Building Wall Assembly
A building wall assembly includes a panel of foamed polymeric material and studs received in channels at the inner side of the panel such that only an outer portion of the stud fits in the channel and an inner portion of the stud projects from the panel to define a utility space at the inside of the panel. Wooden structural sheathing material is joined across an upper portion of the studs at the inner side. Auxiliary sheathing material, for example concrete board, spans the outside of the panel in connection with strapping members recessed into strapping channels at the outside of the panel in which each strapping member is fastened through the panel to a respective stud. The studs may be wooden. Alternatively metals studs are used with utilities apertures therein so that spray foamed material can be connected between opposing sides of the stud channel through the utility apertures.
The present invention relates to a wall assembly for use as an insulated wall in a building, and more particular the present invention relates to a wall assembly including studs which are recessed into rigid panels of foamed polymeric insulating material.
BACKGROUNDVarious examples of wall assemblies for buildings are known in the prior art for being easy to assemble and for providing optimal insulation to the completed building. One common form of insulation is the use of a polymeric foamed panel. As described in U.S. Pat. No. 6,421,972 by Dalphond et al, insulating panels of this type may be used to form a continuous outer layer along an outer side of studs used in a structural wall to provide a thermal break on one side of the studs. No means are provided on conventional polymeric foamed panels for improving the insulation in the space between adjacent ones of the studs.
U.S. Pat. No. 5,265,389 by Mazzone et al and U.S. Pat. No. 5,943,775 by Lanahan et al disclose the use of metal channels as studs which are imbedded into respective mating channels formed in the foamed insulating panels such that some of the foamed insulating material of the panels provides insulation in the space between the studs. Due to the complex cross section of the studs however, the construction of the panels to surround the studs is complex and expensive. Furthermore, the space between the studs is typically filled with material when the studs are imbedded into the foamed material such that there is little or no access for running utilities such as electrical or water lines in the spaces between the studs as desired in conventional construction techniques. In one embodiment of U.S. Pat. No. 5,943,775, the studs are only partially imbedded into the insulating foam panels, however doing so requires a costly and complex manufacturing process to form mating channels into which the studs must be vertically slidable to assemble. Accordingly, the assembly is also awkward and inefficient. Furthermore no clear means are disclosed for securing structural sheathing to the studs as required according to many building codes.
U.S. Pat. No. 4,154,030 by Huguet and U.S. Pat. No. 5,353,560 by Huydon disclose further examples of the use of wooden studs with rigid insulating material. In each instance, the studs are fully embedded in the foam material however, such that the foam completely fills the space between adjacent studs so that there is no ready access for running utilities such as water and electrical lines.
SUMMARY OF THE INVENTIONAccording to one aspect of the invention there is provided a building wall assembly comprising:
a panel of foamed polymeric insulating material having inner and outer sides spanning in a longitudinal direction between opposing ends arranged for abutment in series with other panels of like configuration along a length of the wall assembly;
a plurality of recessed channels formed into the inner side of the panel so as to span vertically between top and bottom ends of the panel parallel to one another and at evenly spaced apart positions in the longitudinal direction between the opposing ends;
a stud received in each recessed channel of the panel;
each recessed channel having a profile corresponding to only an outer portion of a corresponding cross-section of the stud received therein such that a remaining inner portion of the cross-section of the stud projects out of the panel beyond the inner side of the panel so as to define a utility space spanning between the inner portions of each adjacent pair of studs at the inner side of the panel;
structural sheathing material extending parallel to the panel and being joined across the studs;
interior panelling spanning parallel to the panel at an inner side of the studs;
a header member spanning in the longitudinal direction across respective top ends of the studs; and
a footer member spanning in the longitudinal direction across respective bottom ends of the studs.
In some embodiments, each stud comprises a wooden stud abutting the structural sheathing material. The combination of wooden studs which are only partially embedded into foamed polymeric panels results in a simple low cost construction which is easy to manufacture and install.
The simple profile of any rectangular studs in particular allows the studs to be readily slid into the respective channels in a direction perpendicular to the plane of the panel instead of the more awkward vertical sliding of metal channels into a foamed panel. The partially embedded wooden studs also provides for a utility space for ease of running plumbing and electrical lines at the inner side of the wall.
