KR19980019624A - Composite Wall Panels and Structural Walls Using the Same - Google Patents

Abstract

Structural, insulating, insect repellent, and dimensionally stable composite wall panels for building structures are characterized by two side walls bounded by two parallel sidewalls and two parallel end walls bounded by two parallel end walls. A regular rectangular body made of polymer foam having two opposing circumferential walls; One or more light metal gauge hollow studs in the body, each light metal gauge stud extending from at least one end wall to the other end wall and parallel to the sidewall of the body, wherein the polymeric foam is in the center of the stud. Elongate to fix the stud and the main body, and at least one side wall of each stud forms part of the same main wall surface of the main body.

Description

Composite Wall Panels and Structural Walls Using the Same

FIELD OF THE INVENTION The present invention relates to polymer / metal composite wall panels, and more particularly to polymer / metal composite wall panels that are lightweight, heat insulating and soundproof. The panel optionally also preferably constitutes a structural support member.

Composite wall panels are known in the art. Dickens, US Pat. No. 4,953,334, shows a building panel with an expanded porous core with side reinforcement strips. The panels are fitted in a complementary manner with stepped core edges of different step widths, forming a rectangular groove along the edge of the joining panel with respect to the facility line. Panels are used for retrofitting existing building structures, where the panels are attached to existing building walls.

U. S. Patent No. 5,279, 089 to Gulur shows an insulating wall having tubular support members secured to a header and footing. The space between the tubular support members is filled with a three-ply sandwich structure of extruded polymer foam sheets.

The panel of US Pat. No. 4,953,334 is manufactured to attach to an existing wall structure and is not a structural support member. Reinforcement strips are of conventional construction and cannot be purchased as standard.

U. S. Patent 5,279, 089 shows a wall system built from a starting point on site in the same way that wood frame walls are constructed. Structural support panels are not used in US Pat. No. 5,279,089 and are precisely centered so that insulated polymer foam panels can be inserted with minimal cutting and “fitting” into the space between adjacent tubular support members. It must be secured to the footer.

U.S. Patent No. 5,279,089 discloses a wall system of expanded polystyrene and metal frame members under the trade name WALLFRAME by the department of Atlantic Richfield, and a wall system of the same type under the trade name CANOTHERMO by NU-TECH Building System of Cleveland, Ohio. Shows.

It is a technical object of the present invention to provide a polymer / metal composite wall panel which is lightweight, heat-insulated, soundproofed, and insect repellent, and structural walls using the same.

1 is a perspective view of a wall system of the present invention employing the composite wall panel of the present invention

Figure 2: Bottom view of the shown composite wall panel of Figure 1

Figure 3: Longitudinal planar end view of the composite wall panel of Figure 1

Figure 3b: Another longitudinal plan view of the composite wall panel of Figure 1

Figure 4: Plan view of the main wall surface of the composite wall panel of Figure 1

5 is a plan view of the opposing main wall surface of the composite wall panel of FIG.

Figure 6: Perspective view of another embodiment of the wall system of the present invention employing another embodiment of the composite wall panel of the present invention

Figure 7: Bottom view of the composite fin panel of FIG.

Figure 8a: longitudinal plan view of the composite wall panel of Figure 6

Figure 8b: top view of the other longitudinal side of the composite wall panel of Figure 6

Fig.9: Plan view of the main wall surface of the composite wall panel of Fig.6

Figure 10: Plan view of the outer circumferential wall surface of the composite wall panel of Figure 6

Figure 11: Top view of another embodiment of the composite wall panel of the present invention

Figure 12a: longitudinal side plan view of the composite wall panel of Figure 11

Figure 12b: top view of the other longitudinal side of the composite wall panel of Figure 11

Figure 13: Plan view of the main wall surface of the composite wall panel of Figure 11

Fig. 14: Plan view of opposing circumferential wall of the composite wall panel of Fig. 11

Figure 15: Top view of another embodiment of the composite wall panel of the present invention

Figure 16a: longitudinal side plan view of the composite wall panel of Figure 15

Figure 16b: top view of the other longitudinal side of the composite wall panel of Figure 15

Figure 17: Plan view of the main wall surface of the composite wall panel of Figure 15

Figure 18: Plan view of opposing circumferential wall surface of composite wall panel of Figure 15

Figure 19: Top view of another embodiment of the composite wall panel of the present invention

FIG. 20a: Longitudinal plan view of the composite wall panel of FIG. 19

Figure 20b: top view of the other longitudinal side of the composite wall panel of Figure 19

Figure 21: Plan view of the main wall surface of the composite wall panel of Figure 19

Fig. 22: Plan view of opposing circumferential walls of the composite wall panel of Fig. 19

Figure 23: Top view of another embodiment of the composite wall panel of the present invention

FIG. 24a: Longitudinal plan view of the composite wall panel of FIG. 23

Figure 24b: top view of the other longitudinal side of the composite wall panel of Figure 23

Fig. 25: Plan view of the main wall of the composite wall panel of Fig. 23

Fig. 26: A plan view of opposing circumferential walls of the composite wall panel of Fig. 23

