CA2459951C - Continuous structural wall system - Google Patents
Continuous structural wall system Download PDFInfo
- Publication number
- CA2459951C CA2459951C CA2459951A CA2459951A CA2459951C CA 2459951 C CA2459951 C CA 2459951C CA 2459951 A CA2459951 A CA 2459951A CA 2459951 A CA2459951 A CA 2459951A CA 2459951 C CA2459951 C CA 2459951C
- Authority
- CA
- Canada
- Prior art keywords
- composite wall
- wall panel
- panel
- hollow
- affixed
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 239000002131 composite material Substances 0.000 claims abstract description 37
- 230000004888 barrier function Effects 0.000 claims abstract description 18
- 230000001681 protective effect Effects 0.000 claims abstract description 13
- 239000000463 material Substances 0.000 claims description 41
- 238000009413 insulation Methods 0.000 claims description 16
- 238000004891 communication Methods 0.000 claims description 7
- 239000011810 insulating material Substances 0.000 claims description 7
- 239000002184 metal Substances 0.000 claims description 6
- 239000004793 Polystyrene Substances 0.000 claims description 5
- 229920002223 polystyrene Polymers 0.000 claims description 5
- 229920002635 polyurethane Polymers 0.000 claims description 4
- 239000004814 polyurethane Substances 0.000 claims description 4
- 238000009429 electrical wiring Methods 0.000 abstract description 5
- 238000004519 manufacturing process Methods 0.000 abstract description 5
- 230000035515 penetration Effects 0.000 abstract description 3
- 238000010276 construction Methods 0.000 description 14
- 238000000034 method Methods 0.000 description 5
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 239000006260 foam Substances 0.000 description 4
- 238000009432 framing Methods 0.000 description 3
- 238000009434 installation Methods 0.000 description 3
- 239000002023 wood Substances 0.000 description 3
- 239000004567 concrete Substances 0.000 description 2
- 238000004026 adhesive bonding Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 230000001010 compromised effect Effects 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000006261 foam material Substances 0.000 description 1
- 230000002452 interceptive effect Effects 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 239000004616 structural foam Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
- E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
- E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
- E04C2/521—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits serving for locating conduits; for ventilating, heating or cooling
Abstract
A composite wall panel having continuous upper and lower hollow horizontal chases and spaced hollow vertical chases formed throughout the panel to permit passage of electrical wiring and the like. The chases have protective barriers to protect the wiring from penetration and damage due to mechanical fasteners used to manufacture the panel and to construct load bearing walls using a plurality of manufactured panels. Further, the panel has a continuous header to provide structural rigidity and to permit rapid manufacturing of the panel without the need to frame openings, such as doors and windows, at the time of manufacture. Openings are cut in the panels and finished after the walls are constructed.
Description
1 "CONTINUOUS STRUCTURAL WALL SYSTEM"
2
3 FIELD OF THE INVENTION
4 The present invention relates to composite wall systems for modular construction. More particularly the invention relates to formation of 6 chases for services, vertically and horizontally, within the structural elements of 7 the wall system.
Conventional wisdom in construction techniques has been to 11 remain with tried, tested and true materials and methodologies.
Accordingly, 12 conventional wall frame construction continues b utilize either 2' x 4" or 2" x 6"
13 construction in either a stick framing or a unit framing technique.
Additionally, 14 stressed-skin panels have been introduced in which two sheets of building material are sandwiched together about a foam core to provide insulation.
16 In stick frame construction, a wall is generally built in place, using a 17 framework of repeating, evenly spaced wall studs. At openings, such as windows 18 and doors, a custom framework is constructed, including a lintel over the 19 opening, to ensure structural integrity above and across any openings.
In unit framing construction, a wall structure, including lintels and 21 frames about predetermined openings, is built as a complete unit on a pre-22 constructed floor structure and the unit is then erected into place by standing it up 23 and fastening it, at a base, to the floor.
24 In stressed skin construction, individual panels are laid out at the construction site. The structure comprises an assembly of panels which can be 1 cut or stacked to whatever height is required. Typically, panels are available as 4' 2 x 8' or 3' x 8' panels. Most often, conventional construction utilizes panels in 4' 3 lengths by 8' heights. The panels are manufactured having a variety of 4 thicknesses of insulation core, depending upon the desired degree of insulation, creating panels that are the equivalent of conventional 2" x 4" or 2' x 6"
beam 6 lumber.
7 Using any of the aforementioned conventional techniques requires 8 skilled laborers, sophisticated equipment and considerable time to assemble and 9 erect a structure.
Modular systems exist which attempt to overcome the problems 11 related to conventional construction techniques. One such system is disclosed in 12 US Patent 4,068,434 to Day et al. which utilizes wall panels having inner and 13 outer skins or wood sheeting material adhesively bonded on opposite sides of a 14 core of rigid expanded foam material. An integral, horizontal beam having greater vertical height than width is adhesively bonded horizontally at the top of 16 the wall unit from one end of the wall to the other to provide structural rigidity. In 17 one alternate embodiment, Day provides a plurality of vertical wood furring strips 18 which are adhesively bonded to the inner facing of the wall unit for strengthening 19 the wall and to provide an air space between the wall and finishing panels.
Periodic notches are formed across the furring strips for passing wiring. In 21 essence, Day's wall panel utilizes a first structural wall panel, bonded together 22 with adhesives and having a second false wall forming an air gap and wiring 23 access. The structure of Day's panels requires that the wiring be installed before 24 the finishing, typically drywall or sheetrock, is applied. If wiring is not installed prior to installation, subsequent fishing of wiring through the sheeted panel is 1 unsupported and unguided either horizontally through notches between the 2 furring strips or vertically in the spaces created between the furring strips.
3 The use of adhesively assembled wall panels has not yet been 4 approved under many building codes. In Canada, Canada Mortgage and Housing Corporation (CMHC) negatively views the use of any laminates or adhesive 6 bonding that are exposed to the environment. Specifically, known disadvantages 7 of adhesive bonding include de-lamination of the bond when exposed to the 8 elements. It is uncertain how long the bond will hold and thus CMHC believes 9 that it is risky to use where structural integrity is required for an extended time.
US Patent 5,822,940 to Carlin et al. teaches a composite wall panel 11 having a polymer foam core, sandwiched by opposing wall surfaces and having 12 at least one light metal gauge hollow stud in the body of the wall, the foam 13 extending into the center of the stud to secure the stud to the body. No provision 14 is made in the panel for electrical services. Wiring can be passed through holes in the metal studs to extend vertically through the panel, however, the insulation 16 must be removed to permit wiring to extend horizontally through the panel.
Open 17 channels at the top and bottom of the wall panel are utilized for affixing the panel 18 to the floor and to the roof and as such are compromised by fasteners extending 19 through the channels making them incompatible with standard electrical wiring.
Armor jacketed cable that is impervious to fasteners is required, which adds to 21 the overall expense and man hours required.
22 US Patent 5,701,708 to Taraba et al. teaches a structural foam core 23 panel with a built-in header. While providing load carrying support above 24 openings formed in the panel, the header does not provide a passage for 1 electrical services and the like. Passages must be grooved in the insulation prior 2 to sheeting in order to pass wiring therethrough.
3 There is a demonstrated need to provide a modular wall system 4 having readily accessible conduits for providing services integrated within the structural elements of the wall, the services being protected from mechanical 6 fastening means extending into the structural elements during construction.
7 Further, the wall should be easily installed and affixed to adjacent walls, floors 8 and roof members so as to provide a system for construction that requires a 9 minimum of skill, time and equipment.
