SYSTEM AND METHODS FOR EXTRUDED ALUMINUM WALL PANEL FRAMING

BACKGROUND
1. Field of the Invention

The field of the present invention generally relates to the efficient, light weight, high precision, and durable manufacture, assembly, and installation of a variety of styles of extruded aluminum wall panel framing for use in building construction as a componentized and panelized alternative to on-site construction and factory produced wood frames. This invention also generally relates to framing related primary structural components, such as studs, sole plates, sill plates, headers, windowsill, isolation strips, shear panels, and assembly fasteners such as screws, bolts, and nuts, that when used in combination provide a flexible, structurally stable, code compliant and compact alternative to existing wood frames.

This invention generally relates to the reduction in cost, build cycle, assembly, and damage of frames and framing components for use in building construction. This invention also generally relates to the improvement of material weights, precisions, accuracy, tolerances, straightness, jobsite worker productivity, and installation of drywall and exterior finishes related to frames, frame openings, and framing components for use in building construction.

This invention generally relates to the improvement of cabinet, countertop, window, and door installations that are better fit, faster, and more efficient when wall surfaces are uniform, flat, plumb and do not require onsite adjustments.

This invention generally relates to aluminum wall panel framing for use in building construction that remains dimensionally stable and retains its shape and structure under all normal conditions for the life of the structure. This invention also generally relates the ability for quality inspection and quality assurance take place on pre-fabricated factory panelized wall panels in a controlled environment where panel components may be inspected throughout a production process greatly reducing the possibility of site-built errors that are often not discovered until further into the construction process causing costly rework and schedule delays.

2. Description of Related Art

Existing methods and materials for manufacture, transport, and assembly of wood framing and frame components for use in building construction are conventional site-constructed stick frames built on site and factory produced engineered wood frames that have been used in residential and commercial construction projects. Single and multifamily residential and light commercial building construction in North America and other regions are predominately wood framing. Wood frame has been the industry standard for more than a century. Homebuilders currently face a shortage of framing labor with a trend in the market. Numerous alternatives to site constructed wood-framing have been made available to the marketplace over the last 25 years, including factory-built wood framing.

Homebuilders are seeking cost-effective alternatives to site-constructed wood framing as the present industry has capacity and affordability issues stemming in large part in having the lowest worker productivity of any major economic sector.

Another downside and increased cost of wood frame homebuilding is that wood tends to twist, shrink, and expand as moisture content changes leading to movement of the wood that often causes drywall and stucco to crack and fasteners to loosen and movement in a wood frame may also cause other finishes may be damaged or distorted and water intrusion may result likely requiring costly repairs.

Applicant(s) believe(s) that the material incorporated above is “non-essential” in accordance with 37 CFR 1.57, because it is referred to for purposes of indicating the background of the invention or illustrating the state of the art. However, if the Examiner believes that any of the above-incorporated material constitutes “essential material” within the meaning of 37 CFR 1.57(c)(1)-(3), Applicant(s) will amend the specification to expressly recite the essential material that is incorporated by reference as allowed by the applicable rules.

SUMMARY

The present invention provides among other things for the manufacturing, assembling, and installing an extruded aluminum wall panel frame by manufacturing an extrusion profile that comprises a stud, a sole plate, and a sill plate and other components used to configure the extrusion profile into a frame either fully or partially assembled prior to transport and installation at the building site where the frame may be installed as a single-level structure or multi-level structure of varying lengths, widths, and floorplans.

Implementation of the extruded aluminum wall panel framing system may comprise a floor slab, a substantially horizontal rail base, coupled to the floor slab, and a substantially vertical wall panel, coupled to the rail base.

Particular aspects of the extruded aluminum wall panel framing system may comprise a wall panel further comprising a substantially vertical first side, further comprising a first common stud, a substantially vertical second side, further comprising a second common stud, a substantially horizontal bottom side, further comprising a sole plate, and a substantially horizontal top side, further comprising a sill plate, wherein the first common stud is coupled to the sole plate and the sill plate and the second common stud is coupled to the sole plate and the sill plate and the first common stud, the second common stud, the sole plate, and the sill plate are configured as a substantially aluminum material.

Particular aspects of the extruded aluminum wall panel framing system may comprise an extruded aluminum wall panel framing system that is configured as a corner application further comprising a substantially vertical third side, further comprising a corner stud, wherein the first common stud is coupled to the corner stud, the sole plate, and the sill plate and the second common stud is coupled to the corner stud, the sole plate, and the sill plate.

Particular aspects of the extruded aluminum wall panel framing system may comprise an extruded aluminum wall panel framing system that is configured as an extension application comprising a first wall panel, comprising a first end and a second end, and a second wall panel, comprising a first end and a second end, wherein the first end of the first wall panel is coupled to the second end of the second wall panel by a fastener.

Particular aspects of the extruded aluminum wall panel framing system may comprise an extruded aluminum wall panel framing system that is configured as a multi-level application comprising a first wall panel, comprising a top side and a bottom side, and a second wall panel, comprising a top side and a bottom side, wherein the top side of the first wall panel is coupled to the bottom side of the second wall panel by a fastener.

Particular aspects of the extruded aluminum wall panel framing system may comprise a wall panel that further comprises an isolation strip coupled to the wall panel.

Particular aspects of the extruded aluminum wall panel framing system may comprise a wall panel further comprising a shear panel coupled to the wall panel.

Particular aspects of the extruded aluminum wall panel framing system may comprise a wall panel further configured with an opening that comprises a jack stud, a header coupled to the jack stud, and a windowsill coupled the jack stud.

Particular aspects of the extruded aluminum wall panel framing system may comprise a wall panel that is further configured with extra bracing where the extra bracing is selected from at least one of the following: a king stud, an upper cripple stud, and a lower cripple stud.

Particular aspects of the extruded aluminum wall panel framing system may comprise a wall panel that further comprises a substantially vertical third common stud located between the first common stud and the second common stud.

