Structural wall panel assemblies
Novel wall panel assemblies and shear wall assemblies are disclosed herein. Preferred embodiments include novel corner posts, studs, and sill plates for formed of composite materials and suitable for fabricating wall panels and shear wall assemblies for use in the construction of residential and commercial buildings.
The present invention is directed to a novel system of wall construction comprising the use of novel structural components and wall panels for use in the construction of residential and commercial buildings.
Certain aspects of the present invention comprise a structural corner post suitable for engaging a shear wall assembly thereto in the construction of a building. In one embodiment, the corner post has a top end, a bottom end, and a substantially rectangular, longitudinal outer body comprising four corners, the corners including a pair of diagonally opposing corners, each of the opposing corners comprising a longitudinal channel extending from the top end to the bottom end of the corner. The channels are configured to engage an outer edge of a shear wall assembly (e.g. one or more shear wall sheets or cross buck bracing assembly, for example), and are preferably oriented such that when the shear wall sheet(s) or cross buck bracing assembly is engaged within each of the channels, the shear wall sheets or cross buck bracing assemblies are positioned at substantially right angles to one another.
Certain aspects of the corner post may include an interior corner having an indentation sufficiently large for receiving and having fastened thereto an outer edge of an interior wall sheet. Other embodiments of the corner post include a pair of flanges extending from the interior corner of the post at substantially right angles to one another, the flanges being configured for receiving and having fastened thereon an outer edge of an interior wall sheet.
The present invention is also directed to a shear wall corner assembly for use in panelized construction of buildings. The shear wall corner assembly comprises a structural corner post having a top end, a bottom end, and a substantially rectangular, longitudinal outer body comprising four corners, the corners including a pair of diagonally opposing corners, each of the opposing corners comprising a longitudinal channel extending from the top end to the bottom end of the corner, the channels configured to engage an outer edge of one or more shear wall sheets, the four corners further including an interior corner positioned between the diagonally opposing corners. The shear wall corner assembly may further include a pair of vertical connecting studs, each of the connecting studs having a bottom end and a top end and positioned adjacent to one of the diagonally opposed corners of the corner post. A pair of shear wall assembly sections are also included, each having one outer side edge engaged within one of the channels of the corner post and an opposing outer side edge secured to one of the connecting studs such that the shear wall assembly sections are oriented at a substantially right angle to one another. A first interior wall sheet is also provided, the interior wall sheet having an outer side edge secured to the interior corner of the corner post, such that the interior wall sheet is positioned parallel to one of the shear wall assembly sections. A second interior wall sheet is also provided, the interior wall sheet having an outer side edge secured to the interior corner of the corner post, perpendicular to the first interior wall sheet.
The shear wall assembly sections of the corner assembly may comprise of at least one substantially flat sheet of material. Alternatively, the shear wall assembly is a cross buck bracing assembly comprising at least one pair of boards oriented in an overlapping criss-cross pattern between the corner post and one of the connecting studs, each of the boards having opposing ends comprising the outer edge of the shear wall assembly engaged within channels of the connecting stud and the corner post. The shear wall assembly may further include (i) a first board having one outer side edge secured to the corner post near the top end of the corner post and a second outer side edge secured to a top end of one of the adjacent connecting studs, such that the first board is oriented adjacent to and parallel with the sheer wall assembly section and (ii) a second board having an outer side edge secured to the corner post near the bottom end of the corner post and a second outer side edge secured to the bottom end of one of the adjacent studs, such that the second board is oriented adjacent to and parallel with the sheer wall assembly section.
The present invention is also directed to a shear wall assembly suitable for use in panelized building construction. One embodiment of the shear wall assembly comprises a pair of connecting studs, each of the studs having a top end, a bottom end, an exterior flange, and an interior flange, each of the flanges extending perpendicularly from the elongated web portion of the stud and positioned parallel to one another from the top end to the bottom end of the stud. Each of the studs may further include at least one intermediate flange extending perpendicularly from one side of the web portion and positioned subjacent and parallel to a portion of the exterior flange to form, in combination with the exterior flange, a longitudinal channel extending from the top end to the bottom end of the stud. The shear wall assembly further includes one or more solid shear wall sheets, each having two opposing side edges, each of the side edges engaged within one of the channels of one of the connecting studs. Other aspects of the shear wall assembly include at least one of the connecting studs having two of the intermediate flanges, each of the two intermediate flanges oriented opposite one another on opposing surfaces of the web portion such that, in combination with the exterior flange, the intermediate flanges and exterior flange form a pair of adjacent longitudinal channels, each of the channels configured to engage therein the outer edge of the shear wall sheet.
A second embodiment of the shear wall assembly may comprise a pair of connecting studs, each of the studs having a top end, a bottom end, an exterior flange and an interior flange, each of the flanges extending perpendicularly from an elongated web portion of the stud and positioned parallel to one another from the top end to the bottom end of the stud. In this embodiment, each of the studs includes at least one intermediate flange extending perpendicularly from one side of the web portion and positioned subjacent and parallel to a portion of the exterior flange to form, in combination with the exterior flange, a longitudinal channel extending from the top end to the bottom end of the stud. This embodiment includes a cross-buck bracing assembly comprising at least one pair of buck boards oriented in an overlapping, criss-cross pattern between the connecting studs, each of the buck boards having opposing ends secured within one of the channels of the connecting studs. A first board is secured to an outer surface of one of the intermediate flanges near the top end of the panel and spanning the width of the panel, such that the first board is oriented adjacent to and parallel with the cross-buck bracing assembly. A second board is secured to an outer surface of one of the intermediate flanges near the bottom end of the panel and spanning the width of the panel, such that the second board is oriented adjacent to and parallel with the cross-buck bracing assembly. Other aspects of this second embodiment of the shear wall assembly may include at least one of the connecting studs having two of the intermediate flanges, each of the two intermediate flanges oriented opposite one another on opposing surfaces of the web portion such that, in combination with the exterior flange, the intermediate flanges and exterior flange form a pair of adjacent longitudinal channels, each of the channels configured to engage therein the outer edge of the cross buck bracing boards.
