CA2621951A1 - Insulating wall structure - Google Patents
Insulating wall structure Download PDFInfo
- Publication number
- CA2621951A1 CA2621951A1 CA 2621951 CA2621951A CA2621951A1 CA 2621951 A1 CA2621951 A1 CA 2621951A1 CA 2621951 CA2621951 CA 2621951 CA 2621951 A CA2621951 A CA 2621951A CA 2621951 A1 CA2621951 A1 CA 2621951A1
- Authority
- CA
- Canada
- Prior art keywords
- wall structure
- mating
- wall
- insulated wall
- insulated
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 230000013011 mating Effects 0.000 claims abstract description 32
- 239000011810 insulating material Substances 0.000 claims abstract description 14
- 239000006260 foam Substances 0.000 description 15
- 238000009413 insulation Methods 0.000 description 10
- 238000010276 construction Methods 0.000 description 6
- 239000002023 wood Substances 0.000 description 4
- 238000009432 framing Methods 0.000 description 3
- 238000005253 cladding Methods 0.000 description 2
- 239000011120 plywood Substances 0.000 description 2
- 239000008259 solid foam Substances 0.000 description 2
- 125000006850 spacer group Chemical group 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 229910052602 gypsum Inorganic materials 0.000 description 1
- 239000010440 gypsum Substances 0.000 description 1
- 239000011796 hollow space material Substances 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
- 238000001764 infiltration Methods 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000009428 plumbing Methods 0.000 description 1
- 229920000582 polyisocyanurate Polymers 0.000 description 1
- 239000011495 polyisocyanurate Substances 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 238000009431 timber framing Methods 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/78—Heat insulating elements
- E04B1/80—Heat insulating elements slab-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- Electromagnetism (AREA)
- Building Environments (AREA)
Abstract
The present invention describes an insulated wall structure to reduce thermal conductivity. More particularly, the insulated wall structure has a body of insulating material, said body having a front face, a back face, and two opposite mating sides, each mating side mating with the opposite mating side of another insulated wall structure for mating assembly in a wall section, and a structural member extending along at least one of the two opposite mating sides of the insulated wall structure.
Description
INSULATED WALL STRUCTURE
FIELD OF THE INVENTION
The present invention relates to insulated wall structures, and prefab wall panel to build a construction, and particularly to insulated walls of buildings.
BACKGROUND OF THE INVENTION
Prefab wall panels, prefab roof trusses and plywood sheathing are often used to erect a house in a very short time with few workers. Prefab building components are normally preferred by the construction industry as they are assembled with approved materials, according to controlled procedures and under the ideal conditions of a well equipped shop. For these reasons, houses built with prefab components are generally of a better quality than conventional structures built outdoors on a construction site.
An important aspect of the quality of a house is the thermal resistance of its structure. In that respect, home builder associations as well as writers of national building codes specify a minimum level of insulation to be installed in walls, ceilings and around foundations of new houses. Normally the insulation requirement for the walls of a house built in Canada for example, varies between R-16 and R-27 depending on the number of degree-days of a particular region.
A typical conventional prefab wall panel having an insulation value of R-20 is built with nominal 2"×6" wood framing members covered on the outside surface with panels of half-inch plywood or particleboard, half-inch fibreboard sheathing and an exterior cladding. The space between the studs is completely filled with batt type fibreglass insulation. The interior finish may comprise half-inch fibreboard insulation and a gypsum board. This type of prefab wall panel is usually fabricated and transported to a construction site without the batt insulation, interior finish and exterior cladding.
A drawback of this type of construction is the fact that each wall panel is relatively heavy to handle and erect on a floor structure. Also, the batt insulation is still installed in the usual manner, when the new building is closed-in.
As alternatives to the R-20 nominal 2"×6" wall structure, a number of different types of prefab wall panels are made with a solid foam core encapsulating a smaller wood frame. A first example of pre-insulated wall panel having a foam core is described in U.S.
Pat. No. 4,109,436 issued on Aug. 29, 1978 to Adrien Berloty. This building panel comprises a wood frame which is completely filled with foam. The foam forms a rigid block which adheres to the frame. The continuity of the foam block in the frame give the panel a good stability as well as excellent thermal insulation.
A second example of a prefab wall panel having a foam core is disclosed in the U.S. Pat.
No. 4,628,650 issued on Dec. 16, 1986 to Bert A. Parker. The document describes a structural insulated panel system comprising a foam core having channels for receiving fratning studs or rafters. The foam core also has an overhanging portion around its periphery for overlapping the framing members along the edges thereof. The foam core completely covers the framing members for efficiently sealing the wall from infiltration of cold air inside the building.