Particular aspects of the extruded aluminum wall panel framing system may further comprise a fastener wherein the fastener comprises a fastener configuration where the faster configuration is selected from at least one of the following: a screw, a self-drilling screw, a self-tapping screw, an anchor screw, a bolt, a sill bolt, a panel bolt, a nut, a panel nut bolt, and a combination of fastener configurations.

Particular aspects of the extruded aluminum wall panel framing system may comprise a wall panel that further comprises an isolation strip coupled to the wall panel and a shear panel coupled to the wall.

Implementations of the extruded aluminum wall panel framing system may comprise a floor slab, a substantially horizontal rail base, coupled to the floor slab by an anchor screw through a rail base anchor bolt hole, a substantially vertical wall panel coupled to the rail base and further comprising a substantially vertical first side, further comprising a first common stud, a substantially vertical second side, further comprising a second common stud, a substantially horizontal bottom side, further comprising a sole plate, and a substantially horizontal top side, further comprising a sill plate, an opening, further comprising a jack stud, a header coupled to the jack stud, a windowsill coupled to the jack stud, a king stud coupled to the jack stud, an upper cripple stud coupled to the jack stud, and a lower cripple stud coupled to the jack stud, wherein the first common stud is coupled to the sole plate and the sill plate and the second common stud is coupled to the sole plate and the sill plate, an isolation strip coupled to the wall panel, and a substantially vertical shear panel coupled to the wall panel.

Implementations of a method for manufacturing an extruded aluminum wall panel framing may comprise positioning a first common stud substantially vertical, positioning a second common stud substantially vertical, positioning a sole plate substantially horizontal, securing the first common stud to the sole plate, securing the second common stud to the sole plate, positioning a sill plate substantially horizontal, securing the first common stud to the sill plate, and securing the second common stud to the sill plate.

Particular aspects of the method for manufacturing an extruded aluminum wall panel framing of claim 13, further comprising optionally installing an isolation strip, a shear panel, an opening, an extra bracing, and a fastener.

Particular aspects of the method for manufacturing an extruded aluminum wall panel framing may comprise a wall panel that is further configured as a corner panel by dividing the wall panel into a first section and a second section, positioning a corner stud substantially vertical between the first section and the second section, positioning the first section of the wall panel substantially perpendicularly relative to the second section of the wall panel and securing the first section to the corner stud and the second section to the corner stud.

Particular aspects of the method for manufacturing an extruded aluminum wall panel framing may further comprise optionally securing the wall panel to a rail base.

Particular aspects of the method for manufacturing an extruded aluminum wall panel framing may comprise wherein the wall panel is further configured with an opening.

Particular aspects of the method for manufacturing an extruded aluminum wall panel framing may comprise wherein the wall panel is further configured with an extra bracing.

Particular aspects of the method for manufacturing an extruded aluminum wall panel framing may further comprise an isolation strip.

Particular aspects of the method for manufacturing an extruded aluminum wall panel framing may further comprise a shear panel.

Aspects and applications of the invention presented here are described below in the drawings and detailed description of the invention. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts. The inventor is fully aware that he can be his own lexicographer if desired. The inventor expressly elects, as his own lexicographers, to use only the plain and ordinary meaning of terms in the specification and claims unless he clearly states otherwise and then further, expressly sets forth the “special” definition of that term and explains how it differs from the plain and ordinary meaning. Absent such clear statements of intent to apply a “special” definition, it is the inventor's intent and desire that the simple, plain and ordinary meaning to the terms be applied to the interpretation of the specification and claims.

The inventor is also aware of the normal precepts of English grammar. Thus, if a noun, term, or phrase is intended to be further characterized, specified, or narrowed in some way, then such noun, term, or phrase will expressly include additional adjectives, descriptive terms, or other modifiers in accordance with the normal precepts of English grammar. Absent the use of such adjectives, descriptive terms, or modifiers, it is the intent that such nouns, terms, or phrases be given their plain, and ordinary English meaning to those skilled in the applicable arts as set forth above.

Further, the inventor is fully informed of the standards and application of the special provisions of 35 U.S.C. § 112(f). Thus, the use of the words “function,” “means” or “step” in the Detailed Description or Description of the Drawings or Claims is not intended to somehow indicate a desire to invoke the special provisions of 35 U.S.C. § 112(f), to define the invention. To the contrary, if the provisions of 35 U.S.C. § 112(f) are sought to be invoked to define the inventions, the claims will specifically and expressly state the exact phrases “means for” or “step for, and will also recite the word “function” (i.e., will state “means for performing the function of [insert function]”), without also reciting in such phrases any structure, material or act in support of the function. Thus, even when the claims recite a “means for performing the function of . . . ” or “step for performing the function of . . . ,” if the claims also recite any structure, material or acts in support of that means or step, or that perform the recited function, then it is the clear intention of the inventor not to invoke the provisions of 35 U.S.C. § 112(f). Moreover, even if the provisions of 35 U.S.C. § 112(f) are invoked to define the claimed inventions, it is intended that the inventions not be limited only to the specific structure, material or acts that are described in the preferred embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function as described in alternative embodiments or forms of the invention, or that are well known present or later-developed, equivalent structures, material or acts for performing the claimed function.

The foregoing and other aspects, features, and advantages will be apparent to those artisans of ordinary skill in the art from the DETAILED DESCRIPTION, DRAWINGS, and CLAIMS.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

A more complete understanding of the present invention may be derived by referring to the detailed description when considered in connection with the following illustrative figures. In the figures, like reference numbers refer to like elements or acts throughout the figures.

FIG. 1 representatively illustrates an embodiment of an extruded aluminum wall panel framing system configured as a first wall panel with a window and a second wall panel configured as a corner and is depicted as an exterior perspective view.

FIG. 2 representatively illustrates an embodiment of an extruded aluminum wall panel framing system configured as a first wall panel with a window and a second wall panel configured as a corner depicted as an exterior perspective view sectioned horizontally at mid-height with the upper section raised from the lower section and a space is shown at the joint between the corner and the window.

