US20030056456A1

US20030056456A1 - Thermally insulating building wall structure

Info

Publication number: US20030056456A1
Application number: US09/961,568
Authority: US
Inventors: John Heydon
Original assignee: HEYDON INTERNATIONAL Inc
Current assignee: HEYDON INTERNATIONAL Inc
Priority date: 2001-09-24
Filing date: 2001-09-24
Publication date: 2003-03-27
Also published as: AU2002339982A1; WO2003027406A3; US20030192276A1; WO2003027406A2

Abstract

An insulative building wall structure including parallel channel-bearing track and load plate structures with a plurality of spaced apart posts extending perpendicularly there between and a plurality of respective foam panels disposed between the posts. The panels are provided with a plurality of vertical slits such that width adjustment thereof can be accomplished on-site by removing an appropriate number of slitted strips from a panel. Each panel is maintained such that a void is formed between respective interior edges of the channels and the interior surfaces of the foam panels. A wall surface panel is secured to respective interior outer edges of the track and load plate structures to create an insulative dead air space, corresponding to the above-described void, between the interior surface of each foam panel and the wall surface panel.

Description

BACKGROUND OF THE INVENTION

The present invention relates in general to a building wall, and in particular to a building wall structure employing foam panels, preferably multiply-slit for ease of sizing at a work site, in combination with adjacent dead air space between the foam panels and a covering wall surface panel such that superior insulative properties are realized in maintaining economical and comfortable ambient conditions within a building constructed of such wall structures.

It is generally readily recognized that construction in general, and residential construction in particular, many times suffers from poor building materials and/or poor construction practices as exemplified specifically in the amount of air leakage that occurs in an average house over the course of high-temperature and low-temperature seasons. While heat transfer can occur through roof structures, glass windows and doors, chimneys, etc., a major contributor toward heat transfer occurs from typical wall structures. In particular, many such wall structures are little more than an inside sheet of thin drywall, an outside finish material applied over a mesh base, and support posts there between for maintaining these components in a generally vertical position. When this type of construction is employed, outside temperature changes are quickly reflected in inside temperature changes because heat transfer through the wall structure is nearly unimpeded.

One prior art teaching for alleviating this flawed construction approach is disclosed in U.S. Pat. No. 5,353,560, to Heydon, wherein a building structure includes a wall formed of a plurality of solid foam wall sections disposed between and encapsulating vertical floor-to-ceiling posts. These foam wall sections extend the full depth between any inside wall panel and outside finish material as would be found in a finished construction and certainly perform well in insulating against heat transfer. However, a need yet remains for an even better insulative wall structure as well as a more easily-executed on-site construction process for assemblage of such wall structure.

Accordingly, a primary object of the present invention is to provide a building wall structure that includes both foam and integrated dead air space therewith for cumulative heat transfer prohibition.

Another object of the present invention is to provide a building wall structure that incorporates pre-slitted foam panels to permit rapid panel sizing through simple on-site removal of a slitted portion of the panel.

These and other objects of the present invention will become apparent throughout the description thereof which now follows.

BRIEF SUMMARY OF THE INVENTION

The present invention is an insulative building wall structure for use as an outside wall for a building construction. The wall structure includes an elongate track structure including an elongate first channel with a plurality of parallel spaced apart posts extending perpendicularly therefrom and a plurality of respective foam panels respectively disposed between the posts. The panels are provided with a plurality of vertical slits to produce slitted strips such that width adjustment of each panel can be quickly, easily, and accurately accomplished on-site by removing an appropriate number of strips from an inward site of the panel. While the slits can extend through the entire thickness of the panels, it is preferable that they extend only through about 90% of the thickness. When the slits do extend through the full thickness, an adhesive film is adhered to substantially the entire exterior surface of each panel such that the slitted portions remain together. A thermal-resistant material such as a reflective foil sheet is adhered to substantially the entire interior surface of each panel for enhancing heat-transfer prohibition. Each panel has a transverse depth dimension situated in the first channel which is less than the transverse depth dimension of the first channel, and is maintained within the first channel such that a void is formed between the interior edge of the channel and the interior surface of the foam panel. The wall structure additionally includes an elongate load plate structure including an elongate second channel which is parallel to the first channel of the track structure and disposed at the opposite respective ends of the posts such that the posts and foam panels reside between the track and load plate structures. Finally, a wall surface panel is secured to respective interior outer edges of the first and second channel structures. This securement finalizes the creation of a dead air space, corresponding to the above-described void, that resides between the interior surface of each foam panel and the wall surface panel.

Employment of the above-defined wall structure in the construction of houses and other building-types promotes efficiently-operational construction techniques since the structure components are easily and accurately assembled on-site according to predetermined exact size requirements as called out in typical blueprint specifications. Employment of the above-defined wall structure in such construction also promotes exceptional energy conservation through excellent R-values produced with relatively minimal and inexpensive foam product as occupants of so-constructed buildings experience superior interior temperature maintenance without critical regard for, or fluctuation because of, outside temperature readings. Of greatest importance is the combination of the reflective foil sheet facing the dead air space. In particular, and in addition to reducing thermal transfer, the reflective surface facing the dead air space provides a radiant barrier that reflects up to 97% of the sun's heat away from the interior of the building structure to thereby significantly reduce the amount of energy required to cool the structure.

BRIEF DESCRIPTION OF THE DRAWINGS

An illustrative and presently preferred embodiment of the invention is shown in the accompanying drawings in which: [0009]
FIG. 1 is a perspective view of a partially cut-away building wall structure; [0010]
FIG. 2 is a top plan view of the wall structure of FIG. 1; [0011]
FIG. 3 is a top plan view of a wall structure similar to that of FIG. 2 except for slit length; [0012]
FIG. 4 is a perspective view of a partially cut-away interior of a wall structure; and [0013]
FIG. 5 is a perspective view of an exterior of a wall structure. [0014]