A third example of a wall section having a foam core is illustrated and described in the U.S. Pat. No. 5,353,560 issued on Oct. 11, 1994 to John J. Heydon. This invention discloses a plurality of preformed foam blocks, wherein each block is fitted between two adjacent vertical posts of a wall section. Each block has a recess along the edge thereof for encapsulating one post and for overlapping a portion of an adjacent foam block. The plurality of interlocked foam blocks encapsulates completely all posts of a wall framing.
Although a solid foam core has been preferred in the past for obtaining high insulation value with a relatively thin wall section, the foam core takes up all the hollow space between the wall studs. Sub-trade workers such as electricians and plumbers must use hot knives for cutting grooves through the foam core for running plumbing piping and manifolds or an electrical system into the insulated wall section.
For this reason, the work saved by carpenters for erecting a foam filled wall structure is often offset by the additional manpower required by sub-trade workers for grooving the insulation. Hence, a need exists in the industry for a pre-insulated prefab wall panel offering excellent thermal resistance as well as being structurally compatible to the requirement of all tradesmen involved in the construction of a building.
Another exemple if Canadian Pat. No. 1180528 is a structural log-like member for use in constructing walls, having an outer wooden wall and an inner wooden wall.
Wooden spacer members connect the inner and outer walls together in spaced-apart parallel fashion. The spaces between the walls and spacer members can be filled with an insulation material. In use, the structural members can be stacked one on top of the other to form a wall.
Considering the state of the art presented above, it remains highly desirable to be provided with new prefab wall structures with insulating elements SUMMARY OF THE INVENTION
One aim of the present invention is to provide an insulated wall structure having a body of insulating material, the body having a front face, a back face, and two opposite mating sides, each mating side mating with the opposite mating side of another insulated wall structure for mating assembly in a wall section, and a structural member extending along at least one of the two opposite mating sides of the insulated wall structure.
In accordance with the present invention, in the insulated wall structure, the body can have a facing layer of insulating material covering the structural members when two or more adjacent wall panels are matingly adjoined into a wall section.
The person skilled in the art the present invention pertains will understand that the structural member of an insulated wall structure mates with the structural member of another insulated wall structure without offsetting to form a wall section.
Another aim of the present invention is to provide a wall section comprising at least two insulated wall structures, each insulated wall structure having a body of insulating material, the body having a front face, a back face, and two opposite mating sides, each mating side mating with the opposite mating side of another insulated wall structure for mating assembly in a wall section, and a structural member extending along at least one of the two opposite mating sides of the insulated wall structure DESCRIPTION OF THE DRAWINGS
Fig 1 is a top plan view of a wall portion comprising two wall structures adjoined side by side.
It will be noted that throughout the appended drawings, like features are identified by like reference numerals.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown.
This invention, may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
In FIG. 1 two insulated wall structure 11, 11' are assembled to form a wall portion 10.
The insulated wall structure 11 generally has a body 16 and two structural members 12 and 14, each structural member being positioned to form opposite mating sides 18 and 20 of the insulated wall structure 11. Insulated wall structure 11' having mating sides 22 and 24 is builded as is the insulated wall structure 11. The body 16 represents the portion of most insulating material of the wall structure 11. A body 16 made of a self-supporting insulating material having desired insulating characteristics can be used. In the illustrated example, Type 1 polystyrene is used, but other insulating materials can also be used, such as polyisocyanurate, polyurethane, or any insulating material preferably rigid enough to be self supporting.
The body 16 also includes a structural member covering extension 26. Thereby, when two or more wall structures 11 and 11' are adjoined, a continuous facing 28 of insulating material is provided, covering the structural members 12 and 14. This increases the thermal resistance of a wall when compared to a wall in which the structural members are con covered by insulating material. The body 16 and structural covering extension 26 can form a single peace, or can be two parts in contact on to the other.
In this example, the structural member 12 of the insulated wall structure 11 mates and is aligned with the structural member 22 of the insulated wall structure 11'.
Structural member 12 is generally not laterally offset, but preferably in an end-to-end configuration.
In the illustrated embodiment, the structural members 12, 14, 22 and 24 are 2 X 4 wood boards, having a depth of 8.9 cm (3.5 inches) and completely overlap.
Also in the example, the insulated wall structures 11 and 11' are covered on a common face by a covering panel 30, and on the opposite face by spacing members 34 supporting themselves another spacing member 32 perpendicularly secured to spacing members 34.
For example, spacing member 32 can be a 4 x 8 feet panel, or alternatively a 1 x 4 inches panel. Each spacing member is generally made of wood.
