Patent Application
20250146278
The present disclosure relates to building and constructions systems and apparatuses and, in particular, to exterior wall panel systems and associated methods of construction.
Present day methods for constructing residential exterior walls rely on old technologies. In this regard, not much has changed in the residential building process to build homes, or other structures, for the last one hundred plus years. In a common building method, wooden sticks (or studs) are nailed (or attached) together in a pattern creating a wall frame. All insulation, windows, doors and finishes are attached to this framework, usually with nails or screws. There is no detailed design provided for this pattern or layout, only a material selection and a recipe provided by the residential building code. This process requires skilled trades people to fill in the gap of knowledge missing in the lack of design detail. Because there is no detailed design, each tradesperson will fashion a wall differently from the next.
Site built walls are built in a difficult environment where there is no guarantee of a flat building surface and the site is at the mercy of the climatic conditions (e.g., rain, snow and/or cold temperatures). Material is placed wherever it fits, not in a predetermined location that is planned and ideal, quite often in mud, water or dirt as these are the only available locations on a congested work site. The quality of the wall build is at the mercy of the climatic condition's effect on the lumber, wood gets wet, gets dry, cold, etc. There is no control of the conditions of the materials. Some of these impediments can be reduced by factory building of walls (e.g., prefabricated walls built indoors)—however, if the same technology is used, it only has the advantage of being built in a better environment, but with the added cost of a factory and transportation to site (plus installation at the site). An example site environment is shown in
Multiple parts are needed to make a traditional wall-wood, nails, insulation, poly vapour barrier, building wrap and tape. These walls are very heavy and awkward, equipment is required to move any prefabricated walls and/or site materials which come in large lifts from a lumber supplier. Traditional walls are not good for shipping if made in a factory. Nails are not good for the tensile forces required for retention of two pieces, and forces are not uniform when shipping a wall and loading/unloading, as they are when a building is finished and all walls are in a compressive or shear state.
There are many documented safety issues on a traditional construction site, weight of components being lifted, and nails and nail guns being fired at random times and saws to cut almost all materials. Every piece needs to be cut to fit on site if the pieces are not engineered components. Typically, the only engineering performed is to select the materials for structural and environmental performance of the building.
There is no set wall design layout, every tradesman has his own way—building codes do not define precisely how to accomplish a finished building—it is objective based rather than design or specification based.
This background information is provided for the purpose of making known information believed by the applicant to be of possible relevance to the present disclosure. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present disclosure.
It will be appreciated by those skilled in the art that other variations of the embodiments described below may also be practiced without departing from the scope. Further note, these embodiments, and other embodiments will become more fully apparent from a review of the description and claims which follow.
In one embodiment, there is described an exterior wall system 100 (or building envelope system) which includes light weight high impact plastic insulation that meets all building code requirements and acts as a substrate for precision machining a template for a framing layout. The wall system 100 is designed in such a way as to ease wall construction (both from a time and cost standpoint) and to provide protection during the build, shipment and installation phases of construction. In one embodiment, the wall panels 110 described herein are adapted to snap together to create a finished wall.
These and other features will become more apparent in the following detailed description in which reference is made to the appended drawings.
In this respect, before explaining at least one embodiment in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The disclosure is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. In particular, all terms used herein are used in accordance with their ordinary meanings unless the context or definition clearly indicates otherwise. Also, unless indicated otherwise except within the claims the use of “or” includes “and” and vice-versa. Non-limiting terms are not to be construed as limiting unless expressly stated or the context clearly indicates otherwise (for example, “including”, “having”, “characterized by” and “comprising” typically indicate “including without limitation”). Singular forms included in the claims such as “a”, “an” and “the” include the plural reference unless expressly stated or the context clearly indicates otherwise. Further, the stated features and/or configurations or embodiments thereof the suggested intent may be applied as seen fit to certain operating conditions or environments by one experienced in the field of art.