2 A composite panel incorporates a horizontally extending hollow load 3 bearing header having hollow studs spaced at intervals throughout the width of 4 the panel. The hollow header and hollow studs form horizontal and vertical chases for accommodating utilities such as wiring, cabling and conduit. Holes are 6 formed in the horizontal chase coincident with the vertical chases to permit 7 communication therebetween. The utilities are protected from damage as a result 8 of penetration by mechanical fasteners used to assemble the panels into wall 9 structures. Protective barrier members are positioned vtiithin the hollow chases, leaving a core open for the passage of the utilities. Further, the header provides 11 structural rigidity and enables one to provide door and window penetrations 12 substantially anywhere in the wall.
13 The panel is insulated between the spaced studs and has sheeting 14 material affixed on opposing sides. An external layer of sheeting material is affixed with mechanical fasteners to provide sufficient structural integrity to 16 withstand exposure to the elements. An interior layer of sheeting can be 17 mechanically fastened or can be affixed using adhesive.
18 Preferably, an inner surface of the interior layer of sheeting is 19 finished with a layer of finishing material such as drywall or paper which acts as an air barrier and an aesthetic finish.
21 Preferably, the base of the panel further comprises a second hollow 22 horizontal chase and the chase is similarly protected by protective barrier 23 members. More preferably, the second hollow chase is formed by a downward 24 facing U-shaped wall base fitting attached to a bottom of the panel which
Conventional wisdom in construction techniques has been to 11 remain with tried, tested and true materials and methodologies.
Accordingly, 12 conventional wall frame construction continues b utilize either 2' x 4" or 2" x 6"
13 construction in either a stick framing or a unit framing technique.
Additionally, 14 stressed-skin panels have been introduced in which two sheets of building material are sandwiched together about a foam core to provide insulation.
16 In stick frame construction, a wall is generally built in place, using a 17 framework of repeating, evenly spaced wall studs. At openings, such as windows 18 and doors, a custom framework is constructed, including a lintel over the 19 opening, to ensure structural integrity above and across any openings.
In unit framing construction, a wall structure, including lintels and 21 frames about predetermined openings, is built as a complete unit on a pre-22 constructed floor structure and the unit is then erected into place by standing it up 23 and fastening it, at a base, to the floor.
24 In stressed skin construction, individual panels are laid out at the construction site. The structure comprises an assembly of panels which can be 1 cut or stacked to whatever height is required. Typically, panels are available as 4' 2 x 8' or 3' x 8' panels. Most often, conventional construction utilizes panels in 4' 3 lengths by 8' heights. The panels are manufactured having a variety of 4 thicknesses of insulation core, depending upon the desired degree of insulation, creating panels that are the equivalent of conventional 2" x 4" or 2' x 6"
beam 6 lumber.
7 Using any of the aforementioned conventional techniques requires 8 skilled laborers, sophisticated equipment and considerable time to assemble and 9 erect a structure.
Modular systems exist which attempt to overcome the problems 11 related to conventional construction techniques. One such system is disclosed in 12 US Patent 4,068,434 to Day et al. which utilizes wall panels having inner and 13 outer skins or wood sheeting material adhesively bonded on opposite sides of a 14 core of rigid expanded foam material. An integral, horizontal beam having greater vertical height than width is adhesively bonded horizontally at the top of 16 the wall unit from one end of the wall to the other to provide structural rigidity. In 17 one alternate embodiment, Day provides a plurality of vertical wood furring strips 18 which are adhesively bonded to the inner facing of the wall unit for strengthening 19 the wall and to provide an air space between the wall and finishing panels.
Periodic notches are formed across the furring strips for passing wiring. In 21 essence, Day's wall panel utilizes a first structural wall panel, bonded together 22 with adhesives and having a second false wall forming an air gap and wiring 23 access. The structure of Day's panels requires that the wiring be installed before 24 the finishing, typically drywall or sheetrock, is applied. If wiring is not installed prior to installation, subsequent fishing of wiring through the sheeted panel is 1 unsupported and unguided either horizontally through notches between the 2 furring strips or vertically in the spaces created between the furring strips.
3 The use of adhesively assembled wall panels has not yet been 4 approved under many building codes. In Canada, Canada Mortgage and Housing Corporation (CMHC) negatively views the use of any laminates or adhesive 6 bonding that are exposed to the environment. Specifically, known disadvantages 7 of adhesive bonding include de-lamination of the bond when exposed to the 8 elements. It is uncertain how long the bond will hold and thus CMHC believes 9 that it is risky to use where structural integrity is required for an extended time.
US Patent 5,822,940 to Carlin et al. teaches a composite wall panel 11 having a polymer foam core, sandwiched by opposing wall surfaces and having 12 at least one light metal gauge hollow stud in the body of the wall, the foam 13 extending into the center of the stud to secure the stud to the body. No provision 14 is made in the panel for electrical services. Wiring can be passed through holes in the metal studs to extend vertically through the panel, however, the insulation 16 must be removed to permit wiring to extend horizontally through the panel.
Open 17 channels at the top and bottom of the wall panel are utilized for affixing the panel 18 to the floor and to the roof and as such are compromised by fasteners extending 19 through the channels making them incompatible with standard electrical wiring.
Armor jacketed cable that is impervious to fasteners is required, which adds to 21 the overall expense and man hours required.
22 US Patent 5,701,708 to Taraba et al. teaches a structural foam core 23 panel with a built-in header. While providing load carrying support above 24 openings formed in the panel, the header does not provide a passage for 1 electrical services and the like. Passages must be grooved in the insulation prior 2 to sheeting in order to pass wiring therethrough.
3 There is a demonstrated need to provide a modular wall system 4 having readily accessible conduits for providing services integrated within the structural elements of the wall, the services being protected from mechanical 6 fastening means extending into the structural elements during construction.
7 Further, the wall should be easily installed and affixed to adjacent walls, floors 8 and roof members so as to provide a system for construction that requires a 9 minimum of skill, time and equipment.
2 A composite panel incorporates a horizontally extending hollow load 3 bearing header having hollow studs spaced at intervals throughout the width of 4 the panel. The hollow header and hollow studs form horizontal and vertical chases for accommodating utilities such as wiring, cabling and conduit. Holes are 6 formed in the horizontal chase coincident with the vertical chases to permit 7 communication therebetween. The utilities are protected from damage as a result 8 of penetration by mechanical fasteners used to assemble the panels into wall 9 structures. Protective barrier members are positioned vtiithin the hollow chases, leaving a core open for the passage of the utilities. Further, the header provides 11 structural rigidity and enables one to provide door and window penetrations 12 substantially anywhere in the wall.
13 The panel is insulated between the spaced studs and has sheeting 14 material affixed on opposing sides. An external layer of sheeting material is affixed with mechanical fasteners to provide sufficient structural integrity to 16 withstand exposure to the elements. An interior layer of sheeting can be 17 mechanically fastened or can be affixed using adhesive.
18 Preferably, an inner surface of the interior layer of sheeting is 19 finished with a layer of finishing material such as drywall or paper which acts as an air barrier and an aesthetic finish.
21 Preferably, the base of the panel further comprises a second hollow 22 horizontal chase and the chase is similarly protected by protective barrier 23 members. More preferably, the second hollow chase is formed by a downward 24 facing U-shaped wall base fitting attached to a bottom of the panel which
5 1 cooperates with an upward facing U-shaped base plate which is adapted for 2 attachment to a floor structure.
3 Panels of the invention are used to form load bearing wall 4 structures. Particularly, panels are provided with nailing strips as a result of sheeting material extending beyond a width of the panel. The nailing strip can be
3 Panels of the invention are used to form load bearing wall 4 structures. Particularly, panels are provided with nailing strips as a result of sheeting material extending beyond a width of the panel. The nailing strip can be
6 removed from a first panel which is placed perpendicular to the nailing strip of a
7 second panel for forming a corner.