The present invention is also directed to wall panels for use in panelized building construction. In certain aspects, the inventive wall panel includes a pair of panel connecting studs, each of the studs located on one end of the wall panel and each having an interlocking component for engagement with a complementary interlocking component of a second wall panel or a corner post. The wall panel further includes a series of second studs located between the pair of panel connecting studs and an elongated top plate secured to the top ends of the panel connecting studs and the second studs, the top plate having pair of a side walls integral with the top surface of the top plate to form a C-channel within which the studs are engaged. The wall panel also includes at least one exterior wall sheet secured to one of the top plate side walls and at least one interior wall sheet secured to a second of the top plate side walls, thereby creating a hollow interior therebetween within the wall panel. The hollow interior of the wall panel may also contain one or more thermal insulation materials. The wall panel includes one or more window or door opening sections secured between adjacent second studs and one or more shear wall assembly sections secured between adjacent second studs of the wall panel. The wall panel may also include an elongated bottom plate secured to the bottom ends of the panel connecting studs and the second studs, the bottom plate having pair of a side walls integral with the bottom surface of the bottom plate to form a C-channel within which the studs are engaged, and wherein the exterior and interior wall sheets are further secured to one of the side walls of the bottom plate. Preferably, the connecting studs and second studs are formed of a composite material.
The window or door opening sections of the inventive wall panel may further include a pair of vertical studs formed of a composite material and spaced apart to form the left and right sides of each of the openings, each of the window or door opening studs having a top end, a bottom end, and a side section adjacent the window or door opening. The window and door opening further include a pair of elongated boards formed of material selected from the group of wood and thermoplastic composites, each of the pair of boards secured to the side section of each of the pair of vertical studs of the window or door opening to provide a means of attaching a door jamb, door, window jamb, or window within the opening. These elongated boards may also be secured to the top of the door opening and to the top and bottom of the window opening, preferably by securing the board to the top and bottom jambs of the window opening, or just the top jamb of a door opening. The top end of the window or door opening includes a header assembly secured to the top ends of the pair of vertical studs of the door or window opening, thereby spanning the width of the opening. One or more vertical studs are secured at one end to the header assembly and at another end to the elongated connecting member of the wall panel.
The window opening of the wall panel may further include a pair of vertical security shutter studs configured to secure thereto a rolling security shutter assembly, the security shutter studs spaced apart to form the left and right sides of each of the openings, each of the security shutter studs having a top end, a bottom end, and a side section adjacent the opening, wherein the side sections of the security shutter studs face one another. The side section of each of the pair of security shutter studs has a longitudinal channel extending from the top end to the bottom end of the security shutter stud, the channel configured to receive a roller mechanism of the rolling security shutter assembly for movement of a the shutter assembly therein. The security shutter assembly of the security shutter comprises a shutter and a roller mechanism comprising a series of rollers on each outer edge of the shutter, the rollers engaged within one of the channels of the security shutter studs for movement of the shutter assembly therein. Preferably, the security shutter studs are formed of a composite material.
The present invention is also directed to structural studs of various configurations for use in fabricating the shear wall panels and non-shear wall panels. In one aspect, the stud, which is preferably formed of a composite material, is configured to engage a rolling security shutter assembly therein. Specifically, the stud comprises an exterior flange extending perpendicularly from an elongated web portion of the stud. The stud further includes a first intermediate flange extending perpendicularly from one side of the web portion and positioned subjacent with and parallel to a portion of the exterior flange to form, in combination with the exterior flange, a first channel extending the length of the stud, the first channel configured to receive a roller mechanism of a rolling security shutter assembly for movement of a the shutter assembly therein. The stud may further include a second intermediate flange extending perpendicularly from a second side of the web portion and oriented opposite the first intermediate flange such that, in combination with the exterior flange, the second intermediate flanges and a portion of the exterior flange form a second channel adjacent the first channel, the second channel extending the length of the stud and configured to engage therein an outer side edge of at least one wall sheet.
The present invention is also directed to a wall panel system comprising (a) a plurality of wall panels, each of the wall panels comprising (i) a pair of panel connecting studs formed of a composite material, each of the studs located on one end of the wall panel and having an interlocking component for engagement with a complementary interlocking component of a second wall panel or a corner post, the panel connecting studs further having an exterior flange and an interior flange extending perpendicularly from a central elongated web portion; (ii) a series of second studs located between the pair of panel connecting stud, wherein some of the adjacent studs are spaced apart to form a gap therebetween; (iii) one or more braces secured between one or more pairs of adjacent second studs to span the gap between the adjacent second studs; (iv) an elongated top plate secured to the top ends of the panel connecting studs and the second studs, the top plate having pair of a side walls integral with the top surface of the top plate to form a C-channel within which the studs are engaged and (v) at least one exterior wall sheet secured to one of the top plate side walls and at least one interior wall sheet secured to a second of the top plate side walls, thereby creating a hollow interior therebetween within the wall panel. The hollow interior formed between the exterior and interior wall sheets may contain a insulation material, such as those used to file the corner posts as mentioned above. The wall panels are secured to one another at opposing ends via the interlocking and mechanically (or adhesively) fastened components of adjacent wall panels, wherein the interlocking component of the connecting stud of one panel comprises a substantially C-shaped channel formed in part by the exterior and interior flanges and the web portion of the connecting stud, the channel configured for engagement therein of a complementarily configured web portion of the connecting stud of an adjacent panel for interlocking engagement of the wall panels to one another. The wall panels are further secured to one another via a plurality of mechanical fasteners penetrating the flanges of adjacent connecting studs of adjacent wall panels, wherein the flanges of adjacent panels overlap one another. The wall panel may further include a corner post, the corner post having an outer body and an interlocking component extending from the outer body for engagement with a complementarily configured interlocking component of one of the wall panels. The corner post may further have an exterior corner and a diagonally opposing interior corner, the interior corner having a pair of flanges extending therefrom at substantially right angles to one another, with each of the pair of flanges configured for receiving and having fastened thereon an outer edge of the interior wall sheet. Alternatively, the corner post may include an indentation sufficiently large for receiving and having fastened thereto the outer edges of an interior wall sheet.