Heights, lengths, dimensions, and sizing other than those described herein can be used in respect of the various components described.
In some embodiments, a wall system 100 comprises one or more wall panels 110. In some embodiments, the wall system 100 is an exterior wall system 100 which incorporates the use of lightweight high-impact plastic insulation, expanded polypropylene (EPP), that meets building code performance requirements and acts as a substrate for precision machining a template for a framing layout. In some embodiments, the one or more wall panels 110 are each comprised of lightweight high-impact plastic insulation, expanded polypropylene. In some embodiments, the one or more wall panels 110 comprise a different material(s). In some embodiments, the one or more wall panels 110 are substrate for precision machining a template for a framing layout. In some embodiments, the one or more wall panels 110 are insertable in a wall system 100, the wall system 100 comprising a post and beam structure or a frame configured to receive the one or more wall panels 110. In some embodiments, the wall system 100 comprises one or more wall panels 110 include structural framework and are not inserted into a post and beam structure or a frame but themselves provide structural framework.
As shown and described herein, in some embodiments, the wall system 100 is designed to simplify wall construction, for example, the wall panels 110 click and lock together or are locked via use of a small moulded component, all with no nailing. The wall panels 110 also act as packaging to provide protection during the build, shipment, and installation phases of wall construction.
To allow the insertion of windows or doors and allow for easy modifications to the exterior of the building at a later time, a post and beam structure can be used. In this way if a new opening such as a door or window is desired, or if a part of an exterior wall is damaged, a new section of wall can simply be manufactured and installed on site with no consideration for the structural integrity as the walls are non-structural inserts.
However, in situations where this is not an advantage, the structural framework can be designed into the wall system 100 with the appropriate reinforcement for window and door openings and this can be machined or installed into the wall system 100 as outlined. For example, the structural framework can be included in the one or more wall panels 110.
The one or more wall panels 110 can be attached to a steel or wood post and beam frame. The walls in some embodiments are thus not structural as a normal residential wall construction: the post and beam frame is designed to manage all of the building's load.
In order to facilitate easy adoption into the industry, traditional materials have been incorporated into the system, for example: normal fasteners are used to attach the interior and exterior finishes. In some embodiments, other materials or customized materials can be used.
Similar to the walls, a floor system is designed as inserted components rather than part of the building's structure, according to some embodiments. For example, in some embodiments, a floor system comprises one or more floor panels insertable into the floor system, which can comprise structural or framing components. In some embodiments, the one or more floor panels themselves include structural or framing components and are not inserted into a floor system but can be assembled and installed as a floor system by connecting the one or more floor panels.
In some embodiments, a roof is built in small, manageable pieces that can be assembled by hand on site, complementing the hand-assembled wall system 100. For example, in some embodiments, a roof comprises one or more roof panels insertable as a roof system, which can comprise structural or framing components. In some embodiments, the roof comprises one or more roof panels that themselves include structural or framing components and together form the roof system by connecting the one or more roof panels.
As EPP is resistant to mold and fungi, in one embodiment, the wall panels 110 comprised of EPP are of increased durability compared to lumber frames. For example, lumber frames can succumb to dry rot from fungus, forcing homeowners to demolish their houses at a large cost. The wall system 100 is also more durable than a lumber frame in that it is fire-resistant. By contrast, wooden structures and components are at high risk of collapse and complete destruction in events such as wildfires. Furthermore, lumber frames are prone to distortion from moisture absorption and, in the case of factory-built walls, incorrect storage. In some embodiments, the wall system 100 is solid and not distortable, resulting in a building that is more structurally sound and durable. Once in use, the walls provide a high level of insulation (from R12 to R74) due to the material and design. The insulating ability lowers the cost of living while increasing resident comfort levels and environmental sustainability, according to some embodiments.