8 In the broadest aspect of the invention a composite wall panel
9 comprises: a base extending horizontally at a bottom of the panel and adapted for attachment to a floor structure; a continuous hollow header extending 11 horizontally at a top of the panel, the hollow header defining an upper horizontally 12 extending chase for passage of services therethrough; a plurality of vertically 13 extending, hollow studs spaced at intervals intermediate a length of the panel so 14 as to space the base from the header for forming a frame, the hollow studs defining a plurality of vertically extending chases for communication with the 16 upper horizontally extending chase; insulating material positioned intermediate 17 the spaced studs; and opposing layers of sheeting material affixed to opposing 18 surfaces of the frame, at least one of which is affixed to the studs using 19 mechanical fasteners, wherein the vertical studs are fitted with protective barrier members to prevent protrusion of the mechanical fasteners into the vertical 21 chase.
2 Figure 1 is a partially cutaway perspective view of a wall panel of the 3 present invention;
4 Figure 2 is a partial cross-sectional view of the wall panel illustrating a portion of the wall containing the upper chase and a portion of the panel containing the 6 lower chase according to Figure 1;
7 Figure 3 is a cross-sectional view of a base plate and a wall base fitting 8 according to Fig. 1;
9 Figure 4 is a cross-sectional view of a hollow stud according to Figure 1;
Figure 5 is a plan view of adjacent walls of the structure according to 11 Figure 5;
12 Figure 6 is a perspective view of a finished wall panel according to Figure 13 1;
14 Figure 7 is a partially cutaway perspective view of a corner of a structure constructed using wall panels of the present invention; and 16 Figure 8 is a perspective view of a structure according to Fig. 7 having roof 17 trusses secured to resist wind loading.
2 As shown in Figs. 1-3, a composite wall panel 1 is used to form at 3 least a portion of a substantially rectangular structural wall 2 having opposing 4 planar surfaces 3, 4, one of which may be exposed to the environment. The panel I comprises a hollow header 5 formed horizontally across a top 6 of the 6 panel 1 and a base 7 formed horizontally across a bottom 8 of the panel I
for 7 attaching to an existing floor structure (not shown). The hollow header 5 is 8 spaced from the base 6 by a plurality of hollow studs 9 positioned at intervals 9 intermediate a width "w" of the panel, forming a frame 10. Sheeting material 11 is affixed to the frame 10 on the opposing planer surfaces 3,4 for forming the panel 11 1. Once sheeted, the panel 1 has limited access therein for the installation of 12 utilities 12 such as wire, cabling and conduit. The hollow header 5 and studs 9 13 form vertical chases 'VC" and an upper horizontal chase "UC" which can 14 communicate with each other so as to enable ready installation of the utilities 12 throughout the panel 1. Optionally, a wall base fitting 13 in combination with a 16 complementary base plate 14, can used to form a hollow base 15 to be employed 17 as a second and lower horizontal chase "LC", at the bottom 8 of the panel, for 18 interconnection with the vertical chases "VC" in the studs 9.
19 When used to form an external wall 2 of a structure, at least an external planer surface 20 of the wall 2 is exposed to the environment and 21 therefore sheeting material 11 is affixed using mechanical fasteners 21, thus 22 ensuring long term integrity of the wall 2. Mechanical fasteners 21 are prevented 23 from interfering with utilities 12 which are routed through the hollow portions 22 of 24 each vertical chase 'VC" by a protective barrier member 23 positioned in each vertical chase 'VC" adjacent at least the external planar surface 20 of the wall 2.
1 In greater detail, as shown in Fig. 4, the studs 9 are hollow, creating 2 vertical chases "VC" to permit passing electrical wiring 12 and the like 3 therethrough. The studs 9 are typically rectangular having a width portion 4 narrower than a depth 31, the planar surfaces 3,4 of the wall 2 being attached to opposing narrower width portions 30 of the stud 9.
6 As shown in Fig. 1, openings 32 are drilled in the upper horizontal 7 chase "UC", coincident with hollow centers of the studs 9, when required to 8 permit communication between the vertical chase "VC" in the stud 9 and the 9 upper horizontal chase "UC" for running electrical wiring and the like.
Similarly, if a hollow lower horizontal chase "LC" is formed, communicating openings may be 11 drilled in the lower chase "LC" as well.
12 More particularly, the hollow studs 9 are formed of two vertically 13 extending shaped members 33,34 which interlock to define a hollow core 35 14 while providing structural rigidity. One form of shaped members 33,34 are cooperating shapes of the same profile which interlock when mated with mirrored 16 shaped members 33,34.
17 A protective barrier member 23 is positioned inside the hollow core 18 35 of each stud 9 adjacent at least one of the narrow width portions 30 of the stud 19 9 adjacent the planar surfaces 3,4. The protective barrier member 23 is a vertically extending length of material, preferably polystyrene insulation, which is 21 sized so as to fit the narrow width portion 30 of the stud 9 while leaving the 22 remainder of the core 35 open for passage of wiring and the like, as shown in Fig.
23 4. Placement of the barrier member 23 provides protection for services 12 24 passing through the stud 9 from the intrusive mechanical fasteners 21 used to attach sheeting material 11 and the like to the frame 10.
1 Having reference again to Figs. I and 2, the hollow header 5 is a 2 continuous hollow composite header formed atop the hollow studs 9 and 3 extending horizontally substantially the entire width w of the panel 1 to add 4 structural rigidity, load bearing capability, as well as providing the upper horizontal chase "UC" for accommodating electrical wiring and the like. The 6 continuous header 5 also permits panels 1 to be formed having a greater width 7 than height, allowing structures to be built using a minimum number of panels 1 8 and preferably built using a single panel I to form a wall 2. Openings 16 for 9 windows and doors can be formed in the panel 1 after manufacturing, as a result of the strength provided by the continuous header 5, thus allowing rapid and 11 efficient constructions of the panels I without the need to plan openings at the 12 time of manufacture. Preferably, a nailing strip 17 is added around the openings 13 16 to maintain the integrity of the wall panel I once the openings are cut.
More 14 preferably, the nailing strips 17 are formed of U-shaped cap material 73, described later.
16 As shown in Fig. 2, the header 5 is comprised of a bottom rail 40 17 and a top rail 41. The rails 40,41 are vertically spaced apart from one another in 18 parallel arrangement by horizontally extending and laterally opposing spacing 19 members 42,43 positioned therebetween, thus forming a rectangular hollow beam 44 having a hollow core 47. Preferably, the bottom and top rails 40,41 are 21 wood and the opposing spacing members 42,43 are sheeting material 11. More 22 preferably the spacing members 42,43 are offset inwardly so that a layer of 23 insulation 45, such as polystyrene or polyurethane, is affixed to outward facing 24 surfaces 46 of the opposing spacing members 42,43 for providing insulation about the hollow core 47 of the header 5. Holes 32, as shown in Fig. 1, are drilled võo=.- yxno -. _. -'ikkC P,.dirY.lb=b+sbx maR96m- xSiF*K; v, ,A1;Mtl~iYi.. v., qre ..s--yes..m...w. ,. .,.._,.,.. ..,..a:m.rvn...Nn.
,..smrmnvn.m.S.*mvasPCRmC *uvaavw.wc moo.. a.~...wm.=.,e..v.
1 in the bottom rail 41 of the header 5, coincident to the core 35 of the studs 9, 2 when required, to permit communication between the upper horizontal chase 3 "UC" in the header 5 and the vertical chases "VC" in the studs 9.
4 Having reference again to Figs. 1-3 and in another embodiment of the invention, the panel I has a hollow lower horizontal chase "LC" formed at the 6 bottom 8 of the panel 1. Best seen in Fig. 3, a downward facing U-shaped wall 7 base fitting 50 is attached to the bottom 8 of the panel 1 for forming the base 7 of 8 the panel 1. The panel 1 is supported on the existing floor (not shown) by placing 9 the U-shaped wall base fitting 50 over an upward facing U-shaped base plate 51, attached to a floor surface. The combined U-shaped wall base fitting 50 and U-11 shaped base plate 51 form the rectangular hollow lower horizontal chase "LC". At 12 least one vertical edge 52 of the lower horizontal chase "LC" is fitted with a 13 horizontally extending protective barrier member, preferably polystyrene or 14 polyurethane insulation, to protect the wiring and the like from damage caused by protruding mechanical fasteners used to affix sheeting to at least one of the 16 planar surfaces of the panel.