FIG. 3 representatively illustrates an embodiment of an extruded aluminum wall panel framing system configured as a first wall panel with a window and a second wall panel configured as a corner and is depicted as an interior perspective view sectioned horizontally at mid-height with the upper section raised from the lower section and a space shown at the joint between the corner and the window.

FIG. 4 representatively illustrates an embodiment of an extrusion profile configured as a stud profile configured with a stud-fin tab, a stud recess, and a stud profile screw slot and is depicted as end views and exploded perspective views.

FIG. 5 representatively illustrates an embodiment of an extrusion profile configured as a sole plate profile configured with a sole plate fin-tab and a sill plate profile configured with a sill plate recess and a sill plate screw slot and a rail base and is depicted as end views and exploded perspective views.

FIG. 6 representatively illustrates an embodiment of an extrusion profile configured as a corner stud profile and is depicted as an end view and a perspective view.

FIG. 7 representatively illustrates an embodiment of an extruded aluminum wall panel framing system where a sill plate is secured to a common stud by a fastener such as a self-tapping screw through a clearance hole in the sill plate and is depicted as a section of an exploded assembly view.

FIG. 8 representatively illustrates an embodiment of an extruded aluminum wall panel framing system where a first wall panel is secured to a second wall panel by a fastener such as a panel bolt and a panel nut and is depicted as a section of an exploded assembly view.

FIG. 9 representatively illustrates an embodiment of an extruded aluminum wall panel framing system where a wall panel is secured to a floor slab such as a concrete slab by a fastener such as an anchor screw and is depicted as a section of an exploded assembly view.

FIG. 10 representatively illustrates an embodiment of an extruded aluminum wall panel framing system with a first wall panel vertically secured on top of a second wall panel such as in a multi-level application by a fastener such a sill bolt and a sill nut and is depicted as a section of an exploded assembly view.

FIG. 11 depicts a general process diagram for assembly of a wall panel.

FIG. 12 depicts a general process diagram for assembling an opening in a wall panel including a wall panel with an opening and a corner panel with an opening.

FIG. 13 depicts a general process diagram for adding additional extra bracing for reinforcement and strength to a wall panel including a wall panel and a corner panel.

FIG. 14 depicts a general process diagram for an installed application such as securing a wall panel to a floor such as a concrete slab by a fastener such as an anchor screw.

FIG. 15 and FIG. 16 depict a general process diagram for assembling a corner application such as a corner panel.

FIG. 17 depicts a general process diagram for an extension application such as securing a first wall panel end to end with a second wall panel such as in an extension application by a fastener such a panel bolt and a panel bolt nut.

FIG. 18 depicts a general process diagram for a multi-level application such as securing a first wall panel vertically on top of a second wall panel such as in a multi-level application by a fastener such a sill bolt and a sill nut.

Elements and acts in the figures are illustrated for simplicity and have not necessarily been rendered according to any particular sequence or embodiment.

DETAILED DESCRIPTION

In the following description, and for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or discussed more generally in order to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention, particularly when the operation is to be implemented in software. It should be noted that there are many different and alternative configurations, devices and technologies to which the disclosed inventions may be applied. The full scope of the inventions is not limited to the examples that are described below.

In one application, extruded aluminum wall panel framing system may comprise a stud, a sole, and a sill. In one embodiment, an extruded aluminum wall panel framing system, may comprise an extrusion profile. In another embodiment, an extrusion profile may be configured as a stud profile 100, a corner stud profile 210, a sole plate profile 230, and a sill plate profile 270 as shown in FIG. 4, FIG. 5, and FIG. 6. In another embodiment, an extrusion profile may be configured as an aluminum extrusion. In another embodiment, an extrusion profile may be configured to form a framework with a substantially vertical stud on each side, a substantially horizontal base, and a substantially horizontal top that when assembled resembles the structural configuration of wood frame construction. In another embodiment, an extrusion profile may be configured with fin-tabs that are an extension of the plane of the two narrow ends of the extrusion and an opposing recess such that when two stud components are adjoined to each other the fin-tabs on one stud component interlocks with the recess on the other. In another embodiment, an extrusion profile may be configured as a material that is lighter than wood, a metal material such as aluminum, a wood material, a wood composite material, a plastic material, and a combination of materials. In one embodiment, an extrusion profile may be configured as varying in both size, shape, length, cross-section, shape of section such as extrusion profile such as rectangular shaped, and contour. The extrusion profile, may however be configured in any suitable manner to align, support, and transfer loading of framing components and to secure a component of the extruded aluminum wall panel framing system such as a stud, a sole plate, a sill plate, another extrusion, or other component of a frame to another component of the frame, and provide an alternative framing component to an existing wood-based frame component.

In one embodiment, a stud profile 100 may be configured as a common stud 140, a king stud 150, a jack stud 160, an upper cripple stud 170, and a lower cripple stud 180 as shown in FIG. 1 through FIG. 3 and FIG. 7 through FIG. 10. In another embodiment, a stud profile 100 may be optionally configured with a stud-fin tab 110, a stud recess 120, and a stud profile screw slot 130 as shown in FIG. 4. In one embodiment, a stud-fin tab 110 on a first stud profile 100 may be configured to mate with a stud recess 120 on a second stud profile 100 such as to provide two adjoining extruded aluminum wall panel framing systems a mating surface where a stud fin-tab 110 may interlock with the mating surface of a stud recess 120 facilitating alignment of the components and function to transfer loads. In embodiment, a stud profile screw slot 130 may be configured to mate with a sole plate profile 230 and a sill plate profile 270. In one embodiment, a stud profile 100 may be configured to interlock by a stud fin-tab 110 on a first side to a stud recess 120 on a second side of an adjacent configured stud profile 100 or corner stud profile 210 such as to facilitate alignment of the panels and function to transfer loads between panels. In another embodiment, a stud profile 100 may be configured as varying in both size, shape, length, cut, pre-cut, and cut to length. The stud profile 100, may however be configured in any suitable manner to interlock with another framing component, to fasten to another framing component, to align, support, and transfer loading of framing components, to secure a component of the extruded aluminum wall panel framing system such as a stud, a sole plate, a sill plate, another extrusion, or other component of a frame to another component of the frame and provide an alternative framing component to an existing wood-based frame component.

