US20070283662A1

US20070283662A1 - Prefabricated wall component apparatus and system

Info

Publication number: US20070283662A1
Application number: US11/272,948
Authority: US
Inventors: David J. Rades
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-11-14
Filing date: 2005-11-14
Publication date: 2007-12-13
Also published as: WO2007059003A3; WO2007059003A2

Abstract

A pre-fabricated metal stud wall apparatus and system. End studs are placed non-parallel at a 45-degree angle. Abutting adjacent 45-degree walls together, with no loss in square footage can easily create corners. The walls can be made independent of building plan. As such, any 2-foot 8-foot section (or whatever length) can simply be purchased and conformed to any building plan regardless of style or shape (octagonal, hexagonal, square and the like). Each stud includes a series of slots. When the two angled studs are placed side by side, the slots align. A hole present at the end of the wall allows a rod to be placed into it. The rod includes a series of fingers that insert into the aligned slots, thereby locking the adjacent walls together. The walls can include any other number of cutouts for windows, utilities and the like.

Description

BACKGROUND

I. Field of the Invention
The present invention relates generally to the field construction and more particularly to prefabricated wall component apparatus and system.
II. Description of the Related Art
Prefabricated steel stud walls are conventionally used to construct various structures and dwellings, such as modular homes, and are typically fabricated with parallel metal studs in pre-selected lengths, such as 2-foot, 4-foot, 6-foot, 8-foot and the like. The resulting component is a planar generally rectangular wall component with squared ends and edges. When the prefabricated walls are placed together to make a structure such as a home, square footage can be easily lost because the walls must be overlapped to create a corner, generally resulting in the loss of one side of the corner by the thickness of the overlapping panel. In addition, lengths of the prefabricated walls often have to be custom made depending on the building plan.

SUMMARY

In general, the invention features a pre-fabricated metal stud wall as a prefabricated wall component apparatus. In the present invention, the end studs are placed non-parallel at a 45-degree angle. In this way, abutting adjacent 45-degree walls together, with no loss in square footage can easily create corners. More importantly, the walls can be made independent of building plan. As such, any 2- foot 8-foot section (or whatever length) can simply be purchased and conformed to any building plan regardless of style or shape (octagonal, hexagonal, square etc.) Furthermore, each stud includes a series of slots. When the two angled studs are placed side by side (for example, when a corner is formed by placing two adjacent walls), the slots align. A hole present at the end of the wall allows a rod to be placed into it. The rod includes a series of fingers that insert into the aligned slots, thereby locking the adjacent walls together. The walls can include any other number of cutouts for windows, utilities and the like.
In general, in one aspect, the invention features a prefabricated wall apparatus, including an outer wall, an inner wall, vertical studs positioned between the inner and outer walls and connected perpendicular to an top plate and a sill plate and end studs positioned on either ends of the vertical studs and rotated at a 45 degree angle with respective to the inner and outer walls.
In one implementation, the apparatus further includes a thermal break located between the studs and the outer wall.
In another implementation, the thermal break forms an airspace between the studs and the outer wall. The airspace can include a two part expanding foam thermal break, which also provides rigidity in the airspace.
In another implementation, the apparatus further includes a series of slots positioned along the end studs.
In another implementation, the apparatus further includes an upper opening located on the top plate adjacent the end studs.
In still another implementation, the connection between the top plate and the end studs has an isosceles trapezoid profile.
In yet another implementation, the base angles of the isosceles trapezoid profile are 45°.
In another aspect, the invention features a prefabricated wall system, including a first prefabricated wall panels having an top plate and two end studs, the top plate and end studs forming base angles less than 90 degrees, a second prefabricated wall panel having at least one end stud abutted against and flush with one of the end studs of the first prefabricated wall panel, thereby forming an outer corner and a third prefabricated wall panel having at least one end stud abutted against one of the end studs of the first prefabricated wall panel such that a right angle space is formed between the end studs of the first and third prefabricated panels.
In one implementation, the system further includes a series of slots along each of the end studs.
In another implementation, the series of slots on the end stud of the first prefabricated panel that is abutted against and flush with the end stud of the second prefabricated wall panel are aligned with the series of slots on the second prefabricated wall panel.
In another implementation, the system further includes an top plate on each of the second and third prefabricated wall panels.
In another implementation, the system further includes an opening on each of the top plates adjacent the series of slots on the end studs.
In another implementation, the system further includes a rod located within at least one of the openings of the first and second prefabricated panels and positioned parallel the end studs.
In still another implementation, the system further includes a series of fingers positioned along the rod.
In yet another implementation, the fingers are positioned within the aligned slots of the end studs of the first and second prefabricated wall panels.
In another aspect, the invention features a prefabricated wall kit, including a prefabricated wall panel having vertical studs positioned between and perpendicular to an top plate and a sill plate and end studs positioned on either ends of the vertical studs and having base angles of 45 degrees, the end studs having a series of slots along the studs, and an elongated rod having a series of fingers, for insertion in an opening on the top plate so that the fingers fit within the series of slots so that the prefabricated panel can be connected and locked to another prefabricated panel having a corresponding end stud with a series of slots.
One advantage of the invention is that little to no square footage is lost when the panel apparatuses are connected to one another to create walls and corners.
Another advantage of the invention is that the prefabricated panels can be preformed into a variety of dimensions.
Another advantage of the invention is that it enables nominal stock/standard inventory on-hand.
Another advantage of the invention is that it is adaptable to virtually all house plans.
Another advantage of the invention is that corners can be secured by locking adjacent panels forming the corners to one another.
Another advantage of the invention is that panels can be subsequently detached to expand architectural designs.
Other objects, advantages and capabilities of the invention are apparent from the following description taken in conjunction with the accompanying drawings showing the preferred embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a top view of an embodiment of a prefabricated wall system;