Figure 27: Top view of inner composite wall panel of the present invention

Figure 28a: Longitudinal plan view of the composite wall panel of Figure 27

Figure 28b: top view of the other longitudinal side of the composite wall panel of Figure 27

Fig. 29: A plan view of one of the main wall surfaces of the composite wall panel of Fig. 27

30: top view of another embodiment of the composite wall panel of the present invention

FIG. 30a: Partial perspective view of the back side of the light metal gauge stud of the panel of FIG. 30

Figure 31: Top view of another embodiment of the composite wall panel of the present invention

32: A plan view of another embodiment of a composite wall panel of the present invention

* Description of the symbols for the main parts of the drawings *

10: composite wall panel 12a: upper track

12b: lower track 14: side wall

18: open channel 20: horizontal filler member

30 body 32 stud

52: rear wall 56: open slot

57: Central Joint

One embodiment of the present invention relates to a structural, insulating, insect repellent, and dimensionally stable composite wall panel for a building structure, wherein the panel is bounded by two parallel sidewalls with two parallel sides. A regular rectangular body of polymeric foam having two opposing major faces whose ends are bounded by one end wall; One or more light metal gauge studs in the body, the studs having an empty central cavity and having a wide rear wall extending to the width of the stud, two parallel sidewalls, and an open slot parallel to the defecation wall and extending into the central cavity. Rectangular cross section with two narrow front walls separated by each light metal gauge stud extending from at least one end wall of the body to the other end wall and parallel to the side wall of the body, the polymer foam being the center of the stud It extends into the cavity to secure the studs to the body, wherein at least one side wall of each stud forms part of the same main wall surface of the body.

The opposing circumferential walls are the main walls that make up the walls, exterior walls, etc. of the room. The studs used in the present invention are light metal gauge studs that are used nationwide with square or rectangular quadrilateral cross sections.

In composite wall panels employed inside the building, the width of the panel between the two main wall surfaces is normally equal to the width of the studs, and the side walls of the studs form part of both main wall surfaces. In other words, the side walls of the studs appear as part of the main wall surface of the panel.

The ends of the composite wall panels are received in and secured to an open channel of the light metal gauge building structure track to form a structural wall. The panels are secured to the track by self-screwing fixtures that extend through the wall of the track into the sidewall of the stud. The lower track is attached to the floor system of the building, and the upper track supports the ceiling, top and roof members of the building.

In a preferred embodiment of the invention, the stud is one of the side walls of the body. More preferably, the back wall of the stud is one of the side walls of the body.

In a preferred embodiment of the invention, the panels are the standard center to center distance of the stud relative to the standard building structure or an integer multiple thereof. For example, the center to center distance of a standard building stud is 16 inches. The panels may be 60 inches wide, 32 inches wide, 48 inches wide, or the like. In some structures, the center to center distance may be 12 inches, and in other cases the center to center distance may be 24 inches. For exterior structures, the panels preferably have two or more light metal gauge studs spaced apart from each other in the center of the center, and the standard building structure center to center distance to the stud is for example 12 inches, 16 inches, 24 inches or It is his multiple.

If the composite wall panel is wider than the stud width and the stud is placed on the sidewall of the body, the stud is not wide enough to cover the entire width of the sidewall and thus only form part of the sidewall. For composite wall panels wider than the stud, the panel has tongues at each end thereof. The tongue has a width equal to the width of the stud and the tongue is adapted to form a structural wall by being received and fixed in an open channel of the light metal gauge building structure track.

Preferred composite panels of the present invention include structural, insulating, insect repellent, and dimensionally stable composite wall panels for building structures, the composite wall panels being side bounded by two parallel sidewalls. A regular rectangular body of polymer foam having two opposing wall surfaces whose ends are bounded by two parallel end walls; It includes one light metal gauge stud in the body, the stud having a hollow central cavity, two studs separated by a wide rear wall extending the width of the stud, two parallel sidewalls, and an open slot extending into the central cavity. A rectangular cross section with a narrow front wall, the light metal gauge studs extend from at least one end wall of the body to the other end wall and parallel to the side walls of the body, and the polymeric foam extends into the central cavity of the stud to extend the stud into the body. The width of the panel between the two main walls is equal to the width of the stud, the side walls of the stud form part of the main walls, the back wall of the stud is one of the side walls of the body, The ends are received in and secured to the open channel of the light metal gauge building structure track to form a structural wall. It is locked.

Another preferred embodiment of the present invention comprises a structural, insulating, insect repellent, and dimensionally stable composite wall panel for a building structure, the composite wall panel having side boundaries bounded by two parallel sidewalls. A regular rectangular body of polymeric foam having two opposing circumferential walls which are shaped and whose ends are bounded by two parallel end walls; It includes two or more light metal gauge studs within the body, each stud having a hollow central cavity, two studs separated by a wide back wall extending the width of the stud, two parallel sidewalls, and an open slot extending into the central cavity. A rectangular cross section with two narrow front walls, each light metal gauge stud extending from at least one wall of the body to the other end wall and parallel to the side walls of the body. The polymeric foam extends into the central cavity of the stud to secure the stud to the body, the width of the panel between the major wall surfaces being greater than the width of the stud, with one or more sidewalls of each stud forming part of the same main wall surface of the body. A back wall of one stud is part of one of the side walls of the body, the body having a tongue at each of its ends, the tongue having a width equal to the width of the stud, and the tongue being a light metal gauge building It is adapted to form a structural wall by being received in and fixed in an open channel of the structure track.