In one embodiment, a common stud 140 may be optionally configured with a hole such as a common a stud panel bolt hole. In another embodiment, a common stud 140 may be configured as varying in both size, shape, length, cut, cross-section, shape of section, and contour. The common stud 140, may however be configured in any suitable manner to provide a reinforcement, a bearing surface and load path a wall panel, corner panel, or opening such as a door or window and to provide support, sizing, structure, or an interface with other framing components such as for securing and supporting a sole, a sill, a header, a windowsill, an isolator strip, or a shear panel.

In one embodiment, a king stud 150 may be optionally configured with a hole such as a king stud panel bolt hole. In another embodiment, a king stud 150 may be configured as varying in both size, shape, length, cut, cross-section, shape of section, and contour. The king stud 150, may however be configured in any suitable manner to provide a reinforcement, a bearing surface and load path a wall panel, corner panel, or opening such as a door or window and to provide support, sizing, structure, or an interface with other framing components such as for securing and supporting a sole, a sill, a header, a windowsill, an isolator strip, or a shear panel.

In one embodiment, a jack stud 160 may be optionally configured with a hole such as a jack stud panel bolt hole. In another embodiment, a jack stud 160 may be optionally configured as varying in both size, shape, length, cut, cross-section, shape of section, and contour. The jack stud 160, may however be configured in any suitable manner to provide a bearing surface and load path for a window or door opening such as a header or a windowsill and to provide support, sizing, structure, or an interface with other framing components such as for securing and supporting a sole, a sill, a header, a windowsill, an isolator strip, or a shear panel.

In one embodiment, an upper cripple stud 170 may be optionally configured with a hole such as an upper cripple panel bolt hole. In another embodiment, an upper cripple stud 170 may be configured as varying in both size, shape, length, cut, cross-section, shape of section, and contour. The upper cripple stud 170, may however be configured in any suitable manner to provide support, sizing, structure, or an interface with other framing components such as for securing and supporting a sill or a header.

In one embodiment, a lower cripple stud 180 may be optionally configured with a hole such as a lower cripple panel bolt hole. In another embodiment, a lower cripple stud 180 may be optionally configured as varying in both size, shape, length, cut, cross-section, shape of section, and contour. The lower cripple stud 180, may however be configured in any suitable manner to provide support, sizing, structure, or an interface with other framing components such as for securing and supporting a sole or a windowsill.

In one embodiment, a corner stud profile 210 may be configured as a corner stud 220 as shown in FIG. 6. In another embodiment, a corner stud profile 210 may be optionally configured with a corner profile screw slot 215 as shown in FIG. 6. In one embodiment, a corner stud profile screw slot 215 may be configured to mate with a sole plate profile 230 and a sill plate profile 270. In one embodiment, a corner stud profile 210 may be configured to interlock by a stud fin-tab 110 on a first side to a stud recess 120 on a second side of an adjacent configured stud profile 100 or corner stud profile 210 such as to facilitate alignment of the panels and function to transfer loads between panels. In another embodiment, a corner stud profile 210 may be configured as varying in both size, shape, length, cut, pre-cut, and cut to length. The corner stud profile 210, may however be configured in any suitable manner to interface framing components at an angle relative to each other, interlock with another framing component, to fasten to another framing component, to align, support, and transfer loading of framing components, to secure a component of the extruded aluminum wall panel framing system such as a stud, a sole plate, a sill plate, another extrusion, or other component of a frame to another component of the frame and provide an alternative framing component to an existing wood-based frame component.

In one embodiment, a corner stud 220 may be configured as varying in both size, shape, length, cut, cross-section, shape of section, and contour. The corner stud 220, may however be configured in any suitable manner to provide support, sizing, structure, or an interface with other framing components such as for securing and supporting a sole or a sill.

In one embodiment, a sole plate profile 230 may be configured as a sole plate 240 as shown in FIG. 5. In another embodiment, a sole plate profile 230 may be optionally configured with a sole-fin tab 250. In another embodiment, a sole plate profile 230 may be configured as hollow and generally rectangular and extruded with at least one sole fin-tab that is an extension of the plane of the two narrow ends and protrude perpendicular from the bottom face of the extrusion such that when a wall panel is positioned on a rail base 330 for installation the fin-tabs extend over the inner and outer surfaces of the rail base 330 and center the panel on the rail base 330. In one embodiment, a sole plate fin tab 250 may be configured to extend downward outside each of the two opposing vertical faces of a mating sill plate recess 280. In another embodiment, sole plate profile 230 may be configured as varying in both size, shape, length, cut, pre-cut, and cut to length. The sole plate profile 230, may however be configured in any suitable manner to serve as a base for a wall panel or corner panel, to secure a wall panel to a base, to interlock to another sill plate profile from another wall panel, to fasten to another framing component, to align, support, and transfer loading of framing components, to secure a component of the extruded aluminum wall panel framing system such as a stud, a sole plate, a sill plate, another extrusion, or other component of a frame to another component of the frame and provide an alternative framing component to an existing wood-based frame component.

