Patent Grant
11840836
The present invention relates generally to a structural wall panel system and, more particularly, to a structural wall panel system made up of fully- or partially-finished panel assemblies that are comprised of a core of filling material that is covered on at least one side with a cladding material (e.g. cement board, gypsum board, paper, foil, etc.), where structural members (e.g. lightweight galvanized steel members) are embedded within the core and spaced or gapped or “floated” away from at least one face of the core in order to form gaps that separate the cladding material from the structural members and reduce thermal conductivity through the panel assembly, and where the top and bottom ends of the structural members may be connectively accessible via parallel assembly slots that are formed in the gaps at the top and bottom ends of each panel assembly for structural connection to other system components.
There are generally two types of walls: (1) bearing walls; and (2) partitioning walls. A bearing wall carries the weight of building components pressing down on the wall from above, all the way down to the foundation. Such a wall is sometimes known as a “load-bearing” wall because the weight transferred down to the foundation is called the “load.” Other names for a bearing wall are a structural wall or supporting wall. The typical building components supported by a bearing wall include the roof and, if present, the floor and walls of an intervening story.
Exterior walls almost always function as bearing walls and interior walls sometimes function as bearing walls. In a multi-story building, the interior bearing walls are usually directly over one another on each floor because the weight is transferred straight down, through the bearing walls, from one level of the building to the next.
A partitioning wall is an interior wall that divides an interior space without bearing any significant load from above, i.e. without passing any substantial weight from other structure downward toward the foundation.
A structural wall panel system according to the present invention is a quick-to-assemble, cost-effective replacement for conventional wood framed construction, i.e. stud-framed walls which are made from vertical wood members called “studs” which are assembled with nails in a parallel spaced arrangement between horizontal wood members called top and bottom plates. Because they use many separate pieces of wood, stud-framed walls are sometimes called “stick walls.” The vertical studs are usually 2″×4″ in nominal size and are generally spaced from one another at an on-center spacing distance of 16″ or 24″. After the overall frame is constructed, it is clad with dry sheeting on both sides of the framing. The interior walls are often formed from a single layer of gypsum board. The exterior walls may be covered with a wide variety of materials, depending on climate and local practices, e.g. plywood, oriented strand board (OSB) sheathing, cement-board, etc., a vapor barrier, and decorative materials.
Light gauge steel construction is similar to wood framed construction in many respects, but instead of wooden framing members it uses thin steel sections that are usually sized to roughly correspond to conventional wood members. The thin steel sections are connected with self-tapping screws rather than nails. A building frame with light gauge steel members is similarly clad with drywall, plywood, etc.
The labor for wood frame construction or light gauge steel construction is relatively expensive because it requires significant skill and takes a relatively long time to assemble the framing, in the field, according to the designer's plans. In many cases, it would be better if the intended buildings could be designed in advance and then assembled with modular pre-assembled wall panels that already have one or both sides covered with the desired cladding material. However, many of the wall panel systems known to the inventor are intended for interior, non-supporting use (e.g. for use as the walls of trade show booths, or for interior office walls that have a non-structural interface with a suspended ceiling or drop ceiling), and generally do not provide a structural, load-bearing construction.
At the same time, the structural wall panel systems known to the inventor are heavy, overly complicated, require significant onsite labor to finish or are poorly insulated. For example, some systems use oriented strand board on both sides of each panel, making them quite heavy and still very labor intensive to add cladding, vapor barriers and other finishing works. Another system known to the inventor is marketed by Thermasteel. This system uses lightweight metal frames around the edges and across the faces on either side of an expanded polystyrene (EPS) core, somewhat like an exoskeleton, so the metal is exposed directly to the panel's exterior while still not addressing the application of interior and exterior surfaces.
