CA1241815A

CA1241815A - Insulated wall assembly

Info

Publication number: CA1241815A
Application number: CA000472135A
Authority: CA
Inventors: Richard Dettbarn
Original assignee: Individual
Current assignee: Individual
Priority date: 1985-01-15
Filing date: 1985-01-15
Publication date: 1988-09-13
Also published as: BR8600143A; KR960001736B1; KR860005942A; JPH0778341B2; EP0190818A2; DE3678006D1; ATE61641T1; EP0190818B1; JPS61204446A; AU585923B2; EP0190818A3; AU5179686A

Abstract

ABSTRACT OF THE DISCLOSURE

An insulated wall assembly, which is easy to construct, includes a plurality of panels, each defined by an elongated, rectangular, rigid foam plastic body with central, longitudinally extending grooves in each of two opposed ends thereof for receiving splines, so that the panels can be connected to columns and cripples, which are defined by plastic bodies with longi-tudinally extending spline-receiving grooves therein and wooden strips attached to the bodies. The splines can be integral with the columns and cripples.

Description

lrhis inven-tion rela-tes -to a wall assembly, and in particular -to an insulated wall assembly. More specifically, the inven-tion provi.des novel panel and pos-ts for use in an insulated wall assembly, and wall assemblies incorporating the panels and posts.
Insulated wall assemblies are not new. Examples of such assemblies are found in Canadian Pa-ten-ts Nos. 1,116,371, issued to Truefoam Canada Limited on January 19, 1982 and 1,124,482, issued -to Cano Thermo Systems Inc. on June 1, 1982.
While -the patented assemblies provide well insulated struc-tures, there is room for improvement in terms of the structure of the individual elements used in the assemblies, and the assembling of such elements to fo~m walls.
The object of this invention is provide an assembly for building insulated load bearing walls with highly flexible lightweight components. The components are designed to eliminate thermal bridging between the interior and the exterior surfaces of the walls to produce an energy efficient structure for use in extremely hot and extremely cold climates.
Accordingly, the presen-t invention relates to a panel for use in an insulated wall assembly comprising elonga-ted, rectangular, rigid foam plastic body means; central, longi-tudinally extending groove means in each of two opposed end edges of said body means for receiving splines, whereby sai.d body means can be connected -to ano-ther wall assembly component;

and transversel~ ex-tending groove means in one surface of said body means for alignment with similar transversely extending groove means in similar panels for carrying electrical wiring.
The invention will now be described in greater detail with reference to the accompanying drawings, which illustrate preferred embodimen-ts of the inven-tion, and wherein:
Figure 1 is a schematic perspec-tive view from above of a section of one embodiment of wall assembly in accordance wi-th the present invention;
E'igure 2 is a perspective view of a panel for use in the wall assembly of Fig. l;
Figure 3 is a perspective view of a corner pos-t for use in the'assembly of'Fig. l;
Flgure 4 is a perspective view of a column for use in the assembly of Fig. l;
Figure 5 is a perspective view from one end of a cripple for use in the wall assembly of Fig. l;
Figure 6 is an exploded, perspective view of one end of a door frame during construction;
Figure 7 is a schematic perspective view from above of a section of a second embodiment of the wall assembly in accordance with -the present inven-tion;
E`igure 8 is a perspectlve view of a panel for use in -the wall assembly of Fig. 7;
F'igures 9 to 11 are perspective views of cripples for use in the wall assembly of Fig. 7; and Figure 12 is a perspective view from above of sections of two walls constructed wi-th -the elements of Figs. 4, 5~ 6 and 8.
Withreference to Fig. 1, one form of wall assembly in accordance with the inven-tion includes a bottom pla-te l defined by lengths of 2" x 6" spruce, and a top plate 2 defined by -two layers of 2" x 6" spruce. A plurality of panels 3 are disposed between the bottom plate 1 and the -top plate 2 to form walls.
Corners 4 are formed in the walls using corner posts 5, columns 6 defining end posts and a so-called cripple 7. The panels 3 are connected to each other, to the posts 5, to the column 6 and to the crip,ple 7by spli,nes 8~ The splines ~3 are formed of wood or a rigid foam plastic, e.g. expanded polystyrene. A window 9 is formed in one wall using a lintel 10, a sill ll~ cripples 7 and foam panels 3 and 13. Additional panels 14 are also provided where necessary between the end posts 4 and -the cripples 7. The panels 13 and 14 include rectangular grooves (not shown) where necessary for receiving splines 8. A door 16 is formed in much the same manner as the window 9 using a lin-tel 10 and cripples 7. Each of the lintels lO includes a rigid foam plas-tic insert 20 sandwiched between a pair of boards 21.
Referring to Fig. 2, each panel 3 i8 defined by ~n elongated body 25 Eormed of rigid Eoam plastic. Rectangular grooves 26 extending along the entire length of each end 27 of ~24~