FIG. 1B illustrates a side view of an embodiment of a prefabricated wall panel apparatus;

FIG. 2 illustrates a partial top view of an embodiment of a prefabricated wall panel apparatus;

FIG. 3 illustrates a side view of an embodiment of a prefabricated wall panel apparatus;

FIG. 4A illustrates a partial side view of constituent components of a prefabricated wall system;

FIG. 4B illustrates a top view of an embodiment of a connection rod;

FIG. 5 illustrates a partial close up view of an embodiment of a prefabricated wall system;

FIG. 6 illustrates an upper partial view of an embodiment of a prefabricated wall system;

FIG. 7 illustrates a lower partial view of an embodiment of a prefabricated wall system;

FIG. 8 illustrates a top view of another embodiment of a prefabricated wall system;

FIG. 9 illustrates a partial top view of another embodiment of a prefabricated wall system; and

FIG. 10 illustrates two embodiments of connecting plates.

DETAILED DESCRIPTION

Referring to the drawings wherein like reference numerals designate corresponding parts throughout the several figures, reference is made first to FIG. 1A that illustrates a top view of an embodiment of a prefabricated wall system 100. In general, the system 100 includes a number of prefabricated wall panels 105 (prefabricated wall panel apparatuses 105). In a typical embodiment, the panels 105 are steel stud panels, although it is understood that other materials such as wood can be used in other embodiments. Typically, the panels 105 include an inner wall 110 and an outer wall 115. The inner and outer walls 110, 115 can be a variety of known materials such as wood, particle board, ply wood, chip/wafer board and the like. In a typical embodiment, additional interior covering is added such as dry wall, and additional exterior covering is added such as vinyl siding or other suitable materials.
Referring still to FIG. 1A and also to FIG. 1B that illustrates a side view of an embodiment of a prefabricated wall panel apparatus 105, it is appreciated that the panels 105 can generally include an upper and sill plate 120, 125 as well several studs 130. The panel 105 can further include end studs 140. It is appreciated that the studs 130, 140 typically include slots 141. In general, those skilled in the art appreciate that the cutouts are used to decrease weight and increase strength of steel studs. In addition, the cutouts also allow for mechanical chase to be installed as needed for electrical, multi-media and phone lines, as well as for HVAC, Freon and other utilities.
In a typical implementation, the upper and sill plates 120, 125 are arranged parallel to one another. The studs 130 are arranged parallel to one another and in a vertical generally perpendicular position with respect to the upper and lower studs 120, 125. The end studs 140 are also arranged generally orthogonal with respect to the upper and sill plates 120, 125. However, the end studs 140 are arranged in a position that is rotated at an angle such that the ends of the panels 105 form a non-square end. In a typical embodiment, the top profile of each panel 105 is an isosceles trapezoid, the two end studs 140 representing equal non-parallel sides of the trapezoid. Furthermore, the base angles, A, of the top profile are 45 degrees in a typical implementation. It is understood that in other embodiments and implementations, the base angle can be other angles other than 45 degrees. However, it is appreciated that the 45-degree base angle has several advantages that are now discussed in further detail.
In general, it is desirable for panels such as panels 105 to have pre-fabricated and predictable dimensions, thereby allowing a modular home, for example, to be predictably constructed. As such, the panels 105 can be prefabricated into a variety of dimensions (lengths) such as but not limited to 2-foot, 4-foot and 8-foot sections. It is understood that several standard length sections can be made available depending on the needs of the user. When choosing a predictable section, it is desired to maintain the integrity of dimension, particularly when creating corners in the structure. To preserve length integrity when making corners, two adjoining panels 105 can be butted together as shown in FIG. 1 in the four corners of the system 100. By having the ends studs be positioned at 45-degree angles, two end studs of adjacent panels 105 in the corners can be butted together to form a 90-degree corner as desired. The outer walls 115 having the predetermined predictable length can create the corner created without affecting the predictable length. For example, if a corner is to be formed with two 8 foot panels 105, the resulting corner includes two 8-foot panels 105, in contrast to the prior art in which a corner would be formed by overlapping two ends of panels at a corner resulting in the loss of length on one side of the corner by the thickness of the overlapping panel. The 45-degree abutting of adjacent panels 105 when creating a corner has further advantages as discussed further in the description below.