A second embodiment of the inventive wall panel system also comprises a plurality of wall panels, with each of the wall panels including (i) a pair of panel connecting studs formed of a composite material, each of the studs located on one end of the wall panel and having an interlocking component for engagement with a complementary interlocking component of a second wall panel or a corner post, the panel connecting studs further having an exterior flange and an interior flange extending perpendicularly from a central elongated web portion; (ii) a series of second studs located between the pair of panel connecting studs; (iii) an elongated top plate secured to the top ends of the panel connecting studs, the second studs, the top plate having pair of a side walls integral with the top surface of the top plate to form a C-channel within which the studs are engaged; and (iv) at least one exterior wall sheet secured to one of the top plate side walls and at least one interior wall sheet secured to a second of the top plate side walls, thereby creating a hollow interior therebetween within the wall panel which may be filled with an insulation material. The wall panels are secured to one another at opposing ends via the interlocking components of adjacent wall panels, wherein the interlocking component of the connecting stud of one panel comprises exterior and interior flanges of the connecting stud, in combination with a flange subjacent to the exterior flange and extending from a side of the web portion, the exterior flange and subjacent flange forming a groove for engagement of an interior flange of a complementary configured interlocking component of an adjacent wall panel. The wall panels are further secured to one another via a plurality of mechanical fasteners penetrating the flanges of adjacent connecting studs of adjacent wall panels to another, wherein the flanges of adjacent panels overlap one another. The wall panel system of this embodiment may further include a corner post, the corner post having an outer body and an interlocking component extending from the outer body for engagement with a complementarily configured interlocking component of one of the wall panels. Moreover, the corner post includes an exterior corner and a diagonally opposing interior corner, wherein the interior corner may have a pair of flanges extending therefrom at substantially right angles to one another, each of the pair of flanges configured for receiving and having fastened thereon an outer edge of the interior wall sheet. Alternatively, the corner post may include an indentation sufficiently large for receiving and having fastened thereto the outer edges of an interior wall sheet.
The present invention is also directed to a novel sill plate for securing structural studs of a framing assembly to a floor pad. In a preferred embodiment, the sill plate comprises interior and exterior side walls defining a longitudinal recess for engaging therein a structural stud or a stud mount, the side walls extending upward from a floor portion of the sill plate, the floor portion having an inner surface onto which the structural stud or stud mount rests and an opposite outer surface for abutment against the floor pad. The sill plate further includes (a) a shield projecting from an outer surface of the exterior side wall, the shield having a portion angled downward; and (b) an inverted T-shaped anchor mount integral with and extending downward from the outer surface of the floor portion of the sill plate for engagement within the floor pad. The inventive sill plate is preferably formed of a composite material, the composite material more preferably being a thermoplastic composite material.
BRIEF DESCRIPTION OF THE FIGURES
Referring now to
The corner post 10, 101 is secured to an underlying floor pad by means of a corner stud mount 20, as shown in
The inventive corner posts 10, 101 may be used to form a shear wall corner assembly for use in panelized construction of buildings, as shown in
An elongated top plate 72a (preferably a C-channel top plate), is secured to the top end of the corner post and connecting member via fasteners (not shown). The top-plate 72a includes a pair of side walls 77a, 77b, with one end of the interior side wall 74 engaged partially within the indentation of the corner post, as shown more clearly in
Positioning of the shear wall sheets 80 or cross buck bracing 83 more toward the exterior of the building frame is advantageous in that it allows more room for the attachment of electric boxes (not shown), for example, within the wall panel (i.e. between the stiffener board 82, 82a and interior wall sheet 70 or between the shear wall sheet or cross buck bracing and the interior wall sheet 70). In addition, the hollow space 5 created between the stiffener board 82, 82a and interior wall sheet 70 (or between the shear wall sheet(s) 80 (or cross buck bracing 83) and interior wall sheet 70 when no stiffener boards are employed) may be left hollow or filled with a variety of insulating materials such as fiberglass, rock wool, foam insulation, and the like.
The in-line shear wall assembly may comprise the use of a third connecting stud design 60 (
All of the connecting studs illustrated in
As discussed above,
The shear wall panel assemblies discussed above with respect to the shear wall corner assembly may also be placed in other locations of building structure, and are referred herein as in-line shear wall panel assemblies.
The present invention, in certain aspects, is also directed to panelized construction utilizing window and doorway panel segments formed of structural components and materials that are capable of attaching window and door jambs with nail fasteners, as shown in part in
Specifically, the inventive wall panel may comprise one or more openings configured for securing a window or a door via a window jamb or a doorjamb. To form the window or door opening, the wall panel includes a pair of vertical studs 31 spaced apart to form the left and right sides of each of the openings, referenced generally at 403 in
The panel further includes a pair of elongated boards formed of a thermoplastic material or wood 600, each of the pair of boards secured to one of the second vertical studs 30 with screws or adhesives to provide a means of attaching a door or window jamb within the opening using nails. The board 6001 may also be secured horizontally near the top of the door opening (
As mentioned above, and as shown in
Generally, a header 98, 99, as shown in
Specifically, as shown in
Each wall panel further includes a second series of intermediate studs 31, preferably having the single-I configuration as shown in
The wall panel further includes at least one exterior wall sheet 71 and one interior wall sheet 70 secured to the side walls of the top plate 72a and in some embodiments the bottom plate 72b (or sill plate) of the panel as well as to the outside surfaces of the various vertical studs via mechanical fasteners (e.g. screws and the like). The space created between the interior wall sheet 70 and exterior wall sheet 71 may be left hollow or it may be filled with a variety of insulating materials such as fiberglass, rock wool, foam insulation, and the like, where desired. For ease of illustration, the exterior and interior wall sheets are omitted from
As discussed above, the interlocking components of the pair of connecting studs may be of any number of configurations.
One advantage of the inventive of interlocking connecting members of the present invention is that when engaged with one another, the adjacent connecting studs 305, 370 of
Moreover, another advantage of the interlocking component of the present invention is that interlocked panels using the interlocking studs 200 are significantly stronger than the panels that are non-interlocking. Strength tests were performed on the interlock stud component 200 and the single I stud 31, with the data shown herein in Tables 1-4. In particular, the interlock stud components 200, when assembled to one another (i.e. two studs 200 secured to one another via mechanical fastening) was found to be 13.2% stronger than the single-I stud 31 when comparing the critical buckling loads (4,278 lb vs. 3,868 lb) under an area normal load of 44.46 lb/ft2 (Tables 1 and 2) and critical bucking loads of 8,755 lb vs. 7,735 lb under area normal load of 88.15386 lb/ft2 (Tables 3 and 4). Moreover the assembled stud interlocking components 200 exhibited 56.2% les deflection compared to the single I stud 31.
The interlocking mechanism design of the inverted connecting stud member 200 and corner post 378, 380 differs in part from the male/female interlocking stud member 300 design in that once adjacent panels incorporating the inverted connecting stud 200 are secured to one another, a gap is created between the two interlocked panels (or between the panel and corner post 378, 380, 475, 476). No such gap is created in a panel-to-panel or panel-to-corner post connection employing the male/female interlocking stud 300. The creation of this gap between adjacent panels (or corner post and panel) resulting from the employment of the inverted stud 200 and corner post 378, 380, 475, 4776 design is advantageous in that it provides another location within the panels comprising the constructed building for housing various electrical wiring, cables, fiber optic wiring, and the like.
As discussed above, the interlocking components (either designs) of adjacent connecting stud members should be further secured to one another by mechanical fasteners 1b (with or without adhesives) for ultimate strength. As shown in the figures, this mechanical fastening of the interlocking components and all component fastening is always in shear (i.e. 90 degrees to the force) to provide a much stronger connection therebetween. In contrast, it is typical in wood fabrication to drive nails through sill boards and top boards into the ends of the studs. Other wood studs may be toe nailed into the bottom or top studs. These fasteners fail easily in uplift pull out forces as encountered in hurricanes and tornadoes. In the present invention, each screw driven into the construction components in shear has a minimum pullout force of 1,700 pounds each in shear, compared to a 10d nail with a pullout force of 58 pounds in pullout (in recent tests by the inventor).
As shown in
Each of the inventive panels may be lifted separately by a crane C (
Alternatively, the bottom ends of the vertical studs may remain free from attachment to a sill plate, stud mount, or bottom connecting plate 72b during assembly, and instead, may be engaged within a stud mount or sill plate that is pre-set within the floor pad or foundation F. A preferred means for securing the wall panels to the underlying floor pad, however, is the sill plate 100 illustrated in
The present invention is also directed to the use of a novel connecting vertical stud 60 for use in the fabrication of the wall panels, wherein the stud is configured to house the roller mechanism of a security shutter assembly, such as roll-type hurricane shutters, for example, the roller mechanism namely comprising the roller guide bearing and roller hinge located on each side of the shutter. The stud 60 is illustrated in
The various interlocking joints, corner posts, and connecting studs of the present invention may be fabricated of any material (metal and non-metal) commonly known and used in the metal, composite, or construction industries; however, the illustrated designs of the structural components and their assembly are particularly well-suited for fabrication using extruded metals and composite materials, molded composite materials, or pultruded composite materials. The combination of the structural design and use of these lightweight materials provides for a more cost-effective product that is lighter in weight, more precise dimensionally, capable of automated production, faster to erect, and has an improved life cycle performance than currently applied construction support framing technologies, such as pre-cast lintels or cast in place tie beams, used with concrete block buildings, wood fabricated or manufactured lumber headers used in wood buildings, or steel box beams or steel I beams used in steel buildings. The use of composites in the inventive panelized assembly in particular is also more ecologically friendly, requires less material, has superior sustainability, and lower life cycle costs when compared with all other structural support framing assemblies.
As used herein, “composite” material shall mean any material that is formed from fiber materials impregnated with a resin, mats, and filler, also commonly referred to as “fiber-reinforced plastics” (FRP). The fibers and resins used to form the composite material may be combined in an extrusion process, and therefore referred to herein as an “extruded fiber reinforced composite,” or they may be combined in a molding process, and therefore referred to herein as a “molded fiber reinforced composite,” or finally, they may be combined in an pultrusion process, and therefore referred herein as a “pultruded composite.” Exemplary fiber materials for use in the pultruded composites include, but are not limited to, hemp, kenaf, jute, flax, sisal, acralate, polyethylene, polyester, or spectra organic fibers or fiberglass, aramids (e.g. KEVLAR), basalt, carbon, graphite, boron, and quartz inorganic fibers. Generally, the fiber material may be formed from any long, longitudinally oriented, fiber strands woven into ropes or rovings, or processed into woven cloth mats in a variety of orientations, from 15 degrees to 90 degrees, but more preferably in 45-degree and 90-degree warp and weft fiber orientations or other configurations of filaments, such as directionally laid mats, continuously laid mats, and stitched mats. Other exemplary fiber materials include, but are not limited to, silicon carbide, ceramics, stainless steel, and nickel.
