WALL INSULATION SYSTEM AND A METHOD OF INSTALLING THE SAME

Abstract

The embodiments of the invention includes a retrofitting system for the insulation of existing interior walls such as basements; a retrofitting system for the insulation of exterior walls of a structure such as a home needing further insulation without a convenient or economical method to do so within the interior walls, the inclusion of insulation within the concrete walls of a structure constructed by the tilt-up construction method and a use of elements of the insulated wall system to effectively insulate and provide continuous studding in a conventional “cast-in-place” concrete wall assembly, subsequent to placing concrete. The insulated wall systems of these embodiments provide an economical and efficient method of providing the installation of insulation panels to each of the walls described. The insulation panels are generally of a foam structure supported by connecting and/or corner studs. The connecting studs and corner studs are of a unique design that are easily fastened to an existing wall or made part of a Tilt-up Wall system or a “cast-in-place” system. In addition to supporting the Insulation panels, the studs are structured to provide a moisture gap between the insulation and the exiting wall to which they are mounted. The connecting stud and corner studs also provide for wire chase areas for power distribution with a wall system.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to a Provisional Application filed on Jan. 21, 2011, entitled Retro Fit Insulated Wall System having Ser. No. 61/434,870 is hereby incorporated fully herein.

BACKGROUND

The present invention is in the technical field of insulated wall systems. More particularly, the present invention relates to insulated walls systems using PVC studs for support of insulated panels on a wall.

Finished or “club” basements are a common part of residential structures. Conventional wood framing has been widely used to achieve a finished wall surface. Recently the developments of other innovative wall finishing systems have emerged. These systems are comprised of “shape-molded” insulation panels such as: In-So-Fast™; R-Retro™; Re-Fit and BuildLock™. There is a need for a system that addresses the need for full length synthetic wall studs that can easily accept readily available insulation materials. This approach will allow the unskilled novice to now easily install a finished wall system. Moreover, the locally available sourced insulation material will reduce the need to ship product long distances resulting in a reduction of “carbon footprint”

There is an additional need for a system that may be applied to exterior above-grade walls as a true “Retro-Fit” system to provide the additional insulation value to meet energy code requirements as well as provide studding for finish board material or siding attachment.

Furthermore, as it pertains to new construction, “tilt-up” walls are widely used to quickly and efficiently erect buildings. The systems that are currently used today in “tilt-up” construction are designed to position the insulation panel in the middle of the concrete wall and they do not provide attachment strips or studding spaced along the face of the wall; The Thermomass® system is one such system used in this type of construction. There is a need for a system for “Tilt-Up” construction that can provide insulation value and studding to one or both sides of a tilt-up wall assembly which provides design flexibility, faster installation, and attachment strips for subsequent finishing materials.

Lastly, there is a need to effectively insulate and provide continuous studding in a conventional “cast-in-place” concrete wall assembly, prior to placing concrete. There are several systems that have been developed for such a purpose; although these systems currently rely on “proprietary” fabricated foam panels which are shipped from their point of manufacture; these systems include: ThermaEZE®; E-Max®; and ComfortWall®. There is a need for a system to provide insulation and continuous studding within conventional wall forms prior to placing concrete that does not rely on specially fabricated foam panels thereby making the installation process much faster, considerably easier and reducing “carbon foot-printing” through the sourcing of locally and readily available insulation panels (EPS; XPS; or Polyisocyanurate).

The presently available systems all require specially shape molded foam insulation elements, they do not create an air space for moisture protection, and/or lack electrical wire chases.

SUMMARY

The embodiments of the invention include a system retrofitting for the insulation of existing interior walls such as basements; a system for retrofitting for the insulation of exterior walls of a structure such as a home or commercial structure needing further insulation without a convenient or an economical method to do so within a system for the inclusion of insulation and studding within the concrete of a cast-in-place wall and the inclusion of insulation within the concrete walls of a structure constructed by the tilt-up construction method. The insulated wall systems of these embodiments provide an economical and efficient method of providing the installation of insulation panels to each of the walls described. The insulation panels are generally of a foam structure supported by connecting and/or corner studs.

The connecting studs and corner studs are of a unique design that are easily fastened to an existing interior or exterior wall or made part of a Tilt-up Wall system and a cast-in-place wall system. In addition to supporting the Insulation panels, the studs are structured to provide a moisture gap between the insulation and the existing wall to which they are mounted. The connecting stud and corner studs also provide for wire chase areas for power distribution within a wall system.

Since the Insulation panels are commercially available throughout the world, the major elements of the system, the connecting studs and the corner studs are made available as kits to be combined with the Insulation panels that are locally available. This makes is possible for the system to be available to home owners by purchasing the kits and combining them with the locally available Insulation panels. The installation of insulated wall system onto an existing basement interior wall or an exterior home or commercial structure wall requires no special tools and can be done by individuals with minimum construction skills.

The embodiments described below include details of the connecting studs and the corner studs and their relationship with the Insulation panels; the details of an interior wall installation, details on the exterior wall installation; and the use of the system with a tilt-up wall installation; and the use of the system with a cast-in-place wall installation

While the connecting studs and corner studs have been designed for the embodiments described above there are likely embodiments beyond those described herein where this unique design would be applicable.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, accompanying drawings where:

FIG. 1 illustrates elements of the system mounted on a wall;

FIG. 2 illustrates elements of the system mounted on a wall with a window opening and door opening;

FIG. 3 illustrates a top view of the elements of the system mounted onto a wall;

FIG. 4 illustrates details of a connecting stud;

FIG. 5 illustrates details of a corner stud;

FIG. 6 illustrates details of a Connecting Stud mounted to a wall;

FIG. 7 illustrates details of an inside corner;

FIG. 8 illustrates details of an outside corner;

FIG. 9 illustrates the use of Corner Stud material as a trim stop for around window and door openings.

FIG. 10 illustrates a three wall including an inside corner, an outside corner, a window opening and a door opening before any installation of the insulated wall system;

FIG. 11 illustrates the three wall sample with the beginning of the installation of an inside corner between Wall 1 and Wall 3 (Step 2) and includes a Detail A;

FIG. 12 illustrates the completion of the inside corner between Wall 1 and Wall 3 (Step 3) and includes a Detail B;

FIG. 13 illustrates the installation of Insulation Panel between the inside corner and a Window Opening (Step 4);

FIG. 14 illustrates the installation of a pair of Connecting Studs above and below the Window Opening (Step 5) and includes a detail C;

FIG. 15 illustrates the installation of a pair of Insulation panels above and below the Window Opening (Step 6);

FIG. 16 illustrates the installation of a second pair Connecting Studs above and below the Window Opening (Step 7);

FIG. 17 illustrates the preparation of a standard size Insulation Panel to fit around a second side of the Window Opening (step 8);

FIG. 18 illustrates the installation of a Full Length Connecting Stud (step 9);

FIG. 19 illustrates measuring an cutting a Insulation Panel and sliding the panel into a Connecting Stud (step 10);

FIG. 20 illustrates the beginning steps for installing an Outside Corner (step 11):

FIG. 21 illustrates the installation of trim around the Window Opening (step 12)

FIG. 22 illustrates installation of trim along the vertical sides of the Window Opening (step 13);

FIG. 23 illustrates the installation of trim around horizontal sides of the Window Opening;

FIG. 24 illustrates the start the Wall 2 installation (step 14);

FIG. 25 illustrates installation of the insertion of a Second Corner Stud (15);

FIG. 26 illustrates the installation of a first portion of approaching the end of Wall 2 (step 16);

FIG. 27 illustrates the installation of a second portion of approaching the end of Wall 2 (step 17);

FIG. 28 illustrates the completion of the approaching the end of Wall 2 (step 18);

FIG. 29 illustrates Wall 3 before any installation on Wall 3;

FIG. 30 illustrates the beginning stages of the Wall 3 installation (step 19);

FIG. 31 illustrates the installation of a Connecting Stud above the Door Opening (step 20);

FIG. 32 illustrates the installation Insulation Panels around the Door Opening (step 21)

FIG. 33 illustrates the continuing installation of Insulation Panels around the Door Opening (step 22)

FIG. 34 illustrates the beginning details of installing trim around the Door Opening (step 23)

FIG. 35 illustrates the completed installed of the system on Wall 3;

FIG. 36 illustrates the completed installation on the illustrative wall;

FIGS. 37 (a-f) illustrates the illustrative wall including an Inner Corner, an Outer Corner, a Plain Wall, a Wall having a Window Opening, a Wall having a Door Opening and two ends of Wall Configurations;

FIG. 38 illustrates installation of elements of the system on a residential building needing additional insulation;

FIG. 39 illustrates the use of the system in a tilt-up installation;

FIG. 40 illustrates details of the reinforcing bar chairs used in the tilt-up application; and

FIG. 41 illustrates the installation of additional insulation material in the tilt-up embodiment;

FIG. 42 illustrates the installation of one piece insulation material in the tilt up embodiment; and

FIG. 43 illustrates the use of elements of the system used in a cast-in place embodiment.