In one embodiment, a sole plate 240 may be optionally configured with a hole such as a clearance hole 285 such as a sole plate clearance hole and a bolt hole such as a sole plate anchor bolt hole 255, and a sole plate sill bolt hole 355 as shown in FIG. 9 and FIG. 10. In another embodiment, a sole plate 240 may be configured with a straight cut end such as to mate with another sole plate 240 end to end and an angled cut end such as to mate with another sole plate 240 in a corner as shown in FIG. 1 through FIG. 3. In another embodiment, a sole plate 240 may be configured as generally rectangular in cross section with the long dimension being equal to the wide dimension of a stud profile 100. In another embodiment, a sole plate 240 may be configured as a base for a wall panel where the sole plate 240 rests on a rail base 330 with a sole plate fin-tab 250 extending downward outside each of the two opposing vertical faces of the rail base 330 to correctly position and align the wall panel at the installation location such as a jobsite. In one embodiment, a sole plate anchor bolt 255 may be configured to locate the position of the placement of an anchor screw 380 to secure a wall panel to a floor as shown in FIG. 9. In one embodiment, a sole clearance hole may be configured to be aligned with a stud screw slot 130 and allow a fastener to pass through a surface on the sole plate 240. In one embodiment, a sole plate sill bolt 355 may be configured to locate the position of the placement of a first panel to a second panel as shown in FIG. 10. In another embodiment, a sole plate 240 may be configured as varying in both size, shape, length, cut, cross-section, shape of section, and contour. The sole plate 240, may however be configured in any suitable manner to manner to provide support, sizing, structure, or an interface with other framing components such as for securing and supporting a stud.

In one embodiment, a sill plate profile 270 may be configured as a sill plate 300, a header 310, and a windowsill 320 as shown in FIG. 1 through FIG. 3, FIG. 5, and FIG. 7 through FIG. 10. In another embodiment, a sill plate profile 270 may be optionally configured with a sill plate profile screw slot 290 as shown in FIG. 5. The sill plate profile 270, may however be configured in any suitable manner to serve as a top for a wall panel or corner panel, to interlock with a sole plate profile from another wall panel, to fasten to another framing component, to align, support, and transfer loading of framing components, to secure a component of the extruded aluminum wall panel framing system such as a stud, a sole plate, a sill plate, another extrusion, or other component of a frame to another component of the frame and provide an alternative framing component to an existing wood-based frame component.

In one embodiment, a sill plate 300 may be optionally configured with a hole such as a clearance hole 285 such as a sill plate clearance hole and a bolt hole such as a sill plate anchor bolt hole 395 as shown in FIG. 10. In another embodiment, a sill plate 300 may be configured as varying in both size, shape, length, cut, cross-section, shape of section, and contour. In another embodiment, a sill plate 300 may be configured with a straight cut end such as to mate with another sill plate 300 end to end and an angled cut end such as to mate with another sill plate 300 in a corner as shown in FIG. 1 through FIG. 3. The sill plate 300, may however be configured in any suitable manner to provide support, sizing, structure, or an interface with other framing components such as for securing and supporting a stud.

In one embodiment, a header 310 may be optionally configured with a hole such as a header clearance hole. In one embodiment, a header clearance hole may be configured to be aligned with a stud screw slot 130 and allow a fastener to pass through a surface on the header 310. In another embodiment, a header 310 may be configured as varying in both size, shape, length, cut, cross-section, shape of section, and contour. The header 310, may however be configured in any suitable manner to provide support, sizing, or structure for an opening and to provide an interface with other framing components such as for securing and supporting a stud.

In one embodiment, a windowsill 320 may be optionally configured with a hole such as a windowsill clearance hole. In one embodiment, a windowsill clearance hole may be configured to be aligned with a stud screw slot 130 and allow a fastener to pass through a surface on the windowsill 320. In another embodiment, a windowsill 320 may be configured as varying in both size, shape, length, cut, cross-section, shape of section such as extrusion profile, and contour. The windowsill 320, may however be configured in any suitable manner to provide support, sizing, or structure for an opening and to provide an interface with other framing components such as for securing and supporting a stud.

In one embodiment, an extruded aluminum wall panel framing system, may comprise a floor, a base, and a wall panel. In another embodiment, an extruded aluminum wall panel framing system, may comprise a floor, a base, a wall panel, and a fastener. In another embodiment, an extruded aluminum wall panel framing system, may be optionally configured with an internal drywall, an exterior finish, an insulation, a cladding, a barrier, and a weather resistant barrier.

In one embodiment, a floor, may be configured as a floor slab and a concrete floor such as a floor slab 430, a concrete floor, a concreate floor slab, a foundation, a foundation wall, a masonry wall, a recycled surface, a man made surface, a naturally occurring non-man made surface such as rock, sand, dirt, and gravel, a stationary floor, and a non-stationary floor, and another surface at the building site where the wall panels are to be installed as shown in FIG. 1 through FIG. 3 and FIG. 7 through FIG. 10. The floor, may however be configured in any suitable manner to provide a base, support, structure, or connection for an extruded aluminum wall panel framing system.

In one embodiment, a base may be configured as a rail base 330 as shown in FIG. 1 through FIG. 3, FIG. 8, and FIG. 9. In one embodiment, a rail base 330 may be optionally configured with a hole such as a rail base anchor bolt hole 910 shown in FIG. 10. In another embodiment, a rail base 330 may be configured as a non-metallic weatherproof material. In another embodiment, a rail base 330 may be configured as a plastic such as a polyvinyl chloride (PVC) material such as a rigid foam PVC material and a rigid foam high-density PVC material. In another embodiment, a rail base 330 may be configured as a material that is lighter than wood, a metal material such as aluminum, a wood material, a wood composite material, a plastic material, a concrete material, a stone material, a masonry material, and a combination of materials. In one embodiment, a rail base 330 may be configured as varying in both size, shape, length, cut, cross-section, shape of section, and contour. In another embodiment, a rail base 330 may be configured with a rectangular shaped cross section. In another embodiment, a rail base 330 may be configured to be fastened to the floor such as by a mechanically such as by a fastener, a bolt, and a screw. In another embodiment, a rail base 330 may be configured to be adhered to the floor such as by an adhesive. In another embodiment, a rail base 330 may be configured to provide a precise location for installation of a wall panel. In another embodiment, a rail base 330 may be configured to provide thermal insulation between a wall panel and a floor. In another embodiment, a rail base 330 may be configured to provide a space between a wall panel and a floor to limit corrosion of the wall panel. The rail base 330, may however be configured in any suitable manner to provide a surface to install a wall, to separate or isolate the wall panel from the floor, to limit corrosion on the wall panel, and to locate a wall panel in position relative to the floor.

