INSULATED PANEL AND SYSTEM FOR CONSTRUCTION OF A MODULAR BUILDING AND METHOD OF FABRICATION THEREOF
An insulated wall panel, comprises a polystyrene foam block having first and second parallel surfaces, top and bottom parallel ends and two parallel side ends, wherein the block is configured to include slots to receive a plurality of studs spaced apart and in parallel relation to one another within the block between the first and second surfaces and the two side ends so that side surfaces of the studs are not exposed. The panel may also include a first track member that is secured to a slab or building foundation and to a bottom end of the studs, and a second track member that is mounted to a top end of the studs.
This application claims the benefit of U.S. Provisional Application No. 61/173,231 filed Apr. 28, 2009, and incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTIONEmbodiments of the subject invention pertain to building frames for construction of modular buildings. More specifically, the embodiments of the subject invention pertain to the assembly of insulated panels used to construct modular buildings, which panels include a plurality of studs or frame members imbedded or inserted in expanded polystyrene blocks configured or adapted to receive the studs or frame members.
The use of polymer foam panels in building construction is known. With respect to U.S. Pat. No. 5,822,940 (the “'940 Patent”), there is disclosed a wall panel that includes a polymer foam block in which studs are imbedded. The foam block is configured to include a plurality of slots for receiving generally C-shaped studs; however, as shown in FIG. 33BB of the '940 Patent, the slots are formed in the foam block in such a manner that surfaces of the studs are exposed. Such a configuration may unnecessarily expose the foam block to ambient conditions. Accordingly, need exists for a wall panel constructed from a polymer foam material in which the studs are effectively sealed and/or embedded within the foam block so surfaces of the studs are not exposed.
BRIEF DESCRIPTION OF THE INVENTIONAn embodiment of the invention for an insulated wall panel comprises a polystyrene foam block having first and second parallel surfaces, top and bottom parallel ends and two parallel side end. The block is configured to include slots to receive a plurality of studs, and each stud having a generally C-shaped configuration including a web and flanges perpendicular to the web and parallel to one another and the flanges having side surfaces. The studs are spaced apart and in parallel relation to one another within the block between the first and second surfaces and the two side ends of the block so that side surfaces of the flanges on the studs and the webs on the studs are not exposed.
In an embodiment the insulated wall panel may comprise a polystyrene foam block having first and second parallel surfaces, top and bottom parallel ends and two parallel side ends. The block is configured to include slots to receive a plurality of studs spaced apart and in parallel relation to one another within the block between the first and second surfaces and the two side ends. A first track member has a web member secured to a building foundation and two spaced apart vertically disposed flanges that are secured to bottom ends of the studs. The block has channels formed in the bottom end thereof spaced apart and parallel to one another in which the flanges of the first track member are inserted. In addition, an elongated recess is formed in the bottom of the block between the channels and extending from one side end to the other side end, and the web of the first track member is positioned in the elongated recess. The block also comprises parallel flanges at the bottom end thereof on either side of the recess that cover the flanges of the first track member.
A second track member is provided and has a web member and two spaced apart vertically disposed flanges and the block has channels formed in the top end thereof spaced apart and parallel to one another in which the flanges of the second track member are inserted and secured to top ends of the studs. In addition, an elongated recess is formed in the top of the block between the channels and extending from one side end to the other side end of the block and the web of the first track member is positioned in the elongated recess, and the block has parallel flanges at the top end thereof on either side of the recess that cover the flanges of the second track member.
An embodiment of the invention may be described as a wall system that includes a plurality of the above-described wall panels and the studs for each wall panel are spaced inward of each side end of a respective block forming an extension on the blocks at each side end thereof wherein a notch is formed in an extension of each respective block. The notch extends from the bottom end to the top end of each block so that when two wall panels having notches therein are positioned side end to side end a volume is formed between the notches and an insert, having a configuration corresponding to a configuration of the volume, is inserted in the volume to connect the panels.