17 Preferably, the U-shaped base plate 51 and wall base fitting 50 are 18 made of metal.
19 The sheeting material 11 attached to opposing planar surfaces 3,4 of the frame 10 is typically available in 4' X 8" sheets and is fastened to the studs 21 9, using either mechanical fasteners 21, such as screws, or an adhesive. If the 22 surface 3,4 is to be exposed to the elements, such as an external wall surface 20, 23 the sheeting 11 is affixed using mechanical fasteners 21 and the studs 9 and 24 lower horizontal chase "LC" are appropriately fitted with protective barrier members 23, as previously described. The sheeting material 11 is attached to 1 extend vertically sufficient to cover the U shaped wall base fitting 50 at the 2 bottom 8 of the wall 2 and the header 5 at the top 6 of the wall 2. Further, as shown in 3 Figs.1,5 and 6, the external layer 20 of sheeting material 11 is permitted to extend 4 beyond the width w of the panel 1 creating a nailing strip 60 to facilitate assembly to an adjacent panel 1 a to create a corner 61 of a structure 62.
6 Rigid foam insulation 70, such as polystyrene or polyurethane insulation, is 7 sandwiched between the opposing layers 3,4 of sheeting material 11 and from the 8 header 5 to the lower horizontal chase "LC" to act as a vapor barrier. Poly-sheeting may 9 be added, where required by code, to further act as a vapor barrier. As shown in Fig. 5, at opposing ends 71,72 of the wall 2, a vertically extending U-shaped cap member 73 is 11 positioned about an end 74 of the insulation 70 to sandwich the insulation 70 between 12 the cap 73 and an adjacent stud 9.
13 As shown in Figs. 5 and 6, when two adjacent wall panels 1, 1 a are placed 14 perpendicular to one another to form a corner 61, the nailing strip (shown removed) of a first wall panel 1 a is removed. The remaining nailing strip 60 of a second wall panel 1 is 16 affixed to the U-shaped cap 73 of the adjacent first wall panel la using mechanical 17 fasteners 21 which penetrate the sheeting material 11 and the U-shaped cap 73 and 18 embed into the insulation 70 of the adjacent panel 1 a.
19 Preferably and having reference to Fig. 6, a layer of finishing material 80 such as drywall or paper, which acts as an air barrier and an aesthetic finishing, is 21 affixed to an inner surface 81 of an interior layer 82 of the sheeting material 11. The 22 finishing material 80 can be either mechanically fastened or can be adhesively bonded 23 or laminated to the interior layer 82 of 1 sheeting material 11 as the inter surface 81 of the wall panel 1 is not exposed to 2 the elements.
3 In a preferred embodiment of the invention, the sheeting material 11 4 is oriented strand board (OSB) and the finishing material 80 is drywall.
As shown in Fig. 7, an exterior load bearing wall 90 of a structure is 6 formed using a plurality of adjacent composite wall panels 1, 1 a of the present 7 invention. Linear sections of base plate 51, fitted with protective barrier members 8 23 are affixed to a floor surface 91, such as concrete, using mechanical fasteners 9 21. Panels Ma ..... of the present invention, having U-shaped wall base fittings 50 attached to a bottom 8 are affixed over the base plates 51, as previously 11 described, to form the exterior load bearing walls 90,90a of the structure.
Wiring 12 for electrical, communications and the like 12, as shown in Fig. 1, are run through 13 the upper and lower horizontal chases "UC" "LC" and holes 32 are drilled to 14 access the vertical chases "VC", as required, to permit customizing of the locations of outlets 100 along the wall 90. Openings 16 are cut through the 16 panels 1, below the header 5, to form windows and doors at desired locations 17 and are finished in a conventional manner. The remainder of the structure, such 18 as the roof, is completed using conventional construction techniques. A
finishing 19 is applied to the outer surface of the external layer 20 of sheeting material 11 as required. Such finishing may be a siding material, a concrete material, or another 21 suitable finishing chosen to meet or exceed local building codes.
22 Optionally, as shown in Fig. 8, for use in geographical areas that are 23 prone to hurricanes, the header 5 may be constructed using laminated beams, 24 such as beams formed of microlaminated material, in place of traditional wooden lumber and the roof trusses 101 may be joined to the header 5 using metal 1 fasteners 102 that securely attach the truss 101 to the header 5 to reduce the 2 danger of the roof structure lifting as a result of the high winds.
3 Preferably, the fastener 102 has a downward depending planar 4 surface 103 that is affixed to a vertical surface 104 of the header 5 and a cradle 105 which supports the truss 101 and can be affixed to the truss 101 on opposing 6 sides.
2 Figure 1 is a partially cutaway perspective view of a wall panel of the 3 present invention;
4 Figure 2 is a partial cross-sectional view of the wall panel illustrating a portion of the wall containing the upper chase and a portion of the panel containing the 6 lower chase according to Figure 1;
7 Figure 3 is a cross-sectional view of a base plate and a wall base fitting 8 according to Fig. 1;
9 Figure 4 is a cross-sectional view of a hollow stud according to Figure 1;
Figure 5 is a plan view of adjacent walls of the structure according to 11 Figure 5;
12 Figure 6 is a perspective view of a finished wall panel according to Figure 13 1;
14 Figure 7 is a partially cutaway perspective view of a corner of a structure constructed using wall panels of the present invention; and 16 Figure 8 is a perspective view of a structure according to Fig. 7 having roof 17 trusses secured to resist wind loading.
2 As shown in Figs. 1-3, a composite wall panel 1 is used to form at 3 least a portion of a substantially rectangular structural wall 2 having opposing 4 planar surfaces 3, 4, one of which may be exposed to the environment. The panel I comprises a hollow header 5 formed horizontally across a top 6 of the 6 panel 1 and a base 7 formed horizontally across a bottom 8 of the panel I
for 7 attaching to an existing floor structure (not shown). The hollow header 5 is 8 spaced from the base 6 by a plurality of hollow studs 9 positioned at intervals 9 intermediate a width "w" of the panel, forming a frame 10. Sheeting material 11 is affixed to the frame 10 on the opposing planer surfaces 3,4 for forming the panel 11 1. Once sheeted, the panel 1 has limited access therein for the installation of 12 utilities 12 such as wire, cabling and conduit. The hollow header 5 and studs 9 13 form vertical chases 'VC" and an upper horizontal chase "UC" which can 14 communicate with each other so as to enable ready installation of the utilities 12 throughout the panel 1. Optionally, a wall base fitting 13 in combination with a 16 complementary base plate 14, can used to form a hollow base 15 to be employed 17 as a second and lower horizontal chase "LC", at the bottom 8 of the panel, for 18 interconnection with the vertical chases "VC" in the studs 9.
19 When used to form an external wall 2 of a structure, at least an external planer surface 20 of the wall 2 is exposed to the environment and 21 therefore sheeting material 11 is affixed using mechanical fasteners 21, thus 22 ensuring long term integrity of the wall 2. Mechanical fasteners 21 are prevented 23 from interfering with utilities 12 which are routed through the hollow portions 22 of 24 each vertical chase 'VC" by a protective barrier member 23 positioned in each vertical chase 'VC" adjacent at least the external planar surface 20 of the wall 2.
1 In greater detail, as shown in Fig. 4, the studs 9 are hollow, creating 2 vertical chases "VC" to permit passing electrical wiring 12 and the like 3 therethrough. The studs 9 are typically rectangular having a width portion 4 narrower than a depth 31, the planar surfaces 3,4 of the wall 2 being attached to opposing narrower width portions 30 of the stud 9.
