BACKGROUND OF THE INVENTION
The present invention relates to complete Building Enclosure Systems which may be used for conditions such as building remodel and new construction to improve performances of the wall assembly including significantly increased speed of assembly of sheathing and weather barrier process which results in reduction of materials used including elimination of most mechanical fasteners, lighter weight, better thermal performance, and greatly increased weatherproofing of wall assemblies. Walls may also be prefabricated and have no weather-barrier penetrations through the integrated sheathing while having full adjustability to plane and level walls for stick-built applications for improved wall planarity. In both the prefabricated and stick-built environments there is potential for increased structural performance. Each of these improvements would be notable advancements in these fields.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present application, novel and useful Building Enclosure Systems is herein provided which includes new products and methods of manufacture, fabrication, assembly and installation. Included are new framing members which replaces traditional studs, new sheathing/sub-framing combinations to eliminate dis-similar sheathing and sub-framing materials which eliminates sheathing fasteners, and support features for interior and exterior insulation. The new structural sheathing product replaces traditional sheathing such as fiberglass-faced gypsum and all mechanical fasteners to install them, and at the same time replaces weather-proofing membranes such as peel-and-stick and/or fluid applied weather barriers by providing their combined attributes into a single structural sheathing product. A minimal amount of adhesive is used to eliminate almost all mechanical fasteners.
The new products and manufacturing processes include the use of Fiber Reinforced Polymer (FRP) products and processes to make the new structural framing, sub-framing and sheathing component. FRP will also be used to make the new combined sheathing and weather-proofing component. Fibers used in the FRP process may vary depending on project requirements to include fibers such as glass, Kevlar, basalt and carbon. Example, for thermal performance glass fibers may be used, but for ballistic performance Kevlar fibers may be used.
These new products' use of FRP's to create complete building framing and sheathing, as well as the elimination of most mechanical fasteners, will provide for extreme thermal efficiency which will translate to lower operating costs for the life of the building. The use of certain adhesives along with FRP's are also anticipated to help reduce vibration for better acoustic dampening/deadening performance. The FRP's may be made by a number of processes including use of pultrusion equipment, vacuum processes, open mold processes, blown and manual processes.
Metal backing supports will be used minimally for occasions when additional pull-out strength is needed such as for fastening cladding to the new FRP framing member. These metal supports may be made of a material such as galvanized steel which may be cut on a shear and bent on a brake press or made using a roll-forming process with punches for holes and shears to cut to length. These steel components may then be installed into the new framing member by means of sliding the steel into the FRP which will friction-fit into its final position when fully installed with or without adhesives used for additional holding strength.
The new FRP framing members may be used to provide water-proof walls, roofs, floors, soffits and other structural building conditions, sometimes assembled using traditional methods for some circumstances.
Rubber-like seals will be used as a continuous head track seal to not allow water to gain access between prefabricated wall sections mounted to a building in curtainwall fashion. This material will be made of a material such as extruded rubber silicone or neoprene. They will be shaped to partially or fully cover flanges, webs, insulation, and other seals, and may have insulation injected inside its hollow openings to better seal and insulate. This seal may be adhered, frictionally fit, and/or be mechanically fastened to other materials to positionally hold in in place until the wall panels are installed which will then permanently hold them in place. The seal may have one or more sides having an incline plane to shed water, to allow for a premium shape when axial, lateral or bend pressures are applied, and will help hold adjacently placed insulation in place, pinching it between the seal and another surface.
It may be apparent that novel and useful Building Enclosure Systems has been hereinabove described which will work and be used in a manner not consistent with conventional products and methods to provide considerable improvements in many facets of the manufacturing, assembly, installation, and overall performance of building Enclosure systems.
It is therefore an object of the present application to provide Building Enclosure Systems which are lighter, stronger, easier, and less expensive to manufacture compared to traditional practices, and which incorporate formed foam insulation or friction fitted rock mineral wool.
Another object to provide a single structural member which replaces traditional studs, sub-girt framing systems and sheathing fasteners and most of their associated installation labor.
Another object to provide a single sheathing component which replaces traditional sheathing and weatherproofing as well as most of their associated installation labor.