The insulated wall panel system further comprises two corner wall panels that each include two double stud assemblies and each stud assembly is disposed at a respective side ends of each of the foam blocks of the wall panels, and there being a plurality of studs disposed within each block and between the double stud assemblies. Each double stud assembly has a generally I-shaped configuration with a web and two spaced apart flanges that are parallel to one another and perpendicular to the web. Each side end of each block for a respective corner wall panel is cut to include a recess extending the height of the respective side end and to include two slots contiguous with the recess, perpendicular to the recess and parallel to one another, wherein a web of the double stud assembly is seated in the recess and flanges of the double stud assembly are seated in the slots. The two corner panels are secured to a foundation perpendicular to one another forming a corner of a building frame and the double stud assembly for each wall panel. The respective web members thereof are disposed perpendicular to one another and a bracket, having been secured to the foundation, includes a base plate secured to the foundation and two vertically disposed plates perpendicular to one another extending upward from the base plate, and wherein each vertically disposed plate is secured to a web of a respective double stud assembly.
An embodiment of the invention for a method of assembling an insulated wall panel, comprises providing a polystyrene foam block having first and second parallel surfaces, top and bottom parallel ends and two parallel side ends; cutting a series of spaced apart slots into the block between the side ends of the block and parallel to one another, and the slots extend from the bottom end of the block to the top end of the block and wherein each slot includes a first slot is parallel to the side ends of the block and two second slots that are contiguous with the first slot and the second slots are parallel to one another and perpendicular to the first slot and within the parallel surfaces of the block; cutting into the bottom end of the block a first pair of channels that are spaced apart and parallel to one another and extend from one side end to the other side end of the block, wherein the first pair of channels are contiguous with the second slots; cutting into the top end of the block a second pair channels that are spaced apart and parallel to one another and extend from one side end to the other side end of the block, wherein the second pair of channels are contiguous with the second slots; cutting into the bottom end of the block an elongated first recess between the first pair of channels, wherein the first recess extends from one side end of the block to the other side end of the block; cutting into the top end of the block an elongated second recess between the second pair of channels, wherein the second recess extends from one side end of the block to the other side end of the block; and, inserting a stud into each of the slots of the series of slots wherein each stud has a generally C-shaped configuration including a web member and two flanges parallel to one another and perpendicular to the web member, wherein the web member of a stud is inserted in the first slot and the flanges of a stud are inserted into the second slots.
A more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not, therefore, to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings.
A more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained.
With respect to
As shown the wall panel 10 includes or is secured to a bottom track 13A frame member that is mounted to a foundation slab 14 for receiving and securing the studs 12 and the foam block 11 onto the slab 14. In addition, a top track 13B frame member is mounted to the wall panel 10 as will be explained in more detail below; or, the wall panel 10 may be described as including the top track 13B frame member. Both the top track member 13B and bottom track member 13A supplemental the structural integrity of the panel 10, and the top track 13B provides a mechanism for securing other frame members to the panel 10.
With reference to the assembly of the wall panel 10, the foam block 11 is first cut according to building specifications on a hotwire cutting apparatus that is used for cutting and shaping Styrofoam. As shown in
A sample stud 12 is illustrated in
As shown in
As shown in
With respect to
After the slots 27, channels 28 and recesses 16 are cut into the block 11, the studs 12 are inserted into the slots 12. Wall panels 10 thus assembled may be prepared for shipping to a construction site. As noted the panel 10 is secured to or includes a bottom track 13A that is anchored to a concrete slab 14 as shown in
The top track 13B is then secured to a top end of the panel 10 and studs 12. As shown in
In an embodiment, and as shown in
With respect to
With respect to
In
In addition, as shown in
For both the insulated wall panel 10 and the insulated shear wall assembly 36 after the panels are assembled the panel surfaces may be finished to include a cementious or stucco, or other type of wall surface finishing. Typically, a nylon wall mesh may be affixed to the wall surfaces to support a selected wall finishing, so the panels are ready for shipment to a construction site.
In reference to
As shown in
In addition, brackets 48 are used to anchor the double stud assemblies 40 of the shear wall assemblies 36 distal the corner assembly 45. As shown in
With respect to
While the preferred embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those of skill in the art without departing from the invention herein. Therefore, it is intended that the invention not be limited to the particular disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims
1. An insulated wall panel, comprising:
- a polystyrene foam block having first and second parallel surfaces, top and bottom parallel ends and two parallel side ends, wherein the block is configured to include slots to receive a plurality of studs, and each stud having a generally C-shaped configuration including a web and flanges perpendicular to the web and parallel to one another and the flanges having side surfaces, wherein the studs are spaced apart and in parallel relation to one another within the block between the first and second surfaces and the two side ends of the block so that side surfaces of the flanges on the studs and the webs on the studs are not exposed.