DETAILED DESCRIPTION

This application discloses and describes various wall insulation embodiments all using unique connecting studs and/or corner studs supporting standard (not shape molded) insulated panels that provide insulation for an insulated wall system, firstly for a retrofitted basement system, secondly for an outside retrofitted outside exterior of a building, thirdly for a cast-in-place wall system used for construction of a new building or for a “tilt-up” wall system used for construction of a new building. The system described is known commercially as “SnugWall™”.

A first exemplary embodiment of an improved wall system for a retrofit to provide an insulated coverage for concrete or concrete masonry unit (CMU) constructed basement walls. FIG. 1 illustrates an Insulated Wall System 100 mounted to an Existing concrete or CMU Wall 102. The elements of such an insulated coverage of an existing concrete wall or CMU wall include a Connecting Stud 104 supporting an Insulation Panel 106 for a lineal wall insulation system and a Corner Stud 108 and a First Corner Insulation Insert 110 for an Inside Corner 112 and a Corner Stud 108 and a second Corner Insulation Insert 114 for an Outside Corner 116.

FIG. 2 illustrates an interior system with an Inside Corner 112 and an Outside Corner 116. In addition this interior system has a Window Opening 118; and a Door Opening 120. Both the Window Opening 118 and the Door Opening 120 use Corner Studs 108 as trim stop.

FIG. 3 illustrates a top view of FIG. 2. As can be seen, the Existing Wall (concrete or CMU) 102 provides the support for the insulated wall elements: 104, 106, 108, 110 and 130. The Connecting Studs 104 are fastened to the Existing Wall 102 and they support the Insulation Panels 106. The Corner Studs 108 and the Corner Insulation Inserts 110 and 130 provide the transition between connecting sections around an Inside Corner 112 and Outside Corner 116.

FIG. 4 and FIG. 5 illustrates the detailed structure of a Connecting Stud 104 and of a Corner Stud 108 both of which will be discussed in greater detail below. FIG. 4 illustrates a Connecting Stud 104. The Connecting Studs 104 provide the support of and moisture protection of the Insulation Panel 106 between the Connecting Studs 104. These elements include a Base Side 122, two Wire Chase Areas 124, an Insulation Panel Support Area 126 that provides the support for an Insulation Panel 106, a support leg 127 and a top portion 129 of the Connecting Stud 104 completes the Insulation Panel Support Area 126 structure; and an area that provides a Moisture Protection Area 128 for the Insulation Panels 106 between an Existing Wall 102 and the Insulation Panel 106.

The dimensions of a Connecting Stud 104 and a Corner Stud 108 in the insulated wall system are based upon an exemplary embodiment of using Insulation Panels 106 with a 2 inch thickness. This dimension is based upon R factors assumed for the system that is further discussed below. The spacing between Connecting Studs 104 or the spacing between a Connecting Stud 104 and a Corner Stud 108 may be up to 24 inches to be in compliance with code requirements. However exemplary values between 12 inches and 16 inches are normal. The exemplary dimensions of the Insulation Panels are up to 96 inches in height, up to 24 inches in width and up to 2 inches in thickness. FIG. 4 also illustrates the dimensions of a Connecting Stud 104 assuming the inside width of the Insulation Panels Supporting Area 126 is 2 inches. A Top 129 of the Connecting Stud 104 is 2 inches wide centered on top of a Supporting Leg 127. The Supporting Leg 127 is 3 inches long. A Base Side 122 of the Connecting Stud 104 is 3.25 inches wide and is equally divided by the Supporting Leg 132. Two Wire Chase portions 124 on either side of the Supporting Leg 127 each having an inside width of 0.86 inches and an inside height 0.73 inches. The thickness of the various portions of the connecting stud is approximately 0.09 inches. The inside portion of Top Portion 129 of the Connecting Stud 104 has one or more insulating panel Gripping Portions 134 of approximately 0.04 inches. The upper outside portions of the Wire Chase Areas 124 have one or more insulating panel Gripping Portions 136 of approximately 0.04 inches.

FIG. 5 illustrates a Corner Stud 108. Elements of a Corner Stud 108 provide the support of and moisture protection of the Insulation Panels 106 between the Corner Stud 108 and a Connecting Stud 104. In addition Corner Stud 108 provides a structure for the Inside Corners 112 and Outsides Corners 116. The Corner Stud 108 material is also used for providing trim material around a Window Opening 118 or a Door Opening 120. The elements of a Corner Stud 108 include a Base Side 130, a Wire Chase Area 132, an Insulation Panel Support Area 134 that provides the support for a Insulation Panel 106, a Top Portion 136 of the Corner Stud 108 completes the Insulation Panel Support Area 134 structure; an area that provides a Moisture Protection Area 138 for the Insulation Panels 106 between an Existing Wall 102 and the Insulation Panel 106; and a Supporting Leg 140.

FIG. 5 also illustrates the dimensions of the Corner Stud assuming (as discussed above) the inside length of the Insulation Panels Supporting Area 134 is 2 inches. The Top 136 of the Corner Stud 108 is 1.25 inches wide with one end fastened at the top of the Supporting Leg 140. The Supporting Leg 140 is 3 inches long. A Base Side 130 of the Corner Stud 108 is 1.75 inches wide and has a Wire Chase Portion 132 with one side being part of the Supporting Leg 140 has an inside width of 0.91 inches and an inside height 0.91 inches. The thickness of the various portions of the Corner Stud is approximately 0.09 inches. The inside portion of Top Portion 136 of the Corner Stud 108 has one or more insulating panel Gripping Portions 142 of approximately 0.04 inches. The Moisture Protection Area 138 has a height of 1 inch. The upper outside portions of the Wire Chase portions have one or more insulating panel Gripping Portions 142 of approximately 0.04 inches. The inside portion of Top Portion 136 of the Corner Stud has one or more insulating panel Gripping Portions 142 of approximately 0.04 inches. These are exemplary values and may differ as conditions require.

The Connecting Studs and Corner Studs are made from PVC as an exemplary material. However they could be made of aluminum, Polypropylene, reinforced fiberglass, or Polycarbonate. The Insulation Panels and the Corner Insulation Inserts are made from Expanded Polystyrene, Extruded Polystyrene, or Polyisocyanurate as exemplary materials. However, they also could be made of Mineral board, rock-wool or Fiberglass.

FIG. 6 illustrates a detailed description of a connection of two Insulation Panels 106 to a Connecting Stud 104 mounted onto an Existing Wall 102. The Base Side of the Connecting Stud 122 is fastened to the Existing Wall 102. The inside of the Top Plate 129 and the top of Wire Chase Areas 124 provide a Support Area 126 for the support of the inserted connecting insulating panels 106. A Connecting Stud 104 is fastened to the Existing Wall 102 before the insertion of the Insulation Panels 106 to adjacent Connecting Studs 104. As can be observed mounting Insulation Panels 106 into a Connecting Stud 104 leaves a Moisture Protection Area 128 between the Insulation Panels 106 and the Existing Wall 102. This gap provides the Moisture Protection Gap or Area 128 so that any moisture that accumulates on the Existing Wall 102 does not contaminate or injure the Insulation Panels 106.