6 As shown in Fig. 1, openings 32 are drilled in the upper horizontal 7 chase "UC", coincident with hollow centers of the studs 9, when required to 8 permit communication between the vertical chase "VC" in the stud 9 and the 9 upper horizontal chase "UC" for running electrical wiring and the like.
Similarly, if a hollow lower horizontal chase "LC" is formed, communicating openings may be 11 drilled in the lower chase "LC" as well.
12 More particularly, the hollow studs 9 are formed of two vertically 13 extending shaped members 33,34 which interlock to define a hollow core 35 14 while providing structural rigidity. One form of shaped members 33,34 are cooperating shapes of the same profile which interlock when mated with mirrored 16 shaped members 33,34.
17 A protective barrier member 23 is positioned inside the hollow core 18 35 of each stud 9 adjacent at least one of the narrow width portions 30 of the stud 19 9 adjacent the planar surfaces 3,4. The protective barrier member 23 is a vertically extending length of material, preferably polystyrene insulation, which is 21 sized so as to fit the narrow width portion 30 of the stud 9 while leaving the 22 remainder of the core 35 open for passage of wiring and the like, as shown in Fig.
23 4. Placement of the barrier member 23 provides protection for services 12 24 passing through the stud 9 from the intrusive mechanical fasteners 21 used to attach sheeting material 11 and the like to the frame 10.
1 Having reference again to Figs. I and 2, the hollow header 5 is a 2 continuous hollow composite header formed atop the hollow studs 9 and 3 extending horizontally substantially the entire width w of the panel 1 to add 4 structural rigidity, load bearing capability, as well as providing the upper horizontal chase "UC" for accommodating electrical wiring and the like. The 6 continuous header 5 also permits panels 1 to be formed having a greater width 7 than height, allowing structures to be built using a minimum number of panels 1 8 and preferably built using a single panel I to form a wall 2. Openings 16 for 9 windows and doors can be formed in the panel 1 after manufacturing, as a result of the strength provided by the continuous header 5, thus allowing rapid and 11 efficient constructions of the panels I without the need to plan openings at the 12 time of manufacture. Preferably, a nailing strip 17 is added around the openings 13 16 to maintain the integrity of the wall panel I once the openings are cut.
More 14 preferably, the nailing strips 17 are formed of U-shaped cap material 73, described later.
16 As shown in Fig. 2, the header 5 is comprised of a bottom rail 40 17 and a top rail 41. The rails 40,41 are vertically spaced apart from one another in 18 parallel arrangement by horizontally extending and laterally opposing spacing 19 members 42,43 positioned therebetween, thus forming a rectangular hollow beam 44 having a hollow core 47. Preferably, the bottom and top rails 40,41 are 21 wood and the opposing spacing members 42,43 are sheeting material 11. More 22 preferably the spacing members 42,43 are offset inwardly so that a layer of 23 insulation 45, such as polystyrene or polyurethane, is affixed to outward facing 24 surfaces 46 of the opposing spacing members 42,43 for providing insulation about the hollow core 47 of the header 5. Holes 32, as shown in Fig. 1, are drilled võo=.- yxno -. _. -'ikkC P,.dirY.lb=b+sbx maR96m- xSiF*K; v, ,A1;Mtl~iYi.. v., qre ..s--yes..m...w. ,. .,.._,.,.. ..,..a:m.rvn...Nn.
,..smrmnvn.m.S.*mvasPCRmC *uvaavw.wc moo.. a.~...wm.=.,e..v.
1 in the bottom rail 41 of the header 5, coincident to the core 35 of the studs 9, 2 when required, to permit communication between the upper horizontal chase 3 "UC" in the header 5 and the vertical chases "VC" in the studs 9.
4 Having reference again to Figs. 1-3 and in another embodiment of the invention, the panel I has a hollow lower horizontal chase "LC" formed at the 6 bottom 8 of the panel 1. Best seen in Fig. 3, a downward facing U-shaped wall 7 base fitting 50 is attached to the bottom 8 of the panel 1 for forming the base 7 of 8 the panel 1. The panel 1 is supported on the existing floor (not shown) by placing 9 the U-shaped wall base fitting 50 over an upward facing U-shaped base plate 51, attached to a floor surface. The combined U-shaped wall base fitting 50 and U-11 shaped base plate 51 form the rectangular hollow lower horizontal chase "LC". At 12 least one vertical edge 52 of the lower horizontal chase "LC" is fitted with a 13 horizontally extending protective barrier member, preferably polystyrene or 14 polyurethane insulation, to protect the wiring and the like from damage caused by protruding mechanical fasteners used to affix sheeting to at least one of the 16 planar surfaces of the panel.
17 Preferably, the U-shaped base plate 51 and wall base fitting 50 are 18 made of metal.
19 The sheeting material 11 attached to opposing planar surfaces 3,4 of the frame 10 is typically available in 4' X 8" sheets and is fastened to the studs 21 9, using either mechanical fasteners 21, such as screws, or an adhesive. If the 22 surface 3,4 is to be exposed to the elements, such as an external wall surface 20, 23 the sheeting 11 is affixed using mechanical fasteners 21 and the studs 9 and 24 lower horizontal chase "LC" are appropriately fitted with protective barrier members 23, as previously described. The sheeting material 11 is attached to 1 extend vertically sufficient to cover the U shaped wall base fitting 50 at the 2 bottom 8 of the wall 2 and the header 5 at the top 6 of the wall 2. Further, as shown in 3 Figs.1,5 and 6, the external layer 20 of sheeting material 11 is permitted to extend 4 beyond the width w of the panel 1 creating a nailing strip 60 to facilitate assembly to an adjacent panel 1 a to create a corner 61 of a structure 62.
6 Rigid foam insulation 70, such as polystyrene or polyurethane insulation, is 7 sandwiched between the opposing layers 3,4 of sheeting material 11 and from the 8 header 5 to the lower horizontal chase "LC" to act as a vapor barrier. Poly-sheeting may 9 be added, where required by code, to further act as a vapor barrier. As shown in Fig. 5, at opposing ends 71,72 of the wall 2, a vertically extending U-shaped cap member 73 is 11 positioned about an end 74 of the insulation 70 to sandwich the insulation 70 between 12 the cap 73 and an adjacent stud 9.
13 As shown in Figs. 5 and 6, when two adjacent wall panels 1, 1 a are placed 14 perpendicular to one another to form a corner 61, the nailing strip (shown removed) of a first wall panel 1 a is removed. The remaining nailing strip 60 of a second wall panel 1 is 16 affixed to the U-shaped cap 73 of the adjacent first wall panel la using mechanical 17 fasteners 21 which penetrate the sheeting material 11 and the U-shaped cap 73 and 18 embed into the insulation 70 of the adjacent panel 1 a.
19 Preferably and having reference to Fig. 6, a layer of finishing material 80 such as drywall or paper, which acts as an air barrier and an aesthetic finishing, is 21 affixed to an inner surface 81 of an interior layer 82 of the sheeting material 11. The 22 finishing material 80 can be either mechanically fastened or can be adhesively bonded 23 or laminated to the interior layer 82 of 1 sheeting material 11 as the inter surface 81 of the wall panel 1 is not exposed to 2 the elements.
3 In a preferred embodiment of the invention, the sheeting material 11 4 is oriented strand board (OSB) and the finishing material 80 is drywall.
As shown in Fig. 7, an exterior load bearing wall 90 of a structure is 6 formed using a plurality of adjacent composite wall panels 1, 1 a of the present 7 invention. Linear sections of base plate 51, fitted with protective barrier members 8 23 are affixed to a floor surface 91, such as concrete, using mechanical fasteners 9 21. Panels Ma ..... of the present invention, having U-shaped wall base fittings 50 attached to a bottom 8 are affixed over the base plates 51, as previously 11 described, to form the exterior load bearing walls 90,90a of the structure.