The resins may be selected from any number of thermoset or thermoplastic materials. Exemplary thermoplastic materials include, but are not limited to, polyesters, polypropylenes (PP), vinylesters, polycarbonates, nylon, polyvinyl chloride (PVC), and PVC derivatives, polyethylene (PE), high density polyethylene (HDPE), polyphenylene sulfide (PPS), polycarbonate (PBT), acetal, acrylonitrile-butadine-styrene (ABS), polysulfone, polyethersulfone, polyetheramide, polyetheretherkeytone (PEEK), and Teflon. Exemplary thermoset materials include, but are not limited to, phenolics, polyesters, epoxies, and polystyrenes, silicon, vinyl esters, polyesters alkyds, cyanate esters, bismaleimides (BMI), polyimides, melamines, dially phthalate (DAP), urea, furans, silicates and polyurethanes.
Typical composite formulations used in industries such as fiberglass ladders have a bending modulus in the range of 2.5 to 3.0 million PSI (pounds per square inch) are made from formulae such as that recited in Table 5 below.
1350° F. = Die temperature
36 inches per minute = pull speed
In the present invention, more advanced composites generally used in highly specialized applications, such as those used in the military and aerospace industries. These advanced composites have a bending modulus typically in the range of 6.0 to 8.0 million PSI. Preferred composites for the present invention, which the inventor refers to as “advanced construction composites,” are similar to those used in these highest applications, but have a bending modulus in the range of 4.0 to 7.0 million PSI and are made from formulae such as that recited in Table 6 below.
2475° F. = Die temperature
36 inches per minute = pull speed
The pultrusion, molding, and extrusion processes that may be employed, as well as the amounts and combinations of resins and fiber materials used, depending upon the particular manufacturing process employed (i.e. extrusion versus pultrusion versus molding), are those that are commonly known by those of ordinary skill in the art. Preferred resin formulations are described in the inventor's co-pending U.S. patent application Ser. No. 11/116,769, which as discussed above, is incorporated herein by reference in its entirety.
Claims
1. A structural corner post suitable for engaging a shear wall assembly thereto in the construction of a building, said corner post having a top end, a bottom end, and a substantially rectangular, longitudinal outer body comprising four corners, said corners including a pair of diagonally opposing corners, at least one of said of said opposing corners comprising a longitudinal channel extending from said top end to said bottom end of said corner and configured to engage an outer edge of a shear wall assembly.
2. The corner post of claim 1, wherein said post has a hollow interior formed by said outer body.
3. The corner post of claim 1, wherein said post is formed of a composite material.
4. The corner post of claim 2, further including a fill material housed within said hollow interior of said post.
5. The corner post of claim 4, wherein said fill material comprises one or more materials suitable for sound attenuation or thermal insulation.
6. The corner post of claim 1, wherein said shear wall assembly comprises either one or more shear wall sheets or cross buck bracing,
7. The corner post of claim 1, wherein said four corners further include an exterior most corner and a diagonally opposing interior corner, said interior corner having an indentation sufficiently large for receiving and having fastened thereto an outer edge of an interior wall sheet.
8. The corner post of claim 7, wherein said post has a hollow interior formed by said outer body.
9. The corner post of claim 8, wherein said post is formed of a composite material
10. The corner post of claim 1, wherein said four corners further include an exterior most corner and a diagonally opposing interior corner, said interior corner having a pair of flanges extending therefrom at substantially right angles to one another, each of said pair of flanges configured for receiving and having fastened thereon an outer edge of an interior wall sheet.
11. The corner post of claim 10, wherein said post is formed of a composite material
12. A shear wall assembly suitable for use in panelized building construction, said assembly comprising:
- a pair of connecting studs, each of said studs having a top end, a bottom end, an exterior flange, and an interior flange, each of said flanges extending perpendicularly from of an elongated web portion of said stud and positioned parallel to one another from the top end to the bottom end of said stud, and wherein each of said studs further includes at least one intermediate flange extending perpendicularly from one side of said web portion and positioned subjacent and parallel to a portion of said exterior flange to form, in combination with said exterior flange, a longitudinal channel extending from the top end to the bottom end of the stud; and
- one or more shear wall sheets, each having two opposing side edges, each of said side edges engaged in within one of said channels of one of said connecting studs.
13. The shear wall assembly of claim 12, wherein at least one of said connecting studs includes two of said intermediate flanges, each of said two intermediate flanges oriented opposite of one another on opposing surfaces of said web portion such that, in combination with said exterior flange, said intermediate flanges and exterior flange form a pair of adjacent longitudinal channels, each of said channels configured to engage therein the outer edge of a second shear wall sheet.
14. A shear wall assembly suitable for use in panelized building construction, said assembly comprising:
- a pair of connecting studs, each of said studs having a top end, a bottom end, an exterior flange and an interior flange, each of said flanges extending perpendicularly from an elongated web portion of said stud and positioned parallel to one another from the top end to the bottom end of said stud, and wherein each of said studs further includes at least one intermediate flange extending perpendicularly from one side of said web portion and positioned subjacent and parallel to a portion of said exterior flange to form, in combination with said exterior flange, a longitudinal channel extending from the top end to the bottom end of the stud; and
- a cross-buck bracing assembly comprising at least one pair of buck boards oriented in an overlapping, criss-cross pattern between said connecting studs, each of said buck boards having opposing ends secured within one of said channels of said connecting studs.
15. The shear wall assembly of claim 14, further including:
- a first board secured to an outer surface of one of said intermediate flanges near the top end of said panel and spanning the width of said panel, such that said first board is oriented adjacent to and parallel with said cross-buck bracing assembly; and
- a second board secured an outer surface of one of said intermediate flanges near the bottom end of said panel and spanning the width of said panel, such that said second board is oriented adjacent to and parallel with said cross-buck bracing assembly.