FIG. 7 illustrates a detailed description of a connection of two Insulation Panels 106 to an Inside Corner 112 structure using a Connecting Stud 104, a Corner Stud 108 and a First Corner Insulation Insert 110. The Connecting Stud 104 is mounted onto the Existing Wall 102 of a first side of the Inside Corner 112 and supports a first Insulation Panel 106. The Connecting Stud 104 also supports the First Corner Insulating Insert 110 that fits in between the Connecting Stud 104 the second side of the Inside Corner 112. A Corner Stud 108 is fitted next to the Connecting Stud 104 and the First Corner Insulation Insert 110 and is fastened to the second side of the Inside Corner 112. The Corner Stud 108 supports an Insulation Panel 106 alongside of the second wall of the Inside Corner 112. As can be observed, a Moisture Protection Gap 146 exits on both sides of the Connecting Stud 104. The Corner Stud 108 also provides for a Moisture Protection Area 146 alongside of side two of the Existing Wall 102. Both the Connecting Stud 104 and the Corner Stud 108 have Wire Chase Areas 124 and 132. The effect of the Inside Corner 112 structure is to provide a support for the Insulation Panels 106, the First Corner Insulated Insert 110 and to provide a corner structure that parallels the inside corner of the Existing Wall 102.

FIG. 8 illustrates a detailed description of a connection of two Insulation Panels 106 to an Outside Corner 116 structure using two Corner Studs 108. A first Corner Stud 108 is mounted to a first side of an Outside Corner 116 such that the Base Side 130 of the Corner Stud 108 is fastened to the concrete wall with the vertical portion of the corner stud is flush with second side of the Outside Corner 116. A second Corner Stud 108 is fastened to the first Corner Stud 108 such that the Base Side 130 of the second Corner Stud 108 is flush with the top of the first Corner Stud 108. A second Insulation Panel 106 is inserted into the second Corner Stud 108. The effect of the Outside Corner 116 structure is to provide a support for the Insulation panels and provide corner structure that parallels the outside corner wall.

FIG. 9 illustrates the use of Corner Stud 108 material as a trim stop for around window and door openings. Corner Stud 108 is inserted into Insulation Panels 106 around the edges of a Window Opening 118 or a Door Opening 120 and fastened to the Existing Wall 102 to provide the Window Opening 118 trim and Door Opening 120 trim for the later installation of the doors or windows.

Installation of an Insulated Wall System 100 is straight forward and economical if done in a systematic fashion. FIG. 10 illustrates a Three Wall Layout 200 with an Existing Wall 202 having a Wall 1, 204; a Wall 2, 206; and a Wall 3 208 that includes the normal variations found in a typical wall system needing insulation installed on an interior surface such as a concrete wall or a CMU wall.

The tools and hardware need for such system include: Safety goggles; A plurality of 3/16″×1.00 Masonry Screws; Construction Adhesive; A Plastic Pipe saw or similar Saw; A Hammer Drill; A Level and Square; A Tape Measure; A Chalk-Box; A Utility Knife; A plurality of Insulation Panels; A plurality of Connecting Studs; One or more Corner Studs; One or more First Corner Insulation Inserts; and One or more second Corner Insulation Inserts.

The first step of installing an Insulated Wall System (System) to be added to an (concrete or CMU) Existing Wall 202 is to remove all dust, dirt, and loose debris from the Existing Wall 202 to which the System will be applied.

It is useful to start the installation of a System at an Inside Corner 210 as depicted at the juncture of Wall 1, 204 and Wall 3, 208 in FIG. 11. The first step of installing the Inside Corner 210 at the junction of Wall 1, 204 and Wall 3, 208 is to insert a First Corner Insulation Insert 212 into a first side of a Connecting Stud 214 as illustrated in Detail A. Then liberally apply a bead of construction adhesive to the base side of a Connecting Stud 214. Position the Connecting Stud 214 with the First Corner Insulation Insert 212 so that the First Corner Insulation Insert 212 is pushing snug against Wall 3 208 and then press the Connecting Stud 214 against Wall 1 204, allowing the adhesive to form a tack bond as shown in Detail A. Optionally one may use 2 or 3 Masonry Screws through the Base Flanges 216 of the Connecting Stud 214 to further secure the Connecting Stud 214 to Wall 1 202 if needed. This optional fastening method may be used instead or in addition to the adhesive method during the entire installation process.

Next, liberally apply a bead of adhesive to the Base Surface 218 of a Corner Stud 220. Additionally apply a bead of adhesive to the surface of the Top Surface 222 of the Connecting Stud 214 allowing the adhesive to form a tack bond between the Corner Stud 220 and the Connecting Stud 214 as illustrated in FIG. 12 and Detail B. Then press the Corner Stud 220 simultaneously against Wall 3 208 and against the Top Surface 222 of the Connecting Stud 214. Optionally one may use 2 or 3 Masonry Screws through the Mounting Flange 224 of the Corner Stud 220 to further secure the Corner Stud 220 to Wall 3 208 if needed. Details A and B above have illustrated the elements of an Inside Corner Assembly 210.

In a fourth step as illustrated in FIG. 13, begin installing Insulation Panels 226 around a Window Opening 228 in Wall 1 204. Measure or trace onto a 24″ by 96″ Insulation Panel 226 the cut-out for the Window Opening 228, then cut out panel for a the Window Opening 228 creating a first Window Opening Insulation Panel 230. Make the opening ⅛″larger at each cut to compensate for a trim channel. Insert the first Window Opening Insulation Panel 230 into the first Connecting Stud 214 within Inside Corner 210. It is important to start the measurements horizontal measurement from the supporting leg of the Connecting Stud 214 within the Inside Corner 210.

The fifth step is illustrated in FIG. 14 and its Detail C. Measure and cut lengths of Connecting Stud 214 to fit above and below the Window Opening 228, thus creating an Above Window Connecting Stud 232 and a Below Window Connecting Stud 234. Be sure to deduct 1¾″ from the measurement before cutting to compensate for a width of a trim channel that is to be installed later. Apply a liberal amount of adhesive to the back of the Above Connecting Stud 232 and slide the Above Connecting Stud 232 over the edge of the upper portion of the first Insulation Panel 230. Press the Above Window Connecting Stud 232 to the surface of Wall 1 204 allowing the adhesive to form a tack bond. Repeat this step for the Below Window Connecting Stud 234 and a lower portion of the first Window Opening Insulation Panel 230. When in place, the Above Window Connecting Stud 232 and the Below Window Connecting Stud 234 should maintain 1¾″ off-set away from the Window Opening 228 open to allow for trim channel placement.

FIG. 15 illustrates step 6 that continues the installation of the System 100 on Wall 1 204. Measure and cut lengths of an Above Window Insulation Panel 236 and a Below Window Insulation Panel 238. Be sure to deduct ⅛″ from the measurement before a cut in order to compensate for the thickness of a trim channel later. Slide the Above Window Insulation Panel 236 into Above Window Connecting Stud 232 and the Below Window Insulation Panel 238 into the Below Window Connecting Stud 234.

FIG. 16 illustrates step 7 of the installation process. This step incorporates the installation of a second Above Window Connecting Stud 232 on to Wall 1 204 and connection to the Above Window Insulation Panel 236 and a second Below Window Connecting Stud 234 and a Below Window Insulation Panel 238. Essentially, step 7 is a repeat of step 5.