The studs are also readily accessible for directly attaching structural sheathing to the inner ends of the studs instead of the conventional mounting of sheathing to the exterior of a building wall. The direct attachment of the structural sheathing to the studs provides sufficient strength while maintaining an accessible utility space adjacent the inner side of the insulating panels.
The structural sheathing material is preferably coupled to and abutted directly against the inner portion of each wooden stud so as to be arranged to span parallel to and spaced inwardly from the inner side of the panel and such that a portion of the utility space is defined between the inner side of the panel and the structural sheathing material. The structural sheathing material at the inner side of the panel may comprise the only structural sheathing material in the wall assembly, but is preferably located only adjacent the top ends of the studs. The structural sheathing material typically comprises wooden sheathing on the interior. Additional structural sheathing such as concrete board may span the exterior.
When an interior finishing layer of finishing material spans parallel to and alongside an inner side of the structural sheathing material so as to define an inner surface of the wall assembly, an auxiliary insulating layer of insulating material may span parallel to the structural sheathing material between the structural sheathing material and the interior finishing layer.
The panel may further include a plurality of strapping channels formed in the outer side such that each strapping channel is recessed into the panel and spans vertically between top and bottom ends of the panel and is aligned with a respective one of the recessed channels receiving a respective one of the wooden studs therein. In this instance, a strapping member can be supported in each strapping channel so as to be fastened to the respective wooden stud and so as to remain spaced apart from the respective wooden stud by a portion of the panel therebetween. Preferably each strapping member is substantially flush with the outer side of the panel. The auxiliary structural sheathing spanning the exterior can thus be secured in direct abutment with the strapping members while spanning across the outer side of the panel.
In one embodiment, each wooden stud comprises a rectangular cross section and each recessed channel comprises an inner end wall and two side walls spanning parallel and spaced apart from one another between the inner end wall and the inner side of the panel so as to be arranged to receive the wooden stud therebetween. In this instance, the wooden stud may be slidable into the recessed channel in a perpendicular direction relative to a plane of the inner side of the panel.
In an alternative embodiment, each wooden stud comprises an I-joist formed of an outer flange, an inner flange, and a web joined between the inner and outer flanges. In this instance, each recessed channel is preferably generally T-shaped including a flange portion receiving the inner flange of the respective wooden stud therein and a web portion connected between the flange portion and the inner side of the panel which is narrower in the longitudinal than the flange portion so as to be arranged to receive a portion of the web of the respective wooden stud therein.
In a further embodiment, each stud may comprise a metal stud having a generally rectangular cross section including two parallel and opposed side flanges, a connecting flange extending between the side flanges in a U-shaped configuration and a plurality of apertures in the connecting flange at longitudinally spaced positions. In this instance each recessed channel preferably comprises an inner end wall and two side walls spanning parallel and spaced apart from one another between the inner end wall and the inner side of the panel so as to be arranged to receive the stud therebetween. Spray foamed insulating material can then be received within each stud so as to be bonded to the two side walls and connected between the two side walls of the respective recessed channel through the apertures in the connecting flange of the stud.
According to a second aspect of the present invention there is provided a building wall assembly comprising:
a panel of foamed polymeric insulating material having inner and outer sides spanning in a longitudinal direction between opposing ends arranged for abutment in series with other panels of like configuration along a length of the wall assembly;
a plurality of recessed channels formed into the inner side of the panel so as to span vertically between top and bottom ends of the panel parallel to one another and at evenly spaced apart positions in the longitudinal direction between the opposing ends;
a stud received in each recessed channel of the panel;
each recessed channel having a profile corresponding to only an outer portion of a corresponding cross-section of the stud received therein such that a remaining inner portion of the cross-section of the stud projects out of the panel beyond the inner side of the panel so as to define a utility space spanning between the inner portions of each adjacent pair of studs at the inner side of the panel;
a plurality of strapping channels formed in the outer side such that each strapping channel is recessed into the panel and spans vertically between top and bottom ends of the panel and is aligned with a respective one of the recessed channels receiving a respective one of the studs therein, and
a strapping member supported in each strapping channel so as to be fastened to the respective stud and so as to remain spaced apart from the respective stud by a portion of the panel therebetween.