-the body 25 for receiving splines 8. A wooden insert 28 extends along the longitudinal cen-tre line of one side of the body 25, so that finishing material such as panels, drywal], cladding etc.
can be attached to -the panel 3. The insert 28 is in a rec-tangular S groove 29, so that the outer surface 30 (Fig. 1) thereof is flush with the inner surface 32 of -the bocly 25. ~sually, a second s-trip of wood is provided in -the ou-ter surface 33 of the body 25 for connecting cladding or another exterior finish material -to -the panel 3. In the present case, a shallow V-shaped notch 35 is provided in such outer surface 33 oE the body 15. The notch 35 extends along the entire length o-F the body 25 and is aligned with the centre of the bight of the groove 29. Thus, when mounting claddlng another exterior finish on the panels 3, it is a simple matter to ensure that the nails or o-ther fasteners enter the panel in the correct positions to engage the insert 28.
This design is also suitable for structures which are to be clad on the ou-tside wi-th cemen-t or stucco finishes.
The V groove acts as a reinforcing rib, and -the exterior surface has a minimum amount of exposed wood which would require a mesh.
or web covering before the application o:E a cemen-t or stucco finish.
~ s best shown in Fig. 3 each corner pos-t 5 includes an elongated rectangular block 37 of rigid foam plastic with a rectangular, longitudinally extending groove 38 in one side thereof for receiving a spline 8. Wooden inserts 39 are glued ~2~