Wiring 12 for electrical, communications and the like 12, as shown in Fig. 1, are run through 13 the upper and lower horizontal chases "UC" "LC" and holes 32 are drilled to 14 access the vertical chases "VC", as required, to permit customizing of the locations of outlets 100 along the wall 90. Openings 16 are cut through the 16 panels 1, below the header 5, to form windows and doors at desired locations 17 and are finished in a conventional manner. The remainder of the structure, such 18 as the roof, is completed using conventional construction techniques. A
finishing 19 is applied to the outer surface of the external layer 20 of sheeting material 11 as required. Such finishing may be a siding material, a concrete material, or another 21 suitable finishing chosen to meet or exceed local building codes.
22 Optionally, as shown in Fig. 8, for use in geographical areas that are 23 prone to hurricanes, the header 5 may be constructed using laminated beams, 24 such as beams formed of microlaminated material, in place of traditional wooden lumber and the roof trusses 101 may be joined to the header 5 using metal 1 fasteners 102 that securely attach the truss 101 to the header 5 to reduce the 2 danger of the roof structure lifting as a result of the high winds.
3 Preferably, the fastener 102 has a downward depending planar 4 surface 103 that is affixed to a vertical surface 104 of the header 5 and a cradle 105 which supports the truss 101 and can be affixed to the truss 101 on opposing 6 sides.
Claims (24)
EXCLUSIVE PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS
FOLLOWS:
1. A composite wall panel comprising:
a base extending horizontally at a bottom of the composite wall panel and adapted for attachment to a floor structure;
a continuous hollow header extending horizontally at a top of the panel, the hollow header defining an upper horizontally extending chase for passage of services therethrough;
a plurality of vertically extending, hollow studs spaced at intervals intermediate a length of the composite wall panel so as to space the base from the header for forming a frame, the hollow studs defining a plurality of vertically extending chases for communication with the upper horizontally extending chase;
insulating material positioned intermediate the spaced studs; and opposing layers of sheeting material affixed to opposing surfaces of the frame, at least one of which is affixed to the studs using mechanical fasteners, wherein the vertically extending studs are fitted with protective barrier members to prevent protrusion of the mechanical fasteners into the vertically extending chase.
a base extending horizontally at a bottom of the composite wall panel and adapted for attachment to a floor structure;
a continuous hollow header extending horizontally at a top of the panel, the hollow header defining an upper horizontally extending chase for passage of services therethrough;
a plurality of vertically extending, hollow studs spaced at intervals intermediate a length of the composite wall panel so as to space the base from the header for forming a frame, the hollow studs defining a plurality of vertically extending chases for communication with the upper horizontally extending chase;
insulating material positioned intermediate the spaced studs; and opposing layers of sheeting material affixed to opposing surfaces of the frame, at least one of which is affixed to the studs using mechanical fasteners, wherein the vertically extending studs are fitted with protective barrier members to prevent protrusion of the mechanical fasteners into the vertically extending chase.
2. The composite wall panel of claim 1 wherein the at least one opposing layer of sheeting material affixed to the frame using mechanical fasteners is an external layer of sheeting material and the vertical chases are fitted with the protective barrier members adjacent the external layer.
3. The composite wall panel of claim 1 wherein opposing layers of sheeting material are affixed to the frame using mechanical fasteners and the vertical chases are fitted with the protective barrier members adjacent each layer.
4. The composite wall panel of claim 1, 2 or 3 wherein the base is hollow, forming a lower horizontally extending chase for communication with the plurality of vertically extending chases.
5. The composite wall panel of claim 4 wherein the lower horizontally extending chase further comprises:
a downward facing U-shaped wall base fitting attached to a bottom of the frame adapted for fitting over a cooperating upward facing U-shaped base plate for forming a rectangular hollow chase.
a downward facing U-shaped wall base fitting attached to a bottom of the frame adapted for fitting over a cooperating upward facing U-shaped base plate for forming a rectangular hollow chase.
6. The composite wall panel of any one of claims 1 to 5 wherein the continuous hollow header further comprises continuous upper and lower rails held in parallel spaced relationship by horizontally extending and laterally opposing spacing members affixed therebetween forming a rectangular beam having a hollow core.
7. The composite wall panel of claim 6 wherein the opposing spacing members are oriented strand board.
8. The composite wall panel of claim 6 or 7 wherein the opposing spacing members further comprise a layer of rigid insulation affixed to outward facing surfaces of each of the opposing spacing members.
9. The composite wall panel of any one of claims 1 to 8 wherein the studs are metal.
10. The composite wall panel of claim 9 wherein the metal studs further comprise two vertically extending interlocking shaped members defining a hollow chase therebetween.
11.The composite wall panel of claim 1 wherein the sheeting material is oriented strand board.
12.The composite wall panel of any one of claims 1 to 11 wherein the insulating material is rigid.
13. The composite wall panel of claim 12 wherein the rigid insulating material is polystyrene insulation.
14. The composite wall panel of claim 12 wherein the rigid insulating material is polyurethane.
15.The composite wall panel of any one of claims 1 to 14 further comprising a layer of finishing material affixed to an inner surface of an interior layer of the sheeting material.
16. The composite wall panel of claim 15 wherein the layer of finishing material is drywall.
17. The composite wall panel of claim 16 wherein the drywall is mechanically affixed to the inner surface of the interior layer of the sheeting material.
18. The composite wall panel of claim 16 wherein the drywall is adhesively bonded to the inner surface of the interior layer of the sheeting material.
19. The composite wall panel of claim 15 wherein the layer of finishing material is paper adhesively bonded to the inner surface of the interior layer of the sheeting material.
20. A load bearing wall structure constructed using a plurality of composite wall panels as recited in any one of claims 1 to 19.
21. The load bearing wall structure of claim 20 wherein ends of each of the plurality of composite wall panels further comprise vertically extending U-shaped cap members positioned about ends of the insulating material so as to sandwich the insulating material between the U-shaped cap member and an adjacent stud.
22. The load bearing wall structure of claim 20 or 21 wherein an external layer of the sheeting material extends beyond a width of each of the plurality of composite wall panels for forming a nailing strip.
23. The load bearing wall structure of claim 22 further comprising:
at least first and second composite wall panels positioned perpendicular to one another for forming a corner wherein the nailing strip of the first composite wall panel is removed so that the nailing strip of the second composite wall panel can be affixed to an end of the first composite wall panel.
at least first and second composite wall panels positioned perpendicular to one another for forming a corner wherein the nailing strip of the first composite wall panel is removed so that the nailing strip of the second composite wall panel can be affixed to an end of the first composite wall panel.