According to another embodiment of the present invention, the prefab wall structure can be of, for example but not limited to, 1 to 5 ft width, for making the wall part below or above a window or an aperture.
It will be noted that various additional alternatives to the structural members described above are also possible.
While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth, and as follows in the scope of the appended claims.
FIELD OF THE INVENTION
The present invention relates to insulated wall structures, and prefab wall panel to build a construction, and particularly to insulated walls of buildings.
BACKGROUND OF THE INVENTION
Prefab wall panels, prefab roof trusses and plywood sheathing are often used to erect a house in a very short time with few workers. Prefab building components are normally preferred by the construction industry as they are assembled with approved materials, according to controlled procedures and under the ideal conditions of a well equipped shop. For these reasons, houses built with prefab components are generally of a better quality than conventional structures built outdoors on a construction site.
An important aspect of the quality of a house is the thermal resistance of its structure. In that respect, home builder associations as well as writers of national building codes specify a minimum level of insulation to be installed in walls, ceilings and around foundations of new houses. Normally the insulation requirement for the walls of a house built in Canada for example, varies between R-16 and R-27 depending on the number of degree-days of a particular region.
A typical conventional prefab wall panel having an insulation value of R-20 is built with nominal 2"×6" wood framing members covered on the outside surface with panels of half-inch plywood or particleboard, half-inch fibreboard sheathing and an exterior cladding. The space between the studs is completely filled with batt type fibreglass insulation. The interior finish may comprise half-inch fibreboard insulation and a gypsum board. This type of prefab wall panel is usually fabricated and transported to a construction site without the batt insulation, interior finish and exterior cladding.
A drawback of this type of construction is the fact that each wall panel is relatively heavy to handle and erect on a floor structure. Also, the batt insulation is still installed in the usual manner, when the new building is closed-in.
As alternatives to the R-20 nominal 2"×6" wall structure, a number of different types of prefab wall panels are made with a solid foam core encapsulating a smaller wood frame. A first example of pre-insulated wall panel having a foam core is described in U.S.
Pat. No. 4,109,436 issued on Aug. 29, 1978 to Adrien Berloty. This building panel comprises a wood frame which is completely filled with foam. The foam forms a rigid block which adheres to the frame. The continuity of the foam block in the frame give the panel a good stability as well as excellent thermal insulation.
A second example of a prefab wall panel having a foam core is disclosed in the U.S. Pat.
No. 4,628,650 issued on Dec. 16, 1986 to Bert A. Parker. The document describes a structural insulated panel system comprising a foam core having channels for receiving fratning studs or rafters. The foam core also has an overhanging portion around its periphery for overlapping the framing members along the edges thereof. The foam core completely covers the framing members for efficiently sealing the wall from infiltration of cold air inside the building.
A third example of a wall section having a foam core is illustrated and described in the U.S. Pat. No. 5,353,560 issued on Oct. 11, 1994 to John J. Heydon. This invention discloses a plurality of preformed foam blocks, wherein each block is fitted between two adjacent vertical posts of a wall section. Each block has a recess along the edge thereof for encapsulating one post and for overlapping a portion of an adjacent foam block. The plurality of interlocked foam blocks encapsulates completely all posts of a wall framing.
Although a solid foam core has been preferred in the past for obtaining high insulation value with a relatively thin wall section, the foam core takes up all the hollow space between the wall studs. Sub-trade workers such as electricians and plumbers must use hot knives for cutting grooves through the foam core for running plumbing piping and manifolds or an electrical system into the insulated wall section.
For this reason, the work saved by carpenters for erecting a foam filled wall structure is often offset by the additional manpower required by sub-trade workers for grooving the insulation. Hence, a need exists in the industry for a pre-insulated prefab wall panel offering excellent thermal resistance as well as being structurally compatible to the requirement of all tradesmen involved in the construction of a building.
Another exemple if Canadian Pat. No. 1180528 is a structural log-like member for use in constructing walls, having an outer wooden wall and an inner wooden wall.
Wooden spacer members connect the inner and outer walls together in spaced-apart parallel fashion. The spaces between the walls and spacer members can be filled with an insulation material. In use, the structural members can be stacked one on top of the other to form a wall.
Considering the state of the art presented above, it remains highly desirable to be provided with new prefab wall structures with insulating elements SUMMARY OF THE INVENTION
One aim of the present invention is to provide an insulated wall structure having a body of insulating material, the body having a front face, a back face, and two opposite mating sides, each mating side mating with the opposite mating side of another insulated wall structure for mating assembly in a wall section, and a structural member extending along at least one of the two opposite mating sides of the insulated wall structure.
In accordance with the present invention, in the insulated wall structure, the body can have a facing layer of insulating material covering the structural members when two or more adjacent wall panels are matingly adjoined into a wall section.