2. The insulated wall panel of claim 1, further comprising a first track member having been secured to a building foundation and the first track member having a web member secured to the foundation and two vertically disposed, spaced apart and parallel flanges, and the bottom end of the foam block has two parallel channels formed therein to receive the flanges of the first track and the flanges of the first track are secured to a bottom end of the studs.
3. The insulated wall panel of claim 2, wherein the slots formed in the block include a first slot that is contiguous with two second slots that are spaced apart and parallel to one another and perpendicular to the first slot to receive the web member and the flanges of the stud.
4. The insulated wall panel of claim 3, wherein the channels formed in the bottom end of the block are contiguous with the second slots that receive the flanges on the studs.
5. The insulated wall panel of claim 3, further comprising a second track member secured to a top end of the studs and the second track member having a web member and two vertically disposed, spaced apart and parallel flanges wherein the top end of the foam block has two parallel channels formed therein to receive the flanges of the second track, and the flanges of the second track member are secured to a top end of the studs.
6. The insulated wall panel of claim 5, wherein the channels formed in the top end of the block are contiguous with the second slots that receive the flanges on the studs.
7. The insulated wall panel of claim 2, further comprising an elongated recess formed in the bottom end of the block between the channels and the web member of the first track member is seated in the recess and the flanges of the first track member are seated in the channels, and the block having flanges adjacent the channels covering the flanges of the first track member.
8. The insulated wall panel of claim 5, further comprising an elongated recess formed in the top end of the block between the channels and the web member of the second track member is seated in the recess and the flanges of the second track member are seated in the channels, and the block having flanges adjacent the channels covering the flanges of the second track member.
9. The insulated wall panel of claim 1, wherein the panel includes two double stud assemblies and each stud assembly is disposed at a respective side end of the foam block, and there being a plurality of studs disposed within the block and between the double stud assemblies, wherein each double stud assembly includes two studs abutting one another at webs of the studs and are secured to another, wherein each side end of the block having been cut to include a recess extending the height of the respective side end and to include two slots contiguous with the recess, perpendicular to the recess and parallel to one another, wherein a web of the double stud assembly is seated in the recess and flanges of the double stud assembly are seated in the slots.
10. The insulated wall panel of claim 9, wherein two such insulated wall panels are secured to a foundation perpendicular to one another forming a corner of a building frame and the double stud assembly for each wall panel and the respective web members thereof are disposed perpendicular to one another and a bracket, having been secured to the foundation, includes a base plate secured to the foundation and two vertically disposed plates perpendicular to one another extending upward from the base plate, and wherein each vertically disposed plate is secured to a web of a respective double stud assembly.
11. The insulated wall panel of claim 9, wherein the block is further configured to include two diagonal channels formed in the first and second surfaces of the block, and each of channels extending from a top end of one double stud assembly to a bottom end of the other double stud assembly and intersecting therebetween, the channels being formed for receiving straps that are secured to the respective top and bottom ends of the double stud assemblies.
12. The insulated wall panel of claim 1, wherein the studs are offset relative to a lateral centerline of the block, and the block having a thickness dimension on one side of the studs that is greater than a thickness dimension on the other side of the studs, wherein the thicker side of the block is disposed on an exterior side of a building.
13. The insulated wall panel of claim 1, wherein studs are spaced inward of each side end of the block forming an extension of the block at each side end thereof wherein a notch is formed in an extension of the block and the notch extends from the bottom end to the top end of the block so that when two wall panels having notches therein are positioned side end to side end a volume is formed between the notches and an insert, having a configuration corresponding to a configuration of the volume, is inserted in the volume to connect the panels.