It's another object to provide head and sill tracks which incorporate the full or partial shape of commonly used metal flashings. Metal flashings such as those used for window openings and wall enclosures may be made much smaller and adhesively attached to parts of the head and sill tracks. By attaching these smaller adhesively applied metal flashings to the FRP head and sill tracks, the flashings will be much easier to keep a straight-looking appearance, whereas traditional flashings tend to bend with the installation of each mechanical fastener because they warp the flashings when torqued down.
It's another object to provide universal structural members with built-in cavities which allow sheathing, rubber gaskets, inside and outside structural FRP corners and other materials to be inserted into to provide a means to quickly and easily attach many different materials to each other without use of additional materials and labor.
It's an object of this application that all parts and components may be manufactured with additional holes, bends, knurling, and punching, as well as the addition of different or multiple adhesives for use in all locations for the purpose of structural, thermal, acoustic, weather-proofing and other improved performances, including the use of mechanical fasteners, built-in anti-rotation mechanisms and other features which don't depart from the spirit of this application.
It is another object to incorporate a new prefabricated wall panel to wall panel installation means when mounting fully assembled wall panels onto building super-structures.
Another object is to provide head and sill tracks which have built-in drainage, where exposed or required, at a minimum of 2% slope.
Another object is to provide sloped entrances for steel inserts to “snap” into position so that smaller segments may be used instead of full-length, or to simplify the installation process of the steel into the FRP, whether installed with or without adhesives.
Another object is to provide steel angles or other shapes which are snapped into the FRP which allows other sub-framing such as steel angles to be attached to increase the length of the sub-framing for aesthetic or planarity purposes.
Another object is to provide stackable wall, roof and floor sections which attach one to the next using male-female connections with or without adhesives, some of which may snap together, or be slid one onto another, be slid one into another, or a combination of them.
Another object is to provide stackable walls and roofs with exceptional axial loads by stacking FRP sideways, which is their strongest direction, one on top of the other so that together they support more weight than alone.
Another object is to provide stackable walls, roofs and floors which have no “stud” framing, where the stackable wall sections are one-piece with webbing in the middle to trap air to use the air as insulation.
Another object is to provide stackable walls, roofs and floors to provide a means for easy building of residential houses, in kits or normal construction.
Another object is to provide building enclosures sized and spaced accordingly to allow solar mounting sub-framing shapes, on either the stackable or non-stackable wall sections, to fit inside or outside of the frames of solar panels, where solar panel frames are made to match the male-female connections of the sub-framing portions of this invention.
Another object is to provide male-female, male-male, and female-female wall sections, framing members and sheathing so that any connection can be made, and any orientation or directionality of these male and female parts may be changed to suit building conditions.
Another object is to provide stackable wall sections and non-stackable elements of this invention to create flat surfaces with no attached or integrated sub-framing on the outside as a means to provide direct application of EIFS materials and finishes.
Another object is to provide stackable walls which have built-on interior and exterior sub-framing so that the webbed inner portion will not be penetrated by mechanical fasteners, and in that sub-framing holes are made to run conduits, conductors, pipes or anything else on both the interior and exterior of the building, and where the sub-framing is ready to mount drywall or any exterior cladding system with or without insulation both on the inside and outside of the stackable wall sections between the integrated sub-framing.
Another object is to provide multiple locations where the new sheathing and or strips of the new sheathing may be installed into the new structural framing in multiple locations in order to “box” the structural framing together to increase the rigidity between two studs or within a complete wall assembly. Reference the “H” slots on one end and in an intermediate location within the new structural framing member.
Another object is to provide a new structural framing member which uses segmented webs, whether “I-shaped”, “L” shaped, box-shaped, or other to reduce cost and weight.
Another object is to provide “snap-in” sub-framing to framing connections on both sides of the framing to increase structural composite loads, allow for easy dimensional changes, provide a means to connect two separate wall sections together by using sub-framing with snap-in attachments on two or more sides.
Another object is to provide inside and outside corner assemblies which are easy to install into flat wall assemblies.
Another object is to provide replacement systems for buildings being remodeled with new attachments made directly to existing framing to replace traditional sheathing, weather barriers and sub-framing, providing a more weather-proof and thermally efficient building enclosure which eliminates most of the labor required.
Another object is to reduce the thickness and weight of walls by providing better structural performing shapes by directly unifying new “studs”, sub-framing, and an additional interior sub-framing into a single piece along with combined or separate sheathing components.
Another object is to provide sealed sections of walls using the better structural performing shapes mentioned in the prior sentence which are fully enclosed with sealing top and bottom tracks, with the intention of eliminating insulation by trapping air within multiple cavities of the wall assembly.
Another object is to provide structural remodel components which may be used universally with existing studs of various materials such as wood, steel or FRP.
Another object is to provide various thicknesses of sheathing, whether in a unified structural assembly or separate to be used in a combined assembly, which are either solid, hollow, partially hollow, or filled with an insulating material.
Another object is to provide the potential to use more than one sheathing section per structural assembly or within a single unified structural component, such as one inside and one outside to increase structural strengths and to make airtight chambers for insulating using air.
Another object is to provide vibration reduction with the complete unified structural members and with the attachments to existing framing for remodel projects.
Another object is to provide a remodel (retrofit) combination system which uses unified sections of say 16″ or 24″ on centers which are interchangeable with separated/singular members in order to customize size requirements where needed.
Another object is to provide retrofit profiles which allow for adjustability on existing studs, having enough female depth to allow the profiles to be moved in or out to plane and level the wall by just using the profiles and not having to shim.
Another object is to provide the sheathing components with one or more male and/or female appendages which engage into one or more male and/or female appendages in the connecting profile to provide a friction fit and eliminate or minimize adhesives for sealing.
Another object is to provide a flashing type of material, such as painted aluminum sheet, which is formed to snugly and custom-fit over exposed portions of FRP to eliminate FRP's exposure to the sun to prevent degradation over time.
This invention possesses other objects or advantages especially as concerning characteristics and features thereof which will become apparent as the specification continues.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 34 shows an isometric plan section view of a retrofit sub-frame attached to a traditional steel stud with separate sheathings installed.
FIG. 35 shows a close-up of FIG. 4 showing anti-reversal teeth on all sides of the sheathing slot and adhesive channels.
FIG. 36 shows an isometric plan section view of another retrofit sub-frame attached to a different shaped steel stud.
FIG. 37 shows an isometric plan section view of a sub-frame having multiple sheathing attachments, fastened to a roll-formed I-beam shaped stud of this invention.
FIG. 38 shows an isometric plan section view of another sub-frame having sheathing slots on each side and a slide-over attachment to twin roll-formed I-beams of this invention.
FIG. 39 shows an isometric plan section view of another the sub-frame of FIG. 38 with only one of two of the formed I-beams of FIG. 38.
FIG. 40 shows an isometric plan section view of another sub-frame which fits over a triangular structural shape with one sheathing slot on each side.
FIG. 41 shows an isometric plan section view of another sub-frame which fits over a triangular-tee structural shape with two sheathing slots on each side.
FIG. 42 shows an isometric plan section view of another sub-frame which fits over a steel triangular structural shape with knockouts coming off each side in altering locations from a vertical flange which is clinched together in a structural pattern.
FIG. 43 shows an isometric plan section view of a custom triangular roll-formed shape with a rotate-to-fit sub-frame which first slips over the dual flanges on the right, then rotates counter-clockwise until positioned as shown to be fastened.
FIG. 44 shows an isometric plan section view of a complete structural shape which includes a single triangular shaped frame and F-shaped subframe having one sheathing slot on each side.
FIG. 45 shows an isometric plan section view of the structural shape of FIG. 44 which includes built-in sheathing on one side.
FIG. 46 shows an isometric plan section close-up view of the left side of the structural shape of FIG. 45.
FIG. 47 shows an isometric plan section view close-up view of the right side of the structural shape of FIG. 45.
FIG. 48 shows an isometric plan section view of the custom roll-formed shape of FIG. 43 having a sub-framing attachment which includes insulation and cladding mounting.
FIG. 49 shows an isometric plan section view of the system of FIG. 48 shown back-to-back to create a separated wall with or without an air gap between the roll-formed profiles.
FIG. 50 shows an isometric plan section view of two different retrofit sub-frames which can be used for wood, steel or other studs, and able to adjust away from the stud to plane and level walls independently of existing framing's orientation or shape (warped, bowed, etc.), and may be used to reduce vibration to existing framing.