In one embodiment, a wall panel may comprise a first vertical side, a second vertical side, a top, and a bottom. In another embodiment, the first vertical side may be configured as a common stud 100, the second vertical side may be configured as a common stud 100, a top may be configured as a sill plate 300, and a bottom may be configured as a sole plate 240 as shown in FIG. 1 through FIG. 2, and FIG. 7. In another embodiment, a wall panel may be optionally configured with an isolation strip 340. In another embodiment, a wall panel may be optionally configured with a shear panel 350. In another embodiment, a wall panel may be optionally configured with an inner stud. In another embodiment, a wall panel may be optionally configured with an opening. In another embodiment, a wall panel may be optionally configured with extra bracing. In yet another embodiment, a wall panel may be optionally configured with a fastener. In another embodiment, a wall panel may be configured with varying heights and widths such as to accommodate a wide variety of circumstances and conditions that match and comply with architectural building plans. In one embodiment, a wall panel, may comprise installed on floor such as a floor slab 340 as shown in FIG. 9. In one embodiment, a wall panel may be assembled in an orientation different than the final orientation of the wall panel and then positioned relative to the floor. The wall panel, may however be configured in any suitable manner to align, support, and transfer loading of framing components and to secure a component of the extruded aluminum wall panel framing system such as a stud, a sole plate, a sill plate, another extrusion, or other component of a frame to another component of the frame, and provide an alternative framing component to an existing wood-based frame component.

In one application, a wall panel may be assembled by positioning a first common stud with a first end and a second end substantially vertical 1105, positioning a second common stud with a first end and a second end substantially vertical 1110, positioning a sole plate with a first end and a second end substantially horizontal 1115, aligning the stud screw slots on the first end of the first common stud with the sole plate clearance holes on the first end of the sole plate and secure by a fastener 1120, aligning the stud screw slots on the first end of the second common stud with the sole plate clearance holes on the second end of the sole plate and secure by a fastener 1125, positioning a sill plate with a first end and a second end substantially horizontal 1130, aligning the stud screw slots on the second end of the first common stud with the sole plate clearance holes on the first end of the sill plate and secure by a fastener 1135, aligning the stud screw slots on the second end of the second common stud with the sill plate clearance holes the second end of the sill plate and secure by a fastener 1140, optionally install any additional isolation strips, shear panels, openings, bracing, or fasteners required 1145, and optionally install the wall panel on to a rail base and secure by a fastener 1150 as shown in FIG. 11.

In one embodiment, an isolation strip 340 may be configured as a non-metallic weatherproof material. In another embodiment, an isolation strip 340 may be configured as a plastic such as a polyvinyl chloride (PVC) material such as a rigid foam PVC material and a rigid foam high-density PVC material. In another embodiment, an isolation strip 340 may be configured a metal material, a fabric material wood material, a wood composite material, a plastic material, a recycled material, a man-made material, a naturally occurring non-man-made material, and a combination of materials. In one embodiment, an isolation strip 340 may be configured to be fastened to an extrusion profile by a fastener such as a self-drilling screw 360. In another embodiment, an isolation strip 340 may be configured to be positioned over the horizontal and vertical aluminum frame components such that the distance the aluminum frame from the exterior environment acting to provide a thermal break between the aluminum frame and the outside environment. In another embodiment, an isolation strip 340 may be configured allow an exterior finish to be installed outward from the exterior surface of the isolation strip 340 forming a cavity within the grid formed by the isolation strip 340 that may be filled with insulation. The isolation strip 340, may however be configured in any suitable manner to provide a distance between the frame and an outside environment, to provide a thermal break between the frame and an outside environment, to provide a space such as a cavity for installation of insulation, and to provide a surface for installation of an exterior finish.

In one embodiment, a shear panel 350 may be configured as a lightweight composite sheet material that covers the aluminum extrusion frame assembly of individual panels, top to bottom and side to side. In one embodiment, a shear panel 350 may be configured to be fastened to an extrusion profile by a fastener such as a self-drilling screw 360. In another embodiment, a shear panel 350 may be configured as a material that is lighter than wood, a metal material such as aluminum, a wood material, a wood composite material, a plastic material, and a combination of materials. In one embodiment, a shear panel 350 may be configured as varying in both size, shape, length, cut, cross-section, shape of section, and contour. The shear panel 350, may however be configured in any suitable manner to provides in-plane shear strength to each individual wall panel and to the final built structure.

In one embodiment, an isolation strip 340 may be configured to be fastened to the extrusion profile such as a common stud 100 by a fastener such as a self-drilling screw 360 that enters from the exterior side of the isolation strip 340 through the shear panel 350 and into the structural aluminum frame sandwiching the shear panel 350 between the isolation strip 340 and the extrusion profile securing both the isolation strip 340 and the shear panel 350 to the extrusion profile.

In one embodiment, an inner stud may be optionally configured with an inner stud configured as a common stud 140. In another embodiment, an inner stud may be optionally configured with one or more than one common stud 140 positioned at the side of each panel. In another embodiment, an inner stud may be optionally configured with one or more than one common stud 140 spaced on center increments such as spacing that meets common building materials and load requirements such as North America common building materials and load requirements such as placing a common stud 140 at standard increments every 16″ of wall panel, at standard increments every 24″ of wall panel and a other evenly spaced increments of wall panel. In another embodiment, an inner stud may be optionally configured with one or more than one common stud 140 spaced on center increments at less than about 16″, at about 16″, at less than about 24″, at about 24″ inches, and at more than 24″. In another embodiment, an inner stud may be optionally configured with one or more than one common stud 140 spaced on increments of one per wall panel, two per wall panel, and more than two per wall panel. In another embodiment, an inner stud may be optionally configured with one or more than one common stud 140 spaced at non-standard increments and at an uneven increment. In another embodiment, an inner stud may be optionally configured with one or more than one common stud 140 spaced on non-center increments. The inner stud, may however be configured in any suitable manner to provide compatibility with drywall and span requirements for siding, stucco, and other exterior finishes, to accommodate placement of openings such as window and door openings, and provide additional bracing as required for wall panel load bearing requirements.