A preferred wall panel system of the present invention is a structural wall for building construction based on light metal gauge studs, channels and track constructions, the wall having a first light metal gaze track having a fixed open channel for the building flooring system, and a ceiling And a second light metal gauge track having open channels for receiving, fixing, and supporting the roof structure member, wherein the tracks are at least two structural, insulating, insect repellent, and dimensionally stable for building structures. Separated and supported by the composite wall panels and secured to each other, each panel has two opposing major wall surfaces bordered by two parallel sidewalls and bounded by two parallel endwalls. A regular rectangular body of polymeric foam and two or more light metal gauge studs in the body Each stud has an empty central cavity and has two wide front walls extending to the width of the stud, two parallel side walls and two narrow front walls separated by an open slot parallel to and extending into the central cavity. Rectangular cross section, each light metal gauge stud extending from at least one end wall of the body to the other end wall and parallel to the side walls of the body, the polymeric foam extending into the central cavity of the stud to secure the stud to the body, respectively One or more sidewalls of the studs of which form part of the same major wall surfaces of the body, wherein the distance from the center to the center of the studs is the standard building structure center to center distance to the stud, and the studs of the panel are the sidewalls of the tracks. By means of a self-screwing screw extending into the sidewalls of the studs through the Claim is fixed to the second track.

The present invention relates to polymer / metal composites and panels that are lightweight, heat insulating and soundproof. The wall panel is preferably a structural support member for building construction. Panels can be used for exterior and interior walls of buildings. The invention also relates to a wall system constructed of a plurality of assembled lightweight, thermally insulating and soundproof polymer / metal composite wall panels as disclosed herein.

Lightweight, insulating and soundproof polymer / metal composite wall panels (hereinafter referred to as “composite wall panels”) comprise a continuous panel of extruded or expanded hermetically sealed polymer foam, the polymer foam being flat parallel Having an outer surface and an inner surface, a parallel longitudinal side, and a parallel end side, one or more light metal gauge studs are disposed in the polymeric foam with one side of each stud exposed to the inside of the wall panel and extending to the full longitudinal length of the wall panel . Wall panels are housed in and secured to light gauge metal lower tracks and upper tracks for building exterior and interior walls.

Lightweight gauge metal studs are placed on the wall panels at equal intervals, so that when the wall panels are assembled together, they have two metal studs that are equidistant from each other (eg 12 inches, 16 inches, 24 inches and 48 inches) Form the wall system of the above wall panel.

In another preferred embodiment of the invention, the metal studs are rectangular cross sections with open slots extending the length of the stud. The studs optionally have one or more holes in their back wall. The central cavity of each stud is filled with polymeric foam of the wall panel. One of the studs is preferably positioned to form part of one of the longitudinal sides of the wall panel. In one embodiment of the invention, the stud is positioned such that its open slot is exposed on the longitudinal side of the composite wall panel. In this embodiment, some of the polymeric material is removed from the open slots of the studs to form grooves. Tongues are formed on the other end of the composite wall panel so that when the composite wall panels are assembled together, the tongue of one wall panel joins the grooves of the adjacent wall panels to create a continuous wall system having a flat, non-stepped exterior and interior surfaces. Form.

In another embodiment of the present invention, the lightweight gauge metal is disposed inward from the longitudinal side of the composite wall panel such that only one side of each stud is exposed on the inner surface of the composite wall panel. In another embodiment of the invention, such wall panels are assembled by grooves in the panel body along one longitudinal side and tongues in the panel body along the opposite longitudinal side to form a wall system when adjacent composite wall panels are assembled together. The tongues and grooves meet and join together, thereby increasing the strength of the resulting wall system and minimizing air flow through the joints of adjacent panels and the loss of insulation for the resulting wall system.

In another embodiment of the present invention, the inner composite wall panel has a single light metal gauge stud with a wall panel made of polymer foam. The wall panel has two opposing flat surfaces forming two interior walls, two parallel and opposing longitudinal sides and two parallel end sides, namely an upper side and a lower side. The stud may be disposed along the edge of the composite wall panel, ie, it may constitute one of the ends, or the stud may be positioned in the middle of the composite wall panel so that the polymer foam forms the longitudinal side. The stud extends over the entire length of the wall panel and the depth of the wall panel from the building wall is equal to the maximum dimension of the light metal gauge stud. Tongues and grooves as described above may also be formed in the inner composite wall panel.

The composite wall panel of the present invention is prepared in a mold using conventional lightweight gauge metal studs available as standard products.