FIG. 51 shows an isometric plan section view of another retrofit sub-frame on the outside of the wall, and another on the inside of the wall. The outside sub-frame (top) is a singular structural shape having the sheathing attached as a single piece. The inside (bottom) sub-frame helps prevent vibration from reaching the existing frame.
FIG. 52 shows an isometric plan section view of the top sub-frame of FIG. 51, but having male/female protrusions in the sheathing to interconnect with male/female protrusions in the sub-frame base.
FIG. 53 shows an isometric plan section view of another sub-frame over a roll-formed structural member from both sides.
FIG. 54 shows an isometric plan section view of a structural member with built-in sub-frames on each side.
FIG. 55 shows an isometric plan section view of a structural member with built-in sheathing slots.
FIG. 56 shows an isometric plan section view of the structural member of FIG. 55 with alternate built-in sub-framing on each side which allows for fastening other materials from the top or sides, as well as alternate built-in sheathing slots.
FIG. 57 shows an isometric elevation section view of the preferred system of the present invention showing the various components assembled.
FIG. 58 shows an isometric elevation view of the assembled components of FIG. 57 elongated and with insulation positioned between the components.
FIG. 59, starting from the bottom of the assembly of FIG. 58 and working the way up, shows an isometric elevation section view of the Starter sub-frame with an attached flashing over the lower portion of it, and having its male end inserted into the female end of the single-piece sub-frame/sheathing above it.
FIG. 60 shows an isometric elevation section view of the end (top) of the single-piece sub-frame/sheathing inserted into the female end of the single-piece sub-frame/sheathing above it.
FIG. 61 shows an isometric elevation section view of the end (top) of the single-piece sub-frame/sheathing inserted into the female end of a separated sub-frame which then has a separate sheathing component inserted into its top female slot.
FIG. 62, showing the top and end of the assembly of FIG. 58, shows an isometric elevation section view of the top of the separate sheathing of FIG. 61 inserted into the female slot of another separated sub-frame above it. A terminating piece above the separated sub-frame has a male appendage inserted into the top female slot of the separate sub-frame which provides a means to support insulation between the two members.
FIG. 63 shows an isometric elevation view and cross-sectional view of the preferred embodiment of horizontal and stackable wall sections which provide axial, bend, lateral and other strengths, where FRP products traditionally are not strong enough for significant axial loads.
FIG. 64 shows 3 variations of the preferred embodiment stackable wall sections with various webbing to be used for various strength requirements, as well as further trapping of air for insulation purposes with more webbing when the ends are sealed.
FIG. 65 shows a close-up of the top and bottom of one of the preferred embodiment stackable wall sections.
FIG. 66 shows a close-up of one of the preferred embodiment wall sections stacked on top of another in a manner to shed water and prevent water infiltration.
FIG. 67 shows a close-up of the attachment means between the stacked wall sections of FIG. 66 and how the wall sections snap together and are also adhesively affixed to each other.
FIG. 68 shows a slip-type of connection between stackable wall sections.
FIG. 69 shows a slide-into attachment means of a connecting frame to a female wall section end.
FIG. 70 shows a framing section with male attachments on both sides where one side, having dual air chambers within this male end, snaps into a female end of a wall section. The other male side of the framing section slides onto a female end of a wall section from the end as shown on the top example, or snaps-in straight as shown on the bottom example, where only one slide-in or snap-in means would be used, not both.
FIG. 71 shows a different stackable wall assembly system showing its installation sequence from one side to the other.
FIG. 72 shows an inside or outside corner structural member for vertically stacked wall sections. For horizontally stacked wall sections the male-female connection would be slip-fit with only small anti-reversal teeth, if any.
FIG. 73 shows stackable wall sections for vertical or horizontal walls for EIFS or stucco type of finishes to be applied on one or more sides. Where EIFS or stucco will only be applied to one side, the other side may have different types of sub-framing integrated for mounting, lifting, and supporting purposes as well as for running electrical and plumbing through around the inside of a building, in addition to mounting interior drywall to.
FIG. 74 shows an attachment means for direct installation of solar panels without any additional components, whether the wall sections are vertically or horizontally mounted. The solar mounting “T”, having a straight base with a perpendicular member at the end, may also have secondary “T's” or angles protruding off the ends of each side of the perpendicular member to better secure the solar panel to the attachment T.