A problem exists, therefore, in that the conventional framing techniques are costly and the panel systems known to the inventor are heavy, overly complicated, non-structural, with unfinished surfaces or poorly insulated. There remains a need, therefore, for a structural wall panel system comprised of improved wall panels where lightweight galvanized steel members are embedded within an insulating core, but connectively accessible via parallel assembly slots at the top and bottom ends of the wall panel for structural connection to other system components, and spaced from the inner and outer surfaces of the insulating core in order to allow the exterior and interior surface cladding material to be bonded to the insulating core delivering a finished structural wall panel that can be quickly assembled together while reducing thermal conductivity through the panel. The assembly slots at the top and bottom of the wall panel can also be opened perpendicular to or other orientation relative to the metal studs to allow for additional internal metal bracings (i.e. earthquake bracings) to connect with the metal studs and make a structural connection.
The present invention provides structures and methods which overcome the deficiencies in the prior art.
In a first aspect, the invention resides in a structural panel assembly of rectangular parallelepiped shape that is substantially taller and wider than thick, the structural panel assembly having a first broad side, a second broad side, a bottom end, a top end, a left end, and a right end, the structural panel assembly adapted for use in a structural panel building system, the structural panel assembly comprising: a substrate of sheet material forming the first broad side of the structural panel assembly, the substrate having an inner face and an outer face; at least one metal stud having an elongated configuration, the at least one metal stud extending between the bottom and top ends of the structural panel assembly, positioned in parallel with the substrate, and located adjacent to but spaced from the inner face of the substrate to form a gap between the inner face of the substrate and the at least one metal stud to prevent the inner surface of the substrate from making thermal contact with the at least one metal stud and thereby provide the structural panel assembly with increased thermal insulation capability; and a filling material, the at least one metal stud being embedded in the filling material, the filling material making contact with the inner face of the substrate and the at least one metal stud to hold together the substrate, the at least one metal stud, and the filling material.
In a preferred embodiment, the structural panel assembly comprises a plurality of shims that create the gap between the substrate and the at least one metal stud, the shims being positioned on the inner surface of the substrate, beneath the at least one metal stud.
And, in other embodiments, the structural panel assembly further comprises at least one bottom mounting slot formed in the gap between the substrate and the at least one metal stud at the bottom end of the structural panel assembly and at least one top mounting slot formed in the gap between the substrate and the at least one metal stud at the top end of the structural panel assembly, the bottom and top mounting slots exposing a bottom and top end, respectively, of the at least one metal stud for structural connection of the bottom and top ends of the structural panel assembly.
Preferably, there are a pair of mounting slots at the bottom and a pair of mounting slots at the top, and in such case, the structural panel assemblies further comprise a plurality of blind apertures formed in the first broad side and the second broad side of the structural panel assembly, near the top and bottom ends of the structural panel assembly, respectively, the blind holes adapted to permit mechanical fasteners to be inserted through the first and second extensions of the U-channel member and then into the opposite sides of the at least one metal stud to securely connect the first and second extensions of the U-channel member to the at least one metal stud.
The just summarized invention is best understood with referenced to the drawings of which:
Applicant's preferred embodiment is best understood by starting from a more distant view and then coming in closer to understand its details. In other words, start first with a view of the forest and then come closer and view the trees.
Wall Panel Assemblies Generally
As described below and shown throughout the figures, applicant's embodiments are centered around a unique wall panel assembly 10, or just wall panel, that generally comprises a substrate 60 (e.g. cement board, plank-style cement board, gypsum board, etc.), an insulated core 70 which is viscous until cured, provides glue-like properties during manufacture, and provides insulating properties when cured, and an optional second covering layer 160 (e.g. gypsum board, pre-textured panels, metal sheet, etc.) or other surface material (e.g. paper such as butcher paper, foil, rolled steel, etc.) which, if used, may be added during manufacture or later onsite. Moreover, at least two structural members 90 which are embedded in the core 70 and strategically gapped from the substrate 60, the optional second covering layer 160, or both.