FIG. 17 illustrates step 8 that prepares a standard size Insulation Panel 226 to fit around a second side of the Window Opening 228. Measure or trace onto a 24″ by 96″ Insulation Panel 226 the cut-out for the second side of Window Opening 228, then cut out panel for a the Window Opening 228 creating a second Window Opening Insulation Panel 230. Make the opening ⅛″ larger at each cut to compensate for a trim channel. Insert the second Window Opening Insulation Panel 230 into the Above Window Connecting Stud 232 and the Below Window Connecting Window Stud 234. It is important to start the measurements horizontal measurement from the support leg of the Above Window Connecting Stud 232 and the Below Window Connecting Window Stud 234.

FIG. 18 illustrates step 9 wherein a Full Length Connecting Stud 240 is installed. Liberally apply adhesive to the mounting surface of Full Length Connecting Stud 240 and slide it over the second Window Opening Insulated Connecting Panel 230. Press the Connecting Stud 240 firmly against Wall 1 204 allowing the adhesive to form a tack bond with the Wall 1 204 surface. See Detail D within FIG. 18 for details.

FIG. 19 illustrates step 10 which begins with measuring and cutting an Insulation Panel 226 then sliding the Insulation Panel 226 into Connecting Stud 240. Be sure to deduct ⅛″ from the measurement before a cut of the panel in order to compensate for the thickness of the Corner Stud which will be installed in the next step. See Detail E within FIG. 19 for details.

FIG. 20 begins the steps for installing an Outside Corner 242. Step 11 as illustrated in FIG. 20 begins with liberally applying a bead of adhesive to the back side of a full length of a Corner Stud 220, then slide the Corner Stud 220 over the edge of the Insulation Panel 226. Insure that the Corner Stud 220 is flush with the Wall 2 206 corner and press it firmly against Wall 1 204 allowing the adhesive to form a tack bond with surface of Wall 1 204. See Detail F within FIG. 20 for details.

FIG. 21 illustrates step 12 that involves installing the trim around the Window Opening 228. Measure the horizontal distance between the cut edges of the Window Opening Connection Panels 230 that run vertically along the sides of the Window Opening 228 (the measurements should be the same at top and bottom). Next cut lengths of Corner Stud 220 material to that same measurement (Corner Stud material also serves as trim material). Then liberally apply adhesive to the mounting surface of the cut lengths of Corner Stud 220 material. Slide the Corner Stud 220 material over the bottom edge of the Above Window Insulation Panel 230 and over the top edge of the Below Window Insulation Panel 238. Press the Corner Stud material firmly against Wall 1 204 allowing the adhesive to form a tack bond with the wall surface, thus creating a Top of Window Opening Trim 244 and Bottom of Window Opening Trim 246. See FIG. 21 and Detail G.

FIG. 22 illustrates step 13 that involves the installation of trim along the vertical sides of Window Opening 228. First measure the vertical distance between the top and bottom trim (the measurements should be the same on both sides). Cut a length of Corner Stud 220 material to that same measurement and then liberally apply adhesive, to the mounting surface of the cut lengths. Slide the Corner Studs over the vertical edge of the first and second Window Opening Insulation panels 230 at each vertical side of the Window Opening 228. Press each Corner Stud material firmly against the Wall 1 204 surface. Be sure that the Vertical Trim channels 248 and 250 are flush with the Window Opening 228. See Detail H of FIG. 22 for details.

FIG. 23 illustrates Window Opening 228 on Wall 1 204 with all the trim material installed using Horizontal Trim Channels 244 and 246 and Vertical Trim Channels 248 and 250.

FIG. 24 illustrates the start of the Wall 2 206 installation with step 14. Step 14 begins with the application of adhesive to the mounting surface of the newly installed Corner Stud 220 on Wall 1 204 and the positioning of a second Corner Stud 252 flush to it as illustrated in Detail I of FIG. 24. Press the second Corner Stud 252 against the existing Corner Stud 220 allowing the adhesive to form a tack bond.

The Wall 2 206 installation continues as illustrated in FIGS. 25, 26, and 27. Apply adhesive to the 2″ side of the previously installed Second Corner Stud 252 and apply it as illustrated in Detail J of FIG. 25. Insert a Second Corner Insulation Insert 254 onto the adhesive applied to the Second Corner Stud 252. Insert an Insulation Panel 226 into the Second Corner Stud 252 thus beginning the installation along Wall 2 206.

FIG. 26 illustrates Step 16 with the approaching the end of Wall 2 206. Apply a liberal amount of adhesive to a Connecting Stud 214 mounting surface and place it against Wall 2 206, flush with the Insulation Panel 226. Check for plumb. Press the Connecting Stud 214 firmly against Wall 2 206 allowing the adhesive to form a tack bond with the Wall 2 206 surface.

FIG. 27 illustrates a second portion of approaching an end Wall 2 206. Step 17 begins with measuring the distance from the support leg of Connecting Stud 214 to the end of the Wall 2 206. Be sure to deduct ⅛″ when cutting another Insulation Panel 226 to compensate for a Corner Stud's material thickness. Slide the End Insulation Panel 226 into the Connector Stud 214.

To complete the Wall 2 206 portion as illustrated in FIG. 28 there is a need to install a full length Corner Stud 220 flush with the end of the wall. Apply a liberal amount of adhesive to the back mounting surface of the Corner Stud 220 and slide the Corner Stud 220 onto the edge of the End Insulation Panel 226. Then press the Corner Stud 220 firmly against Wall 2 206 allowing the adhesive to form a tack bond with surface of Wall 2 206. This completes Wall 2 206 portion of the System.

FIG. 29 illustrates Wall 3 208 before any installation on Wall 3 208. The Wall 3 208 installation begins at the end of Wall 1 204 at the Inside Corner 210 that was started in the first steps. Note that Wall 3 includes a Door Opening 258.

Step 19 starts the installation of the System 100 onto Wall 3 208, as illustrated in FIG. 30. Measure or trace, from an Insulation Panel 226, a cut-out for the Door Opening 258 then cut the panel accordingly making a First Door Opening Insulation Panel 260. Make the opening ⅛″ shorter at each cut to compensate for the trim channel. Insert the First Door Opening Insulation Panel 260 into the existing Corner Stud 220 at the Inside Corner 210. See Detail K for details. Be sure to start a horizontal measurement from the inside face of the Corner Stud 220.

FIG. 31 illustrates Step 20. Next, measure the distance between the top of the Door Opening 258 and the top of Wall 3 208; cut a length of Connecting Stud 214 creating a First Above Door Connecting Stud 262 to fit above the Door Opening 258. Be sure to deduct 1¾″ from the measurement before the cut in order to compensate for the width of the trim channel that is to be installed. Apply a liberal amount of adhesive to the mounting surface of the First Above Door Connecting Stud 262 and slide the First Above Door Connecting Stud 262 over the edge of the First Above Door Insulation Panel 260 and make sure that end of The First Above Door Connecting Stud 262 is flush with top of Wall 3 208. Press the stud firmly against the wall surface allowing adhesive to form a tack bond.

FIG. 32 illustrates Step 21. Measure and cut a length of an Insulation Panel 226 creating a Second Above Door Opening Insulation Panel 264 to fit above the Door Opening 258. Be sure to deduct ⅛″ from the measurement in order to compensate for the thickness of the trim channel that will be installed later. Slide the Second Above Door Insulation Panel 264 into the First Above Door Connecting Stud 262 and be sure the top edge of Insulation Panel 264 is flush with top of Wall 3 208.

FIG. 33 illustrates Step 22. Next, measure the distance between the top of the Door Opening 258 and the top of Wall 3 208; cut a length of Connecting Stud 214 to fit above the Door Opening 258, thus creating a Second Above Door Connecting Stud 266. Be sure to deduct 1¾″ from the measurement before a cut in order to compensate for the width of the trim channel that is to be installed. Apply a liberal amount of adhesive to the mounting surface of Second Above Door Connecting Stud 266 and slide it over the edge of Second Above Door Insulation Panel 264 and make sure that end of the stud is flush with top of Wall 3 208. Press the stud firmly against wall surface allowing adhesive to form a tack bond.