Framing a house takes an average of 2-6 weeks and is often just under ⅕ of the total build cost. The wall system 100 is designed to be rapidly assembled with ease: it takes one week or less to assemble, significantly reducing overall building costs by ending a project quickly. In regard to safety, the wall system 100 eliminates the required use of nails, rendering the risk of nail gun injury nil, according to some embodiments. The lightweight components also eliminate the use of heavy machinery, thus resulting in a safer building site than those that require such machines for transportation and/or assembly of the structure's walls, according to some embodiments. Traditional wall framing results in a high amount of material waste due to human-error, such as erroneous lumber measurements. The components of the wall system 100 are precision machined according to some embodiments, thereby providing the building site with materials that are already prepared for assembly and reducing on-site material waste.
The foundation used in connection with the wall system 100 can be of any type commonly found in residential or commercial construction, such as, concrete slab, frost-protected shallow slab, piers, and full basement foundations.
In some embodiments, the wall system 100 consists of a factory-built exterior wall system for construction of buildings using high-impact polypropylene-based insulation material (EPP) as a thermal insulator. In some embodiments, the wall system comprises one or more wall panels 100.
Packaging material for protection of the walls during transport and manufacturing: The EPP panel is very durable, thus it is able to protect the wall system 100 during the handling, transportation and installation phases of construction.
In some embodiments, the one or more wall panels 100 provide a wall framing template. For example, the one or more wall panels 100 (e.g., solid EPP panels) can be machined with a pre-engineered framing layout for insertion and assembly of the framing members 130. Other design features of the wall system can be incorporated into the one or more wall panels 100, such as to accommodate doors, windows, or other configurations.
In some embodiments, other materials (such as for wall panels 110) can be used in place of EPP, such as expanded polystyrene (EPS) or polyurethane (PU). EPP may be selected for its significant insulation properties, high-impact properties and environmental resilience. EPP is not susceptible to water damage and does not support fungal growth; this is extremely important for communities that experience mould problems in housing, such as Indigenous communities in Canada, or anywhere with high levels of precipitation, humidity or large swings in temperature that cause moisture to settle on the inside of walls or the cavity of a wall.
In some embodiments, at least one of the one or more wall panels 110 comprise one or more features (e.g., holes, slits, ridges, grooves) arranged in a framing layout (e.g., pattern), the one or more features 150 configured for engagement (e.g., attachment, insertion, etc.) with at least one framing member 130 (e.g., structural panel, windows, doors, other features). In some embodiments, an engineered, pre-designed template for a framing layout is machined into the wall panel 110 (e.g., an insulating EPP wall panel) that clearly shows the layout for wood framing members (
In some embodiments, the framing layout is a pre-engineered pattern of the features, such as made by machining the features according to a pre-defined pattern or template. This can be performed while the wall panel 110 is constructed, prior to arrival of the wall panel 110 at a construction site for assembly into a wall system 100.
In some embodiments, for example, wood or steel studs/lumber (framing) are added into a machined template comprising one or more wall panels 110 (
In some embodiments, a structural frame is defined by at least one framing members. For example, the structural frame is configured to provide structural support to the wall panel 110 and, where assembled with additional wall panel(s) 110, structural support to a wall system 100. Accordingly, in some embodiments, wall system 100 is configured to be installed as a wall without requiring further structural support such as a post and beam structure. In some embodiments, the frame may provide some or less structural support and wall system 100 is configured to be installed at a post and beam structure for additional structural support.
In some embodiments, the one or more wall panels 110 comprising a first wall panel 110a sealingly joined to a second wall panel 110b to reduce permeation of air and vapour therebetween. In some embodiments, the joints between walls (e.g., wall panels 110) and transitions are sealed to prevent air and vapour from permeating the building. When properly sealed at its joints, the wall system 100 can act as the air and vapour barrier, which eliminates the need to install a polyethylene vapour barrier and weatherable building wrap. The standard vapour barrier and weatherable building wrap can be applied as normal if joint sealing is not used-this may be a simpler application depending on the circumstances.