It is appreciated that since the panels 105 desirably prefabricated, the same panels 105 are used to create straight walls of a structure and not just corners of the structure. The same panels 105 can advantageously abutted together side by side to create a straight wall section, as further illustrated in FIG. 1. The resulting abutment of the panels 105 side by side to create a straight wall section results in a right angle at the end studs 140 joined side by side. The inner walls 110 of the adjacent panels easily cover the right angle during construction. It is appreciated that the right angle created between the straight walls allows an access space that can advantageously be used to access desirable floor space. For example, if the walls are built on a basement or crawlspace on a wood floor, holes can be cut into the floor for use with utilities such as electrical lines, plumbing gas lines etc and chase for other mechanical installation. Such access is easy and is easily concealed once the inner walls are installed.
FIG. 3 illustrates a side view of an embodiment of a prefabricated wall apparatus panel 105 illustrating the many features described above and below.
FIG. 2 illustrates a partial top view of an embodiment of a prefabricated wall apparatus panel 105. As described above, the panel 105 includes an top plate 120 shown in partial breakaway view to illustrate the top plate 120 connection to the studs 130 in the panel 105. One of the end studs 140 is shown connected to the top plate 120. The end stud 140 is connected to the panel at an angle as discussed above such that the end stud 140 is rotated at angles of A and A′ with respect to the inner and outer walls 110, 115 as shown. It is appreciated that in a typical implementation A=45° and A′=135°. It is further understood that other angles are possible in other embodiments to create other corner orientations. However, it is appreciated that the 45° angle orientation of the end studs are desirable for to create corners for structures as discussed above. In a typical implementation, the angles A, A′ are supplementary angles.
Still referring to FIG. 2, the panel 105 further includes the inner and outer walls 110, 115 as discussed above. It is generally appreciated that the walls 110, 115 are used to provide walls for the prefabricated panels 105 onto which other suitable wall material can be mounted. Therefore, it is appreciated that, for example, dry wall can be further connected to the inner wall upon completion of the structure. In addition, for example, suitable external walls can be connected to the outer wall 115, such as vinyl or brick. In addition, the panel 105 generally includes spacing, d, between the studs 130 and the inner and outer walls 110, 115 to provide general thermal insulation as well as a space to add additional insulation. In general, a thermal break 145 can be positioned between the studs 130 and the outer wall 115.
Referring again to FIG. 1A, the system 100 further includes openings 150 cut into the top plates thereby creating access to the butted end studs 140 at the corners. In addition, as mentioned above, a right angle is formed between the end studs 140 for those panels 105 on the straight walls. Both the openings 150 and the right angles provide access to the slots 141 on the end studs. This access provides one of the additional advantages of the end studs 140 being butted together or placed side by side, which is now discussed.
FIG. 4A illustrates a partial side view of constituent components of a prefabricated wall system 100. As described above, the panels 105 can generally include an upper and sill plate 120, 125 as well several studs 130. The panel 105 can further include end studs 140. It is appreciated that the studs 130, 140 typically include slots 141. In a typical implementation, when two of the corner panels 105 are abutted to one another the slots 141 on each of the end studs align with one another. This alignment creates a conduit through which the end studs 140 of the respective panels 105 can be coupled to one another thereby connecting the respective end studs 140 and therefore the two panels comprising the corner to one another. In this way, the panels 105 can be secured to one another. A connection rod 200 can be inserted into either of the panel openings 150 to accomplish this coupling.
In general, the connection rod 200 is elongated and runs the entire height of the structure or individual panel 105. In one embodiment, the rod 200 can include two elongated rectangular panels 205, 210 connected to each other at a right angle (or orthogonal). FIG. 4B illustrates a top view of an embodiment of a connection rod 200 illustrating the orthogonal arrangement of the rod 200. The rod 200 can further include a series of fingers 215 that are generally pointed in a downward direction. As such, when the rod 200 is inserted into the openings 150, the fingers 215 engage with the aligned slots 141 thereby locking the abutted end studs 140 to one another.
FIG. 5 illustrates a partial close-up top view of an embodiment of a prefabricated wall system 100. AS discussed above, two panels 105 can be abutted to one another to form a corner. Each panel includes the top plate 120 having an opening 150 into which the rod 200 has been placed allowing the fingers 215 to insert into the aligned slots 141. Each of the end studs 140 can further include one or more sleeves 170 into which the rod 200 is placed so that the rod 200 can be guided along the inner portions of the end studs 140. In this way, as the rod 200 is inserted into the openings, the sleeves 170 help prevent the rod 200 from moving in directions other than the desired direction along the end studs, thereby allowing the fingers 215 to be efficiently inserted into the aligned slots 141.