FIG. 34 begins the details installing the trim around Door Opening 258 on Wall 3 208. Corner Stud material is used as trim material for finishing a Door Opening 258. Step 23 begins the Door Opening 258 trim installation by installing the Horizontal Door Opening Trim 268 on the upper portion of the Door Opening 258. First measure the horizontal distance between the vertical cut edge of the First Door Opening Insulation Panel 260 and the right hand vertical side of the top of Door Opening 258. Next, cut a length of Corner Stud 220 material to that same measurement, thus creating the Horizontal Trim 268 for the Door Opening 258. Then liberally apply adhesive to the mounting surface of the cut length of Corner Stud 220 material. Slide Horizontal Trim Door Opening Trim 268 onto the top of the Door Opening 258. Press the Horizontal Door Opening Trim 268 firmly against the Wall 3 208 surface. The Horizontal Door Opening Trim 268 should be flush with the Door Opening 258.

FIG. 34 further illustrates a part of step 23 that involves the installation of the Vertical Door Opening Trim 270 of Door Opening 258. First measure the vertical distance between the Horizontal Door Opening Trim 268 on the top of Door Opening 258 and the bottom of the Door opening 258 (the measurements should be the same on both sides). Cut two lengths of Corner Studs 220 material to that same measurement thus creating two Vertical Door Opening Trim 270 and then liberally apply adhesive, to the mounting surface of the cut lengths. Slide the first Vertical Door Opening Trim 270 over the vertical edge of the First Above Door Insulation Panel 260 and press the first Vertical Door Trim 270 firmly against the Wall 3 208 surface. Be sure that the Corner trim Stud 220 is flush with the Door Opening 258. Press the second Vertical Door Opening Trim 270 flush with right hand side of Door Opening 258.

FIG. 34 further illustrates as part of Step 23 a portion of approaching the end of Wall 3 208. Step 23 continues with measuring the distance from the web of right side Vertical Door Opening Trim 270 to the end of the Wall 3 208. Be sure to deduct ⅛″ when cutting the Insulation Panel 226 to compensate for the Corner Stud 220 (to be installed in the next step) material thickness. Slide the Insulation Panel 226 into the Connector Stud 266 and right Vertical Door Opening Trim 270.

To complete the Wall 3 208 portion as illustrated in FIG. 34 we need to install a full length Corner Stud 220 flush with the end of the wall. Apply a liberal amount of adhesive to the back mounting surface of a Corner Stud 220 and slide the Corner Stud 220 onto the edge of Insulation Panel 226. Then press the Corner Stud 220 firmly against Wall 3 208 allowing the adhesive to form attack bond with surface of Wall 3 208. This completes the Wall 3 portion.

FIG. 35 illustrates the completed installation of an Insulated Wall System 100 on an illustrative wall. FIG. 36 illustrates a completed insulated wall system includes an Inner Corner 210, an Outer Corner 242, a Plain Wall 272, a Wall Having a Window Opening 274 a Wall Having a Door Opening 276 and two ends of Wall Configurations 278 and 280. This installation narrative is descriptive of the installation of the four basic parts of the system, a Corner Stud, a Connecting Stud, a Corner Insulation Insert (two sizes) and an Insulation Panel. FIG. 36 illustrates a total wall system and each of the elements described above.

FIGS. 37 (a-f) illustrate a summary of the installation subsystems described above including: the overall three wall example 282; first end of wall example 284; a typical inside corner 286; a typical outside corner 288; a second end of wall example 290; and a window opening (a door opening has many of the same elements as a window opening) 292.

In addition to the retro-fit system for concrete or CMU basements and other indoor applications described above, an Insulated Wall System 100 can be applied to exterior above-grade walls as a true “retro-fit” system to provide the additional insulation value to meet emerging energy code requirements as well as to provide studding for finish board material or siding attachment.

FIG. 38 illustrates a residential building needing additional insulation, but does not have an economical or practical way of installing insulation on or in the above grade, exterior perimeter walls.

The method of installation for an external wall is very similar to that of an interior wall. The major difference is that there is a significant likelihood that such a wall system will use Outside Corners, Window Openings and Door Openings more frequently than an interior basement retro-fit project. Additionally, it is more likely that the fastening of the Corner Studs and the Connecting Studs to an outside wall assembly will require nail or screw fasteners rather than or in addition to adhesives due to an irregular nature of an exterior wall surface. Otherwise the installation procedures described above for an interior wall are relevant to an exterior wall. FIG. 38 illustrates an Insulated Wall System as installed on the exterior wall before any siding is put on top of the insulated panels.

As discussed above there is a need for a system for “Tilt-Up” construction that can provide insulation value and studding to one or both sides of a tilt-up wall assembly which provides design flexibility, faster installation, and attachment strips for subsequent finishing materials. Furthermore, as it pertains to new construction, “tilt-up” walls are widely used to quickly and efficiently erect buildings. The systems that are currently used today in “tilt-up” construction are designed to position the insulation panel in the middle of the concrete wall and they do not provide attachment strips or studding spaced along the face of the wall.

The installation of the Insulated Panel System in a Tilt-Up installation is in the middle of the process, therefore much of the preparation and finishing of the Tilt-up Installation uses standard tilt-up construction procedures.

Prior to the tilt-up construction process beginning a concrete slab is poured to create a floor, where the tilt-up panels will be created. The first step in creating a tilt-up panel is to draw lines on the concrete floor slab where the concrete panels will be formed and poured. Once the lines have been drawn, brackets are placed to outline where the tilt-panels' outside boundaries, windows and door openings will be. Ensuring the exact placement of the concrete formwork is important to the success of the project. The tilt-up concrete panels need to be sized and positioned in precisely the correct dimensions and location. Tilt-up panels forms made of wood are connected to the braces. Once assembled, the tilt-up construction panel forms create a jigsaw puzzle pattern on the floor slab. Each form is positioned precisely to allow them to be tilted into their final 310 spot when completed.

Typically form release agent and bond breaker materials are applied to the slab and forms, but this process may also be eliminated herein as the Insulated Wall System provides a barrier between the newly placed concrete and the slab surface further reducing material and production labor costs.

At this stage in a tilt-up installation the preparation of the walls begins. When using elements of the Insulated Wall System the elements are installed into the tilt-up wall panel form and the installation follows many of the steps previously described with an Insulated Wall System with an existing wall as a base. As illustrated in FIG. 39 an Insulated Wall System in a Tilt-up Wall Application 300 begins with installing a First Corner Stud 302 next to a first edge of a Tilt-Up Wall Panel Form 304. A first Insulation Panel 306 is inserted into the Corner Stud 302. A Connecting Stud 308 is placed on the Slab 310 and inserted on to the first Insulation Panel 306. This procedure is continued with one or more additional Connecting Studs 308 and one or more additional Insulation Panels 306. At least one of the additional Insulation Panels 306 may need to be cut into a shorter width in order to fit within the Tilt-Wall Panel Form 304 including a Second Corner Stud 312. The last step of this portion is to insert the Second Corner Stud 312 onto the last Insulation Panel 306 prior to a second portion of the Tilt-Up Wall Panel Form 304 and placing the second Corner Stud 312 up against the second portion of the Tilt-up Wall Panel Form 304. Note that the top of the Connecting Studs 308 are located next to the Slab 310.

The next steps involve pouring concrete into Tilt-up Wall Panel Form 304. The first step is the installation of a rebar system. Rebar is an important component of tilt-up construction. The rebar strengthens the tilt up concrete panels, making them safe to lift into standing position and more durable once in place. The first portion is the installation of an Insulated Wall System Rebar Chair (Rebar Chair) 314. These Rebar Chairs are fastened (with an adhesive) or may be snapped to the top of each Connecting Stud 312 and/or Corner Stud 302. Using the Rebar Chairs, a first layer of rebar is then installed into the Rebar Chairs and if desired a second layer of rebar may be placed perpendicular upon the first layer of reinforcement bar. See FIG. 40.

