Rigid wall panel system

Abstract

The invention is a prefabricated rigid wall panel assembly constructed of a plurality of C-shaped studs inserted into kerfs in a foam block. The closed ends of the C-shaped studs and the foam block form substantially planar longitudinal edges of the panel assembly capable of abutting an adjacent panel assembly. Optionally, a header and / or footer plate inserted is into a transverse kerf such that the plate overlaps the ends of the studs, and the header and / or footer plate and the foam block form a substantially planar transverse edge of the panel assembly. Adjacent panel assemblies are preferably secured to one another using a clip, the shape of which depends on the angle at which the panel assemblies abut. Each panel assembly may also have a wire chase.

Description

CROSS REFERENCES[0001]This application claims priority to U.S. Application Ser. No. 60 / 967,502, filed Sep. 5, 2007.GOVERNMENTAL RIGHTS[0002]None.BACKGROUND OF THE INVENTION[0003]This invention relates to a preformed rigid wall panel system that is durable and easy to manufacture, transport, and install on-site.[0004]Wall structures for buildings are generally manufactured on either a wooden or metal skeletal system of spaced-apart vertical studs bordered by a top plate and a bottom plate. Such wall structures have historically been built on-site with workers manually joining together the vertical studs and top and bottom plates, then raising the wall structure into place and securing it to the floor system of the building. A surface covering is then applied over the frame section, such as gypsum board, drywall, or plaster. Often, insulation is positioned between the vertical studs prior to installation of the surface covering.[0005]In recent years, manufacturers have begun preparing...

AI Technical Summary

Benefits of technology

[0006]U.S. Pat. No. 6,167,624 (the “'624 patent”), issued to Lanahan et al., discloses a prior art foam panel having embedded metal studs. The lateral, vertical edges of the panel have a tongue-and-groove connector formed into the foam block. Adjacent panels are fitted together using the tongue-and-groove connectors. The '624 patent is representative of the deficiencies in the prior art, as no prior art wall panel known to the inventor has disclosed a method of joining the vertical edges of adjacent wall panels together u

Problems solved by technology

This method presents serious structural deficiencies insofar as the adjacent panels are held together with foam, rather than stronger structural materials such as metal.

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