into each o~ the two corners opposi-te -the groove 38. The ou-ter surfaces of the inserts 39 are ~lush wi-th the adjacent surfaces of -the block 37. The groove 38 and the inserts 39 extend -the entire leng-th of -the block 37.
Referring to Fig. 4, each column 6 is defined by an elongated, rec-tangular block 40 of rigid foam plastic. A
rectangular, longitudinally extending groove 41 is provided in each of two opposed sides of the block 40 Eor receiving splines 8. A strip 42 of wood is glued to each of -the other two sides oE the block 40. The s-trips 42 are connected to each other by screws or nails (not shown). ~ -The cripples 7 are similar in structure to the colu~ms 6, except ~hat a groove is provided in one side only for receiving a spline 8. As shown in Fig. 5, the cripple 7 is defined by a pair of wooden strips 44 connected to the sides of an elongated rectangular block 45 of rigid foam plastic. A longitudinally extending slot 46 is provided in the centre of one end of each strip 44. For some uses, the slot 46 can be omitted. A
rectangular, longitudinally extending groove 48 in one side of the block 45 receives a spline 8.
When assembling the struc-ture of Fig. 1 or simllar structures, it will be apprecia-ted that the foo-t plate 1 is nailed in position. The wooden elements of the panels 3, posts 4 columns 6, cripples 7, window 9 and door 16 are nailed -to each o-ther and to the foot plate 1 and top plate 2. With rigid foam _ 5 plastic splines ~, -the wall assembly provides maximum insulation, since -there is a virtually unin-terrup-ted plastic barrier along the length o:E the assembly.
There are no slots 46 in the cripple 7 used in -the corners 4. The slotted cripples 7 are used when forming doors or windows in whi.ch case, the slot-ted end of the cripple is cut -to the slots 46 to form a ledge for receiving -the lintel 10 (Fig. 6). The top of the lintel 10 is aligned with the top of the cripple 7, so tha-t an accurate cu-t can be made. Alternativel.y, the llntel can be measured to determine the location of the cut in the cripple 7.
Referring to Fig. 7, whenever possible the same reference numerals have been used to identify the same or similar elements.
The wall assembly of Fig. 7 includes the bottom plate 1, the top plate 2, and a plurality of panels 50 disposed between such plates to form walls. The corners 4 are formed in the walls usi.ng two cripples 7 of the type shown in Fig. 5, a column 6 of the type shown in Fig. 4, and splines 8~ The corners are constructed as shown in the detail of Figure 12. In the structure of Figure 12, the columns 6 and cripples 7 are used in combination to achieve a strony s-tructural corner wi-th a nailing surface on both inside surfaces to at-tach interior cladding. It also provides an exterior nailing surface to attach exterior siding. The window 9 is formed uslng a lintel 10, a sill 11, and cripples 51 of the type shown in Fig. 9. For such purpose, slo-ts (no-t shown) similar -to the slots ~6 (Fig. 6) are provided in the cripples 51 forming the sides of the window to Eacilitate cutting of shoulders or ledges 52 for receiving the lin-tel 10. A cripple 5~ of the type shown in Fig. 10 is provided beneath -the cen-tre of the sill 11 be-tween two panels 50. Additional panels 50 are provided where necessary between the end posts 4, columns 6 and cripples 7. The panels 50 have a variety of wid-ths depending on the dis-tance required between centre, i.e. between the centre of the wooden portions of the end posts, columns and cripples. The door 16 is formed in the same manner as the window 9 using a lintel 10 and a pair of cripples 51 of the type shown in Fig. 9. In this embodiment of the inventlon, panels 50 are never connected directly -to each other. For structural strength, there is always a column or cipple between adjacent panels. In general, except when constructing basement or interior, non-supporting walls, it is preferable -to include a wood-containing cripple or column between adjacent panels 50.
With reference to Fig. 8, each panel 50 is defined by an elongated, rectangular body 56 formed of rigid foam plastic.
Rectangular grooves 57 ex-tend along the entire length of each end 58 of the body 56 formed of rigid foam plastic.
Rectangular grooves 57 extend along -the entlre length of each end 58 of the body 56 for receiving splines 8. Wi-th a view to simplifying the structure even more, the splines 8 can be in-corporated in the body 56, i.e. -the splines and body can define a single unit for connecting the panel to grooved columns or cripples. ~ transversely extending groove 60 is provided in one side of the body 56 for electrical wiring (no-t shown).
One form of cripple 51 (Fig. 9) for use in the wall assembly is defined by~an elongated, rectangular body 62 formed of rigid foam plastic, and a strip 63 of wood extending along each slde -thereof. The body 62 extends outwardly beyond -the ends of the wooden strips 63 to define a spline for connecting the cripple 51 to a panel 50 or column 6. A slot 64 extends trans-versely along one surface of the body 62 defining a channel for electrical wiring.
Second and third forms of cripples 5~ and 66 are shown in Fic3s. 10 and 11. Each of the cripples 54 and 66 is defined by an elongated, rectangular, rigid foam plastic body 67, and a strip 68 of wood extending along each side thereof. In each case, the body 67 extends outwardly beyond the side edges of the wood to define sp:Lines integral with the body. A slot 70 extends trans~
versely of the body 67 to define a channel for electrical wiring.
In the cripple 66 of Fig. 11, longitudinally extending slots 72 are provided in the centre of one end of each strip 68. The slots 72 act as a guide for cutting the cripple 66 when a lintel or the like is -to be suppor-t~d thereby.
When producing a wall assembly using the panel 60 of Fig. 8, the column 6 of E'ig. ~ and the cripple 7 of Fig. 5, -the first step i5 posi.tioning the bottom plates 1 on edge, since the components are attached to the plates 1 by nailing through the 8~i plates into the wooden por~ions (studs) of -the various elemen-ts.
The panels 60, columns 6, cripples 7 and splines 8 are placed in position and nailed to the bot-tom plate, wi-th -the electrical wiring slots 60, 64 and 70 properly aligned. A single top pla-te 2 is then nailed -to the assembled elements. The finished wall assembly is raised, braced and toe-nai]ed into a subfloor. A
second top plate 2 is nailed on top of the wall assembly. At corners 4, the uppermost top plate 2 of one section will overlap the lowermost top plate of the adjacent wall section. In s-traight walls including more than one section, the top plate of one section must overlap the top plate of the next wall sec-tion.
Any normal roof structure can be mounted directly on the top pla-tes