16. The shear wall assembly of claim 15, wherein at least one of said connecting studs includes two of said intermediate flanges, each of said two intermediate flanges oriented opposite of one another on opposing surfaces of said web portion such that, in combination with said exterior flange, said intermediate flanges and exterior flange form a pair of adjacent longitudinal channels, each of said channels configured to engage therein the outer edges of a second set of cross buck bracing boards.
17. A wall panel for use in panelized building construction, said panel comprising:
- a) a pair of panel connecting studs, each of said studs located on one end of said wall panel and each having an interlocking component for engagement with a complementary interlocking component of a second wall panel or a corner post;
- b) a series of second studs located between said pair of panel connecting studs, said second studs spaced apart to form a gap between adjacent second studs;
- c) one or more braces secured between one or more pairs of adjacent second studs to span the gap between said adjacent second studs;
- d) an elongated top plate secured to the top ends of said panel connecting studs and said second studs, said top plate having pair of a side walls integral with a top surface of said top plate to form a C-channel within which said studs are engaged;
- e) at least one exterior wall sheet secured to one of said top plate side walls and at least one interior wall sheet secured to a second of said top plate side walls and said studs, thereby creating a hollow interior therebetween within said wall panel;
- f) one or more window or door opening sections secured between adjacent second studs; and
- g) one or more shear wall assembly sections secured between adjacent second studs of said wall panel.
18. The wall panel of claim 17, wherein said pair of panel connecting studs and second studs are formed of a composite material.
19. The wall panel of claim 17, further including a elongated bottom plate secured to the bottom ends of said panel connecting studs and said second studs, said bottom plate having pair of a side walls integral with a bottom surface of said bottom plate to form a C-channel within which said studs are engaged, and wherein said at least one exterior wall sheet and said at least one interior wall sheet are further secured to one of said side walls of said bottom plate and said studs.
20. The wall panel of claim 19, wherein said hollow interior created within said wall panel contains one or more thermal insulation materials.
21. The wall panel of claim 19, wherein said pair of panel connecting studs and second studs are formed of a composite material.
22. The wall panel of claim 21, wherein said window or door opening section further comprises:
- a) a pair of vertical studs formed of a composite material and spaced apart to form the left and right sides of each of said openings, each of said window or door opening studs having a top end, a bottom end, and a side section adjacent said opening;
- b) a pair of elongated boards formed of material selected from the group of wood and thermoplastic composites, each of said pair of boards secured to said side section of each of said pair of vertical studs of said window or door opening to provide a means of attaching a door jamb, door, window jamb, or window within said opening;
- c) a second elongated board formed of a material selected from the group of wood and thermoplastic composites, said second board secured near a top jamb of said window or door opening;
- d) said top end of said window or door opening having a header assembly secured to the top ends of said pair of vertical studs of said door or window opening, thereby spanning the width of said opening; and
- e) one or more second vertical studs secured at one end to said header assembly and at another end to said elongated connecting member of said wall panel.
23. The wall panel of claim 17, wherein said panel comprises a window opening section, said window opening section further comprising:
- a) a pair of vertical security shutter studs configured to secure thereto a rolling security shutter assembly, said security shutter studs spaced apart to form the left and right sides of each of said openings, each of said security shutter studs having a top end, a bottom end, and a side section adjacent said opening, wherein said side sections of said security shutter studs face one another;
- b) said side section of each of said pair of security shutter studs having a longitudinal channel extending from the top end to the bottom end of said security shutter stud, said channel configured to receive a roller mechanism of said rolling security shutter assembly for movement of a said shutter assembly therein; and
- c) a third elongated board formed of a material selected from the group of wood and thermoplastic composites, said second board secured near a bottom jamb of said window opening
24. The wall panel of claim 23, wherein said security shutter studs are formed of a composite material.
25. The wall panel of claim 23, further including said rolling security shutter assembly, said security shutter assembly having a shutter and a roller mechanism comprising a series of rollers on each outer edge of said shutter, said rollers engaged within one of said channels of said security shutter studs for movement of said shutter assembly therein.
26. The wall panel of claim 25, wherein said security shutter studs are formed of a composite material.
27. A wall panel suitable for use in panelized building construction, said panel comprising:
- a) a pair of panel connecting studs, each of said studs located on one end of said wall panel and having an interlocking component for engagement with a complementary interlocking component of a second wall panel or a corner post;
- b) a series of second studs located between said pair of panel connecting studs, said second studs spaced apart to form a gap between adjacent second studs;
- c) an elongated top plate secured to the top ends of said panel connecting studs and said second studs, said top plate having pair of a side walls integral with a top surface of said top plate to form a C-channel within which said studs are engaged;
- d) at least one exterior wall sheet secured to one of said top plate side walls and at least one interior wall sheet secured to a second of said top plate side walls, thereby creating a hollow interior therebetween within said wall panel;
- e) one or more window opening sections secured between adjacent second studs; and
- f) at least one or more of said window openings further including (i) a pair of vertical security shutter studs configured to secure thereto a rolling security shutter assembly, said security shutter studs spaced apart to form the left and right sides of each of said window opening, each of said security shutter studs having top end, a bottom end, and a side section adjacent said opening, wherein said side sections of said security shutter studs face one another, and (ii) said side section of each of said pair of security shutter studs having a longitudinal channel extending from the top end to the bottom end of said security shutter stud, said channel configured to receive a roller mechanism of a rolling security shutter assembly for movement of a said shutter assembly therein.
28. The wall panel of claim 27, wherein said panel connecting studs, said second studs, and said security shutter studs are formed of a composite material.