FIG. 6 illustrates an upper partial view of an embodiment of a prefabricated wall system 100. This view illustrates the same orientation of the rod 200 as it is placed into the openings 150 to lock the end studs 140 to one another. Each panel includes the top plate 120 having an opening 150 into which the rod 200 has been placed allowing the fingers 215 to insert into the aligned slots 141. Each of the end studs 140 can further include one or more sleeves 170 into which the rod 200 is placed so that the rod 200 can be guided along the inner portions of the end studs 140. It is further appreciated that FIGS. 5 and 6 illustrate that the rod 200 can be placed into either of the openings 150 to accomplish the coupling or locking together of the end studs 140 and thereby the respective panels 105. As such, the sleeve on the left side of FIG. 6 is illustrated as without a rod.
FIG. 7 illustrates a lower partial view of an embodiment of a prefabricated wall system 100. This view illustrates that each panel includes the sill plate 125 connected to the end studs 140 as described above. Each of the end studs 140 can further include one or more additional sleeves 170. As described above, the sleeves 170 help prevent the rod 200 from moving in directions other than the desired direction along the end studs, thereby allowing the fingers 215 to be efficiently inserted into the aligned slots 141. In addition, the end studs 140 can further include a terminal sleeve 175 that tapers from top to bottom so that the rod 200 can fit into the top of the terminal sleeve 175 but not exit from the bottom of the terminal sleeve 175. The tapered profile of the terminal sleeve 175 therefore allows the rod 200 to move even closer to the end studs and forced the fingers 215 further into the aligned slots 141. In this way, the weight of the rod 200 forces the rod 200 into an even more secured position against the end studs 140.
In general, the end studs 140 that are abutted to one another in the straight wall portions are generally secured in the structure by being connected to the respective foundations. The rods 200 allow the corner applications of the structures to be secured. In this way, the corners, where structural vulnerability tends to be located are further reinforced by the insertion of the rods 200. Furthermore, it is appreciated that top caps 180 can be placed over the openings 150 to cover the rods 200. If it is desired to subsequently expand the structure, the top caps 180 can be removed and the rods 200 can be pulled out of the openings. Panels 105 can subsequently be removed and additional panels 105 added in order to expand on the structure.
It is appreciated that many architectural designs are possible with the embodiments of the prefabricated wall system 100 and panel apparatuses 105 described herein. For example, the corners of the structure may be formed such that the end studs 140 are not abutted to one another but share a common plane of orientation, P, such as illustrated in FIG. 8 at 405. It is further appreciated that a corner 410 can be constructed as needed for those end studs 140 that share the common plane of orientation.
It is further appreciated that other architectural designs are possible with the embodiments of the standardized prefabricated systems and apparatuses described herein. For example, FIG. 9 illustrates a partial top view of another embodiment of a prefabricated wall system 500. The example illustrates that several panels 105 can be used for an architectural profile of a partial hexagon, which can be used for bay windows and the like. In general, the internal angles of a hexagon are 120°. Therefore, the space 505 that remains between the end studs 140 is 30° after subtracting out the 45° of the two end studs. It is understood that the angles described are illustrative only and can differ in actual practice. In addition it is understood that various other designs can further be contemplated using the embodiments of the systems and apparatuses described herein, such as but not limited to octagonal and decagonal profiles and the like.
FIG. 10 illustrates two embodiments of connecting plates 600, 650. The connecting plate 600 is typically used to cover the corners formed when respective end studs have been connected as described above. The connecting plate 650 is used to cover the straight connections when two of the end studs are placed side by side to create long walls as described above. It is appreciated that other angles can be formed into the connecting plates 600, 650, such as to accommodate the top corner formed, say, between two adjacent walls of the hexagonal example illustrated in FIG. 9. It is further appreciated that the connecting plates 600, 650 provide additional stability and alignment of the adjacent walls.
Steel studs have been described in the embodiments herein. However, it is understood that other materials can be advantageously implemented such as but not limited to wood, fiberglass and extruded fiberglass.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, various modifications may be made of the invention without departing from the scope thereof and it is desired, therefore, that only such limitations shall be placed thereon as are imposed by the prior art and which are set forth in the appended claims.