The fixtures may move up from the floor of the building or down from the ceiling through the composite wall panels, or optionally through the wall panels horizontally through openings or openings in the metal studs. The location of the holes and openings in the metal studs may be indicated on the outer major surface of the wall panel. However, for equipment such as wiring and plumbing to move longitudinally through the studs, the foam must be worked out of the central cavity and holes or openings of the stud, which is why the equipment is more likely to move from the top of the panel or from the bottom. Easy, fast and economic Guides or channels for the installation may be cut into the polymeric foam of the panel body using a heat gun readily available on the market. Holes, cutouts or pre-punches in the light gauge metal upper or lower tracks allow the facility to move through the track into the panel. Guides or channels may be cut in the panel to block such holes. Once the facility is placed in the guide or channel, the channel can be refilled with foam from the foam gun or left open because the surface of the composite wall panel is normally decorated. . The interior is decorated with plasterboard or paint and plaster structures or composite panels, or the exterior is decorated with Tyvek or equivalent film or targe, then stucco, paneling, cobblestone, brick, stone, composite paneling, elastic It is decorated with a polymer coating or the like. Refilling equipment guides or channels with polymeric foam is desirable to prevent equipment from moving freely in the channels to generate noise, provide a shield against fire, and provide a shield against air flow.

Studs are exposed on one side of the wall panel to fully secure the gypsum board or other wall covering to the surface of the composite wall panel, and to allow for the installation of seismic straps required for earthquake-prone geological and windy areas Should be. Composite wall panels cannot be properly strapped if the studs are completely enclosed by polymer foam that is 1/4 inch thick or more.

Wall systems using composite wall panels are manufactured by securing a U-shaped open lightweight gauge metal track to the perimeter of the floor, or the perimeter of the building slab, or the floor system. Panels are housed in side-by-side tracks and the metal studs of each panel are secured to the side walls of the track using self-tapping metal screws. The location of the studs covered with the polymeric foam is indicated by the stud indicators on the outer surface side of the wall panel.

Hereinafter, with reference to the accompanying drawings will be described a preferred embodiment of the present invention.

Referring to FIG. 1, the wall system of the present invention includes an upper track or plate 12A, a lower track or plate 12B, a composite wall panel 10, and a horizontal filler member 20. As shown in FIG. The tongue of the bottom end 38B of the composite wall panel 10 is received in the open channel 18 of the lower track 12B. The panels are aligned together to form a continuous wall system 9 with flat outer and inner surfaces. Composite wall panels are secured to the lower track by a self-tapping metal screw 24 that extends through the sidewalls 14 of the track into the sidewalls of the stud 32. After the composite wall panels are assembled together and secured to the lower track, the upper track 12A couples to the tongue at the upper end 38A of the panels. The upper track is secured to the wall panels by screwing the sidewalls 14 into the studs 32 with a self tapping metal screw 24.

Doors for wall structures (not shown) are manufactured with lightweight metal studs and tracks in a conventional manner. The transverse width, i.e. the width from one longitudinal side 40A of the panel 10 to the other longitudinal side 40B (side to side width) can be cut with a heat gun to the size at which the door can be fitted. Similarly, windows (not shown) may also be constructed in a conventional manner, with light metal gauge studs and tracks, and optionally, the panel is cut with a heat gun to accommodate small windows in the space between the two studs. can do.

For lightweight gauge metal studs, the “on center” for studs is typically 24 inches compared to 16 inches for wood studs. Buildings made of light metal gauge studs and tracks are much stronger than building beams with wooden “2 × 4” frame construction. The gauge of the metal used in the lightweight gauge metal studs may vary for certain applications. Gauges range from 12 to 25, but other gauges are also useful. It is difficult to measure the gauge of a lightweight gauge metal stud when the panel is formed. Accordingly, the display unit 46 may be disposed on the inner surface or the outer surface, and optionally on both sides, so that the metal gauge can be confirmed. This indicator is shown as element 46 in FIG. 1. The location of the stud on the outer surface 36 is indicated by the display 44, which may be a cut, a recess, a small groove, a diamond mark, or a paint mark. This allows the carpenter and installer to measure the position of the stud in the panel to secure the track to the panel and to attach the elements such as wall boards to the stud to the stud in the panel. One of the studs of the composite wall panel 10 is located on one of the longitudinal sides of the wall panel, and the indicator 44 can be omitted for the end studs, because the carpenter and the installer have 3 / We know that the studs are centered at 4 inches. However, the wall panels may also optionally have an indicator representing the end studs. As described above, after the wall baffles have been assembled and secured to the lower track and the upper track with the fixing device 24, the space partially formed by the shoulders 42A and 42B is provided with horizontal filler members 20. Partially filled with This allows the face 36 of the wall system 9 to be flat, smooth and continuous in side to side and from the sea to the top of the connected panels.