In one embodiment, an opening may be configured as a door and a window. In one embodiment, an opening may comprise an opening side 1 configured as a jack stud 160, an opening side 2 configured as a jack stud 160, an opening top configured a header 310, and an opening bottom configured as a windowsill 320 as shown in FIG. 1 through FIG. 3. In another embodiment, an opening may be configured with a jack stud 160 installed next to an adjacent king stud 150, jack stud 160, or other configured stud profile 100 such as a common stud 140 or a corner stud 220. In another embodiment, an opening may be configured with jack studs 160 configured to provide a primary bearing surface or load path for the horizontal components of the opening such as the header 310 and the windowsill 320. In one embodiment, an opening, may be assembled in an orientation different than the final orientation of the wall panel and then positioned relative to the floor or another wall panel.

In one application, an opening may provide a configuration for a door or a window by positioning and fastening at least two jack studs, a header, and a windowsill in any order by positioning a first jack stud with a first and a second end substantially vertically on a first side of an opening 1210, positioning a second jack stud with a first and a second end substantially vertically on a second side of the opening 1220, positioning a header with a first and a second end substantially horizontal at the top of the opening 1230, aligning the stud screw slots on the first end of the first jack stud to the clearance holes on the first end of the header, aligning the stud screw slots on the first end of the second jack stud to the second end of the header, and securing the each jack stud to the header by a fastener 1240, positioning a windowsill with a first and a second end substantially horizontal at the bottom of the opening 1250, aligning the stud screw slots on the second end of the first jack stud to the clearance holes on the first end of the windowsill, aligning the stud screw slots on the second end of the second jack stud to the second end of the windowsill, and securing the each jack stud to the header by a fastener 1260, and optionally securing either jack stud to an adjacent king stud, jack stud, or other configured stud profile such as a common stud or a corner stud 1270 as shown in FIG. 12.

In one embodiment, an extra bracing be optionally configured extra bracing such as a king stud 150, an upper cripple stud 170, and a lower cripple stud 180 as shown in FIG. 1 through FIG. 3. In one embodiment, a king stud 150 may be installed near a jack stud 160. In another embodiment, a king stud 150 may be installed near another king stud 150. In one embodiment, an upper cripple stud 170 may be installed between a header 310 and below a sill plate 270. In one embodiment, a lower cripple stud 180 may be installed between a windowsill 320 and a sole plate 240. In another embodiment, an extra bracing may be installed on a wall panel, a wall panel with an opening, and a corner panel. The extra bracing, may however be configured in any suitable manner to reinforcement and strength to a wall panel, a wall panel with an opening, and a corner panel.

In one application, an extra bracing may provide additional reinforcement and strength for a wall panel and any associated openings by optionally securing a substantially vertical king stud adjacent to a jack stud on each side of the opening such as a door or window and arranged so that the stud fin-tab on the king stud engages with the stud recess on the jack stud 1310, optionally securing multiple substantially vertical king studs, adjacent to each other, arranged so that a stud fin-tab on each king stud engages with a stud recess on the next king stud 1320, optionally securing one or more substantially vertical upper cripple studs between a header and a sill plate 1330, and optionally securing one or more substantially vertical lower cripple studs between a sole plate and a windowsill 1340 as shown in FIG. 13.

In one embodiment, a fastener may comprise a screw, a bolt, and a nut. In one embodiment, a screw may be configured as a self-drilling screw 360, a self-tapping screw 370, and an anchor screw 380 as shown in FIG. 3, FIG. 7, FIG. 9, and FIG. 10. In one embodiment, a bolt may be configured as a sill bolt 390 and a panel bolt 410 as shown in FIG. 8. In one embodiment, a nut may be configured as a sill nut 400 and a panel bolt nut 420 as shown in FIG. 8. The fastener, may however be configured in any suitable manner to secure components within a wall panel or corner wall panel, to secure a wall panel or corner panel to a base or a floor, to secure a wall panel or corner panel to another wall panel or corner panel, and to provide support, structure, or an interface with other framing components such as for securing and supporting a sole, a sill, a header, a windowsill, an isolator strip, a shear panel, a base, or a floor.

In another embodiment, an extruded aluminum wall panel framing system, may be configured as an installed application such as installed on a floor, as a corner application such as a corner panel, an extension application, and a multi-level application.

In one embodiment, an installed application may be configured to be installed on the floor. In another embodiment, a wall panel, may be configured to be fastened to the floor such as by a mechanically such as by a fastener, a bolt, and a screw. In another embodiment, a wall panel, may be configured to be adhered to the floor such as by an adhesive. In another embodiment, a wall panel, may be configured to be installed on the floor by an anchor screw 380 as shown in FIG. 9. In another embodiment, a wall panel, may be configured to be installed on the floor by an anchor screw 380 through sole plate anchor bolt hole 255 and a rail base anchor bolt hole 910 as shown in FIG. 9.

In one application, an installed application may provide for an optionally configured wall panel such as a wall panel and a corner panel to be installed on a floor by positioning a rail base near a floor such as a floor slab 1410, optionally aligning a rail base anchor bolt hole in the rail base with a hole in the floor configured for an anchor screw 1420, positioning a wall panel near the rail base 1430, aligning a sole plate anchor bolt hole in the wall panel with the rail base anchor bolt hole in the rail base 1440, and securing the wall panel through the sole plate anchor bolt hole and the rail base anchor bolt hole to the floor by an anchor screw 1450 as shown in FIG. 14.

In one embodiment, a corner panel may comprise a first vertical side, a second vertical side, a top, a bottom, and a corner. In another embodiment, the first vertical side may be configured as a common stud 100, the second vertical side may be configured as a common stud 100, a top may be configured as a sill plate 300, a bottom may be configured as a sole plate 240, and a corner configured as a corner stud 220. In another embodiment, the first vertical side may be configured as a common stud 100, the second vertical side may be configured as a common stud 100, a top may be configured as a corner sill plate 300 and a cut to fit sill plate, a bottom may be configured as a corner sole plate 240 and a cut to fit sole plate, and a corner configured as a corner stud 220 as shown in FIG. 1 through FIG. 3. In another embodiment, a corner panel may be optionally configured with an isolation strip 340. In another embodiment, a corner panel may be optionally configured with a shear panel 350 and more than one shear panel 350. In another embodiment, a corner panel may be optionally configured with an inner stud. In another embodiment, a corner panel may be optionally configured with an opening. In another embodiment, a corner panel may be optionally configured with extra bracing. In yet another embodiment, a corner panel may be optionally configured with a fastener. In another embodiment, a corner panel may be configured with varying heights and widths such as to accommodate a wide variety of circumstances and conditions that match and comply with architectural building plans. In another embodiment, a corner panel may be configured from a first wall panel and a second wall panel fastened at an angle relative to each other. In one embodiment, a corner panel, may be assembled in an orientation different than the final orientation of the wall panel and then positioned relative to the floor. The corner panel, may however be configured in any suitable manner to align, support, and transfer loading of framing components and to secure a component of the extruded aluminum wall panel framing system such as a stud, a sole plate, a sill plate, another extrusion, or other component of a frame to another component of the frame, and provide an alternative framing component to an existing wood-based frame component.

In one application, a corner application may provide for a first wall panel to be formed at an angle to a second wall panel by assembling a first side of a corner panel by positioning a corner stud with a first end and a second end substantially vertical 1510, positioning a first common stud with a first end and a second end substantially vertical 1520, positioning a first sole plate with a first end and a second end substantially horizontal 1530, aligning the stud screw slots on the first end of the corner stud with the sole plate clearance holes on the first end of the first sole plate and secure by a fastener 1540, aligning the stud screw slots on the first end of the first common stud with the sole plate clearance holes on the second end of the first sole plate and secure by a fastener 1550, positioning a first sill plate with a first end and a second end substantially horizontal 1560, aligning the stud screw slots on the second end of the corner stud with the sole plate clearance holes on the first end of the first sill plate and securing by a fastener 1570, and aligning the stud screw slots on the first end of the second common stud with the sill plate clearance holes on the second end of the first sole plate and securing by a fastener 1580 and assembling a second side of the corner panel by positioning the first side of the corner panel substantially vertical 1610, positioning a second common stud with a first end and a second end substantially vertical 1620, positioning a second sole plate with a first end and a second end substantially horizontal 1630, aligning the stud screw slots on the first end of the corner stud with the sole plate clearance holes on the first end of the second sole plate and securing by a fastener 1640, aligning the stud screw slots on the first end of the second common stud with the sole plate clearance holes on the second end of the second sole plate and securing by a fastener 1650, positioning a second sill plate with a first end and a second end substantially horizontal 1660, aligning the stud screw slots on the second end of the corner stud with the sole plate clearance holes on the first end of the second sill plate and securing by a fastener 1670, aligning the stud screw slots on the second end of the second common stud with the sill plate clearance holes on the second end of the second sill plate and securing by a fastener 1680, optionally installing any additional isolation strips, shear panels, openings, bracing, or fasteners required 1690, and optionally installing the corner wall panel on to a rail base and secure by a fastener 1695 as shown in FIG. 15 and FIG. 16.

In one embodiment, an extension application may comprise a first wall panel and a second wall panel configured vertically end-to-end. In another embodiment, an extension application may comprise a first wall panel, a second wall panel, and a fastener configured as a panel bolt 410 and a panel bolt nut 420 as shown in FIG. 8. In another embodiment, a wall panel, may be configured as an extension application comprising a first wall panel, a second wall panel, and a fastener configured as a panel bolt 410 and a panel bolt nut 420 as shown in FIG. 8. In one embodiment, an extension application, may be assembled in an orientation different than the final orientation of the wall panel and then positioned relative to the floor.

In one application, an extension application may provide more than one wall panel to be joined with another wall panel in order to achieve a longer span by placing a configured stud profile such as a common stud, a king stud, a jack stud, an upper cripple stud, or a lower cripple stud of a first wall panel near a configured stud profile such as a common stud, a king stud, a jack stud, an upper cripple stud, or a lower cripple stud of a second wall panel 1710, engaging a stud fin-tab extending outward on the first wall panel with the stud recess on the second wall panel 1720, securing the first wall panel to the second wall panel by a fastener such as a panel bolt and a panel bolt nut 1730, and optionally securing either wall panel to the floor 1740 as shown in FIG. 17.

In one embodiment, a multi-level application may be configured as a two-story building, a three-story building, and a multi-story building. In another embodiment, a multi-level application may comprise a first wall panel and a second wall panel configured top-to-bottom. In another embodiment, a multi-level application may comprise a first wall panel, a second wall panel, and a fastener configured as a sill bolt 390 and a sill nut 400 as shown in FIG. 10. In one embodiment, an multi-level application, may be assembled in an orientation different than the final orientation of the wall panel and then positioned relative to the floor.

In one application, a multi-level application may provide more than one wall panel be stacked on top of another wall panel in order to achieve a taller span by placing a sole plate located at the base of a first upper wall panel near a sill plate located at the top of a second lower wall panel 1810, engaging a sole plate fin-tab extending downward on the first upper wall panel with sill plate recess on the second lower wall panel 1820, securing the first wall panel to the second wall panel by a fastener such as a sill bolt and a sill nut 1830, and optionally securing either wall panel to the floor 1840 as shown in and FIG. 18.

In places where the description above refers to particular implementations of systems and methods for an extruded aluminum wall panel framing system, it should be readily apparent that a number of modifications may be made without departing from the spirit thereof and that these implementations may be applied to other to systems and methods for an extruded aluminum wall panel framing system.

	Number	Date	Country
Parent	17493728	Oct 2021	US
Child	18212990		US

SYSTEM AND METHODS FOR EXTRUDED ALUMINUM WALL PANEL FRAMING

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CPC

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CROSS REFERENCE TO RELATED APPLICATIONS

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