Preferred Wall Panels—Cement Board Substrate with Gypsum Board
The substrate 60 defines an outer face 61 and the additional covering layer 160 defines an outer face 161. Generally speaking, if the substrate 60 is a cement board then the wall 10 would be installed with the substrate 60 facing the exterior, and if the substrate 60 were gypsum board then the wall 10 would be installed with the substrate 60 facing the interior (and with some other material, e.g. metal, facing the exterior). In
The preferred core 70 is formed from a thermally insulating material that when not yet cured has glue like characteristic to encase the structural members 90 and to bond the interior and exterior surface materials (e.g. substrate 60 and, if used, additional covering layer 160) to the core 70 which encases the structural members. The presently preferred core 70 comprises foamed polyurethane, but other insulating materials such as expanded polystyrene (EPS) or foamed polyisocyanurate (PIR) may be used.
The preferred wall panel 10 further comprises at least one structural load-bearing member 90 that is embedded within the core 70 during manufacture—typically metal studs. In this preferred panel 10, the two load-bearing members 90 comprise C-shaped studs formed from lightweight galvanized steel (LGS), sometimes called LGS studs. As shown by the broken lines, in addition to a C- or U- shaped profile, the metal stud 90 can have other suitable profiles such as an L-shaped, Sigma-shaped, or Z-shaped profile. There can also be a stud on each end and one in the center for a total of three or even four studs, along with horizontal connecting steel members that enhance the structural integrity of the vertical studs. Additionally, for stronger structural panels that resist lateral or shear movement, there can be horizontal or diagonal cross members offset from the surface as with the placement of the vertical studs. Similarly, for headers on top of doors and windows that require greater support, diagonal LGS members may be used between studs. Finally, for additional support for a second floor deck, a panel with an internal truss like cross member bracing design can be used.
The material used to form the core 70 has glue like characteristics to allow the surface cladding, including at least substrate 60, to securely bond to one or both surfaces of the core 70 during the manufacturing process. Referring again to
The structural member 90 is transversely oriented relative to the substrate 60, somewhat akin to the orientation of a wood or metal stud in a building frame. However, as best shown in cross-section in
In some sense, the studs 90 become floating studs relative to the substrate 60, the additional cladding layer 160, or both. The floating studs inside the wall allowing for the nearly complete bonding of the surface materials within the thermal gaps 91 which are created by placing a plurality of small spacers or shims 93 (see e.g.
As shown, the preferred method of connecting adjacent wall panels 10 to each other is based on the top and bottom U-channels 210, 310 discussed above and shown in
Further Developed System
Third Alternative Embodiment Suitable for Multi-Story Construction
The wall panel assemblies 10 discussed above include two structural members 90 (e.g. LGS studs) that are spaced from the left and right end of the wall panel assemblies. In other embodiments, however, the wall panel assemblies may be rigidified and strengthened from three LGS studs, i.e. with two at each end and with one located in the middle. The LGS studs at each end make the overall panel stronger and, because they are placed near to or even in contact with the LGS studs of adjacent wall panels when cam-locked together, effectively double up the thickness and strength of the support in that location. Such wall panel assemblies may be more suitable for multi-story constructions.
Moreover, the wall panel assemblies may be structurally reinforced between structural members with diagonal or horizontal members. The diagonal and horizontal reinforcement members embedded in the wall panels would ordinarily be hidden in the panels and not visible from the exterior. There are embodiments, however, where the studs and reinforcing members may be purposely exposed on an interior surface prior to an onsite application of gypsum board or other cladding material as discussed below.