FIG. 2 has a main body 30 and two lightweight metal studs 32 partially embedded in the polymer foam body. The studs extend at least from one end 38A of the panel to the other end 38B. The studs and the body 30 may have the same length. As the polymer foam shrinks during manufacture of the panels, the body 30 becomes slightly shorter and narrower than the studs 32. This slight size difference is harmless to the panel, its use or wall system assembled from the panel. Panels are manufactured in a mold by injection, extrusion, or the like of a polymer or polymer foam. The polymeric foam flows into the central cavity of the stud through the openings 56 of the studs 32 and the holes 58 in the back wall 52. It is easier for the beams of holes 58 to fill the central cavity 57 with polymer foam through the open slot during the manufacturing process. Thus, in a preferred embodiment, the open slots of the studs are directed inside the polymer foam body 30 as shown in panel 10 of FIGS. 1-5 to thereby direct the central cavity of the stud with the polymer foam. Guarantee to fill Filling the central cavity with polymeric foam reinforces the studs and prevents displacement of the stud sidewalls 52 during fastening to the panel studs track, such as with screw fasteners.

The panel may have two or more studs, and may have three studs on the same center, for example a 16 inch center for a 48 inch wide panel. The body is a continuous piece of polymeric foam, which in some embodiments extends into the central cavity 57 of the stud through the open slot 56 and, in some embodiments, through the holes 58 in the stud to expand the stud and the body. Secure together. Optionally, the stud sides can be treated with an adhesive or primer to assist in bonding the polymeric foam to the walls of the stud.

The studs are separated by two narrow sidewalls 50, a back wall 52 along the width of the studs, and a slot 56 in communication with the central cavity 57 and two small front walls 54 parallel to the back wall. Has One of the narrow walls 50 of the studs 32 is exposed to the surface 34 of the panel. The body 30 of the panel shields the other walls of the studs to prevent corrosion from water and chemicals. In this embodiment, one stud located on one 40A of the longitudinal sides of the panel has one side wall 50 and its back wall 52 is also exposed to the outside. Lightweight gauge metal studs are conventional galvanized steel, optionally painted with corrosion resistant paint. The back wall of the studs typically has one or more holes 58 that can be used to move facility lines and the like through the panel (see also FIG. 3B).

The top of each panel has shoulders 42A and the bottom of each panel has shoulders 42B. These shoulders provide a large tongue in the top 38A and bottom 38B of the panel. These tongues are the width of the studs and fit into the open channel 18 of the upper and lower tracks as described above. One side of each stud is exposed on the inner surface 34 of the panel. It is easy to assemble the panels with studs exposed on one main wall, such as main wall 34. However, because the studs are only exposed on one wall, the polymeric foam of the body 30 protects the various sides of the studs from corrosion as described above. The side wall 50 of each stud is exposed. If the studs are disposed on the sides 40A and 40B with the back walls 50 facing out, these walls are also exposed. As shown in FIG. 5, the outer surface has stud indicators 44 representing the centers of the narrow walls 50 of each stud, so that the installer is able to thread the studs of the wall panel with screw fasteners (not shown). Know where to put paint boards, etc. The outer surface may also have one or more markings indicating the gauge of the lightweight gauge metal studs. Optionally, the marker may appear on the inner surface or both sides of the wall panel. The marking may be raised on the face of the panel polymer foam, or painted with paint or ink.

The body 30 of the panel is one continuous piece of polymer foam. These foam and light metal gauge studs are dimensionally stable and are not affected by humidity or moderate temperature changes. Preferably, the polymeric foam is preferably a sealed cell that is waterproof. Panels can be used in desert, tropical, subtropical, extreme and temperate environments and climates.

Panels can be designed for different earthquakes, wind pressure, live loads, dead loads and axial loads as defined by building codes and structure engineers. Polymeric foams, in particular expanded polystyrene, have good compressive strength and prevent torsion of the studs, which provide significant shear resistance.

6 shows another embodiment of the wall system of the present invention. Common elements between the wall system 9A of FIG. 6 and the wall system 9 of FIG. 1 have the same description and the same numbers as described above. The wall system 9A of FIG. 6 employs another embodiment of the composite wall panel 10A of the present invention. The wall panel has a longitudinal shoulder 43 that extends the length of the panel along one of the longitudinal sides 40 of the panel. When the panels 10A are assembled together, a slot 26 is formed which is filled with the vertical pillar member 22 as shown in FIG. In all other respects, the wall system of FIG. 6 is similar to the wall system of FIG.

7-10, the composite wall panel 10A has a shoulder 43, with two panels 10A facing the longitudinal side 40A and the longitudinal side 40B of the adjacent panel. Upon contact with each other in a state, a slot 26 is formed as described above, which is filled with the vertical pillar member 22 as described above after assembly of the wall system. In all other respects, panel 10A is similar to panel 10.

The back side 52 of the lightweight gauge metal stud 32 has a hole 58A of rectangular or other shape. The polymeric foam extends into the holes 58 and the open slot 56 to fill the central cavity 57 of the stud.

Referring to FIG. 11, composite wall panel 10B has two light metal gauge metal studs 32 disposed between the side walls 40A and 40B of the panel. The studs are not disposed on the sidewalls 40 like the panel 10. In all other respects, the composite wall panel 10B is similar to the composite wall panel 10A.