29. The wall panel of claim 28, further including said rolling security shutter assembly, said security shutter assembly having a shutter and a roller mechanism comprising a series of rollers on each outer edge of said shutter, said rollers engaged within one of said channels of said security shutter studs for movement of said shutter assembly therein.
30. The wall panel of claim 27, further including one or more braces secured between one or more pairs of adjacent second studs to span the gap between said adjacent second studs.
31. A sill plate for securing structural studs of a framing assembly to a floor pad, said sill plate comprising:
- a) interior and exterior side walls defining a longitudinal recess for engaging therein a structural stud or a stud mount, said side walls extending upward from a floor portion of said sill plate, said floor portion having an inner surface onto which the structural stud or stud mount rests, and an opposite outer surface for abutment against said floor pad;
- b) a shield projecting from an outer surface of said exterior side wall, said shield having a portion angled downward;
- c) an inverted T-shaped anchor mount integral with and extending downward from said outer surface of said floor portion of said sill plate for engagement within said floor pad.
32. The sill plate of claim 31, wherein said sill plate is formed of a thermoplastic composite material.
33. A shear wall corner assembly for use in panelized construction of buildings, said shear wall corner assembly comprising:
- a structural corner post having a top end, a bottom end, and a substantially rectangular, longitudinal outer body comprising four corners, said corners including a pair of diagonally opposing corners, each of said opposing corners comprising a longitudinal channel extending from said top end to said bottom end of said corner, said four corners further including an interior corner positioned between said diagonally opposing corners;
- a pair of vertical connecting studs, each of said connecting studs having a bottom end and a top end and positioned adjacent to one of said diagonally opposed corners of said corner post;
- a pair of shear wall assembly sections, each having one outer side edge engaged within one of said channels of said corner post and an opposing outer side edge secured to one of said connecting studs such that said shear wall assembly sections are oriented at a substantially right angle to one another;
- a first interior wall sheet having an outer side edge secured to said interior corner of said corner post, such that said interior wall sheet is positioned parallel to one of said shear wall assembly sections; and
- a second interior wall sheet having an outer side edge secured to said interior corner of said corner post, perpendicular to said first interior wall sheet.
34. The shear wall corner assembly of claim 33, wherein said interior corner of said corner post includes an indentation sufficiently large for receiving and having fastened thereto said outer edges of said second interior wall sheets.
35. The shear wall corner assembly of claim 33, wherein said interior corner has a pair of flanges extending therefrom at substantially right angles to one another, each of said pair of flanges configured for receiving and having fastened thereon said outer edges of said interior wall sheet.
36. The shear wall corner assembly of claim 33, wherein each of said connecting studs comprises an exterior flange and an interior flange, each of said flanges extending perpendicularly from an elongated web portion of said stud and positioned parallel to one another from the top end to the bottom end of said stud, and wherein each of said studs further includes at least one intermediate flange extending perpendicularly from said web portion and positioned subjacent with and parallel to said exterior flange to form, in combination with said exterior flange, a longitudinal channel extending the top end to the bottom end of said stud.
37. The shear wall corner assembly of claim 33, wherein said corner post and connecting studs are formed of a composite material, and wherein said corner post has a hollow interior formed by said outer body.
38. The shear wall corner assembly of claim 33, further including a fill material housed within said hollow interior of said corner post.
39. The shear wall corner assembly of claim 38, wherein said fill material comprises one or more materials suitable for sound attenuation or thermal insulation.
40. The shear wall corner assembly of claim 33, wherein said shear wall assembly comprises at least one solid, substantially flat sheet of material.
41. The shear wall corner assembly of claim 33, wherein said shear wall assembly is a cross buck bracing assembly comprising at least one pair of boards oriented in an overlapping criss-cross pattern between said corner post and one of said connecting studs, each of said boards having opposing ends comprising the outer edge of said shear wall assembly engaged within channels of said connecting stud and said corner post.
42. The shear wall corner assembly of claim 41, further including (a) a first board having one outer side edge secured to said corner post near the top end of said corner post and a second outer side edge secured to a top end of one of said adjacent connecting studs, such that said first board is oriented adjacent to and parallel with said sheer wall assembly section; and (b) a second board having an outer side edge secured to said said corner post near the bottom end of said corner post and a second outer side edge secured to said bottom end of one of said adjacent studs, such that said second board is oriented adjacent to and parallel with said sheer wall assembly section.
43. An elongated structural stud for use in building construction, said stud having an exterior flange extending perpendicularly from an elongated web portion of said stud, said stud further having a first intermediate flange extending perpendicularly from one side of said web portion and positioned subjacent with and parallel to a portion of said exterior flange to form, in combination with said exterior flange, a first channel extending the length of said stud, said first channel configured to receive a roller mechanism of a rolling security shutter assembly for movement of a said shutter assembly therein.
44. The stud of claim 43, wherein said stud is formed of a composite material.
45. The stud of claim 43, wherein said stud further comprises a second intermediate flange extending perpendicularly from a second side of said web portion and oriented opposite said first intermediate flange such that, in combination with said exterior flange, said second intermediate flanges and a portion of said exterior flange form a second channel adjacent said first channel, said second channel extending the length of said stud and configured to engage therein an outer side edge of at least one wall sheet.