24. The load bearing wall structure of any one of claims 20 to 23 wherein the base further comprises a downward facing U-shaped wall base fitting attached to the bottom of each of the plurality of composite wall panels for cooperating with an upward facing U-shaped base plate adapted to be attached to a floor structure.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/386,697 US6854230B2 (en) | 2003-03-13 | 2003-03-13 | Continuous structural wall system |
US10/386697 | 2003-03-13 |
Publications (2)
Publication Number | Publication Date |
---|---|
CA2459951A1 CA2459951A1 (en) | 2004-09-13 |
CA2459951C true CA2459951C (en) | 2011-06-21 |
Family
ID=32961729
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA2459951A Expired - Lifetime CA2459951C (en) | 2003-03-13 | 2004-03-05 | Continuous structural wall system |
Country Status (2)
Country | Link |
---|---|
US (2) | US6854230B2 (en) |
CA (1) | CA2459951C (en) |
Families Citing this family (50)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7254925B2 (en) * | 1999-02-09 | 2007-08-14 | Efficient Building Systems, L.L.C. | Insulated wall assembly |
JP4057411B2 (en) * | 2002-12-20 | 2008-03-05 | 積水化学工業株式会社 | Insulated wall structure |
US6854230B2 (en) * | 2003-03-13 | 2005-02-15 | Charles Starke | Continuous structural wall system |
US20050188632A1 (en) * | 2004-02-27 | 2005-09-01 | Mike Rosen | Modular core wall construction system |
EP1851396B1 (en) * | 2005-02-25 | 2016-05-04 | Nova Chemicals Inc. | Lightweight compositions |
AU2006216558B2 (en) * | 2005-02-25 | 2010-05-13 | Nova Chemicals, Inc. | Composite pre-formed building panels, a building and a framing stud |
US8752348B2 (en) * | 2005-02-25 | 2014-06-17 | Syntheon Inc. | Composite pre-formed construction articles |
CA2601642C (en) | 2005-03-22 | 2014-06-03 | Nova Chemicals Inc. | Lightweight concrete compositions |
US20070011972A1 (en) * | 2005-07-14 | 2007-01-18 | Black Hills Development Corp., Llc | Steel-frame construction systems and methods |
US8327592B2 (en) | 2005-08-05 | 2012-12-11 | Lafferty Iii George A | Structural reinforcing system components |
US7549263B1 (en) * | 2006-06-20 | 2009-06-23 | Sip Home Systems, Inc. | Structural insulated panel with hold down chase |
US7677009B2 (en) * | 2007-02-02 | 2010-03-16 | Nova Chemicals Inc. | Roof truss system |
PL1961534T3 (en) | 2007-02-26 | 2010-08-31 | Homag Holzbearbeitungssysteme Ag | Method for sticking edging material to lightweight building boards and lightweight building boards manufactured by this method |
DE502007001395D1 (en) * | 2007-02-26 | 2009-10-08 | Homag Holzbearbeitungssysteme | Method for adhering edge material to lightweight panels |
US7975448B2 (en) * | 2007-03-29 | 2011-07-12 | Chicago Metallic Corporation | Drywall channel with pre-punched locating tabs |
WO2009015228A1 (en) * | 2007-07-23 | 2009-01-29 | Sunrez Corporation | Sandwich panel end effectors |
US8048219B2 (en) | 2007-09-20 | 2011-11-01 | Nova Chemicals Inc. | Method of placing concrete |
US20090205277A1 (en) * | 2008-02-19 | 2009-08-20 | Gibson A David | Construction Panel System And Method Of Manufacture Thereof |
US20090229199A1 (en) * | 2008-03-10 | 2009-09-17 | Peapod Homes, Llc | Building structure with having spaces having improved temperature stability |
US8424835B2 (en) | 2008-04-03 | 2013-04-23 | Paladin Industrial, Llc | Method of supporting panel structures over concrete footings utilizing tie system for forming poured concrete walls |
US10533331B2 (en) | 2008-04-03 | 2020-01-14 | Paladin Industrial Llc | Concrete wall forming system and method thereof |
US9260874B2 (en) | 2008-04-03 | 2016-02-16 | Paladin Industrial, Llc | Wall forming system and method thereof |
US20100107539A1 (en) * | 2008-11-05 | 2010-05-06 | Martens Clark M | Insulating wall panel apparatuses, systems, and methods |
CN102301077B (en) * | 2008-12-19 | 2014-08-20 | 蓝野钢铁有限公司 | Fixing System And Method |
GB2459358B (en) * | 2009-04-09 | 2010-06-02 | Beattie Passive Build System Ltd | Building and method of constructing a building |
US20100325999A1 (en) * | 2009-06-29 | 2010-12-30 | Ravi K Devalapura | Continuous Insulation Envelope For A Building |
US8590262B1 (en) * | 2009-08-14 | 2013-11-26 | EnergySmart Building Method, LLC | Energy efficient building construction |
US8650832B2 (en) * | 2010-03-24 | 2014-02-18 | Joachim Fiedrich | In-wall hydronic thermal control system and installation method |
US8898997B2 (en) | 2010-03-24 | 2014-12-02 | Joachim Fiedrich | In-wall hydronic thermal control system and installation method |
WO2012174377A1 (en) | 2011-06-17 | 2012-12-20 | Basf Se | High performance wall assembly |
CA2839425C (en) * | 2011-06-17 | 2019-10-15 | Basf Se | Prefabricated wall assembly having an outer foam layer |
US8789338B2 (en) * | 2011-10-03 | 2014-07-29 | Johns Manville | Methods and systems for sealing a wall |
US8875461B2 (en) * | 2012-03-09 | 2014-11-04 | Wesley F. Kestermont | Foundation wall system |
US8671636B2 (en) * | 2012-06-11 | 2014-03-18 | Walter Kim Bruner | Stud frame wall system |
US9702147B2 (en) * | 2013-01-07 | 2017-07-11 | Clifford Eugene Babson | Panels for framing and constructing a building structure |
GB2510620A (en) | 2013-02-11 | 2014-08-13 | Beattie Passive Build System Ltd | Method of retrospectively insulating existing exterior walls of a building |
CA2865118C (en) * | 2013-09-27 | 2022-12-06 | Bayer Materialscience Llc | Foam wall structure |
US10011989B2 (en) * | 2014-07-22 | 2018-07-03 | Wanessa Sue Pence | Composite building panel |
CA2973733C (en) | 2015-01-19 | 2023-07-25 | Basf Se | Wall assembly |
US10801197B2 (en) | 2015-01-19 | 2020-10-13 | Basf Se | Wall assembly having a spacer |
US9302709B1 (en) * | 2015-06-15 | 2016-04-05 | New England Wheels, Inc. | Lightweight modular structural panel |
ES2611806B1 (en) * | 2015-11-10 | 2017-11-17 | Sustainable Energy&Housing, S.L. | Enclosure for modular construction systems |
WO2019070485A1 (en) * | 2017-10-03 | 2019-04-11 | 500 Group, Inc. | Wheeled assembly for item transport |
US10801200B2 (en) * | 2017-11-29 | 2020-10-13 | Victor Figueroa | Covertec wall module building system and method |
CA3056094A1 (en) | 2018-09-21 | 2020-03-21 | Cooper E. Stewart | Insulating concrete form apparatus |
AU2020221056B2 (en) | 2019-02-14 | 2024-02-08 | Boxabl Inc | Foldable building structures with utility channels and laminate enclosures |
US11499306B2 (en) * | 2019-10-03 | 2022-11-15 | Thermacrete Llc | Differential settlement anchors |
MX2022004692A (en) | 2019-12-20 | 2022-05-10 | Knauf Gips Kg | Drywall and method for constructing a drywall. |
US11739547B2 (en) | 2021-01-12 | 2023-08-29 | Build Ip Llc | Stackable foldable transportable buildings |
US11718984B2 (en) | 2021-01-12 | 2023-08-08 | Build Ip Llc | Liftable foldable transportable buildings |
Family Cites Families (53)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3001615A (en) * | 1959-04-24 | 1961-09-26 | Wheeling Steel Corp | Studding |
US3217452A (en) * | 1961-06-28 | 1965-11-16 | Melvin A Steele | Wall and partition construction |
US3641720A (en) * | 1969-11-06 | 1972-02-15 | Omnico Systems Int | Prefabricated building construction with interfitting stud splines |
US3712004A (en) | 1970-10-12 | 1973-01-23 | V Loebsack | Building construction system |
GB1446205A (en) * | 1973-06-19 | 1976-08-18 | Bendow D | Article supporting panelling |
