plurality of panel fasteners are releasable.

18. The frame forming panel system as claimed in claim 13, wherein at least one interstitial member is fixed in said frame.