Details of the Rebars Chairs are illustrated in FIG. 40 including: FIG. 40 (a) illustrating a front view of a Snap-On Rebar Chair 314; FIG. 40 (b) illustrating a side view of a Snap-On Rebar Chair 314; FIG. 40 (c) illustrating a top view of a Snap-On Rebar Chair 314; FIG. 40 (d) illustrating a front view of a Snap-On Rebar Chair 314 mounted on a Connecting Stud 312; and FIG. 40 (e) illustrating a side view of a Snap-On Rebar Chair 314 mounted on a Connecting Stud 312.

At this point concrete is poured into the Tilt-Up Wall Panel Forms 304 on top of the Insulated Wall System elements and on to the rebars in a manner similar to the way the floor slab was poured. Once the concrete has been poured, the concrete is troweled for a smooth consistent finish. Once the building of the perimeter forms, installing the insulated wall elements and the reinforcing bar and pouring the concrete are completed, the tilt-up panels go up quickly. An experienced crew can take a large project from a bare slab to completed tilt-up panels in a matter of two weeks or less.

The description of installing the insulated wall system in a tilt-up wall form did not take into account the existence of windows and doors. The installation of the tilt-up construction panel forms would include form areas for window areas and door areas. The techniques used in steps 6-8 and 12-13 and 19-23 of an Inside Insulated Wall System for an existing building would be used.

Once the concrete has cured for the tilt-up wall panel with its insulated panels, the wood forms are removed leaving the tilt-up panels lined up on the floor slab. Drill places for brackets are connected to the concrete wall.

The completed tilt-up panels are poured into forms that provide the size, shape and door openings to meet the design specifications.

A crane is used to lift the tilt-up panel and tilts it into position over the footing. The panels with Insulated Wall Panels need to have the Insulated Wall Panels facing the inside of the building once installed. Once a concrete panel is set in place, braces are attached to the slab to keep it standing until is attached to other tilt-panels and the roof system.

The major advantage of placing an insulated wall system within the concrete walls in a tilt-up system is that it eliminates the need to install insulation panels and studs on the inside surface of walls or outside surface of walls at a later date, thus significantly reducing the cost of the building and the construction time.

As noted above the system is based upon using 2″ thick insulation panels. This thickness of insulated panels allows for R values of insulation up to 9 for Expanded Polystyrene material and an R value up to 15 for Polyisocyanurate material. If R values of greater value are required for specific geographic locations the thickness of the Insulation Panels Supporting Area of the Connecting Stud and the Corner Stud may be increased to accommodate thicker insulation panels. Another method of accommodating the need for a higher R values is to place an Additional Insulation Panel 306 on top of each Insulation Panel 306 as illustrated in FIG. 41. Furthermore, the placement of the additional insulation panel provides a structural element to the wall assembly dry creating a structural rib.

As illustrated in FIG. 42, another method of adding additional insulation in a “tilt-up-construction” is to use a thicker One Piece Insulation Panel 316. As can be seen this One Piece Insulation Panel 316 has “legs” on it with the normal 2 inch thickness and a center area greater than the 2 inch leg thickness. As with the two piece method described above this creates a higher R value and some structural benefits as well.

It is contemplated that the Connecting Studs 104, Corner Studs 108 and the Corner Insulated Inserts 110 and 114 would be available as one or more kits of parts to be used with locally available Insulation Panels 106 in the form of insulated foam, expanded polystyrene or extruded polystyrene. This method of distribution eliminates the need to transport foam products to satisfy the need to install the insulated wall system at a lower cost and in a more convenient package. One such kit may contain one or more Connecting Studs, one or more Corner Studs and one or more Corner Connecting Inserts. Even though the Corner Connecting Inserts are also made of insulated foam, expanded polystyrene or extruded polystyrene, they are not of a standard size and it may be more convenient for the purchaser to obtain these elements as part of the kits. Other combinations of kits having different combinations of elements may be made available to suit the needs of various applications.

As discussed above there is a need to effectively insulate and provide continuous studding in a conventional “cast-in-place” concrete wall assembly, subsequent to placing concrete. The Applicants in their U.S. Pat. No. 6,079,176 ('176) entitled “Insulated Concrete Wall issued on Jun. 27, 2000 (incorporated herein in full hereby by reference) described such a cast-in-place concrete wall assembly. The '176 assembly is commercially available under the ThermaEZE® name. The elements of the Insulated Wall System make it possible to provide insulation and continuous studding within conventional wall forms subsequent to placing concrete that does not rely on specially fabricated foam panels thereby making the installation process much faster, considerably easier and reducing “carbon foot-printing” through the sourcing of locally and readily available insulation panels (EPS; XPS; or Polyisocyanurate).

The '176 patent relates to poured concrete walls and more particularly, to poured concrete walls including a layer of thermal insulation in which the insulation layer is secured to the concrete wall at the time of pouring the concrete. The '176 patent provides an apparatus and method for securing an insulation layer in place while the concrete is poured between conventional forms, and for continuing to secure the insulation to the poured concrete wall after the forms have been removed.

Prior to the '176 patent design concrete walls were commonly formed by pouring concrete between inner and outer forms and, after hardening, insulation materials may be added to the concrete walls. In order to do so, frame members may be applied to the concrete wall, such as by using pneumatic nails guns and concrete nails, and then the insulation materials may be secured to the frame members. Alternatively, the insulation may be secured to the concrete wall by concrete nails. Such multi-step assembly procedures were both costly and time consuming. Thus, there was a need for a system and a method whereby poured concrete walls may be formed and insulated at the same time in one step.

FIG. 43 illustrates a “Cast-in-place” Concrete Wall Assembly 400 embodiment with removable and re-usable Wall Forms 402 being held in place conventionally by Wall Ties 404. The embodiment shows connector studs 104 and Insulation Panels 106 installed between Wall Ties 404. The Insulation Panels 106 are cut to size in order to create uniform spacing between Connector Studs 104. Typical spacing of the Connector Stud 104 is 12 inches on center up to 24 inches on center but not to exceed 24 inches on center spacing. The Connector Stud 104 is installed with a Base Side 122 protruding into the open wall Cavity 406 prior to placement of concrete into the Cavity 406. Once concrete is placed in the Cavity 406 between the Wall Forms 402 the Connector Stud 104 Flange 128 will become imbedded into the concrete and be securely held in place. The Corner Stud 108 is placed in the Corner 408 and Insulation Panels 106 are installed into the Corner Studs 108. The Corner Studs 108 are joined together using adhesive and/or mechanical fasteners prior to placing into the Corner 408. One of the Corner Studs 108 is positioned such that the Base Side 130 protrudes into the open wall Cavity 406 prior to placement of concrete in the cavity 406. Once concrete is placed in the Cavity 406 within the Wall Forms 402 the Corner Stud 108 Base Side flange 130 will become imbedded into the concrete and securely held in place. As with all “cast in place systems, once the concrete has hardened, the Wall Forms 402 are removed and can be reused in another construction project.

The use of the elements of the insulated wall system including one or more Connecting Studs 104, one or more Corner Studs 108, and a plurality of Insulation Panels within an insulated concrete wall (cast-in-place) as described in the '176 patent provides for an improved insulated concrete wall. These improvements include the use of continuous wall studs. An integrated wire chase and a profile that is designed so that it becomes fully imbedded into the concrete. Such an insulated concrete wall utilizes readily available, non-proprietary insulation, such as: expanded polystyrene, extruded polystyrene, and polyisocyanurate foam. These insulation products may be sourced by the installer from most building supply outlets. The Corner Studs are used to easily create the corner assembly within the conventional forms. Additionally simplistic design, the use of the Insulated Wall System of the embodiments of this invention will save considerable labor and time when used within the '176 design.