Preferably each strapping member is substantially flush with the outer side of the panel and an auxiliary sheathing layer comprising concrete board is joined to the strapping members to span across the outer side of the panel.
According to a further aspect of the present invention there is provided a building wall assembly comprising:
a panel of foamed polymeric insulating material having inner and outer sides spanning in a longitudinal direction between opposing ends arranged for abutment in series with other panels of like configuration along a length of the wall assembly;
a plurality of recessed channels formed into the inner side of the panel so as to span vertically between top and bottom ends of the panel parallel to one another and at evenly spaced apart positions in the longitudinal direction between the opposing ends; and
a stud received in each recessed channel of the panel;
wherein each recessed channel has a profile corresponding to only an outer portion of a corresponding cross-section of the stud received therein such that a remaining inner portion of the cross-section of the stud projects out of the panel beyond the inner side of the panel so as to define a utility space spanning between the inner portions of each adjacent pair of studs at the inner side of the panel;
wherein each stud comprises a metal stud having a generally rectangular cross section including two parallel and opposed side flanges, a connecting flange extending between the side flanges in a U-shaped configuration and a plurality of apertures in the connecting flange at longitudinally spaced positions;
wherein each recessed channel comprises an inner end wall and two side walls spanning parallel and spaced apart from one another between the inner end wall and the inner side of the panel so as to be arranged to receive the stud therebetween; and
wherein foamed insulating material is received within each stud so as to be connected between the two side walls of the respective recessed channel through the apertures in the connecting flange of the stud.
Various embodiments of the invention will now be described in conjunction with the accompanying drawings in which:
In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTIONReferring to the accompanying figures there is illustrated a building wall assembly generally indicated by reference numeral 10. The wall assembly 10 is suited for use as a wall in various buildings including commercial and residential applications.
The wall assembly 10 includes a plurality of studs 12 which span vertically between a header member 14 at a top end of the wall and a footer member 16 at the bottom end of the wall. The header and footer member extend in the longitudinal direction along the wall so as to span across all of the studs of the wall which are evenly spaced apart in the longitudinal direction by a standard spacing, for example 16 inches between centers.
The studs may comprise a wooden stud of rectangular cross section as shown in
The wall assembly further includes a plurality of insulating panels 18 comprising rigid foamed polymeric insulating material which spans the exterior side of the wall assembly. Each panel 18 is arranged to span the full height of the studs between the top and bottom ends of the wall with a length in the longitudinal direction which spans across several studs between the two opposing ends 20 of the panel. The opposing ends of each panel are arranged for abutting the ends of other panels of similar configuration so that the panels are abutted in a series in the longitudinal direction of the wall assembly.
Each end 20 includes a vertical groove formed therein spanning the full height of the panel at a location substantially laterally centered between an inner side 22 and an outer side 24 of the panel. The grooves 26 are arranged to be aligned with one another at each abutted seam such that the grooves can be filled with a suitable spray foam or silicone filling and bonding compound for example.
The inner side 22 of each panel includes a plurality of recessed stud channels 28. Each channel comprises a recessed groove which is open to the inner side of the panel and which extends vertically the full height of the panel between the top and bottom edges. The channels are spaced apart in the longitudinal direction to correspond to the spacing between adjacent studs 12 such that each stud channel 28 receives a respective one of the studs 12 therein.
The profile of the channels 28 corresponds to the profile of an outer portion of the respective stud received therein such that only the outer portion of the stud nearest to the exterior of the wall assembly is received into the channel. The opposing inner portion 32 of the stud which is nearest to the interior side of the wall assembly projects inward out of the panel beyond the inner side thereof such that the inner ends of the studs are located in a common plane which is parallel and spaced inwardly from the inner side of the panel. The space between the common plane of the inner ends of the studs and the inner side of the panel between each adjacent pair of studs defines a utility space 34 for receiving electrical and water lines for example.