14. An insulated wall panel, comprising:
- a polystyrene foam block having first and second parallel surfaces, top and bottom parallel ends and two parallel side ends, wherein the block is configured to include slots to receive a plurality of studs spaced apart and in parallel relation to one another within the block between the first and second surfaces and the two side ends;
- a first track member having a web member secured to a building foundation and two spaced apart vertically disposed flanges that are secured to bottom ends of the studs and the block having channels formed in the bottom end thereof spaced apart and parallel to one another in which the flanges of the first track member are inserted, and an elongated recess formed in the bottom of the block between the channels and extending from one side end to the other side end, and the web of the first track member is positioned in the elongated recess, and the block having parallel flanges at the bottom end thereof on either side of the recess that cover the flanges of the first track member; and,
- a second track member having a web member and two spaced apart vertically disposed flanges and the block having channels formed in the top end thereof spaced apart and parallel to one another in which the flanges of the second track member are inserted and secured to top ends of the studs, and an elongated recess formed in the top of the block between the channels and extending from one side end to the other side end of the block and the web of the first track member is positioned in the elongated recess, and the block having parallel flanges at the top end thereof on either side of the recess that cover the flanges of the second track member.
15. The insulated wall panel of claim 14, wherein each stud has a generally C-shaped configuration including a web member and two spaced apart parallel flanges attached to the web member and perpendicular thereto, and wherein the slots formed in the block extend from the top end to the bottom end of the block and include a first slot in which the web of the stud is inserted and the first slot is contiguous with two second slots that are spaced apart and parallel to one another and perpendicular to the first slot and in which the flanges of the stud are inserted, and wherein the channels on the bottom end and top end of the block are contiguous with the second slots.
16. The insulated wall panel of claim 14, wherein the panel includes two double stud assemblies and each stud assembly is disposed at a respective side end of the foam block, and there being a plurality of studs disposed within the block and between the double stud assemblies, wherein each double stud assembly includes two studs abutting one another at webs of the studs and are secured to another, and the block is further configured to include two diagonal channels formed in the first and second surfaces of the block, and each of channels extending from a top end of one double stud assembly to a bottom end of the other double stud assembly and intersecting therebetween, the channels being formed for receiving straps that are secured to the respective top and bottom ends of the double stud assemblies.
17. The insulated wall panel of claim 14, wherein the studs are offset relative to a lateral centerline of the block, and the block having a thickness dimension on one side of the studs that is greater than a thickness dimension on the other side of the studs, wherein the thicker side of the block is disposed on an exterior side of a building.
18. A method of assembling and installing an insulated wall panel, comprising:
- providing a polystyrene foam block having first and second parallel surfaces, top and bottom parallel ends and two parallel side ends;
- cutting a series of spaced apart slots into the block between the side ends of the block and parallel to one another, and the slots extend from the bottom end of the block to the top end of the block and wherein each slot includes a first slot is parallel to the side ends of the block and two second slots that are contiguous with the first slot and the second slots are parallel to one another and perpendicular to the first slot and within the parallel surfaces of the block;
- cutting into the bottom end of the block a first pair of channels that are spaced apart and parallel to one another and extend from one side end to the other side end of the block, wherein the first pair of channels are contiguous with the second slots;
- cutting into the top end of the block a second pair channels that are spaced apart and parallel to one another and extend from one side end to the other side end of the block, wherein the second pair of channels are contiguous with the second slots;
- cutting into the bottom end of the block an elongated first recess between the first pair of channels, wherein the first recess extends from one side end of the block to the other side end of the block;
- cutting into the top end of the block an elongated second recess between the second pair of channels, wherein the second recess extends from one side end of the block to the other side end of the block; and,
- inserting a stud into each of the slots of the series of slots wherein each stud has a generally C-shaped configuration including a web member and two flanges parallel to one another and perpendicular to the web member, wherein the web member of a stud is inserted in the first slot and the flanges of a stud are inserted into the second slots.
19. The method of claim 18, further comprising:
- securing a first track member to a building foundation wherein the track member includes a web member that is secured to the building foundation and two spaced apart parallel flanges that are perpendicular to the web member of the track member;
- positioning the block, with studs having been inserted therein, on the first track member with the flanges of the track member being inserted in the first pair of channels and the web of the first track member seated on the first recess;
- positioning a second track member, having a web member and two spaced apart parallel flanges that are perpendicular to the web member of the second track member, on the top end of the block with the flanges of the second track member being inserted in the second pair of channels and the web member of the second track member is seated in the second recess;
- securing the flanges of the first track member to bottom ends of the studs; and,
- securing the flanges of the second track member to top ends of the studs.