Single Side Offset
The inventor understands that some municipalities or inspection officials may demand to see the studs prior to them being covered by a gypsum board cladding layer 160. With that possibility in mind,
Other Substrate Options and Opposed Surface Materials
The preferred wall panel assembly 10 is formed with a substrate 60 comprised of cement board and an opposite side cladding layer 160 comprised of gypsum board. However, as already noted, numerous other materials can be used. For example, the substrate 60 could be formed from flat cement board, plank-style cement board, gypsum board, etc. Usually, the substrate 60 would be relatively thick and rigid for manufacturing purposes, but in theory, the substrate could also be formed from thinner, less rigid surface material (e.g. paper, foil, rolled steal, etc.). In addition, the optional second cladding layer 160 could also be formed from gypsum board, pre-textured panels, metal sheet, etc.), or other thinner, less rigid surface material (e.g. paper, foil, rolled steel, etc.), or absent altogether such that the core 70 is exposed until it is covered on-site.
With this in mind,
Alternative Bottom U-Channel Member
Method of Manufacturer
The inventor contemplates two different methods of manufacturing structural panel assemblies and other related components.
Discontinuous Press Method
A simple production system is to have a large press cavity with four sides closed in which one or multiple substrates are placed (e.g. 4×8 cement board panels). It can vary, but a press arrangement contemplated of this nature could create one panel at a time, or it could use a vertically stacked arrangement or horizontally extended arrangement to process multiple panels at the same time. Then, LGS studs 90 are placed on top of the substrates while using thin spacers or shims that gap the LGS studs 90 slightly away from the substrates. The camlocks are placed at the ends of the panels, on the substrate, with a suitable attachment mechanism. Then polyurethane or other suitable filling material is applied through apertures in the side walls to reach the arrangement of substrates, shims, and LGS studs, the polyurethane making extensive contact with the substrates and capable of flowing around, between, under and over the LGS studs as it expands. Next, a top layer of just paper, or factory-installed gypsum board panels if desired, is placed prior to closing the top of the press for the required curing time. Then the press is opened and the panels are removed. An alternative version of the above processes can be to use gypsum board or other cladding material as the substrate (instead of the cement board) and to use coated steel instead of paper and/or gypsum board on the upper surface.
Continuous Press Method
The presently preferred method of manufacturing the wall panels 10 is a large continuous production system that is about 300 feet long. At the input end of the process, a succession of substrates (item 60 in the above figures) are laid onto a conveyor (e.g. 4×8 cement board panels). Next, LGS studs 90 are laid across each cement board panel 60, on top of thin spacers or shims that gap the LGS studs 90 slightly away from the cement board panel 60, and then the studs 90 are lightly secured to the cement board panel 60 with glue or short tack screws that do not exit the other side. Next, with the sides of the assembly constrained to prevent spreading, polyurethane is sprayed over the gypsum panel/LGB stud assemblies so that it begins to expand. Next, a 4×8 gypsum board is placed on top or a roll of paper or a steel coil is rolled out over the top, and then the CB panel/LGB stud assemblies are compressed between upper and lower tractor drives with a desired surface topography to cure. After a suitable curing time, the moving assemblies are cut by a cross-saw mechanism that advances with the assembly line during the cutting and then returns to a start position for the next cut. Finally, the cut panels 10 are stacked up, and workers use hand tools to manually cut in the U-channel grooves 22, 32 on the top and bottom edges of each panel to expose the LGS studs 90 for connection to other system elements. The cement boards or alternative face material can also be fed into the laminator with studs pre-attached to the cement board before feeding or even in a framed jig set to hold everything in desired place.
There are many possible assembly options. Two exemplary options are: (1) Cement Board exterior—On the bottom is the exterior cement board and on the top is the paper. The metal studs are attached to the bottom cement board on the continuous line. The paper covers the top as the polyurethane expands. Once the panel comes off the line, the interior drywall is screwed onto the paper side or installed on-site. (2) Steel exterior—On the bottom is the interior drywall (e.g. gypsum board) with the metal studs attached to it. In this case on top will be the steel that is rolled onto it.
This application claims the benefit of provisional patent application No. 62/878,934, filed Jul. 26, 2019, now pending, the entire contents of which are hereby incorporated by reference.
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