Depending on the specific building design, framing members 130 can be inserted into features 150 (e.g., slots) that are cut out of the EPP insulation panels. The inserted framing members 130 can be of any size, e.g., 2×4, 2×6, 2×8, etc. (see e.g.,
In some embodiments, the manual insertion of the framing members 130 (e.g., 130a, 130b) is made feasible by bending the wall panel 110 over a mandrel (see e.g.,
In some embodiments, such as shown in
In some embodiments, one side of the wall can be assembled with wall panel(s) 110 (e.g., EPP) (
If two sides of EPP are used with any stud and no batt insulation to fill the cavity, an R-value of 24 (RSI 4.23) is achieved, according to some embodiments. A wall with one side of EPP and 3½″ batt insulation will have an R value of 26 (RSI of 5.6).
Flexible and high levels of insulation are beneficial for northern communities, where it may be difficult to properly build walls that are suitable for the cold climate due to the hard-to-access sites: unlike other prefabricated building systems, the wall system 100 is specifically designed to be shipped to these sites in a practical manner without sustaining damage. In all other climates where a large amount of insulation is not required, the thinner wall design allows for lower costs. In summary, the wall can be easily tailored to the climate by adjusting the insulation.
To support the remainder of the build, windows can be installed in the factory prior to shipping as the EPP panel insulation used in the wall construction can be extremely robust and can act as protective packaging as well as an insulation material. Top and bottom wall plates can also be installed for installation of structural sheathing if required, and for installation to the superstructure (see
The wall panels 110 can be attached to the building's structural framing by screws or bolts. Adhesives can be used for wall attachments if the adhesives meet the structural load requirements. Finishes, such as interior paneling or exterior siding, are screwed, adhered, or nailed (not ideal as previously discussed) to the inserted framing members using the same technology, tools, and skills as are used in traditional construction.
Electrical conduits can be installed in holes drilled or punched in framing members 130, or using any other code-compliant methods, resulting in reduced electrical site work (see
The design of the components and the final wall can be engineered for manufacturing in a factory. The assembly of the pieces is detailed and not left to interpretation, according to some embodiments. Wall panels 110 (e.g., comprising EPP) can be attached to each other to extend both height and length: the edges of three sides of each wall panel 110 are configured to securely fit together with another wall panel 110 (see
In some embodiments, each wall panel 110 defines a connecting feature defined in at least one perimeter of the wall panel, the connecting feature configured to connect an adjacent wall panel. For example, the connecting feature can be a click-and-lock feature including repeating protrusions and indentations along the perimeter (edge) of the wall panel 110, where each protrusion and indentation is sized and dimensioned to engage with complementation indentations and protrusions on an adjacent wall panel 110, such as shown in
In some embodiments, the connecting feature comprises a click-and-lock feature and each wall panel 110 comprises a locking feature defined at a perimeter of the wall panel 110, the locking feature configured to receive, in a tight fit, a locking component connectible to an adjacent wall panel 110. In some embodiments, the locking component comprises a moulded dogbone-shaped component and the locking feature comprising a moulded groove shaped to receive the moulded dogbone-shaped component. In some embodiments, different shaped components and/or interlocking elements can be used for the locking component and the locking feature.
Two wall panels 110 can be used in the vertical assembly to extend the wall to the height of 9′, for example. In some embodiments, this is accomplished using a click-and-lock feature (see e.g.,
An unlimited number of wall panels 110 can be used in the horizontal assembly to extend the length of the wall. In some embodiments, this is accomplished using a locking feature such as a slide-together feature (e.g.,
In some embodiments, a click-and-lock feature is substituted with a locking feature using a small moulded component, such as a slide-together feature secured with the insertion of a separate moulded element into a moulded groove in the wall panels. The moulded element can be in a dogbone shape, for example. In some embodiments, a locking feature using a small moulded component, such as a slide-together feature secured with the insertion of a separate moulded element into a moulded groove in the wall panels, is substituted for a click-and-lock feature.
