Component wall system
This invention is of a component wall system that is cost effective and flexible enough to be adapted for both interior partitions and exterior walls. The basic component system is comprised of a number of component types: two main wall panel component types, opening header panel type, and other supplementary types that allow the other components to be assembled into closets, interior wall sections with or without door openings, and all exterior wall sections including openings.
This application claims the benefit of earlier provisional applications No. 61/198.856 filed on Nov. 8, 2008 and No. 61/204,649 filed on Jan. 10, 2009 in the U.S. Patent & Trademark Office, the disclosures of which are incorporated by reference herein.
FIELD OF THE INVENTIONThe present invention relates to a component building system with main panel components having integrated supporting frame and an optional closing sheathing panel of equal size.
BACKGROUND OF THE INVENTIONBuilding structures are often built on site in many parts of the world. The problems of site construction are well documented in past journal articles. The major documented problems are higher labor cost and inconsistent labor cost in almost every stage of construction, higher material waste, and poor and inconsistent quality.
In recognizing these problems, many people have tried to come up with many types of standardized modular wall panels and components that can be mass-produced to reduce cost and to be speedily assembled into walls at building site. Unfortunately, previous attempts have failed and have made little or no impact in the building industry . The reasons for past failures are high material cost of modular panels, cost of manufacturing the modular panels, the complexity of system or difficulty of implementation, and lack of a flexible system that can do both interior and exterior walls to make the building system easier for builders to use in the field and present a clear cost saving in utilizing it.
There is a need for a viable modular wall system that is simple to assemble, simple to manufacture, less material cost, and flexible enough to adapt for both exterior and interior walls in a building structure. This patent application represents such a wall system.
SUMMARY OF THE INVENTIONThis invention is of a component wall system that is cost effective and flexible enough to be adapted for both interior partitions and exterior walls. The basic component system is comprised of a number of component types: two main wall panel component types, opening header panel type, and other supplementary types that allow the other components to be assembled into closets, interior wall sections with or without door openings, and all exterior wall sections including openings. There are two main wall panel component types and they all share a basic open panel design with the supporting steel frame made of standard c-section studs and tracks attached to a sheathing. The difference between the three wall panel component types is the size of the steel frame in relation to the sheathing and how the frame attaches to the sheathing at the sheathing's edge. The first main wall panel component is comprised of a c-section steel frame attached to a sheathing, with frame width at least half but not equal to the width of the sheathing and with frame height equal to or shorter than the sheathing height, and with the frame attached flush on one of the sheathing's vertical edge or side. The second main wall panel component is comprised of a c-section steel frame attached to a sheathing, with frame width at least half to equal to the sheathing width and with frame height equal to or shorter than the sheathing height, and with the frame attached slightly off on one of the sheathing's vertical edges extending half the width of stud in distance. The opening header type is comprised of a c-section steel frame attached to a sheathing, with frame width equal to the sheathing width and with frame height equal to or shorter than the sheathing height, and with the frame attached flush on both sides of the sheathing's vertical edges. The sheathing's top or bottom edge may extend over the top or bottom of the frame's edge to cover top or bottom tracks that tie the wall panel components together at the top and bottom. The other supplemental types are the track type and corner piece type.
The component wall system has two major wall panel component types (10 and 20), opening header type (30), track type (40), and corner piece type (50) as illustrated in
For clear illustrations of how the various components can fit in various assembly types, the closing board pieces and top and bottom track are not shown in
The same wall component system can be adapted for exterior application.
As demonstrated in the illustrations, this component system is highly adaptable for both exterior walls, interior walls with or without openings, and interior closet. One can have one set of components for exterior application and another set of components for interior application.
Claims
1. A modular construction panel comprised of a construction board and a supporting frame attached to it, wherein the frame has a width at least half but not equal to the width of the construction board, and the frame has a height equal to or shorter than the construction board, and the frame left side is flush with that of the construction board.
2. The modular construction panel according to claim 1, wherein the supporting frame is made of c-section steel studs and tracks.
3. The modular construction panel according to claim 1, wherein the construction panel has another construction board of equal dimensions to serve as the panel closing sheathing.
4. The modular construction panel according to claim 1, wherein the construction board is gypsum board, cement board, magnesium board, thin precast concrete slab, or any construction board engineered for sheathing purpose.
5. The modular construction panel according to claim 1, wherein the frame is made of c-section steel studs or wood studs or combination of both wood and steel studs.
6. A modular construction panel comprised of a construction board and a supporting frame attached to it, wherein the frame has a width from half to equal to the width of the construction board, and the frame has a height equal to or shorter than the construction board, and the frame left side is extended half the width of the stud over the left edge of the construction board.
7. The modular construction panel according to claim 6, wherein the supporting frame is made of c-section steel studs and tracks.
8. The modular construction panel according to claim 6, wherein the construction panel has another construction board of equal dimensions to serve as the panel closing sheathing.
9. The modular construction panel according to claim 6, wherein the construction board is gypsum board, cement board, magnesium board, thin precast concrete slab, or any construction board engineered for sheathing purpose.
10. The modular construction panel according to claim 6, wherein the frame is made of c-section steel studs or wood studs or combination of both wood and steel studs.
11. A wall component system comprised of three modular wall panel component types and other complementary types;
- wherein, the first modular wall panel component type is comprised of a construction board and a supporting frame attached to it, and the frame has a width at least half but not equal to the width of the construction board, and the frame has a height equal to or shorter than the construction board, and the frame left side is flush with that of the construction board;
- wherein, the second modular wall panel component type is comprised of a construction board and a supporting frame attached to it, and the frame has a width from half to equal the width of the construction board, and the frame has a height equal to or shorter than the construction board, and the frame left side is extended half the width of the stud over the left edge of the construction board;
- wherein, the third modular wall panel component type is comprised of a construction board and a supporting frame attached to it, and the frame has a width equal to the construction board, and the frame has a height equal to or shorter than the construction board, and the frame left side and right side are flush with that of the construction board;
- wherein, the complementary types are a track type which can be plain strip of wood or metal u-section track, and a corner piece type which can be metal stud with bent ends or L-shaped piece made from assembled metal studs.
Type: Application
Filed: Nov 4, 2009
Publication Date: May 13, 2010
Inventor: Thuan Bui (Philadalphia, PA)
Application Number: 12/590,215
International Classification: E04B 2/76 (20060101); E04B 2/56 (20060101);