Claims

1. A prefabricated wall apparatus, comprising:

an outer wall;

an inner wall;

vertical studs positioned between the inner and outer walls and connected perpendicular to an top plate and a sill plate; and

end studs positioned on either ends of the vertical studs and rotated at a 45 degree angle with respective to the inner and outer walls.

2. The apparatus as claimed in claim 1 further comprising a thermal break located between the studs and the outer wall.

3. The apparatus as claimed in claim 2 wherein the thermal break forms an airspace between the studs and the outer wall.

4. The apparatus as claimed in claim 1 further comprising a series of slots positioned along the end studs.

5. The apparatus as claimed in claim 4 further comprising an upper opening located on the top plate adjacent the end studs.

6. The apparatus as claimed in claim 1 wherein the connection between the top plate and the end studs have an isosceles trapezoid profile.

7. The apparatus as claimed in claim 6 wherein the base angles of the isosceles trapezoid profile are 45°.

8. A prefabricated wall system, comprising:

a first prefabricated wall panels having an top plate and two end studs, the top plate and end studs forming base angles less than 90 degrees;

a second prefabricated wall panel having at least one end stud abutted against and flush with one of the end studs of the first prefabricated wall panel, thereby forming an outer corner; and

a third prefabricated wall panel having at least one end stud abutted against one of the end studs of the first prefabricated wall panel such that a right angle space is formed between the end studs of the first and third prefabricated panels.

9. The system as claimed in claim 8 further comprising a series of slots along each of the end studs.

10. The system as claimed in claim 9 wherein the series of slots on the end stud of the first prefabricated panel that is abutted against and flush with the end stud of the second prefabricated wall panel are aligned with the series of slots on the second prefabricated wall panel.

11. The system as claimed in claim 10 further comprising an top plate on each of the second and third prefabricated wall panels.

12. The system as claimed in claim 11 further comprising an opening on each of the top plates adjacent the series of slots on the end studs.

13. The system as claimed in claim 12 further comprising a rod located within at least one of the openings of the first and second prefabricated panels and positioned parallel the end studs.

14. The system as claimed in claim 13 further comprising a series of fingers positioned along the rod.

15. The system as claimed in claim 14 wherein the fingers are positioned within the aligned slots of the end studs of the first and second prefabricated wall panels.

16. A prefabricated wall kit, comprising:

a prefabricated wall panel comprising:

vertical studs positioned between and perpendicular to an top plate and a sill plate;

end studs positioned on either ends of the vertical studs and having base angles of 45 degrees, the end studs having a series of slots along the studs; and

an elongated rod having a series of fingers, for insertion in an opening on the top plate so that the fingers fit within the series of slots so that the prefabricated panel can be connected and locked to another prefabricated panel having a corresponding end stud with a series of slots.