In some embodiments, the wall system 100 is a repetitive building system and is manufactured using a controlled manufacturing system. The moulded wall panels 110 are made in a factory with a fixed mould and are always made within the manufacturing tolerances. The manufacture of the slots for the framing members 130 is a pre-engineered layout; whether it is made on a computerized machine or using a manual process, it is measurable for quality and tolerance and the process is repeatable, according to some embodiments
The packaging method of inserting the framing members 130 into the wall panels 110 (such as described in the foregoing) results in a very practical and robust wall for shipping, according to some embodiments. Wall components can be shipped flat or upright in the position they are to be installed in; this increases job site and hand assembly efficiency as the walls do not need to be flipped into position. Upright shipping also allows for safer installation at site because the wall panels 110 do not need to be manipulated into a vertical position; any manipulation of a larger, awkward component increases the risk of damage and injury. In some embodiments, during transport, upright shipping protects assembled components, such as windows, as there is no risk of the damage that often occurs when wall panels 110 are stacked on top of one another.
The lightweight of the components and the robustness of the assembled wall system 100 also allows for easier transportation in a regular landscaper's trailer or a pickup truck bed, according to some embodiments. The walls are durable and may not be easily destructible or damaged by regular or aggressive handling: they can survive impacts that a wall would reasonably endure as it is transferred from a factory to the building site, according to some embodiments. This robust self-protected design also allows for the installation of windows prior to delivery to the site. With windows installed, there is less damage on site, as glass is not laying around in an unorganized site environment.
In some embodiments, the wall system 100 can be used for exterior walls of residential, mid-rise, high-rise, and commercial buildings. It can also be used for replacement of concrete precast wall panels on building facades 110. The requirements for structural loading, such as wind loads and seismic loads, and for fire code depend on the height of the building. In some embodiments, the wall system 100 can meet these varying structural requirements by way of modification of the structural matrix of framing, and incorporating compliant finishes can ensure that the wall is up to varying fire codes.
As the wall system 100 components are lightweight (a 8′ tall by 6′ long double-sided wall component weighs from 124 lbs.), they are ideal and practical for hand installation for a crew of 2 or 3 and no heavy equipment is required.
In some embodiments, the wall system 100 circumvents the long-term trade shortage as there is no reliance on the framing trade to build the structure; the erection of such a building can be done by any skilled trade or semi-skilled individual that has practical skill and aptitude and can follow technical instructions. Additionally, the wall system 100 is more cost-effective than contracting a framer. It is also not reliant on wood for structural framing. The materials are resistant to mold and fungi; therefore, it is of increased durability compared to wood frames. For example, wood frames can succumb to dry rot fungus, forcing homeowners to demolish their houses at a large cost. Furthermore, the wall system 100 is more durable in that it is fire-resistant. In contrast, wooden structures and components are at high risk of collapse and complete destruction in events such as wildfires. Once in use, the wall system 100 provides a high level of insulation (R-value from 12 to 74) due to the material. The insulating ability lowers the cost of living while increasing resident comfort levels and environmental sustainability. Wooden frames are prone to distortion from moisture absorption and, in the case of factory-built walls, incorrect storage. In some embodiments, the wall system 100 is solid and will not distort, resulting in a building that is more structurally sound and durable than a building with a wooden frame.
In some embodiments, the wall system 100 is designed to work with finishes besides drywall, which is the typical interior wall finishing material. As drywall is brittle and is very susceptible to water absorption and mould, it may be desirable to not use drywall during transportation; eliminating drywall from the wall system 100 can result in a more durable wall fit for transportation. If a wall system 100 is two-sided (wall panels 110 on both sides of the framing members 130), the inside face of the building will be a continuous solid surface, which provides a backing of any type of approved finish. If required for fire protection as in the separation of living units, drywall can also be used in the same manner as traditional drywall construction. In some embodiments, the wall system 100 can work with any wood or steel post and beam structure.