Structural sheathing is provided in a layer which extends across the inner ends of the studs adjacent the top ends of the studs. The sheathing thus defines a portion of the utility space between the sheathing and the inner side of the panels. The structural sheathing comprises wooden sheets 36, for example plywood or other suitable lumber sheets such as OSB having a height in the order of two feet to span across only the upper portion of the studs. The sheets abut each other to form a continuous layer spanning in the longitudinal direction of the wall assembly. The sheets 36 are attached directly to the inner ends of the inner portion of the studs to be fastened thereto in a suitable manner using screws or nails and the like such that the sheets provide adequate structural shear strength to the studs. A typical thickness of the wooden sheets is in the range of half an inch.
The header member and footer member are formed of dimensional wooden lumber 38. The header member includes two pieces of lumber stacked above one another so that each extends the full width of the studs between inner and outer sides thereof while extending in the longitudinal direction across the top ends of the studs. The footer member comprises only a single piece of lumber extending the full width of the studs and extending in the longitudinal direction across the bottom ends of the studs.
The top and bottom edges of each panel include a recessed channel 42 at the inner side to extend in the longitudinal direction for receiving the respective header or footer member therein such that the insulating panels project outwardly beyond the exterior side of the studs and header and footer members. By sizing the channels 42 to match the height of the header and footer members, the top and bottom edges of the panel are flush with the top side of the header member and the bottom side of the footer member.
The outer side of the panels 18 include a plurality of strapping channels 44 formed therein which extend vertically the full height of the panels between the top and bottom ends thereof. Each strapping channel 44 is aligned with a respective stud channel on the opposing inner side such that the strapping channels are similarly evenly spaced in the longitudinal direction and parallel to one another. An inner end of the strapping channel remains spaced outwardly from the corresponding inner end wall of the respective stud channel such that the strapping channel remains spaced apart from the respective stud channel in the lateral direction of the thickness of the wall assembly by a portion of the foamed polymeric material therebetween.
A strapping member 46 is received in each strapping channel so as to have a mating cross section in a horizontal plane with the strapping channel such that the strapping member is substantially flush with the outer side of the panels 18 when received within the respective channel 44. Fasteners serve to join each strapping member to the respective stud by penetrating through the foamed insulating material between the strapping member in the strapping channel and the stud in the stud channel.
At the exterior side of the wall assembly, an auxiliary sheathing layer 48 is mounted directly to the outer side of the panels 18 by securement to the strapping members. The sheathing layer 48 comprises concrete board sheets in direct abutment with the outer side of the strapping members and the outer side of the panel of insulating material. The auxiliary sheathing layer 48 spans parallel alongside the outer side of the panels across the full height and length of the wall assembly in the longitudinal direction. Typical finishing material including siding, brick, or stucco for example can then be applied to the outer surface of the auxiliary sheathing layer 48.
Once installed, at the interior side of the wall assembly an auxiliary insulating layer 50 of insulating material is typically provided along the inner side of the sheathing material. The auxiliary insulating layer 50 typically comprises foam or fibreglass insulating material in the range of 1 to 2 inches of thickness for example. The auxiliary insulating layer 50 also includes a reflective foil layer incorporated on one side thereof. Interior finishing material can then be provided as an interior layer 52 spanning parallel to the panels along the inner side of the auxiliary insulating layer 50 such that the insulating layer 50 is sandwiched between the wooden sheets 36 of the structural sheathing material layer and the interior finishing layer 52. Typical interior finishing materials include drywall or other finished panelling for example.
Turning now more particularly to the embodiment of
Turning now to the embodiment of
Turning now to the embodiment of
The mating profile of the stud channels in this instance is similar to the embodiment of
Spray foam insulating material 76 is sprayed into the hollow interior of each stud once each stud is mounted into the respective channel. The spray foam insulating material is arranged to be bonded to both side walls 56 of the channel by being connected through the apertures in the connecting flange of the stud between the two side walls of the channel.
In use, the wall assembly may be available as a plurality of preassembled modular panels abutted with one another in series in the longitudinal direction. More preferably the wall assembly is assembled on site onto an existing floor or foundation structure 64 such that a subsequent overhead structure 66 such as another floor or roof trusses can then be supported thereon.
Initially, the studs are inserted into the respective stud channels of the insulating panels 18. The header and footer can then be mounted to the opposing ends of the studs by being received in the respective channels at the top and bottom edges of the panels. The wall assembly is then positioned onto the floor or foundation structure in its finished position. While the utility space remains accessible, utilities can be run through the utility spaces. The sheathing at the inner side may then be mounted onto the inner sides of the studs adjacent the top ends of the studs.
In further embodiments, the sheathing at the inner side may be attached to the studs prior to mounting the wall assembly in position. Openings can be subsequently cut into the sheathing layer when running utility lines if required. To finish the interior side of the wall assembly, the auxiliary insulating layer and the interior finishing layer are then attached to the inner side of the sheathing layer. Typically both the interior finishing and the auxiliary insulation are fastened either to the studs directly or through the sheathing layer, or fastening adjacent the top end of the studs to the sheathing layer may be sufficient. With strapping members provided in the strapping channels at the exterior side and with the auxiliary sheathing at the outer side, the exterior finishing layer can then be installed on the auxiliary sheathing.
Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without department from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
Claims
1. A building wall assembly comprising:
- a panel of foamed polymeric insulating material having inner and outer sides spanning in a longitudinal direction between opposing ends arranged for abutment in series with other panels of like configuration along a length of the wall assembly;
- a plurality of recessed channels formed into the inner side of the panel so as to span vertically between top and bottom ends of the panel parallel to one another and at evenly spaced apart positions in the longitudinal direction between the opposing ends;
- a stud received in each recessed channel of the panel;
- each recessed channel having a profile corresponding to only an outer portion of a corresponding cross-section of the stud received therein such that a remaining inner portion of the cross-section of the stud projects out of the panel beyond the inner side of the panel so as to define a utility space spanning between the inner portions of each adjacent pair of studs at the inner side of the panel;
- structural sheathing material extending parallel to the panel and being joined across the studs;
- interior panelling spanning parallel to the panel at an inner side of the studs;
- a header member spanning in the longitudinal direction across respective top ends of the studs; and
- a footer member spanning in the longitudinal direction across respective bottom ends of the studs.
2. The assembly according to claim 1 wherein each stud comprises a wooden stud abutting the structural sheathing material.
3. The assembly according to claim 1 wherein the structural sheathing material is coupled to the inner portion of each stud so as to be arranged to span parallel to and spaced inwardly from the inner side of the panel and such that a portion of the utility space is defined between the inner side of the panel and the structural sheathing material.
4. The assembly according to claim 1 wherein the structural sheathing material is supported at the inner side of the panel only adjacent the top ends of the studs.
5. The assembly according to claim 1 wherein the structural sheathing material is abutted directly against the inner portion of each stud.
6. The assembly according to claim 5 wherein the structural sheathing material comprises wooden sheathing.
7. The assembly according to claim 1 wherein each stud comprises a rectangular cross section and wherein each recessed channel comprises an inner end wall and two side walls spanning parallel and spaced apart from one another between the inner end wall and the inner side of the panel so as to be arranged to receive the stud therebetween.
8. The assembly according to claim 7 wherein the stud is slidable into the recessed channel in a perpendicular direction relative to a plane of the inner side of the panel.
9. The assembly according to claim 1 wherein each stud comprises an I-joist formed of an outer flange, an inner flange, and a web joined between the inner and outer flanges.
10. The assembly according to claim 9 wherein each recessed channel is generally T-shaped including a flange portion receiving the inner flange of the respective stud therein and a web portion connected between the flange portion and the inner side of the panel which is narrower in the longitudinal than the flange portion so as to be arranged to receive a portion of the web of the respective wooden stud therein.
11. The assembly according to claim 1 wherein the panel includes a plurality of strapping channels formed in the outer side such that each strapping channel is recessed into the panel and spans vertically between top and bottom ends of the panel and is aligned with a respective one of the recessed channels receiving a respective one of the studs therein, and wherein there is provided a strapping member supported in each strapping channel so as to be fastened to the respective stud and so as to remain spaced apart from the respective stud by a portion of the panel therebetween.