20. The method of claim 19, further comprising:
- cutting a first pair of channels into the first surface of the block wherein the first pair channels are diagonally disposed on the surface and intersect;
- cutting a second pair of channels into the second surface of the block wherein the second pair of channels are diagonally disposed on the surface and intersect;
- inserting a strap into each channel on the first surface and each channel on the second surface; and,
- securing each strap to a top end of a stud and/or a flange of the second track member and to a bottom end of a stud and/or a flange of the first track member.
20. The method of claim 19, further comprising:
- cutting a notch into a side end of the foam block for a first wall panel wherein the notch extends from the bottom end of the block to the top end of the block;
- cutting a notch into a side end of a foam block for a second wall panel wherein the notch extends from the bottom end of the block to the top end of the block;
- positioning the first wall panel adjacent to the second wall panel wherein notches on the respective wall panel face each other forming a volume therebetween; and,
- inserting a polystyrene foam insert into the volume to connect together the first and second wall panels.
22. The method of claim 21, further comprising applying an adhesive to the surface of each end of the block for the respective first and second wall panels at the notches and/or applying the adhesive to the insert.
23. An insulated wall panel system, comprising:
- a plurality of polystyrene foam blocks each having first and second parallel surfaces, top and bottom parallel ends and two parallel side ends, wherein each block is configured to include slots to receive a plurality of studs spaced apart and in parallel relation to one another within the block between the first and second surfaces and the two side ends and the blocks are aligned side end to side end;
- a plurality of first track members each having a web member secured to a building foundation and two spaced apart vertically disposed flanges that are secured to bottom ends of the studs and the blocks having channels formed in the bottom end thereof spaced apart and parallel to one another in which the flanges of the first track members are inserted, and an elongated recess formed in the bottom of each block between the channels and extending from one side end to the other side end, and each web of the first track member is positioned in the elongated recess, and the blocks having parallel flanges at the bottom end thereof on either side of the recesses that cover the flanges of the first track members; and,
- a plurality of second track members each having a web member and two spaced apart vertically disposed flanges and the blocks having channels formed in the top ends thereof spaced apart and parallel to one another in which the flanges of the second track members are inserted and secured to top ends of the studs, and an elongated recess formed in the top of each block between the channels and extending from one side end to the other side end of each block and the web of each first track member is positioned in the elongated recess, and each block having parallel flanges at the top ends thereof on either side of the recesses that cover the flanges of the second track members.
24. The insulated wall panel system of claim 23, studs for each wall panel are spaced inward of each side end of a respective block forming an extension on the blocks at each side end thereof wherein a notch is formed in an extension of each respective block and the notch extends from the bottom end to the top end of each block so that when two wall panels having notches therein are positioned side end to side end a volume is formed between the notches and an insert, having a configuration corresponding to a configuration of the volume, is inserted in the volume to connect the panels.
25. The insulated wall panel system of claim 23, further comprising two corner wall panels that each includes two double stud assemblies and each stud assembly is disposed at a respective side ends of each of the foam blocks of the wall panels, and there being a plurality of studs disposed within each block and between the double stud assemblies, wherein each double stud assembly includes has a generally I-shaped configuration with a web and two spaced apart flanges that are parallel to one another and perpendicular to the web, wherein each side end of each block for a respective corner wall panel having been cut to include a recess extending the height of the respective side end and to include two slots contiguous with the recess, perpendicular to the recess and parallel to one another, wherein a web of the double stud assembly is seated in the recess and flanges of the double stud assembly are seated in the slots.
26. The insulated wall panel system of claim 24, wherein the two corner panels are secured to a foundation perpendicular to one another forming a corner of a building frame and the double stud assembly for each wall panel and the respective web members thereof are disposed perpendicular to one another and a bracket, having been secured to the foundation, includes a base plate secured to the foundation and two vertically disposed plates perpendicular to one another extending upward from the base plate, and wherein each vertically disposed plate is secured to a web of a respective double stud assembly.
Type: Application
Filed: Apr 26, 2010
Publication Date: Oct 28, 2010
Inventor: Adrian Thomas Morrisette (Port St. Lucie, FL)
Application Number: 12/767,340
International Classification: E04C 2/34 (20060101); E04C 2/20 (20060101); E04B 2/72 (20060101); E04B 2/08 (20060101);