Example building processes will now be described, according to some embodiments.
An example wall assembly process will now be described, according to some embodiments. The wall assembly process can use moulded EPP panels.
At step one, design the wall attachment, including: wall heights and lengths, framing layout, openings (windows, doors, HVAC, etc.), fastener locations, layout of interior and exterior finishes, and/or layout of mechanical, electrical and plumbing. At step two, assemble the EPP panels. For example, this is performed by clicking and locking the EPP panels together if a height above 4′ is required (
At step four, machine the framing layout into the EPP panel using a router or another suitable cutting tool (
At step eight, install joint sealer or weather barrier and vapour barrier. At step nine, exterior finishes and interior finishes are attached to the wall as per the manufacturer's specifications. At step ten, the wall is assembled lengthwise at the site from the individual components. At step eleven, the wall length is determined during the design stage. The number of EPP panel components required to build the full wall lengths is calculated by dividing the wall length by panel length (6′), and the pieces are manufactured in the factory setting.
An example building process will now be described, according to some embodiments.
At step one, the foundation and service connections for water, waste, and electrical are installed/constructed on the site as per the design using normal methods. At step two, once the foundation system has been installed, the post and beam frame, whether it is of steel or wood, is erected. This is also done on site using normal methods. At step three, the roof is installed. The roof is designed and manufactured as components smaller and lighter than the standard roof trusses, weighing approximately 150 lbs. The roof components are fully finished with insulation, structural members and sheathing. They are 2′ wide and typically as long as the width or half the width of the building, typically ˜12′. The roofing membrane is also installed at this step, thereby protecting the building materials, processes, and workers from precipitation and sun: two common delay and safety factors in construction.
At step four, the wall framing member layout is designed based on the design inputs for the building. The framing layout includes: stud spacing, openings (windows, doors, HVAC, etc.), and any required accessory blocking (e.g., bathroom grab handles). For the stud spacing, this can be 24″ or 16″, however, the stud spacing can be any distance as there is no structural reliance on the framing elements. Attachment requirements for exterior or interior trim may use tighter or non-standard stud spacing; either is possible with this wall system 100.
At step five, insulation panels are moulded from EPP of 3.25″ thickness. Optionally, the panels can be moulded from PU or EPS panels of similar thickness. Each individual EPP panel is manufactured to be 6′ wide. The EPP panels are 4.5′ in height. If the wall section is 4.5′ or less, the EPP panel can be used as is. If more than 4.5′ is required, two EPP panels are attached together with a click-and-lock system to create a 9′-high wall (
At step six, the EPP panels are then cut to the correct height as required using a router or another suitable cutting tool. They are also cut to length if desired (e.g., if the wall length is not evenly divisible by the wall panel length (6′), then one of the wall panels 110 must be cut).
At step seven, the framing layout is input into a NC router or other machine (e.g., band saw, water jet, milling machine) to cut the shape of the framing layout into the EPP panels. The framing layout can also be cut by hand using standard hand tools and a manual layout. The insert can be 2× lumber, any type of steel framing element, steel tubing, composite stud or other wall building technology.
At step eight, the framing member is inserted at this time. The framing members stiffen the EPP panel. If wood is used as the framing member, the EPP panel protects the wood: EPP's high compressive strength and ductility keeps the wood from warping. The insert can be screwed, nailed (not preferred), or glued into the slotted shape that has been cut into the wall panel. The inserted framing members are fastened together as per the engineering plan for the appropriate wall section. The wall section can be finished at this time if the insulation criteria are met.