15 through 18, the composite wall panel 10C has a stud 32 disposed in one of the longitudinal walls of the panel 40A, with its open channel 56 outward. In contrast, composite wall panel 10 has an open channel 56 of lightweight gauge metal studs 32 located on one end 40A of the panel inwardly into body 30. As in all wall panels, the central cavity 57 of the studs is filled with polymer foam. The polymeric foam extends from the body 30C into the central cavity through the holes 58 in the back wall 52 of the stud to firmly bind the body and the stud. However, the central cavity may not be completely filled with polymer foam. The end studs 32 of panel 10C with open channels exposed to the outside form grooves 49 by having the polymer foam portion of the cut central cavity. The other longitudinal side 40B of the panel 10C is formed with a tongue 48 which is adapted to engage the groove 49 of the adjacent panel 10C (not shown) when the panels are placed and contacted together to form a wall system. It is. This tongue and groove structure binds the panels together and prevents drafts and air leakage through the joint formed by the side walls 40A and 40B between adjacent panels, thus increasing the strength of the wall system. In all other respects, panel 10C is similar to panel 10.

19 to 22, the composite wall panel 10D is shaped into a groove 49A formed into the body 30D on the longitudinal wall 40A and into a body 30D on the other longitudinal wall 40B. Similar to composite wall panel 10B except having 48A. When adjacent panels 10D are contacted or joined together within tracks 12A and 12B, hop 49A engages with tongue 48A of adjacent panel to form a strongly interlocking locking wall system of the composite wall panel. . The tongue and groove structure bind the individual panels together and prevent air flow between joints or joints of adjacent panels.

23 to 26, the composite wall panel 10E draws a lip 41 on the circumferential wall surface 36 of the panel on which the composite wall panel 10E is located on the longitudinal side wall 40A. It is similar to the composite wall panel 10 except that the shoulder 43 is formed on the main wall surface 36 at the other longitudinal side wall 40B of the panel. The lip 41 is adapted to engage the shoulder 43 of adjacent panels to form an overlap joint when the panels are joined in close contact with each other within the light metal gauge tracks 12A and 12B. The overlap joint prevents air flow between joints or joints of adjacent panels. Some studs 32 available on the market have round holes, rectangular holes 58, square holes or other detective holes in their back wall 52. In all other respects, the composite wall panel 10E is similar to the composite wall panel 10.

Referring to FIG. 27, the composite wall panel 70 is shown with a normal half of the width of the composite wall panels 10A to 10E. Panel 70 can be used primarily for interior wall systems. However, it can also be used for exterior wall systems. Preferably, composite wall panels 10 to 10E are used for inner walls. Conveniently, the width of the panel 70 between the longitudinal walls 74A and 74B is the center to center distance between the studs of the standard building structure required for the wall structure. Typically, 24 inches or 16 inches, the inner composite wall panel 70 has a body 72 made of polymer foam and a lightweight gauge metal stud 32 fixed to one end of the body. The polymeric foam extends into the central cavity 57 of the stud. The width of the panel between the circumferential walls 76A and 76B is the width of the stud 32. The inner return wall panel 70 is thinner than the composite wall panels 10-10E because the insulation requirements of the inner wall are less than the outer wall. Panels 70 are used and assembled in the same manner as panels 10-10E.

28A, 28B, and 29, the lower track 12B is attached to the floor system 17. Lower side 78B of one or more panels 70 is inserted into open channel 18. Lower track 12B and upper track 12A are shown in phantom in FIG. Multiple panels are inserted into the tracks to contact each other to form a continuous smooth inner wall (not shown). In this way, the studs 32 of each panel will be "on center" as required by the building code. After the panels are assembled to the lower track, the upper track 12A is lowered onto the upper side 78A of the panel 78 with the open channel extending over the upper side 78A and on the upper side. Sidewalls 14 of the upper and lower tracks allow the walls to be aligned to form a smooth continuous wall on each axis of the panels. The panels screw into the tracks by screwing the self-tapping metal screw lamp 24 into the side walls 50 of the stud 32 of the panel through the side wall 14 of the track. Panel surfaces 76A and 76B may be mortar coated, covered with flagstone, tiled, or the like. The flagstone or other paneling may be adhesively attached to the panel or screwed into the studs of the panel.

Doors or other elements in the wall can be made of light metal gauge studs and light metal gauge tracks in conventional manner. The equipment is carried from top to bottom or from bottom to top through guides or channels in the polymer foam of the body cut with holes in the tracks and the heat cutting blade. Alternatively, the installations can be moved horizontally through the panels.

Looking at FIG. 30, another embodiment of the inner composite wall panel 70A has a light metal gauge stud 32 located within the body 72A of the panel between the longitudinal walls 74A and 74B. The main body 72A of the panel extends on both sides of the stud, and the foam polymer of the main body extends into the central cavity 57 of the stud. The back wall of the stud 52 has a number of holes 58 (see FIG. 30A) which may be circular, rectangular, square, diamond, oval. The polymeric foam extends into the central cavity through open slots 56 and holes 58 to securely bind the studs to the polymeric foam body.

Referring to FIG. 31, the inner composite wall panel 70B of another embodiment includes a body 72B and a stud 32. The body 72B is composed of a polymer foam, like the other composite wall panels of the present invention, wherein the polymer foam has a central cavity of the stud through holes 58 (not shown) in the back wall 52 of the stud 32. I stretch in (57). The polymeric foam extending through the hole 58 between the central cavity and the body 72 binds the studs 32 with the body.