The Connecting Studs and the Corner Studs are of a unique design created to hold standard Insulation Panels. These applications and the uniqueness of the studs may not be limited to use within a wall system. The Insulated Wall System provides several advantages over the prior systems including: continuous wall studs; an integrated wire chase; a profile that is designed so that it becomes fully imbedded with the concrete; provides a moisture gap; and utilizes readily available, non-proprietary insulation, such as: expanded polystyrene, extruded polystyrene, and polyisocyanurate foam. These insulation products may be sourced by the installer from most building supply outlets. Additionally due to the simplistic design, the Insulated Wall System will save considerable labor time. While the studs may come in some standard lengths i.e. 96 inches, it is possible that shorter values of length can be used in series to match the total length needed since they are fastened to a wall.

Various modifications to the embodiments of the resent invention will become apparent to those skilled in the art from the foregoing description and accompanying drawings. Accordingly, the present invention is to be limited solely by the scope of the following claims.

NUMERALS ASSOCIATED WITH DRAWINGS

• • 100 Insulated Wall System,
  • 102 Existing Wall,
  • 104 Connecting Stud,
  • 106 Insulation Panel,
  • 108 Corner Stud,
  • 110 First Corner Insulation Insert,
  • 112 Second Corner Insulation Insert,
  • 114 Inside Corner,
  • 116 Outside Corner,
  • 118 Window Opening,
  • 120 Door Opening,
  • 122 Base Side of Connecting Stud,
  • 124 Connecting Stud Wire Chase Area,
  • 126 Connecting Stud Insulation Panel Support Area,
  • 128 Connecting Stud Moisture Protection Area,
  • 130 Base Side of a Corner Stud,
  • 132 Wire Chase Area for Corner Stud,
  • 134 Corner Stud Insulation Panel Support Area,
  • 136 Corner Stud Moisture Protection Area,
  • 138 Inside Corner Structure,
  • 140 Outside Corner Structure,
  • 142 Connecting Stud Supporting Leg,
  • 144 Insulation Panel Gripping Portion,
  • 146 Corner Stud Supporting Leg,
  • 147-198 Not Used,
  • 200 A Three Wall Layout,
  • 202 Existing Wall,
  • 204 Wall 1,
  • 206 Wall 2,
  • 208 Wall 3,
  • 210 Inside Corner,
  • 212 First Corner Insulation Insert,
  • 214 Connecting Stud,
  • 216 Connecting Stud Base Flange,
  • 218 Base Surface of a Corner Stud,
  • 220 Corner Stud,
  • 222 Top Surface of Connecting Stud,
  • 224 Corner Stud Inward Flange,
  • 226 Insulation Panel,
  • 228 Window Opening,
  • 230 Window Opening Insulation Panel,
  • 232 Above Window Connecting Stud,
  • 234 Below Window Connecting Stud,
  • 236 Above Window Insulation Panel,
  • 238 Below Window Insulation Panel,
  • 240 Full Length Connecting Stud.
  • 242 Outside Corner.
  • 244 Top of Window Opening Trim.
  • 246 Bottom of Window Opening Trim.
  • 248 Left Hand Vertical Trim Channel.
  • 250 Right Hand Vertical Trim Channel.
  • 252 Second Corner Stud,
  • 254 Second Corner Insulation Insert,
  • 256 End Insulation Panel,
  • 258 Door Opening,
  • 260 First Door Opening Insulation Panel,
  • 262 First Above Door Opening Connecting Stud,
  • 264 Second Above Door Opening Insulation Panel,
  • 266 Second Above Door Connecting Stud,
  • 268 Horizontal Door Opening Trim,
  • 270 Vertical Door Opening Trim,
  • 272 Plain Wall,
  • 274 Wall Having a Window Opening,
  • 276 Wall Having a Door Opening,
  • 278 Wall Having a First End of Wall Configuration,
  • 280 Wall Having a Second End of Wall Configuration,
  • 282 Three Wall Example,
  • 284 First End of Wall Example,
  • 286 Typical Inside Corner,
  • 288 Typical Outside Corner,
  • 290 Second End of Wall Example,
  • 292 Window Opening,
  • 292-298 Not Used,
  • 300 Tilt-wall Application,
  • 302 First Corner Stud,
  • 304 Tilt-up Wall Panel Form,
  • 306 Insulation Panel,
  • 308 Connecting Stud,
  • 310 Slab,
  • 312 Second Corner Stud, and
  • 314 Rebar Chair.
  • 316 One Piece Insulation Panel
  • 318-398 Not Used
  • 400 “Cast-in-place” Assembly
  • 402 Wall Forms
  • 404 Wall Ties
  • 406 Cavity
  • 408 Corner
    End of Numerals

Claims

1. A stud comprising:

a. a top portion;

b. a supporting leg;

c. wall mounting portion;

d. one or more wire chase portions;

e. one or more insulation panel support areas; and

f. one or more moisture protection areas

g. wherein said studs provide support for insulation panels, provide one or more wire chase areas and protect said insulation panels from moisture.

2. The stud of claim 1 comprising:

a. a connecting stud that provides support of up to two insulation panels and further comprises:

b. two insulation panel support areas for supporting up to two insulation panels;

c. two said wire chase areas;

d. two said moisture protection areas.

3. The stud of claim 1 comprising:

a. a corner stud that supports one insulation panel and provides a corner structure for a wall system and

b. further comprises: one insulation panel support area supporting a single insulation panel;

c. one said wire chase area;

d. one said moisture protection area.

4. The stud of claim 2 wherein said connecting stud comprises:

a. a wall mounting portion 3.25 inches in width and a depth of approximately 0.093 inches;

b. a connecting portion 3.00 inches in height and a width of approximately 0.093 inches centered upon;

c. a top portion 2.00 inches in width centered upon said wall mounting portion;

a pair of wire chase portions mounted on either side of said connecting portion upon said wall portion, each wire portion having a width of 0.86 inches and a height of approximately 0.73 inches; and

an overall length of up to 96 inches or a length governed by height of said wall.

5. The stud of claim 2 wherein said corner stud comprises:

a bottom portion 1.75 inches in width and a thickness of approximately 0.93 inches;

a. a connecting portion 3.00 inches in height and approximately 0.90 inches in width; and

b. a top portion 1.25 inches wide and 0.093 inches thick and a length of up to 96 inches.

6. The system of claim 1 wherein a material of said studs is selected from the group consisting of PVC, aluminum, Polypropylene, reinforced fiberglass, or Polycarbonate.

7. The system of claim 1 wherein said studs are made of durable PVC.

8. An insulated wall system comprising:

a. one or more connecting studs;

b. one or more corner studs;

c. one or more insulation panels;

d. one or more corner insulation inserts;

e. wherein said studs are mounted to a wall;

f. further wherein said insulation panels are coupled to a pair of one or more studs and said corner insulation inserts are coupled to one or more studs.

9. The system of claim 8 wherein said connecting studs are glued to said wall.

10. The system of claim 8 wherein said connecting studs are mechanically fastened to said wall.

11. The system of claim 8 wherein said connecting studs are incorporated within a linear portion of an insulated wall system.

12. The system of claim 8 wherein a connecting stud and/or one or more corner studs are used to form a corner within said wall system.

13. The system of claim 8 wherein said system is mounted on to an interior wall.

14. The system of claim 8 wherein said system is mounted on to an exterior wall.

15. The system of claim 8 wherein said wall is made of concrete.

16. The system of claim 8 wherein said wall is a concrete masonry unit constructed wall.

17. The system of claim 8 wherein said insulation panels are made of materials selected from the group consisting of Expanded Polystyrene, Extruded Polystyrene, or Polyisocyanurate, Mineral board, rock-wool or Fiberglass.

18. The system of claim 8 wherein said insulation panels are up to 24″ in width, 2″ in depth and a length of up to 96″ or a length governed by a height of said wall.