At step nine, if more insulation is required for the thermal barrier, step 4 can be mirrored on the opposite side of the wall. If even more insulation is still required or desired, the center stud can be increased in size to accommodate either more rigid insulation or batt insulation, such as fiberglass or mineral wool (
At step ten, once the wall section is machined and the framing structure is installed, the wall system 100 can be fastened together. Regular large-head nails or cap nails can still be used; screws or adhesives can all be used as fasteners for the EPP panels. This connection serves no structural purpose other than to transport the assembled wall to its destination. If the wall system 100 has been designed to have the exterior and interior finishes pre-installed on the wall prior to shipment to the site, they can be added at this step since the framing members that are used to fasten these are installed.
At step eleven, to accomplish the length of the wall required for the building, wall components are simply placed onto the post and beam structure (or other frame) and slid together and locked in place with the locking (e.g., dogbone) feature. This assembly is then attached to the structure using the screw and attachments as specified in the design layout.
At step twelve, the insulation type and specific building requirements may dictate the use of vapour barrier and building wrap; these can be added in the factory or on site. If finishes are added in step 6 in the factory, building wrap and vapour barrier must be added prior to the installation of the finishes.
At step thirteen, interior and exterior finishes can be assembled to the wall section using the manufacturer's recommended method. This can be done in the factory (preferred) or on site, where it is less practical.
At step fourteen, for buildings with more than one floor, they will require a manufactured floor to be installed. This will fit into the post and beam frame and the process essentially is identical other than the work is duplicated vertically. The floor components are similar to the roof in that the pieces are built in 2′ increments with sheathing on the top and bottom and an engineered joist layout installed (
An example inserted structural framing process without a post and beam structure will now be described, according to some embodiments.
At step one, the foundation and service connections for water, waste, and electrical are installed/constructed on the site as per the design using normal methods.
At step two, while the foundation system is being installed, the walls are manufactured.
At step three, the wall framing member layout is designed based on the design and structural inputs for the building. The framing layout includes: stud spacing, normally 24″ or 16″ or some other, depending on structural requirements; openings (windows, doors, HVAC, etc.); any desired accessory blocking (e.g., bathroom grab handles); all structural loading for the building.
At step four, insulation panels are moulded from EPP of 3.25″ thickness. Optionally, the panels can be moulded from PU or EPS panels of similar thickness. Each individual EPP panel is manufactured to be 6′ wide. The EPP panels are 4.5′ in height. If the wall section is 4.5′ or less, the EPP panel can be used as is. If more than 4.5′ is required, two EPP panels are attached together with a click-and-lock system to create a 9′-high wall (
The EPP panels are attached together to reach the desired wall width using a slide-together feature and a separate moulded element to lock the panels into place. The slide-together feature is proprietary to the wall system 100 and allows smaller units to be made into larger units when required (see
At step five, the EPP panels are then cut to the correct height as required using a router or another suitable cutting tool. They are also cut to length if desired (e.g., if the wall length is not evenly divisible by the wall panel length (6′), then one of the wall panels 110 must be cut).
At step six, the framing layout is input into a NC router or other machine (e.g., band saw, water jet, milling machine) to cut the shape of the framing layout into the EPP panels. The framing layout can also be cut by hand using standard hand tools and a manual layout. The insert can be 2× lumber, any type of steel framing element, steel tubing, composite stud or other wall building technology.
At step seven, the framing member is inserted at this time. The framing members stiffen the EPP panel. If wood is used as the framing member, the EPP panel protects the wood: EPP's high compressive strength and ductility keeps the wood from warping. The insert can be screwed, nailed (not preferred), or glued into the slotted shape that has been cut into the wall panel. The inserted framing members are fastened together as per the engineering plan for the appropriate wall section. The wall section can be finished at this time if the insulation criteria are met.