Referring to FIG. 32, a panel 100 is shown having a large, i.e. wide, stud 32A and a thick body 30F. Such large size panels can be easily manufactured and used. These parons may be required for heavy-duty constructions where the ceiling, ridge, or roof loads are practically greater than in typical one- and three-story frame buildings. The polymeric foam fills the body 30F and extends through the open slot 56A into the central cavity 57A of the stud.

Composite wall panels of the present invention provide many advantages over conventional metal / polymer composite wall panels. Composite wall panels are made from commercially available materials including light metal gauge studs 32 and polymeric foams. Many types of polymeric foams can be used, including extruded polymers such as polystyrene, polyethylene, polyisosaulite and lollyurethane and expanded polymers such as polystyrene and polyurethane. Panels are dimensionally stable and can be easily covered with paint, plaster, gypsum board, composite panels, tiles and the like. The panels are lightweight and can be easily carried by one person, even if they contain up to four studs and have dimensions as large as 4x12 '. Composite wall panels cannot withstand combustion. Polymeric foams include refractory materials known in the art, such as halogenated phosphates, oxides, and the like. The polymeric foam is preferably a closed cell foam, which prevents water penetration and provides a very high degree of insulation and sound insulation. The panels are not completely damaged against dry rot and are completely resistant to damage by termites. The inert interaction of the studs with the polymeric foam body and the inert interaction of the assembled panels in the fixed and wall systems with the top track and the bottom track provide significant lateral rigidity and very large vertical load carrying capacity than the wood frame walls being compared. Provide a very strong and solid wall to provide.

Composite wall panels offer additional benefits because they are already accepted and widely used in the industry and do not require extensive testing to obtain building and structural approvals from government agencies, ICBOs, BOCCA, etc.

Panels can be used to build the structure using standard wood framing techniques. Wall / frame assembly using the panels is done on the ground or floor and then lifts the wall / frame assembly with complete work, such as line and verticalization of the wall when the wall is on, and completes the fixing of the track and stud.

The panels are square and have straight flat walls. Thus, panels and tracks can be assembled with minimal verticalization compared to straight wood or light metal frames. However, the assembled wall system allows some stacking of the assemblies to verticalize the assembled wall system when the floor system is not exactly horizontal.

In a typical light metal frame, the stud sidewalls 50 must be secured to the track sidewall prior to fastening, because the fasteners screw into the sidewall 50 of the stud 32 through the sidewall 14 of the track 12. When combined, the stud's sidewall bends inward toward the open slot 56 of the stud, causing a gap to form between the track's sidewall and the stud's sidewall. This gap weakens the connection between the stud and the track, so that the stud sidewall is fixed to the sidewall of the track to prevent this gap. This gap problem is fixed to the side walls of the track to prevent the panel of the present invention. This gap problem can be avoided by using the panel of the present invention because the polymer foam body, which at least partially fills the central cavity 57 of the stud, has the side wall of the stud bowed inwards towards the open slot 58. Because it prevents. Thus, the track and panel studs can be fastened without the need for fixing.

Panels are manufactured in a mold to form a continuous body of polymeric foam. The stud can be easily positioned in the mold with one side wall 50 of the stud 32 aligned with the inner surface of the wall panel and positioned at the bottom of the mold. The polymeric foam is injected, cast or extruded into a mold to form the composite wall panel described herein.

Lightweight gauge steel studs, lightweight cold-formed steel members, cold-formed steel structural members, metal studs or steel studs, conventional light metal gauge studs, also known as joists, are 1 and 3/8 inches, 1 and 1 It can be employed in the present invention including SHD, XSHD, and XX SHD studs having various leg sizes, such as / 2 inches, 2 inches, and various web sizes, such as 2 and 1/2 inches to 8 inches. The web size is the width of the stud and the leg size is the thickness of the stud. The width of the back wall is equivalent to the web of the stud and the length of the side wall is the length of the legs of the stud. The light metal gauge studs used in the present invention comply with the 1986 edition of the American Institutes of Steel (ASI) publication “Specifications for the Design of Cold Formed Steel Structure Members” and its 1989 revision and conform to the Uniform Building Code. It is preferably configured.