DETAILED DESCRIPTION OF THE INVENTION
Various aspects of the present application will evolve from the following detailed description of the preferred system and embodiments thereof which should be taken in conjunction with the prior described drawings.
Embodiments and elements of the invention are identified by reference capital letter A followed by another capital letter to denote a variation of a component, if any. Assembled embodiments and elements are identified with a numeral 10.
FIG. 34 shows separate sheathing KK with hollows 293 and ribs 295 encased within the outer core (not numbered), with one end of sheathing KK inserted into sub-frame REA slots 298 on each side and are permanently fixed, in part, with adhesive 296. Pointing out only new material, sub-frame REA consists of segment 300 which rests against stud return 309. Segment 300 terminates perpendicularly to bottom 302 which terminates at an angle to segment 306 at bend 304. Fastener 310 is inserted through metal support 312 and through flange 316 and into steel stud 308. Arms 314 positionally fix metal support 312. End 318 extends away from flange 316 and stud 308. Sub-frame REA is installed by placing segment 306 over stud return 309 and then rotating it clockwise until end 318 slips over the other side of stud 308 and flange 316 is flush with stud 308.
FIG. 35 shows a close-up of FIG. 34 sub-frame REA having adhesive 296 fully within and pushed out of slot 298 and into channels 320 in outer core 24 and sub-frame REA. Slot 298 may be made smaller or larger at the end (not shown) to provide a location for adhesive 296 to be pushed.
FIG. 36 shows a different stud 322 having an additional small flange 309 and a perpendicular flange 324 to bottom 302.
FIG. 37 shows arms 324 and 326 creating slot 325 for sheathing KK (labeled on other side) to be inserted with adhesive attachment (not shown). Arms 326 and 330 provide slot 328 to fit over I-beam 342. Arms 334 and 338 create slot 336 for sheathing KK (labeled on other side) to be inserted into with adhesive attachment (not shown). Mechanical fasteners 341 are inserted into open areas including opening 332.
FIG. 38 shows back-to-back I-beams 344 inserted into sub-frame RED with fastener 341 through two flanges 340 and two I-beams 334.
FIG. 39 shows fastener 341 inserted through two flanges 340 and one I-beam 334.
FIG. 40 shows sub-frame REE with lower flanges 348 creating slots 346 for insertion of sheathing KK (shown both sides), and sub-frame REE attached to roll-formed shape (not numbered) with fasteners 341.
FIG. 41 shows sub-frame REF with additional flanges 354 creating slots 352 for mounting four sheathings KK. Top 356 encompasses roll-formed shape (not numbered) with adhesive 296 in all areas between sub-frame REE and roll-formed shape (not numbered).
FIG. 42 shows sub-framing REG inserted over roll-formed top of profile ZZ′ and its perpendicular flanges 360, with sub-framing REG having façade attachment assembly 358 extending beyond.
FIG. 43 shows sheathings KK inserted into slots (not numbered) of sub-frame REH having fastener 310 inserted though metal support 312 and flange 314 and into roll-formed shape ZZ. Roll-formed shape ZZ having top flange 368 extending at an angle to flange 372 at corner 370. Flange 372 extending at an angle to base 378 at final bend 374 which is facilitated by slots 376. Base 378 extends to flange 382 at bend 380 which extends to sharp bend 384 which then extends to flange bottom flange 364. Top flange 368 and bottom flange 364 are partially encased by sub-frame REH in slot 386 by leg 366 which is supported by end 362. Roll-formed shape ZZ is then clinched together at top flange 368 and bottom flange 364 to hold the shape permanently. Sub-frame REH installs onto roll-formed shape ZZ at the ends of top flange 368 and bottom flange 364 by inserting into slot 386 and then rotating sub-frame assembly REH counter-clockwise until flange 314 rests against flange 372 of roll-formed shape ZZ.
FIG. 44 shows full framing member REI as having keeper 386 which terminates perpendicularly to end 387 which then terminates perpendicular to top flange 388 which is parallel to keeper 386, which terminates at corner 390 and perpendicular to arm 392 which is parallel to end 387 and terminates at intersection 396. Intersection 396 extends to keeper 418 which is parallel to arm 392. Metal support 394 is held in place by keepers 387 and 418 against the inside of arm 392 and top flange 388. At intersection 396, upper slot arms 398 and 420 extend away from each other and are parallel to lower slot arms 404 and 405 which extend outwards opposite of each other and from triangle sides 408 and 409. Triangle sides 408 and 409 extend away from intersection 396 at angles away from each other substantially opposite the direction of metal support 394. Triangle sides 408 and 409 terminate to base 412 at corners 410 to form a complete triangular base section (not labeled).