At step eight, if more insulation is required for the thermal barrier, step four can be mirrored on the opposite side of the wall. If even more insulation is still desired, the center stud can be increased in size to accommodate either more rigid insulation or batt insulation, such as fiberglass or rockwool (see, for example,
At step nine, once the wall section is machined and the framing structure is installed, the wall system 100 can be fastened together. Regular large-head nails or cap nails can still be used; screws or adhesives can all be used as fasteners for the EPP panels. If the wall system 100 has been designed to have the exterior and interior finishes preinstalled on the wall prior to shipment to the site, they can be added at this step since the framing members that are used to fasten these are installed.
At step ten, to accomplish the length of the wall required for the building, wall components are simply fastened onto the foundation layout using the appropriate fasteners and assembled together.
At step eleven, the insulation type and specific building requirements may dictate the use of vapour barrier and building wrap; these can be added in the factory or on site. There is no preferred method of this installation. If finishes are added in Step 6 in the factory, building wrap and vapour barrier are added prior to the installation of the finishes.
At step twelve, interior and exterior finishes can be assembled to the wall section using the manufacturer's recommended method. This can be done in the factory (preferred) or on site, where practical.
At step thirteen, for buildings with more than one floor, they will require a manufactured floor to be installed. The process essentially is identical other than the work is duplicated vertically. The floor components are similar to the roof in that the pieces are built in 2′ increments with sheathing on the top and bottom and an engineered joist layout installed (
At step fourteen, the roof is installed. The roof is designed and manufactured as components smaller and lighter than the standard roof trusses, weighing approximately 150 lbs. The roof components are fully finished with insulation, structural members and sheathing. They are 2′ wide and typically as long as the width or half the width of the building, typically ˜12′. The roofing membrane is also installed at this step, thereby protecting the building materials, processes, and workers from precipitation and sun: two common delay and safety factors in construction.
In some embodiments, a method for constructing a wall system includes bending a wall panel 110 to expand at least one receiving member (e.g., a feature 150) defined in the wall panel 110; and inserting a framing member 130 in at least one of the receiving members. An example method is shown in
In some embodiments, a method for constructing a wall system 100 includes defining one or more features arranged in a framing layout in a wall panel 110; and insertably securing the wall panel 110 with at least one framing member 130 according to the framing layout. The one or more features 150 can be indentations, grooves, or other feature configured for engagement with a framing member 130. The framing layout can be a pattern entered into a machine, where the machine is used to create the features 150 in wall panel 110, for example.
In some embodiments, removably securing the wall panel 110 with an adjacent wall panel 110 at a perimeter of the wall panel can be by using a connecting feature such as a click-and-lock feature and/or using a locking feature such as a slide-and-lock feature.
In some embodiments, insertably engaging a second wall panel 110 with the at least one framing member 130, the wall panel 110 and the second wall panel 110 opposingly disposed. For example, the framing member 130 can be one or more elongated portions of wood where at least one of the portions of wood are inserted into one wall panel 110, while the same or another elongated portion of wood of the framing member 130 is inserted into the second wall panel 110. An example configuration is shown in
In some embodiments, sealingly joining the wall panel with the adjacent wall panel includes using sealing material to reduce movement of air and vapour between adjacent connected wall panels.
As used herein, references to a wall, wall panel, or wall system can be substituted for like components of a roof or of a floor in other embodiments. For example, materials can be customized for the particular application, whether wall, roof, or floor, according to some embodiments. An example floor system is shown in
The scope of this disclosure encompasses all changes, substitutions, variations, alterations, and modifications to the example embodiments described or illustrated herein that a person having ordinary skill in the art would comprehend. The scope of this disclosure is not limited to the example embodiments described or illustrated herein. Moreover, although this disclosure describes and illustrates respective embodiments herein as including particular components, elements, functions, operations, or steps, any of these embodiments may include any modification, combination or permutation of any of the components, elements, functions, operations, or steps described or illustrated anywhere herein that a person having ordinary skill in the art would comprehend. All such modifications, combinations and permutations are believed to be within the sphere and scope of the disclosure.
| Number | Date | Country | |
|---|---|---|---|
| 63596833 | Nov 2023 | US |