46. The stud of claim 45, wherein said stud is formed of a composite material.
47. A wall panel system for use in panelized construction, said system comprising
- a) a plurality of wall panels, each of said wall panels comprising:
- i) a pair of panel connecting studs formed of a composite material, each of said studs located on one end of said wall panel and having an interlocking component for engagement with a complementary interlocking component of a second wall panel or a corner post, said panel connecting studs further having an exterior flange and an interior flange extending perpendicularly from a central elongated web portion;
- ii) a series of second studs located between said pair of panel connecting stud, said second studs spaced apart to form a gap between adjacent second studs;
- iii) an elongated top plate secured to the top ends of said panel connecting studs and said second studs, said top plate having pair of a side walls integral with a top surface of said top plate to form a C-channel within which said studs are engaged; and
- iv) at least one exterior wall sheet secured to one of said top plate side walls and at least one interior wall sheet secured to a second of said top plate side walls, thereby creating a hollow interior therebetween within said wall panel; and
- b) said wall panels secured to one another at opposing ends via the interlocking components of adjacent wall panels, said interlocking components of adjacent wall panels further secured to one another by a plurality of mechanical fasteners, and wherein said interlocking component of the connecting stud of one panel comprises a substantially C-shaped channel formed in part by said exterior and interior flanges and said web portion of said connecting stud, said channel configured for engagement therein of a complementarily configured web portion of the connecting stud of an adjacent panel for interlocking engagement of said wall panels to one another.
48. The wall panel system of claim 47, wherein each of said plurality of mechanical fasteners penetrates said flanges of adjacent connecting studs of adjacent wall panels, wherein said flanges of adjacent panels overlap one another.
49. The wall panel system of claim 47, wherein said wall panels are further secured to one another via an adhesive applied between overlapping flanges of adjacent panels.
50. The wall panel of claim 47, further including one or more braces secured between one or more pairs of adjacent second studs to span the gap between said adjacent second studs.
51. The wall panel system of claim 47, further including a corner post, said corner post having an outer body and an interlocking component extending from said outer body for engagement with a complementarily configured interlocking component of one of said wall panels.
52. The wall panel system of claim 51, wherein said corner post had an exterior corner and a diagonally opposing interior corner, said interior corner having a pair of flanges extending therefrom at substantially right angles to one another, each of said pair of flanges configured for receiving and having fastened thereon an outer edge of said interior wall sheet.
53. A shear wall assembly suitable for use in panelized building construction, said assembly comprising:
- a pair of connecting studs, each of said studs having a top end, a bottom end, a first flange, and a second flange, each of said flanges extending perpendicularly from opposing ends of an elongated web portion of said stud and positioned parallel to one another from the top end to the bottom end of said stud, and wherein each of said studs further includes at least one intermediate flange extending from one side of said web portion and positioned subjacent and parallel to a portion of said exterior flange to form, in combination with said exterior flange, a longitudinal channel extending from the top end to the bottom end of the stud;
- each of said connecting studs having an interlocking component extending from said web portion of said stud and comprising said exterior and interior flanges, said interlocking component configured to engage a complementary interlocking component of a connecting stud of an adjacent wall panel; and
- a shear wall assembly section having opposing outer edges, each of said edges engaged within one of said channels of said connecting studs.
54. The shear wall assembly of claim 53, wherein said exterior and interior flanges of said connecting stud, in combination with a flange subjacent to said exterior flange and extending from a side of said web portion, comprise said interlocking component of said stud, said exterior flange and subjacent flange forming a groove for engagement of an interior flange of a complementary configured interlocking component of an adjacent wall panel.
55. A wall panel system for use in panelized construction, said system comprising
- a) a plurality of wall panels, each of said wall panels comprising:
- i) a pair of panel connecting studs formed of a composite material, each of said studs located on one end of said wall panel and having an interlocking component for engagement with a complementary interlocking component of a second wall panel or a corner post, said panel connecting studs further having an exterior flange and an interior flange extending perpendicularly from a central elongated web portion;
- ii) a series of second studs located between said pair of panel connecting studs, said second studs spaced apart to form a gap between adjacent second studs;
- iii) an elongated top plate secured to the top ends of said panel connecting studs and said second studs, said top plate having pair of a side walls integral with a top surface of said top plate to form a C-channel within which said studs are engaged;
- iv) at least one exterior wall sheet secured to one of said top plate side walls and at least one interior wall sheet secured to a second of said top plate side walls, thereby creating a hollow interior therebetween within said wall panel; and
- b) said wall panels secured to one another at opposing ends via the interlocking components of adjacent wall panels, said interlocking components of adjacent wall panels further secured to one another by a plurality of mechanical fasteners, and wherein said interlocking component of the connecting stud of one panel comprises said exterior and interior flanges of said connecting stud, in combination with a flange extending from a side of said web portion subjacent to said exterior flange, said exterior flange and subjacent flange, in combination, forming a groove for engagement of an interior flange of a complementary configured interlocking component of an adjacent wall panel;
56. The wall panel system of claim 55, wherein each of said plurality of mechanical fasteners penetrates said flanges of adjacent connecting studs of adjacent wall panels, wherein said flanges of adjacent panels overlap one another.
57. The wall panel system of claim 55, wherein said wall panels are further secured to one another via an adhesive applied between overlapping flanges of adjacent panels.
58. The wall panel of claim 55, further including one or more braces secured between one or more pairs of adjacent second studs to span the gap between said adjacent second studs.
59. The wall panel system of claim 55, further including a corner post, said corner post having an outer body and an interlocking component extending from said outer body for engagement with a complementarily configured interlocking component of one of said wall panels.
60. The wall panel system of claim 59, wherein said corner post has an exterior corner and a diagonally opposing interior corner, said interior corner having a pair of flanges extending therefrom at substantially right angles to one another, each of said pair of flanges configured for receiving and having fastened thereon an outer edge of said interior wall sheet.
61. The wall panel system of claim 59, wherein said corner post had an exterior corner and a diagonally opposing interior corner, wherein said interior corner of said corner post includes an indentation sufficiently large for receiving and having fastened thereto said outer edge of an interior wall sheet.
Type: Application
Filed: Oct 13, 2005
Publication Date: May 3, 2007
Inventor: James Antonic (Ft. Myers, FL)
Application Number: 11/249,650
International Classification: E04C 2/38 (20060101);