FIG. 45 shows female slot 434 on the left terminating at intersection 436. Sheathing skins 424 extend out to the opposite side of intersection 436 to create attached sheathing member 428. Sheathing skins 436 are parallel to each other and have ribs 26 perpendicularly separating them to form hollows 422 between them. Ribs 432 are in end 430 to prevent teeth 435 of adjacent sub-frame REJ from backing out when inserted.
FIG. 46 shows a close-up of teeth 435.
FIG. 47 shows a close up of end 430 with ribs 432.
FIG. 48 shows sub-frame REK having insulation 444 inserted between slot arm 438 and support metal 440, and with extended arm 442 with no support metal 440.
FIG. 49 shows sub-framing REK assemblies with installed insulation (not numbered in this drawing) on one side, and sub-frame REK mounted to roll-formed shape ZZ and having sheathings KK mounted to each side. This described assembly is mirrored to the opposite direction to form a split wall assembly (not labeled).
FIG. 50 shows embodiment sub-frame REL mounted on one side of a stud (not labeled), and preferred embodiment sub-frame REM mounted to the opposite side of the same stud (not labeled).
FIG. 51 shows sub-frame with sheathing REN mounted to a steel stud and having a second end 315 inserted into its slot 317 to form a weatherproof wall assembly (not labeled). Sub-frame REN has base 311 which extends seamlessly to sheathing 313. Sub-frame REN is mounted to stud 318 by fastener 310 which in mounted through support metal 312 and flange 314 and ultimately into stud 318. Bent flanges 316 make it easy to install sub-frame REN over stud 318. Sub-frame REO contains stopper 448 to create a minimum and/or consistent distance to stud 318.
FIG. 52 shows sub-frame REP additionally having interlocking arms 448, 450, 452, 454, 456 and 458 which allows a certain amount of space (not shown) for differing distances between studs (not labeled) and to prevent the use of adhesives at this male/female connection by creating a circuitous path with enough friction (not shown) to prevent water infiltration.
FIG. 53 shows sub-frames REQ attached to roll-formed structural member ZZZ, wrapping each side 460 and base 461 with flanges 462, mechanically fastened (not shown).
FIG. 54 shows structural member RER with integrated sub-framings 463 and installed support metals 464 and having gap 466 between base 468. Intersection 474 extends in 4 directions with sides 470 to create triangle shapes on either side when terminating at bases 468. Each side of intersection 474 mirrors the opposite side.
FIG. 55 shows double inverted triangle structural shape RET as a single piece including built-in sheathing slots 476 on all sides formed inside of multiple flanges 475 and 478, multiple flanges 475 and 478 and built-in façade attachment angles (not labeled) coupled with the inverted triangles (not labeled) act together to increase bend strength (not shown) of the structural shape RET.
FIG. 56 shows preferred embodiment double inverted triangle structural shape REU as a single piece. Built-in attachment rectangles (not labeled) consist of top 480 and bottom 486 connected together by two sides 483 to form the rectangles and having metal support channel 482 installed inside attachment rectangles (not labeled). Gaps 484 is thereby formed inside of attachment rectangles (not labeled). On each end of double inverted triangles 496 attachment rectangles (not labeled) separated from each other by separators 492 which creates sheathing slots 488 on all 4 sides of double inverted triangle structural shape REU. Between separators 492, bottom 486 and Z-base 490 is box gap 494 formed between them. Box gap 494 may also be solid, not hollow. Triangle gaps 491 and gaps 484 may be filled with insulation for better thermal performance. Sides 483 may be cut into against the length of structural shape REU at bottom 486 and into sides 483 but below metal support channel 482 to provide installation of top and bottom tracks (not shown) to form air-tight wall assemblies when sheathing (not shown) are installed. Sheathing (not shown) may be cut to length and width to accommodate various distances between structural shapes REU.