12. The assembly according to claim 11 wherein each strapping member is substantially flush with the outer side of the panel.
13. The assembly according to claim 11 further comprising an auxiliary sheathing layer spanning across the outer side of the panel and being joined to the strapping members.
14. The assembly according to claim 13 wherein the auxiliary sheathing layer comprises concrete board.
15. The assembly according to claim 1 wherein:
- each stud comprises a metal stud having a generally rectangular cross section including two parallel and opposed side flanges, a connecting flange extending between the side flanges in a U-shaped configuration and a plurality of apertures in the connecting flange at longitudinally spaced positions;
- each recessed channel comprises an inner end wall and two side walls spanning parallel and spaced apart from one another between the inner end wall and the inner side of the panel so as to be arranged to receive the stud therebetween; and
- foamed insulating material is received within each stud so as to be connected between the two side walls of the respective recessed channel through the apertures in the connecting flange of the stud.
16. A building wall assembly comprising:
- a panel of foamed polymeric insulating material having inner and outer sides spanning in a longitudinal direction between opposing ends arranged for abutment in series with other panels of like configuration along a length of the wall assembly;
- a plurality of recessed channels formed into the inner side of the panel so as to span vertically between top and bottom ends of the panel parallel to one another and at evenly spaced apart positions in the longitudinal direction between the opposing ends;
- a stud received in each recessed channel of the panel;
- each recessed channel having a profile corresponding to only an outer portion of a corresponding cross-section of the stud received therein such that a remaining inner portion of the cross-section of the stud projects out of the panel beyond the inner side of the panel so as to define a utility space spanning between the inner portions of each adjacent pair of studs at the inner side of the panel;
- a plurality of strapping channels formed in the outer side such that each strapping channel is recessed into the panel and spans vertically between top and bottom ends of the panel and is aligned with a respective one of the recessed channels receiving a respective one of the studs therein, and
- a strapping member supported in each strapping channel so as to be fastened to the respective stud and so as to remain spaced apart from the respective stud by a portion of the panel therebetween.
17. The assembly according to claim 16 wherein each strapping member is substantially flush with the outer side of the panel.
18. The assembly according to claim 16 further comprising an auxiliary sheathing layer spanning across the outer side of the panel and being joined to the strapping members.
19. The assembly according to claim 18 wherein the auxiliary sheathing layer comprises concrete board.
20. A building wall assembly comprising:
- a panel of foamed polymeric insulating material having inner and outer sides spanning in a longitudinal direction between opposing ends arranged for abutment in series with other panels of like configuration along a length of the wall assembly;
- a plurality of recessed channels formed into the inner side of the panel so as to span vertically between top and bottom ends of the panel parallel to one another and at evenly spaced apart positions in the longitudinal direction between the opposing ends; and
- a stud received in each recessed channel of the panel;
- wherein each recessed channel has a profile corresponding to only an outer portion of a corresponding cross-section of the stud received therein such that a remaining inner portion of the cross-section of the stud projects out of the panel beyond the inner side of the panel so as to define a utility space spanning between the inner portions of each adjacent pair of studs at the inner side of the panel;
- wherein each stud comprises a metal stud having a generally rectangular cross section including two parallel and opposed side flanges, a connecting flange extending between the side flanges in a U-shaped configuration and a plurality of apertures in the connecting flange at longitudinally spaced positions;
- wherein each recessed channel comprises an inner end wall and two side walls spanning parallel and spaced apart from one another between the inner end wall and the inner side of the panel so as to be arranged to receive the stud therebetween; and
- wherein foamed insulating material is received within each stud so as to be connected between the two side walls of the respective recessed channel through the apertures in the connecting flange of the stud.
Type: Application
Filed: Sep 14, 2012
Publication Date: Mar 20, 2014
Inventor: Faustino V. Mercado (Edmonton)
Application Number: 13/617,905
International Classification: E04B 2/26 (20060101); E04B 1/62 (20060101);