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Claims (20)

In a structural, insulating, insect repellent, and dimensionally stable composite wall panel for a building structure, two side walls are bounded by two parallel sidewalls and two parallel end walls bounded by two parallel end walls. A regular rectangular body of polymer foam having two opposing circumferential walls; One or more light metal gauge studs in the body, the studs having an empty central cavity and having a wide rear wall extending to the width of the stud, two parallel sidewalls, and parallel to the bowel wall and into the central cavity; A rectangular cross section having two narrow front walls separated by elongated opening slots, each light metal gauge stud extending from at least one end wall to the other end wall and parallel to the side wall of the body, wherein the polymer foam And extending into the central cavity of a stud to fix the stud to the body, wherein at least one side wall of each stud forms part of the same circumferential wall of the body. The method of claim 1, The width of the panel between two major wall surfaces is equal to the width of the stud, and the side walls of the stud form part of the major wall surfaces. The method of claim 2, At least one stud is one of the sidewalls of the body. The method of claim 2, And end portions of the body are received in and secured to an open channel of a light metal gauge building structure track to form a structural wall. The method of claim 2, A back wall of one stud is one of the side walls of the body. The method of claim 1, Composite wall panel, characterized in that the composite wall panel has two or more light metal gauge studs. The method of claim 6, Wherein the distance between the centers of the studs to the centers is a standard building structure center to center distance to the stud. The method of claim 7, wherein At least one stud is one of the sidewalls of the body. The method of claim 8, A back wall of one stud is part of one of the side walls of the body. The method of claim 8, The width of the panel between the peripheral wall side is greater than the width of the stud composite wall panel. The method of claim 10, The body has a tongue portion at each of its ends, the tongue having a width equal to the width of the stud, the tongue being received in and secured to an open channel of a light metal gauge building structure track to form a structural wall. Composite wall panel, characterized in that. The method of claim 10, 5, wherein at least one stud is part of one of the sidewalls of the body. The method of claim 10, A composite wall panel, wherein the back wall of one stud is part of one of the side walls of the body. In a structural, insulating, insect repellent, and dimensionally stable composite wall panel for a building structure, two side walls are bounded by two parallel sidewalls and two parallel end walls bounded by two parallel end walls. A regular rectangular body of polymer foam having two opposing circumferential walls; It includes one light metal gauge stud in the body, the stud having an empty central cavity, two studs separated by a wide rear wall extending the width of the stud, two parallel sidewalls, and an open slot extending into the central cavity. A rectangular cross-section with two narrow front walls, a light metal gauge stud extending from at least one end wall to the other end wall and parallel to the side walls, wherein the polymeric foam extends into the central cavity of the stud to extend the stud to the body Fixing, the width of the panel between two major wall surfaces is equal to the width of the stud, the side walls of the stud form part of the major wall surfaces, the back wall of the stud is one of the side walls of the body, The ends of the body are received in and secured to the open channel of the light metal gauge building structure track. Writing the composite wall panel, characterized in that which is to form the structural wall. In a structural, insulating, insect repellent, and dimensionally stable composite wall panel for a building structure, two side walls are bounded by two parallel sidewalls and two parallel end walls bounded by two parallel end walls. A regular rectangular body made of polymer foam having two opposing circumferential walls; It includes two or more light metal gauge studs within the body, each stud having an empty central cavity, separated by a wide back wall extending the width of the stud, two parallel sidewalls, and an open slot extending into the central cavity. A rectangular cross section having two narrow front walls, each light metal gauge stud extending from at least one end wall to the other end wall and parallel to the side walls, wherein the polymeric foam extends into the central cavity of the stud to A stud is fixed to the body, the width of the panel between the major wall surfaces is greater than the width of the stud, at least one sidewall of each stud forms part of the same main wall surface of the body, and the back wall of one stud A part of one of the side walls of the body, the body having a tongue at each of its ends, the tongue And a portion having a width equal to the width of the stud, the tongue being adapted to form a structural wall by being received in and secured to an open channel of a light metal gauge building structure track. The method of claim 1, Wherein the width between its sides of the wall panel is equal to the standard building structure center to center distance to the stud, or an integer multiple thereof. The method of claim 14, Wherein the width between its sides of the wall panel is equal to the standard building structure center to center distance to the stud, or an integer multiple thereof. The method of claim 15, Wherein the width between its sides of the wall panel is equal to the standard building structure center to center distance to the stud, or an integer multiple thereof. The method of claim 15, Composite wall panel, characterized in that the distance between the center to the center of the studs is the center to center distance of the standard building structure with respect to the stud. Structural walls for building construction based on light metal gauge studs, channels and track structures, the first light metal gauge track having fixed open channels for building floor systems, and receiving, fixing and supporting ceiling and roof structure members A second light metal gauge track having an open channel for the construction, the tracks being separated and supported by two or more composite wall panels that are structural, insulating, insect repellent, and dimensionally stable for a building structure and are secured to one another. Each panel comprises a regular rectangular body of polymer foam having two opposing major wall surfaces bounded by two parallel sidewalls and bounded by two parallel endwalls; Including two or more light metal gauge studs in the body, each stud having an empty central cavity A rectangular cross section having a wide rear wall extending to the width of the studs, two parallel side walls, and two narrow front walls separated by an open slot parallel to the bowel wall and extending into the central cavity, A light metal gauge stud extends from at least one end wall to the other end wall and is parallel to the side walls of the body, wherein the polymeric foam extends into the central cavity of the stud to secure the stud to the body, one of each stud The above sidewalls form part of the same circumferential walls of the body, the distance from the center to the center of the studs is the standard building structure center to center distance to the stud, the studs of the panel through the sidewalls of the tracks. The first and second by self-screwing screws that extend into the sidewalls of the studs Structural wall for building construction, characterized by being fixed to tracks.