FIG. 57 shows preferred embodiment assembly system XXX comprised of starter sub-frame REV at the bottom attached by male/female connection (not labeled) to field sub-frame sheathing REW above by male/female connection (not labeled), which attaches to another field sub-frame sheathing REW above by male/female connection (not labeled), which attaches to sub-frame REX above by male/female connection (not labeled), which attaches to preferred embodiment sheathing KK above by male/female connection, which attaches to another sub-frame REX above by male/female connection, which terminates into head sub-frame REY above by male/female connection. Insulation (not numbered) may be installed between all preferred sub-framings REV, REW, REX and REY with insulation (not numbered) installed outside of sub-frame sheathing REW and KK or inside of them between existing stud wall (not shown). All preferred embodiments of preferred embodiment assembly system XXX may be independently shimmed from each individual studs in the back-up wall assembly (not shown) to plane and level the complete outer wall. Assembly system XXX is installed in sequence from bottom to top (shown), top to bottom (shown), left to right (not shown), or right to left (not shown).
FIG. 58 shows preferred embodiment assembly system XXX with insulation installed (not numbered).
FIG. 59 shows starter sub-frame REV having male end 498 extending to small metal support mount 500 at base 502, and base 502 extending to substantially perpendicular angled extension 510 at corner 508. Parallel to base 502 and coming back in the same direction from corner 508 is large metal support 506. Slot (not numbered) between large metal support 506, base 502 and end 508 is serrated along the length of sub-frame REV to allow for easy installation of metal support 504. Large metal support 506 provides a flat surface (not numbered) to allow flashing 512 to be form-fitted and mounted flush with fastener 514. Field sub-frame sheathing REW consists of sheathing 518 extending to base 520 near protruded top metal support 522 and extending down to intersection 537. Extending substantially perpendicular to base 520 from intersection 537 is arm 538 which has fingers 536 substantially perpendicular to it extending off and terminating in both directions. Intersection 537 extends downwards parallel with base 52 to slot flanges 534 which create female slot 530 for inserted male end 498. All male/female connections are shaped to allow for easy insertion to each other (shapes shown but not labeled). Extending upwards and parallel with base 520 and from intersection 537 is bottom metal support holder 528. Arm 538 terminates perpendicularly into top 535 which is substantially perpendicular to base 520 at location of first metal support holder 533, top 535 terminates perpendicular to end 537 which then terminates perpendicular to second support metal holder 539. First metal support holder 533 and second metal support holder 539 keep metal support 540 fixed in place by friction and/or adhesives (not shown).
FIG. 60 shows preferred embodiment and bottom field sub-frame sheathing REW sheathing 518 terminating at male end 542 which inserted into preferred embodiment and top field sub-frame sheathing REW female slot 530 with or without adhesive (not shown) and with or without female teeth (not shown) to help prevent male end 542 from backing out and to help prevent water (not shown) from entering into female slot 530 when male end 542 is inserted.
FIG. 61 shows male end 542 of preferred embodiment field sub-frame sheathing REW inserted into bottom female slot 547 of preferred embodiment sub-frame REX at tapered slot walls 543 and 545. Sub-frame REX is almost identical in profile to sub-framing sheathing REW except that sub-frame REX replaces integrated sheathing with top female slot 544 which is comprised of tapered or rounded slot walls 546 and 548. First male end 549 of sheathing KK is inserted into top of sub-frame REX at slot 544 with adhesive (not shown). Sub-frame REX and sheathing KK may be used independently of all other sub-framing preferred embodiments, stand-alone for any application, and sub-frame REX may be used without sheathing KK stand-alone for any application.
FIG. 62 shows preferred embodiment sub-frame REX installed onto second male end 555 of sheathing KK at bottom female slot 547. Preferred embodiment head sub-frame REY is comprised of male end 554 inserted into top female slot 544 with adhesive (not shown) and terminating substantially perpendicular to arm 558 at tapered corner 556 which substantially matches the profile of top female slot 544 overall profile (shown but not labeled). Arm 558 terminates perpendicularly to end 562 and has protrusion 560 extending downwards and substantially perpendicular between end 562 and tapered corner 556.
FIG. 63 shows preferred embodiment assembly system YYY having 3 separate wall sections LEA stacked one on top of the next.
FIG. 64 shows preferred embodiments stackable wall sections LEA, LEB and LEC having different density and shaped web infills (not numbered or labeled).
