Rigid wall panel system
The invention is a prefabricated rigid wall panel assembly constructed of a plurality of C-shaped studs inserted into kerfs in a foam block. The closed ends of the C-shaped studs and the foam block form substantially planar longitudinal edges of the panel assembly capable of abutting an adjacent panel assembly. Optionally, a header and/or footer plate inserted is into a transverse kerf such that the plate overlaps the ends of the studs, and the header and/or footer plate and the foam block form a substantially planar transverse edge of the panel assembly. Adjacent panel assemblies are preferably secured to one another using a clip, the shape of which depends on the angle at which the panel assemblies abut. Each panel assembly may also have a wire chase.
This application claims priority to U.S. Application Ser. No. 60/967,502, filed Sep. 5, 2007.
GOVERNMENTAL RIGHTSNone.
BACKGROUND OF THE INVENTIONThis invention relates to a preformed rigid wall panel system that is durable and easy to manufacture, transport, and install on-site.
Wall structures for buildings are generally manufactured on either a wooden or metal skeletal system of spaced-apart vertical studs bordered by a top plate and a bottom plate. Such wall structures have historically been built on-site with workers manually joining together the vertical studs and top and bottom plates, then raising the wall structure into place and securing it to the floor system of the building. A surface covering is then applied over the frame section, such as gypsum board, drywall, or plaster. Often, insulation is positioned between the vertical studs prior to installation of the surface covering.
In recent years, manufacturers have begun preparing prefabricated wall framing sections off-site and transporting them to the construction location. Piecing the prefabricated wall sections together is done using conventional methods. Specific to the instant invention, prefabricated wall sections manufactured with metal studs and plates are insulated with EPS foam. These wall systems are intended for use in commercial construction, although they can be used in residential construction as well. The known wall systems are generally manufactured by spacing apart metal studs and inserting foam insulation into the void between the stud spacing. The foam is often attached to the metal studs using a variety of conventional means, such as adhesives. Prefabricated wall panels may also be attached to one another using conventional means such as adhesives, bolts and flat plates, or tongue and groove connectors. It is an object of the invention to provide a foam wall panel system that is easy to transport and assemble and that has integrated means for securing adjacent panels.
U.S. Pat. No. 6,167,624 (the “'624 patent”), issued to Lanahan et al., discloses a prior art foam panel having embedded metal studs. The lateral, vertical edges of the panel have a tongue-and-groove connector formed into the foam block. Adjacent panels are fitted together using the tongue-and-groove connectors. The '624 patent is representative of the deficiencies in the prior art, as no prior art wall panel known to the inventor has disclosed a method of joining the vertical edges of adjacent wall panels together using structural materials. Rather, prior art methods utilized top and bottom plates overlapping the horizontal edges of the panels to secure the panels together. This method presents serious structural deficiencies insofar as the adjacent panels are held together with foam, rather than stronger structural materials such as metal. It is an object of the invention to provide a foam wall panel in which vertical edges of adjacent panels are secured using metal structural materials to provide the panel with additional strength.
BRIEF SUMMARY OF THE INVENTIONThe rigid wall panel of the instant invention is more rigid than those produced in the prior art due to the spacing and placement of the metal studs with respect to the foam block. The instant invention utilizes a plurality of spaced-apart, C-shaped studs that are inserted into a foam block. A C-shaped stud is also provided at each end of each wall panel section so that when two panels are joined together, two C-shaped studs abut to form a rigid connection point. Optionally, the foam block may receive top and bottom plates that communicate at three points of contact with each stud forming the panel. Preferably, the panel may be secured together using clips that engage with and are secured to each of the abutted metal studs.
These and other advantages provided by the invention will become apparent from the following detailed description which, when viewed in light of the accompanying drawings, disclose the embodiments of the invention.
101—rigid wall panel assembly
103—C-shaped studs
105—foam block
107—longitudinal edge
109—longitudinal kerfs
111—exterior surface
113—interior surface
115—recess
117—wallboard
119—transverse kerfs
121—top/bottom plate
122—transverse edges
123—first lip
125—second lip
127—points of contact
129—parallel clip
131—tabs
133—angled clip
DETAILED DESCRIPTION OF THE INVENTIONThe instant invention is drawn to a rigid wall panel assembly for use in residential and commercial construction.
Referring to
The method of constructing rigid wall panel assembly 101 is shown in more detail in
Longitudinal kerfs 109 are shaped such that a portion of C-shaped studs 103 are recessed within foam block 105 so that a predetermined width of foam, typically 1.5 inches according to many local building codes, remains between C-shaped studs 103 and the exterior surface 111 of foam block 105. Also preferably, C-shaped studs 103 also protrude from the interior surface 113 of foam block 105 to allow wire chases or other necessary materials to be installed in the recess 115 between interior surface 113 of foam block 105 and wallboard 117 that is mounted to rigid wall panel assembly 101.