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. [0015] 1-5, a building wall structure 10 is illustrated. The structure 10 includes a track structure 12 having an interior outer wall 14, an exterior outer wall 16, and an elongate first channel 18 with a vertical depth dimension, a transverse depth dimension, an interior longitudinal edge 20, and an exterior longitudinal edge 22. A plurality of parallel spaced apart metal posts 24 each have a first end 26 thereof disposed in the first channel 18 for perpendicular projection from the track structure 12. Each post 24 non-limitedly is configured as a generally flat-walled U-shape configuration forming a post channel 28 with a channel entry thereto formed by opposing terminals 30, 32 of said U-shape and accessible from one lateral side in line with the first channel 18, with each post 24 positioned with respect to a sequentially-next post such that each channel entry faces the same direction.
Each of a plurality of [0016] respective foam panels 34, preferably constructed of polystyrene, is disposed between two sequentially disposed posts 24, and is provided with a plurality of slits 36 situated between the interior and exterior 38, 40 thereof and perpendicular to the track structure 12. The slits 36 are spaced from each other a variable distance, with distances preferably represented at 0.5 inch, 1.75 inch, and 2.25 inches in each panel 34. As shown in FIGS. 1, 2, 4, and 5, as preferred, each slit 36 does not extend through the entire thickness of each panel 34, but rather terminates at a site 37 no greater than about 90% of the thickness (exemplified as no less than about 0.5 inch from the exterior surface 40) of each panel 34. However, and as shown in FIG. 3, each slit 36 a can extend through the entire thickness. When this embodiment is chosen, the exterior surface 40 of each panel 34 is covered with an adhesive film 41 for maintaining the slitted panel 34 together.
At least one lateral edge of each [0017] foam panel 34 is provided with a tongue 60 which is disposed within the post channel 28 of an adjacent post 24. Each foam panel 34 has a transverse depth dimension situated in the first channel 18 which is less than the transverse depth dimension of the first channel 18, and each panel 34 must be spatially maintained such that a void 39 is formed and maintained between the interior 38 of the panel 34 and the interior longitudinal edge 20 of the first channel 18. Such maintenance is accomplished with a maintenance structure here exemplified as an extension 44 of the exterior 40 of each panel 34. In particular, each extension 44 bears against a respective outside surface site 46 of the exterior outer wall 16 of the track structure 12. In this manner, the panel 34 is retained in place such that the void 39 is present. As clearly shown in FIG. 2, a tab 44 a of one extension 44 extends toward, and overlaps a tab 44 b of an adjacent extension 44 also extending toward, but beneath, the first tab 44 a to meet at an outside site 48 bridging a post 24 disposed between the adjacent panels 34 and behind the extensions 44 a , 44 b . To assure a substantially air-tight retention of panel junction sites, each extension 44 a is provided with a notch 45 which substantially aligns with the midpoint of the post 24. This notch 45 serves as a guide for aligning a center opening 47 (FIG. 5) of a series of standard lathe anchors 49 which are pressed into the extension 44 preferably at 10-12 inch spacing as clearly shown in FIG. 5. Fasteners 51, non-limitedly exemplified by screws and air-driven pins as known in the art, are inserted through the respective openings 47 and extend to the post 24 for securement therewith and resulting tight retainment of the extensions 44 a and 44 b to each other. The interior surface 38 preferably is covered with a thermally-resistant material such as an adhesive reflection material 33 (e.g. a standard foil) for enhancement of insulative properties as earlier described.
An elongate load plate structure [0018] 50 substantially identical to and parallel with the track structure 12 finishes the second end of the wall structure 10. In particular, the load plate structure 50 has a second channel 54 that receives the second end 52 of each post 24, possesses the same transverse depth dimension of each foam panel 34 (i.e. less than the transverse depth dimension of the channel 54 for void maintenance), positions the extension 44 and extension placement identically to that earlier described for the track structure 12, and, in concert with the track structure 12, generally stabilizes the wall structure 10. A wall surface panel 58 as exemplified by drywall wall-board is secured to the respective interior outer walls 14, 15 of the track structure 12 and load plate structure 50 for finishing the interior of the wall structure 10. As shown in the drawing figures, the void 39 is positioned and maintained immediately behind a wall surface panel 58 (e.g. drywall) to thereby provide a dead air space for substantially the entire expanse of the wall structure 10.
Operationally, the [0019] wall structure 10 can be assembled at a work site. Specifically and sequentially, the track structure 12 is secured to a standard foundation member (not shown), the posts 24 are placed and the foam panels 34 are slid into place. If a particular panel 34 is too wide to fit between posts 24, a builder easily cuts through appropriate slits 36 to thereby remove a portion of the panel 34 and thus produce a panel 34 whose width correctly fits the available spacing. Once this operation is completed, the load plate structure 50 is placed to replicate post- 24 and panel- 34 connectivity substantially identical to that found in the identical relationships with the track structure 12. The wall surface panel 58 then is attached, preferably with an adhesive, to the interior outer walls 14, 15 of the track structure 12 and load plate structure 50 to thus create the dead air space (void 39) there behind, and thereafter can be painted or otherwise used to finish the decor of a room. The exposed exterior surface 40 of each panel 34 can be traditionally covered with stucco, brick, wood, or the like to provide a visually acceptable structural appearance. In this manner, a highly thermally-efficient yet traditionally-appearing building is produced.
While an illustrative and presently preferred embodiment the invention has been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by prior art. [0020]

Claims

What is claimed is:

1. A building wall structure comprising:

a) an elongate track structure having an interior outer wall, an exterior outer wall, and an elongate first channel with a vertical depth dimension, a transverse depth dimension, an interior longitudinal edge, and an exterior longitudinal edge;

b) a plurality of parallel spaced apart posts each having a first end thereof disposed in the first elongate channel and a second end, with each said post substantially perpendicular to the track structure and having a transverse depth dimension;

c) a plurality of respective foam panels each disposed between two respective sequential posts, each said panel having a transverse depth dimension situated in the first channel which is less than the transverse depth dimension of the first channel, an interior surface, and an exterior surface;

d) a maintenance structure for maintaining the interior surface of each panel spaced from the interior longitudinal edge of the first channel, whereby a void is formed between the interior longitudinal edge of the first channel and the interior surface of each foam panel;

e) an elongate load plate structure having an interior outer wall, an exterior outer wall, and an elongate second channel with a vertical depth dimension, a transverse depth dimension, an interior longitudinal edge, and an exterior longitudinal edge, said load plate structure parallel to the track structure and housing within said second elongate channel the second end of each said post; and

f) a wall surface panel secured to the respective interior outer walls of the track structure and load plate structure, whereby a dead air space corresponding to said void exists between the interior surface of each foam panel and the wall surface panel.

2. A building wall structure as claimed in claim 1 wherein the foam panels are formed of polystyrene.

3. A building wall structure as claimed in claim 1 wherein each post comprises a generally flat-walled U-shape configuration forming a post channel with a channel entry thereto formed by opposing terminals of said U-shape and accessible from one lateral side in line with the elongate first channel, with each post positioned with respect to a sequentially-next post such that each channel entry faces the same direction.

4. A building wall structure as claimed in claim 3 wherein each foam panel is configured at at least one lateral end thereof as a tongue, whereby said at least one said tongue is disposed within the post channel.

5. A building wall structure as claimed in claim 1 wherein the maintenance structure is an extension of the exterior surface of each panel, whereby said extension bears against a respective outside surface site of the exterior outer walls of the track and load plate structures.

6. A building wall structure as claimed in claim 5 wherein the extension of one panel additionally extends toward an extension of an adjacent panel to meet at an outside site in an aligned relationship with a midpoint of the post disposed between said adjacent panels and behind said extensions.

7. A building wall structure as claimed in claim 6 additionally comprising at least one elongate fastener extending from an exterior site such that said at least one elongate fastener passes through extensions adjacent each other and is secured within said post.

8. A building wall structure as claimed in claim 7 wherein a plurality of fasteners extend from respective exterior sites through said extensions adjacent each other and are respectively secured within said post.

9. A building wall structure as claimed in claim 6 wherein each foam panel has a plurality of slits between the interior and exterior surfaces thereof and perpendicular to the track and load plate structures.

10. A building wall structure as claimed in claim 9 wherein the slits extend about 90% from said interior to said exterior surfaces.

11. A building wall structure as claimed in claim 9 wherein the slits extend 100% from said interior to said exterior surfaces.

12. A building wall structure as claimed in claim 11 additionally comprising an adhesive film adhered to substantially the entire exterior surface of each foam panel.

13. A building wall structure as claimed in claim 1 wherein each foam panel has a plurality of slits between the interior and exterior surfaces thereof and perpendicular to the first and second load plate channel structures.

14. A building wall structure as claimed in claim 13 wherein the slits extend about 90% from said interior to said exterior surfaces.

15. A building wall structure as claimed in claim 13 wherein the slits extend 100% from said interior to said exterior surfaces.

16. A building wall structure as claimed in claim 15 additionally comprising an adhesive film adhered to substantially the entire exterior surface of each foam panel.

17. A building wall structure as claimed in claim 13 additionally comprising a thermal-resistant material adhered to substantially the entire interior surface of each foam panel.

18. A building wall structure as claimed in claim 9 additionally comprising a thermal-resistant material adhered to substantially the entire interior surface of each foam panel.

19. A building wall structure as claimed in claim 3 additionally comprising a thermal-resistant material adhered to substantially the entire interior surface of each foam panel.

20. A building wall structure as claimed in claim 1 additionally comprising a thermal-resistant material adhered to substantially the entire interior surface of each foam panel.