US3999343A (en) * | 1974-01-01 | 1976-12-28 | United States Gypsum Company | Partition and stud therefor |
USRE31733E (en) * | 1975-09-22 | 1984-11-13 | Haworth Mfg., Inc. | Wall panel with prewired power system |
US4060294A (en) * | 1975-09-22 | 1977-11-29 | Haworth Mfg., Inc. | Wall panel with prewired power system |
US4068434A (en) | 1976-04-05 | 1978-01-17 | Day Stephen W | Composite wall panel assembly and method of production |
US4163349A (en) * | 1977-05-26 | 1979-08-07 | Smith Glenn W | Insulated building panels |
US4330921A (en) | 1978-09-21 | 1982-05-25 | White Jr Olin N | Insulated wall sections and methods of and apparatus for prefabricating the same |
US4370838A (en) * | 1980-08-14 | 1983-02-01 | The Columbus Show Case Company | Curtain wall |
US4641468A (en) | 1982-11-16 | 1987-02-10 | Cano International, N.V. | Panel structure and building structure made therefrom |
US4578909A (en) | 1982-12-30 | 1986-04-01 | Enercept, Inc. | Insulated building construction |
US5124109A (en) * | 1984-07-18 | 1992-06-23 | Contech Construction Products Inc. | Method for producing a double wall pipe |
US4813193A (en) * | 1984-08-13 | 1989-03-21 | Altizer Wayne D | Modular building panel |
US4628650A (en) | 1985-09-09 | 1986-12-16 | Parker Bert A | Structural insulated panel system |
US4712352A (en) | 1985-12-04 | 1987-12-15 | Low R Glenn | Modular construction system |
US4674253A (en) | 1986-01-27 | 1987-06-23 | Young Lewis C P | Insulated construction panel and method |
US4716698A (en) * | 1986-06-06 | 1988-01-05 | Haworth, Inc. | Wall system with split pole for lay-in wiring |
US4765105A (en) | 1986-06-19 | 1988-08-23 | Seven S Structures Inc. | Wall panel with foam insulation |
US4841710A (en) | 1987-07-23 | 1989-06-27 | The Original Lincoln Logs Ltd. | Structural wall panel, method of manufacture and assembly system for a housing unit |
US4896469A (en) * | 1987-08-19 | 1990-01-30 | Wright John T | Prefabricated building panel assembly |
US5067296A (en) | 1989-07-10 | 1991-11-26 | Robert T. K. Brown | Modular insulated wall panel system |
US5060695A (en) * | 1990-04-02 | 1991-10-29 | Coltec Industries Inc | Bypass flow pressure regulator |
US5081810A (en) | 1990-06-11 | 1992-01-21 | Emmert Second Limited Partnership | Building panel |
US5127760A (en) * | 1990-07-26 | 1992-07-07 | Brady Todd A | Vertically slotted header |
US5072569A (en) | 1990-08-13 | 1991-12-17 | Vantassel James | Building panels and method thereof |
US5349796A (en) | 1991-12-20 | 1994-09-27 | Structural Panels, Inc. | Building panel and method |
US5279089A (en) | 1992-03-19 | 1994-01-18 | Gulur V Rao | Insulated wall system |
US6189269B1 (en) * | 1992-05-29 | 2001-02-20 | Royal Building Systems (Cdn) Limited | Thermoplastic wall forming member with wiring channel |
US5722198A (en) | 1993-02-03 | 1998-03-03 | Bader; Harold | Building wall assembly method |
US5497589A (en) | 1994-07-12 | 1996-03-12 | Porter; William H. | Structural insulated panels with metal edges |
US5628158A (en) | 1994-07-12 | 1997-05-13 | Porter; William H. | Structural insulated panels joined by insulated metal faced splines |
US5638651A (en) | 1994-08-25 | 1997-06-17 | Ford; Vern M. | Interlocking panel building system |
US5701708A (en) | 1996-04-09 | 1997-12-30 | Taraba; Emil M. | Structural foam core panels with built-in header |
US5787651A (en) * | 1996-05-02 | 1998-08-04 | Modern Materials, Inc. | Sound deadening wall assembly |
US5822940A (en) | 1996-07-17 | 1998-10-20 | Carlin; Steven | Composite wall panel |
US5787665A (en) | 1996-07-17 | 1998-08-04 | Carlin; Steven W. | Composite wall panel |
US6223485B1 (en) | 1996-06-07 | 2001-05-01 | Herman Miller, Inc. | Wall panel system |
CA2182242C (en) | 1996-07-29 | 1999-07-06 | Michel V. Richard | Pre-insulated prefab wall panel |
US5839249A (en) | 1996-10-16 | 1998-11-24 | Roberts; Scott J. | Foam block wall and fabrication method |
US5724779A (en) * | 1996-10-18 | 1998-03-10 | Chang; Ching-Chang | Partition wall unit |
US5906080A (en) * | 1997-05-15 | 1999-05-25 | Digirolamo; Edward R. | Bracket for interconnecting a building stud to primary structural components |
US5899037A (en) | 1997-07-29 | 1999-05-04 | Josey; Gary L. | Composite wall structure |
GB9725306D0 (en) * | 1997-11-28 | 1998-01-28 | Cableship Ltd | Cable management system |
US20020069600A1 (en) * | 1998-10-09 | 2002-06-13 | American Structural Composites, Inc. | Composite structural building panels and systems and method for erecting a structure using such panels |
US6195950B1 (en) | 1998-12-15 | 2001-03-06 | Edwin Randall Harris | Engineered structural modular units |
FR2831216B1 (en) * | 2001-10-24 | 2004-01-16 | Wecosta | THERMOFORMED INTAKE DUCT IN NON-WOVEN MATERIAL WITH DOUBLE BENDS |
US20030196401A1 (en) * | 2002-04-17 | 2003-10-23 | Matt Surowiecki | Wall construction |
DE10261334B4 (en) * | 2002-12-28 | 2010-04-15 | Tracto-Technik Gmbh | sewer pipe |
US6854230B2 (en) * | 2003-03-13 | 2005-02-15 | Charles Starke | Continuous structural wall system |
US7073302B2 (en) * | 2003-11-17 | 2006-07-11 | Strawmen L.P. | Wall and partition construction and method using hat-channel members |
-
2003
- 2003-03-13 US US10/386,697 patent/US6854230B2/en not_active Expired - Lifetime
-
2004
- 2004-03-05 CA CA2459951A patent/CA2459951C/en not_active Expired - Lifetime
-
2005
- 2005-02-04 US US10/906,159 patent/US7640700B2/en active Active
Also Published As
Publication number | Publication date |
---|---|
CA2459951A1 (en) | 2004-09-13 |
US20050138890A1 (en) | 2005-06-30 |
US7640700B2 (en) | 2010-01-05 |
US6854230B2 (en) | 2005-02-15 |
US20040177581A1 (en) | 2004-09-16 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CA2459951C (en) | Continuous structural wall system | |
US4671032A (en) | Thermally insulating structural panel with load-bearing skin | |
US8833023B2 (en) | Composite panel for a wall and method for making same | |
US5515659A (en) | Construction system using panelized insulation having integral structural frame | |
JP3761582B2 (en) | Structural foam core panel with built-in header | |
US7100342B2 (en) | Building panel | |
US5743056A (en) | Building panel and buildings made therefrom | |
US4435928A (en) | Low energy building | |
US20090300999A1 (en) | New type of building, method and means for erecting it | |
US20140090321A1 (en) | Modular building system utilizing composite, foam core panels | |
US20070125042A1 (en) | Structural insulated panel construction for building structures | |
CA1124482A (en) | Panel structure and building structures made therefrom | |
CA2383643A1 (en) | Laminated construction elements and method for constructing an earthquake-resistant building | |
CA3121067C (en) | Building construction system | |
WO2011033289A1 (en) | A building panel assembly | |
US20220090377A1 (en) | Wall assembly | |
ZA200505335B (en) | Mechanism for securing together building modules | |
CA2081651A1 (en) | Modular prefabricated building panels | |
US11840836B2 (en) | Structural wall panel system | |
GB2192916A (en) | Channel section joint | |
GB2318596A (en) | Insulated panel for use in wall, floor or roof structures | |
US3665664A (en) | Building panel and structure constructed therewith | |
US20240084593A1 (en) | Structual Wall Panel System | |
CA2093237A1 (en) | Panel building component | |
AU2023204018A1 (en) | Wall panel and panel system |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
EEER | Examination request |