Optionally, as shown in
Depending on the height and width of rigid wall panel assembly 101, longitudinal kerfs 109 may be shorter than, the same length as, or longer than transverse kerfs 119. Persons having ordinary skill in the art will recognize that the terms longitudinal and transverse are used for the convenience of the reader and are not intended as a functional limitation of the dimensions of the rigid wall panel assembly 101 disclosed herein.
As shown in
As shown in
While the inventors have described above what they believe to be the preferred embodiments of the invention, persons having ordinary skill in the art will recognize that other and additional changes may be made in conformance with the spirit of the invention and the inventors intend to claim all such changes as may fall within the scope of the invention.
Claims
1. A rigid wall panel assembly comprising:
- a foam block having a center, an exterior surface, and an interior surface;
- a plurality of longitudinal kerfs spaced across the interior surface of the foam block that do not puncture the exterior surface of the foam block; and
- a plurality of C-shaped studs having an open edge and a closed edge wherein a portion of the C-shaped studs are located within the longitudinal kerfs, and wherein two of C-shaped studs are oriented with respect to the foam block such that the open edge of the two C-shaped studs are oriented towards the center of the foam block, and wherein the closed edge of the two C-shaped studs and the foam block form two substantially planar longitudinal edges of the rigid wall panel assembly.
2. The rigid wall panel assembly of claim 1, further comprising:
- a transverse kerf in the foam block;
- a U-shaped top/bottom plate having an open edge and a closed edge, wherein a portion of the U-shaped top/bottom plate is located within the transverse kerf, and wherein the U-shaped top/bottom plate is oriented with respect to the foam block such that the open edge of the U-shaped top/bottom plate is directed towards the center of the foam block, and wherein the closed edge of the U-shaped top/bottom plate and the foam block form at least one substantially planar transverse edge of the rigid wall panel assembly.
3. The rigid wall panel assembly of claim 1, further comprising one or more wire chases within a recess between a wallboard mounted to the studs and an interior surface of the foam block.
4. A wall, comprising a plurality of adjacent rigid wall panel assemblies, each rigid wall panel assembly further comprising:
- a foam block having a center, an exterior surface, and an interior surface;
- a plurality of longitudinal kerfs spaced across the interior surface of the foam block that do not puncture the exterior surface of the foam block; and
- a plurality of C-shaped studs having an open edge and a closed edge wherein a portion of the C-shaped studs are located within the longitudinal kerfs, and wherein two of C-shaped studs are oriented with respect to the foam block such that the open edge of the two C-shaped studs are oriented towards the center of the foam block, and wherein the closed edge of the two C-shaped studs and the foam block form two substantially planar longitudinal edges of the rigid wall panel assembly.
5. The wall of claim 4, each rigid wall panel assembly further comprising:
- a transverse kerf in the foam block;
- a U-shaped top/bottom plate having an open edge and a closed edge, wherein a portion of the U-shaped top/bottom plate is located within the transverse kerf, and wherein the U-shaped top/bottom plate is oriented with respect to the foam block such that the open edge of the U-shaped top/bottom plate is directed towards the center of the foam block, and wherein the closed edge of the U-shaped top/bottom plate and the foam block form at least one substantially planar transverse edge of the rigid wall panel assembly.
6. The wall of claim 4 wherein the longitudinal edges of adjacent rigid wall panel assemblies abut along a plane.
7. The wall of claim 4 wherein the longitudinal edges of adjacent rigid wall panel assemblies abut along a plane, further comprising one or more parallel clips having tabs formed to engage the open edge of two of the C-shaped studs forming the longitudinal edges of adjacent rigid wall panel assemblies.
8. The wall of claim 4 wherein the longitudinal edges of adjacent rigid wall panel assemblies abut along a line.
- The wall of claim 4 wherein the longitudinal edges of adjacent rigid wall panel assemblies abut along a line, further comprising one or more angled clips having tabs formed to engage the open edge of two of the C-shaped studs forming the longitudinal edges of adjacent rigid wall panel assemblies.
Type: Application
Filed: Sep 5, 2008
Publication Date: Mar 5, 2009
Applicant: GREENSTEEL TECHNOLOGY, INC. (Bentonville, AR)
Inventor: Steven Barton (Bella Vista, AR)
Application Number: 12/205,526
International Classification: E04C 1/00 (20060101);