2. Building paper and~siding can be connected directly to the wall assembly.
It will be appreciated that each cripple 7 and spline 8 combination of Fig. 12 can be replaced with the cripple 51 of Fig. 9, and that each column 6 and pair of splines 8 of Fig. 12 can be replaced with the cripple 54 of Fig. 10. Thus, the simplest form of wall assembly ln accordance with the present invention has relatively few components, including the panels 60, columns defined by cripples 5~ and cripples 51 for use in forming door or window frames. When using the cripples 51 and 5~, a corner ~ is forrned using a plane rectangular corner column (not shown) defined by a central, elongated, rectangular block of rigid roam plastic and a pair of strips of wood co-extensive with g _ opposite sides of -the block. Thus, the column is similar in struc-ture and orientation to the cripple 7, except for the groove 48. The column 6 and the second cripple 7 at the corner 4 are bo-th replaced by cripples 51.

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A panel for use in an insulated wall assembly comprising elongated, rectangular, rigid foam plastic body means;
central, longitudinally extending groove means in each of two opposed end edges of said body means for receiving splines, whereby said body means can be connected to another wall assembly component; and transversely extending groove means in one surface of said body means for alignment with similar trans-versely extending groove means in similar panels for carrying electrical wiring.

2. A wall assembly comprising a plurality of panels, each said panel including elongated, rectangular, rigid foam plastic body means, central, longitudinally extending groove means in each of two opposed end edges of said body means for receiving splines, whereby said body means can be connected to a similar body means; and column means for interconnecting adjacent panels, said column means including an elongated, rigid foam plastic body, and a wooden strip on each of two opposed sides thereof, the body extending outwardly beyond each end of the wooden strip for defining said splines.

3. A wall assembly according to claim 2, including cripple means for defining a door or window frame, said cripple means including an elongated, rigid foam plastic body and a wooden strip on each of two opposed sides thereof, the body extending outwardly beyond one end of said wooden strip for defining a spline, and a longitudinally extending slot means in a top end of each wooden strip for facilitating the formation of a lintel supporting shoulder.

4. A wall assembly comprising a plurality of panels, each said panel including first elongated, rectangular, rigid foam plastic body means, central longitudinally extending groove means in each of two opposed end edges of said body means for receiving splines; column means including second elongated rigid foam plastic body means, central, longitudinally extending groove means in each of two opposed end edges of said second body means for receiving splines, and a wooden strip on each of two opposed sides thereof; spline means adapted to be inserted between said panels and said column means whereby said panels and said column means may be interconnected; cripple means for defining a door or window frame, said cripple means including an elongated, rigid foam plastic body and a wooden strip on each of two opposed sides thereof, the body being fully formed so as to have central longi-tudinally extending groove means in each of two opposed end edges for receiving said splines; and a longitudinally extending slot means in a top end of each said wooden strip for facilitating the formation of a lintel supporting shoulder.

5. A panel for use in an insulated wall assembly com-prising elongated rectangular rigid foam plastic body means; spline means on each of two opposed side edges of said body means, said spline means extending longitudinally of said body means between the ends thereof, whereby said panel may be connected to another wall component; and transversely extending groove means in one surface of said body means for alignment with similar transversely extending groove means in an adjacent wall assembly component for carrying electrical wiring.