19. The system of claim 8 comprises a series of sections further comprising sections of continuous studding and insulation panels.

20. The system of claim 8 wherein said system as mounted to said wall includes an air space between said one or more insulation panels and said wall.

21. The system of claim 8 comprising one or more wire chases within each of said one or more studs.

22. The system of claim 8 comprising one or more inner corner subsystems further comprising:

a. a corner stud;

b. a connecting stud; and

c. a first corner insulated insert.

23. The system of claim 22 wherein said corner insulated insert has a depth of 2 inches and width of 3 inches and an overall length of up to 96 inches or a length governed by a height of said wall.

24. The system of claim 8 comprising one or more outer corner subsystems further comprising:

a. a corner stud; and

b. a second corner insulated insert.

25. The system of claim 24 wherein said corner insulated insert has a depth of 2 inches and width of 5 inches and an overall length of up to 96 inches or a length governed by a height of said wall.

26. A kit of parts for an insulated wall system of claim 1 comprising:

a. one or more connecting studs;

b. one or more corner studs;

c. one or more corner insulation inserts;

d. wherein said parts are combined with user supplied one or more insulation panels for installation on or as part of a wall.

27. A kit of parts for an insulated wall system of claim 1 comprising:

a. one or more connecting studs;

b. one or more corner studs; and

c. one or more corner insulation panels;

d. one or more insulation panels;

e. wherein said parts are combined for installation on a or as part of a wall.

28. A kit of parts for an insulated wall system of claim 1 comprising:

a. one or more connecting studs;

b. one or more corner studs; and

c. wherein said parts are combined with user supplied one or more insulation panels and user cut and shaped insulation panels to form one or more corner insulation inserts for installation on to or fabricated as part of a wall.

29. A method of installing an insulated wall system comprising the acts of:

a. installing an inside corner portion of said system an inside corner of an existing wall if said wall has one or more inside corners;

b. installing one more connecting portions having no openings;

c. installing one or more door portions, if said wall comprises one or more door openings;

d. installing one or more window portions, if said wall has one or more window openings;

e. coupling one or more additional connecting portions to said openings;

f. installing one or more outside corner portions, if said wall has one or more outside corners; and

g. installing a first end of wall portion; and/or installing a second end of wall portion.

30. The method of claim 29 wherein installing an inside corner portion further comprises the acts of:

a. insert a first corner insulation insert into a first side of a connecting stud;

b. liberally apply a bead of construction adhesive to a base side of said connecting stud;

c. position said connecting stud with said first corner insulation insert so that the first corner insulation insert is pushing snug against said first wall;

d. then press said connecting stud against said first wall allowing said adhesive to form a tack bond;

e. liberally apply a bead of adhesive to a base surface of a corner stud;

f. apply a bead of adhesive to a surface of a top surface of said connecting stud allowing said adhesive to form a tack bond between said corner stud and said connecting stud; and

g. press said Corner Stud simultaneously against a second wall and against said Top Surface of said Connecting Stud.

31. Said method of claim 28 wherein 2 or 3 Masonry Screws through a mounting flange said corner stud may be used to further secure said corner stud to said second wall and/or said screws through a mounting flange of said connecting stud to further secure said connecting stud to said first wall or may be used in place of said adhesive.

32. The method of claim 29 wherein installing an outside corner portion further comprises the acts of:

a. liberally applying a bead of adhesive to a back side of a corner stud;

b. liberally applying a bead of adhesive to a back side of a corner stud;

33. insure that said corner stud is flush with a wall corner and press it firmly against said wall allowing the adhesive to form a tack bond with a surface of said wall. The method of claim 29 wherein installing one more connecting portions having no openings comprising the acts of:

a. liberally apply a bead of adhesive to a back side of a first connecting stud;

b. Slide said a first side of said first connecting stud over a first Insulation panel;

c. Apply said first connecting stud to a wall; and

d. Slide a second Insulation panel into a second side of said first connecting stud; and repeat above steps as necessary.

34. The method of claim 29 wherein installing a connecting portion having a window opening further comprises the acts of:

a. installing an Insulation panel around a first side of said wind opening;

b. installing a first above window connecting stud;

c. installing a first below window connecting stud;

d. installing an above window insulation panel and a below window insulated panel;

e. installing an insulation panel around a second side of said window opening; and;

f. Installing trim around window opening edges.

35. The method of claim 29 wherein installing a connecting portion having a door opening further comprises the acts of:

a. installing an insulation panel around a first side of said door opening;

b. installing a first above window connecting stud;

c. installing an above window Insulation panel;

d. installing an Insulation panel around a second side of said door opening; and

e. installing an Insulation panel around a second side of said door opening; and;

installing trim around door opening edges.

36. The method claim 20 wherein the method of installing a first end of wall portion comprises the steps of:

a. apply a liberal amount of adhesive to a connecting stud mounting surface and place it against said wall flush with an existing insulation panel and check for plumb;

b. press said connecting stud firmly against said wall allowing said adhesive to form a tack bond with said wall surface;

c. measure a distance from a support leg of said connecting stud to an end of said wall;

d. cut an end insulation panel to said measurements while allowing an additional ⅛ inch to compensate for a corner stud's material thickness;

e. slide said end insulation panel into said connector stud;

f. apply a liberal amount of adhesive to a back mounting surface of said corner stud and slide said corner stud onto an edge of said end insulation panel; and

g. press said corner stud firmly against said wall allowing said adhesive to form a tack bond with a surface of said wall.

37. The method claim 20 wherein the method of installing a second end of wall portion comprises the steps of:

a. apply a liberal amount of adhesive to a back mounting surface of a corner stud and slide said corner stud onto an edge of an insulation panel at said end of the wall; and

b. press said corner stud firmly against said wall allowing said adhesive to form a tack bond with surface of said wall.

38. A method of installing an insulated wall system within a tilt-up wall system comprising the acts of:

a. installing a first corner stud next to a first interior edge of a tilt-up wall panel form;

b. inserting a first side of a first insulation panel into said Corner Stud;

c. placing a first connecting stud is placed on a slab portion of said tilt-up wall panel form and inserted on to a second side of said first insulation panel;

d. continuing step c with one or more additional connecting studs and one or more additional insulation panels with at least one of the additional insulation panels may be needing to be cut into a shorter width in order to fit within said tilt-wall panel form including a second corner stud;

e. installing one or more rebar chair on top of each connecting stud;

f. installing rebar on to said rebar chairs; and

g. pouring concrete into said tilt-up wall panel form.

39. The method of claim 38 further comprising the act of:

a. installing an additional insulation panel above each said insulation panel and in between said studs, wherein said additional insulation panels improves the R rating of said tilt-up system.

40. The method of claim 38 further comprising the act of:

a. installing a one piece insulation panel having “legs” on it with the thickness that fits within corner stud or connecting stud and having a center area greater than between said studs, wherein said one piece insulation panels improve the R rating of said tilt-up system;

b. mounting rebar chairs on to each stud; and

c. creates a structural element to the wall assembly

41. A method of installing an insulated wall system within a cast-in-place application: comprising the acts of:

a. installing a series of wall forms into which a “cast-in-place” system is installed;

b. installing a plurality of wall ties;

c. installing a plurality of connector studs with a base side protruding into an open wall cavity;

d. installing one or more corner studs with a base side protruding into said open wall cavity;

e. cutting insulation panels to spacing between connector studs or between connector studs and a corner stud;

f. installing one or more connector studs and one or more insulation panels between one or more wall ties.

42. The method of claim 41 wherein said connector studs are spaced 12 inches on center up to 24 inches on center.

43. The method of claim 42 wherein said insulation panels are cut to size in order to create uniform spacing between connector studs.

44. A method of installing an insulated wall system onto an existing exterior of a building comprising the acts of:

a. applying the acts of claims 29 through 35 to said exterior of a building.