FIG. 65 shows a close-up of the top and bottom of stackable wall section LEA, with the top of stackable wall section LEA having top 580 extending side to side to arms 576 which may have a light downturn (not shown) and which terminate perpendicularly to segment 578 which terminates perpendicularly to end 574 which terminates to beveled support metal holder 570. Top 580 also is also perpendicular to sides 586 and at an angle to web 584. Similarly, bottom 594 extends side to side to arms 587 which may have a slight turndown (not shown) and which terminate perpendicularly to segment 588 which terminates at end 592 which terminates into beveled end 590. Bottom 594 is also perpendicular to sides 585 and at an angle to web 584 which have extended down from top 580.
FIG. 66 shows that stackable wall section LEA is on bottom with stackable wall section LEB mounted above it. Between bottom 594 of stackable wall section LEB and top 580 of stackable wall section LEA is adhesive 596 and support metal 598, both on all sides of the “U” shaped connection.
FIG. 67 shows a close-up of one side of the connection between stackable wall sections LEA and LEB at the sub-framing portions of each (to be described here) to show how they inter-connect and inter-lock. With adhesive applied to the inside of the female attachment section (not labeled) of stackable wall section LEB, it is placed over the top of the male section (not labeled) of stackable wall section LEA. Beveled ends 590 are used as a ramp to slide over support metals 598, over beveled support metal holders 570. Pushing segments 588 outwards until beveled ends 590 pass beyond ends 570 of stackable wall section LEA and snap-fit behind it as shown.
FIG. 68 shows first stackable wall section LED slip-fit male end 602 into female end 600 of second stackable wall section LED.
FIG. 69 shows female attachment 606 of stackable wall section (not labeled) with slid-into male 604 of separate framing member LEE, separate framing member LEE having a female receptor 607.
FIG. 70 shows male attachment 609 of separate framing member LEF installed into female receptor 611 of stackable wall section (not labeled). Snap fit male 608 of female receptor 611 is positionally fixed in female receptor 610 of separate framing member LEF.
FIG. 71 shows embodiment assembly system VVV having ramped male stops 624 with matching female acceptors 612 for friction-fit and snap-fit connections. Bevel 614 allow for excess adhesives (not shown) a location to go to prevent hydro-locking (not shown) during installation (not shown). Sub-framing portions 616 have slots 618 in them and the matching support metals 620 for conduits, conductors, pipes and other materials to pass through (none shown) without being exposed at the drywall for interiors (not shown) or cladding for exteriors (not shown). Walls 622 are never fastened into using mechanical fasteners (not shown) because all mechanical fasteners will be used in sub-framing portions 616 only. Generally shown female end 630 of stackable wall section (not labeled) is snap-fit into generally shown female end 632. Formed adhesive gap 626 and sub-framing portion 628 of terminating framing member (not labeled) match assembly system VVV.
FIG. 72 shows preferred corner LEH having an integrated interior or exterior sub-framing portion 634, integrated webbing portion 636, integrated interior or exterior sub-framing 638, integrated slide-into attachment system 640 and integrated snap-into attachment system 642.
FIG. 73 shows preferred embodiment assembly system TTT having snap-fit attachments (not numbered) for all segments (not numbered or labeled) including beginning and ends (not numbered or labeled).
FIG. 74 generally shows framing and sub-framing assembly LEJ with solar panel SP attached. Solar panel SP has a custom frame 648 to fit custom sub-framing attachment 646. Fireproof insulation 645 is installed between structural framing flange 644 and dual female stackable wall section 647 and hardware struts (not shown here). Hardware struts (not shown) support in place and organize (not shown) conductors 643 and conduits (not shown) before and after passing through slots 650 in sub-framing attachment 646.
It should be considered that all configurations and/or portions of configurations, parts and pieces, shapes and/or other aspects of each drawing may be added to in whole or in part to any other drawing to create hybrid products and systems without departing from the intent and spirit of the current invention. All adhesives, components, parts and pieces are to be considered one or more in quantity, and all male-female connections may be made in any direction or configuration, have snap-in, lock-in or slip-fit connections of any architecture, not just what is shown in these drawing, without departing from the intent and spirit of this invention. Adhesives and mechanical fasteners may be included in any location, even if not explicitly shown on the drawings.
Patent Application
20250230666