The person skilled in the art the present invention pertains will understand that the structural member of an insulated wall structure mates with the structural member of another insulated wall structure without offsetting to form a wall section.
Another aim of the present invention is to provide a wall section comprising at least two insulated wall structures, each insulated wall structure having a body of insulating material, the body having a front face, a back face, and two opposite mating sides, each mating side mating with the opposite mating side of another insulated wall structure for mating assembly in a wall section, and a structural member extending along at least one of the two opposite mating sides of the insulated wall structure DESCRIPTION OF THE DRAWINGS
Fig 1 is a top plan view of a wall portion comprising two wall structures adjoined side by side.
It will be noted that throughout the appended drawings, like features are identified by like reference numerals.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown.
This invention, may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
In FIG. 1 two insulated wall structure 11, 11' are assembled to form a wall portion 10.
The insulated wall structure 11 generally has a body 16 and two structural members 12 and 14, each structural member being positioned to form opposite mating sides 18 and 20 of the insulated wall structure 11. Insulated wall structure 11' having mating sides 22 and 24 is builded as is the insulated wall structure 11. The body 16 represents the portion of most insulating material of the wall structure 11. A body 16 made of a self-supporting insulating material having desired insulating characteristics can be used. In the illustrated example, Type 1 polystyrene is used, but other insulating materials can also be used, such as polyisocyanurate, polyurethane, or any insulating material preferably rigid enough to be self supporting.
The body 16 also includes a structural member covering extension 26. Thereby, when two or more wall structures 11 and 11' are adjoined, a continuous facing 28 of insulating material is provided, covering the structural members 12 and 14. This increases the thermal resistance of a wall when compared to a wall in which the structural members are con covered by insulating material. The body 16 and structural covering extension 26 can form a single peace, or can be two parts in contact on to the other.
In this example, the structural member 12 of the insulated wall structure 11 mates and is aligned with the structural member 22 of the insulated wall structure 11'.
Structural member 12 is generally not laterally offset, but preferably in an end-to-end configuration.
In the illustrated embodiment, the structural members 12, 14, 22 and 24 are 2 X 4 wood boards, having a depth of 8.9 cm (3.5 inches) and completely overlap.
Also in the example, the insulated wall structures 11 and 11' are covered on a common face by a covering panel 30, and on the opposite face by spacing members 34 supporting themselves another spacing member 32 perpendicularly secured to spacing members 34.
For example, spacing member 32 can be a 4 x 8 feet panel, or alternatively a 1 x 4 inches panel. Each spacing member is generally made of wood.
According to another embodiment of the present invention, the prefab wall structure can be of, for example but not limited to, 1 to 5 ft width, for making the wall part below or above a window or an aperture.
It will be noted that various additional alternatives to the structural members described above are also possible.
While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth, and as follows in the scope of the appended claims.
Claims (6)
1. An insulated wall structure having a body of insulating material, said body having a front face, a back face, and two opposite mating sides, each mating side mating with the opposite mating side of another insulated wall structure for mating assembly in a wall section, and a structural member extending along at least one of the two opposite mating sides of the insulated wall structure.
2. The insulated wall structure of claim 1, wherein said body has a facing layer of insulating material covering the structural members when two or more adjacent wall panels are matingly adjoined into a wall section.
3. The insulated wall structure of claim 1, wherein the structural member mates with the structural member of another insulated wall structure without offsetting to form a wall section.
4. A wall section comprising at least two insulated wall structures, each insulated wall structure having a body of insulating material, said body having a front face, a back face, and two opposite mating sides, each mating side mating with the opposite mating side of another insulated wall structure for mating assembly in a wall section, and a structural member extending along at least one of the two opposite mating sides of the insulated wall structure
5. The wall section of claim 4, wherein said body has a facing layer of insulating material covering the structural members when two or more adjacent wall panels are matingly adjoined into a wall section.
6. The wall section of claim 4, wherein the structural member mates with the structural member of another insulated wall structure without offsetting to form a wall section.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2621951 CA2621951A1 (en) | 2008-03-25 | 2008-03-25 | Insulating wall structure |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2621951 CA2621951A1 (en) | 2008-03-25 | 2008-03-25 | Insulating wall structure |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2621951A1 true CA2621951A1 (en) | 2009-09-25 |
Family
ID=41111057
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2621951 Abandoned CA2621951A1 (en) | 2008-03-25 | 2008-03-25 | Insulating wall structure |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2621951A1 (en) |
-
2008
- 2008-03-25 CA CA 2621951 patent/CA2621951A1/en not_active Abandoned
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |