US20240240454A1

US20240240454A1 - Wall assembly for building structures and methods for manufacturing thereof

Info

Publication number: US20240240454A1
Application number: US18/412,118
Authority: US
Inventors: Joseph Trednic
Original assignee: Profab Construction LLC
Current assignee: Profab Construction LLC
Priority date: 2023-01-12
Filing date: 2024-01-12
Publication date: 2024-07-18

Abstract

A wall assembly including: a plurality of stud assemblies, each of the stud assemblies including a plurality of metal studs, the stud assemblies being spaced apart from each other and forming a window opening therebetween; a sill wedge connected between the stud assemblies and forming a lower edge of the window opening; and a board layer extending around a periphery of the window opening and being attached to the stud assemblies.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Patent Application Ser. No. 63/438,754, filed Jan. 12, 2023, the complete disclosure of which is included herein by reference.

FIELD

One or more aspects of embodiments according to the present disclosure relate to wall assembly and methods for manufacturing thereof.

BACKGROUND

Construction of a building structure, such as a residential or commercial structure, may be expedited by use of prefabricated components of the structure. The prefabricated components may be manufactured at a site separate from the construction site of the structure and may be manufactured in bulk, taking advantage of mass production techniques generally unavailable when building traditional structures. Further, the prefabricated components may be transportable and prepared for installation in the structure. The manufacture of the components at a separate location can help reduce the amount of construction time of the components at the construction site as well as preserve space at the construction site. However, the use of prefabricated wall assembly including one or more window assemblies may present additional challenges due to the inherent interaction a building window has with exterior environmental conditions, for example, a need to maintain air and moisture protection at the interaction of different materials. Accordingly, some window assemblies may include embedded weather protecting elements that can offer protection from exterior temperatures, moisture (e.g., waterproofing), wind, and other environmental conditions. However, such weather protecting elements may be cost prohibitive or may not offer adequate weather protection, especially energy efficient structures are increasingly desired. A wall assembly with cost efficient embedded elements that provide adequate weather protection may be needed.
The above information disclosed in this Background section is only for enhancement of understanding of the background of the present disclosure, and therefore, it may contain information that does not form prior art.

SUMMARY

One or more aspects of embodiments according to the present disclosure relate to a wall assembly and methods for manufacturing thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects and features of the present disclosure will become apparent by describing, in more detail, embodiments thereof with reference to the accompanying drawings, in which:

FIG. 1 is a schematic view of a window assembly installed in a wall according to an embodiment of the present disclosure.

FIG. 2A shows a cutaway perspective view of a stud assembly that may be used with the window assembly according to an embodiment of the present disclosure.

FIG. 2B is a plan view of the stud assembly shown in FIG. 2A according to an embodiment of the present disclosure.

FIG. 3A is a cutaway perspective view of a board attached to a stud assembly according to an embodiment of the present disclosure. FIG. 3B is a plan view of the board attached to the stud assembly according to an embodiment of the present disclosure.

FIGS. 4A-4C show some steps for adding a mesh to the board and stud assemblies of the window assembly according to an embodiment of the present disclosure.

FIG. 4D is a plan view of the mesh attached to the stud assemblies according to an embodiment of the present disclosure.

FIG. 5 is a cutaway perspective view of a coating added to the surface of the board according to an embodiment of the present disclosure.

FIG. 6 is a plan diagram of a window being attached to the window assembly shown in FIG. 4D according to an embodiment of the present disclosure.

FIG. 7 is a plan diagram of a wallboard and a building panel being attached to the window assembly shown in FIG. 6 according to an embodiment of the present disclosure.

FIG. 8 is a plan diagram of additional layers of coating and an additional mesh layer added to the window assembly shown in FIG. 7 according to an embodiment of the present disclosure.

FIG. 9 is a plan diagram of a finish layer and paint layer added to the window assembly shown in FIG. 8 according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

Various embodiments of the present disclosure are directed toward a wall assembly (e.g., a prefabricated window assembly) for a building structure and a method for manufacturing the wall assembly. The wall assembly may include a window assembly, which further includes a window and attendant support structures that are used for installing the window within an envelope of the building structure. Additionally, the window assembly may be prefabricated at one location (e.g., a location separate from the building construction site) and readily transportable to a construction site for the structure. Further, the window assembly may be ready to be installed within the envelope of the structure at the construction site and may be suitable for various structures, including commercial and residential buildings. The relevant support structures used for installing the window assembly within the envelope of the structure may include one or more studs (e.g., recessed cold-pressed steel studs) and one or more weather protecting layers (e.g., weather protecting elements). The weather protective layers may provide protection from exterior temperatures, moisture (e.g., waterproofing), wind, and other environmental conditions. In various embodiments, the weather protecting layers may include one or more layers of the following components: a board (e.g., ProFab™ board), a mesh (e.g., ProFab™ mesh), a coating (e.g., ProFab™ Platinum Coat and/or ProFab™ Base Coat), a wallboard (e.g., gypsum wallboard), a panel (e.g., ProFab™ structural building panel), a finish layer (e.g., green cork spray finish). The weather protective layers, according to embodiments of the present disclosure, offer suitable weather protection and can be constructed using cost effective materials and methods.
FIG. 1 is a schematic view of a window assembly installed in a wall according to an embodiment of the present disclosure.
Referring to FIG. 1 , various embodiments of a wall assembly 100 may be configured to be installed within a wall 140 of a structure. The structure may include various building structures, such as residential and commercial buildings. In some embodiments, the wall assembly 100 may include stud assemblies 110 and 115 and a weather protecting portion (or envelope) 120 surrounding a periphery of (or defining) a window opening 130. In some embodiments, the stud assemblies 110 and 115 may define the window opening 130 at opposites sides of the window opening 130 (e.g., may define the vertical sides of the window opening 130). Additionally, the weather protecting portion 120 may extend along the perimeter of the window opening 130 and may be attached to the stud assemblies 110 and 115.
In some embodiments, each of the stud assemblies 110 and 115 may include one or more studs 220 and/or 230 mechanically connected to each other by, for example, crimping, welding, screwing, using nuts and bolts, etc. For example, the stud 220 may be a 2″×6″ metal stud, and the stud 230 may be a 2″×4″ metal stud (see, e.g., FIG. 2B). Further, the weather protecting portion 120 may include one or more layers for providing weather proofing protection. In some embodiments, the weather protecting portion 120 may include a board (e.g., ProFab™ board), a mesh (e.g., ProFab™ mesh), and one or more layers of coating (e.g., ProFab™ Platinum Coat, ProFab™ Base Coat, Green cork finish, etc.). When the wall assembly 100 is installed within the envelope of a completed building structure, the stud assemblies 110 and 115 and the border portion 120 may be embedded in the wall 140 such that they may not be visible from the interior or exterior of the structure.
FIGS. 2A-9 illustrate some steps for manufacturing a window assembly according to various embodiments of the present disclosure. FIG. 2A is a cutaway perspective view of a stud assembly that may be used with the window assembly according to an embodiment of the present disclosure, and FIG. 2B is a plan view of the stud assembly showing a recessed portions of the stud assembly according to an embodiment of the present disclosure.
Referring to FIGS. 2A and 2B, a method for assembling a window assembly of the present disclosure may begin with a stud assembly 110 (e.g., a recessed cold-pressed steel-stud assembly). For convenience of explanation, only the stud assembly 110 is described in detail, but it should be understood that the same description applies to the stud assembly 115. In some embodiments, the stud assembly 110 may include one or more studs 220 and 230 mechanically connected together. For example, the stud assemblies 110 and 115 may include three 2″×6″ metal studs 220 and two 2″×4″ metals stud. The studs 220 and 230 may have an open box shape with a flat center section 220.1 and 230.1, respectively, and two sides 220.2 and 230.2 bent to be perpendicular from the flat center section 220.1 and 230.1, respectively. The distal ends of the sides may be bent to form flanges 220.3 and 230.4 that are perpendicular to the sides 220.2 and 230.2 and parallel to the flat center section 220.1 and 230.1.
The length and width of the stud assembly 110 may vary depending on the size of the window assembly and may be achieved by selecting the appropriate number of studs 220 and 230 and arranging them in the appropriate orientation. In some embodiments, the studs 220 and 230 forming the stud assembly 110 may be arranged as shown in FIG. 2B. Further, the stud assembly 110 may have a side 211 that faces away from the window opening, a side 212 that faces toward the window opening, a side 213 that faces toward the interior of the structure, and a side 214 that faces toward the exterior of the structure. In the stud assembly 110 shown in FIGS. 2A and 2B, by including the particular arrangement of studs 220 and 230, an approximately 1″ recess is formed at where the window assembly is attached to the stud assembly 110 while using only conventionally size metal studs.
FIG. 3A is a perspective view of a board attached to a stud assembly according to an embodiment of the present disclosure. FIG. 3B is a plan view of the board attached to the stud assembly according to an embodiment of the present disclosure.
As shown in FIG. 3A, a board 310 (e.g., ProFab™ board) may be attached to the stud assemblies 110 and 115 (e.g., may be inserted into the 1″ recess in each of the stud assemblies 110 and 115 and attached to the stud assemblies 110 and 115 therein). In some embodiments, the board 310 may be attached to sides of the stud assemblies 110 and 115 that face the exterior of the structure and may provide surface area for adding weather protecting elements. In some embodiments, the board 310 may include one or more portions (e.g., separate portions) 311 and 312. In the embodiment shown in FIG. 3A, the board 310 includes four portions. In such embodiments, each portion of the board 310 may be attached one of the stud assemblies 110 and 115. Further, an edge of a one portion may be positioned adjacent to an edge of another portion such that the two edges come into contact with each other. For example, an edge of a first portion 311 may be positioned adjacent to an edge of a second portion 312 such that the two edges come into contact with each other at a contact point 320. This arrangement may be repeated for each of the portions 311 and 312 to form a closed (or continuous) window opening periphery. Additionally, a sill wedge 330 may be added to the wall assembly 100, such as along a lower edge of the window opening between and attached to the stud assemblies 110 and 115. In some embodiments, the sill wedge 330 may be a ProFab™ board, may be another stud assembly, or may be a single stud.
FIGS. 4A-4C show some steps for adding a mesh to the board and stud assemblies of the window assembly according to an embodiment of the present disclosure.
Referring to FIGS. 4A-4C, a mesh 410 (e.g., ProFab™ mesh) may be added over the board 310 and the stud assemblies 110 and 115. As shown in FIG. 4A, the mesh 410 may first be added over corners of the board 310 surrounding the window opening 130. When the mesh 410 is added over the corners surrounding the window opening 130, the mesh 410 also cover at least a portion of the sill wedge 330, at least a portion of the board 310, and at least a portion of the stud assemblies 110 or 115.
As shown in FIG. 4B, the mesh 410 may then be added over contact points 320 at where the individual portions 311 and 312 of the board 310 contact each other, on the sill wedge 330 and over a corresponding portion of the board 310, and a portion of the stud assemblies 110 and 115 adjacent to the sill wedge 330. In this manner, the lower edge of the window opening 130 has an innermost layer of mesh 410, further ensuring watertightness along the window opening 130.
As shown in FIG. 4C, the mesh 410 may finally be added to the remaining surface of the sill wedge 330 (in some embodiments, an additional layer of the mesh 410 may be added over the entire surface of the sill wedge 330), the edge of the board 310 facing the window opening 130, and the surface of the stud assemblies 110 and 115 facing the window opening 130.
FIG. 4D is a plan view of the mesh attached to the stud assembly according to an embodiment of the present disclosure.
Referring to FIG. 4D, the mesh 410 may be added over the board 310 facing the exterior of the structure and along a side of the stud assembly 110 facing the window opening 130.
FIG. 5 is a perspective view of a coating added to the surface of the board according to an embodiment of the present disclosure.
Referring to FIG. 5 , a coating 510 (e.g., ProFab™ Platinum Coat) may be applied over the mesh 410 and the board 310.
FIG. 6 is a plan view of a window being attached to the board and the stud assembly according to an embodiment of the present disclosure.
Referring to FIG. 6 , a window (e.g., a vinyl clad window) 610 may be attached to the stud assembly 110 by using a screw (e.g., a flange screw) 620. Additionally, a spacer 630 (e.g., ⅛″ spacer) may be attached to the board 310 at where it meets the studs 220 to create a flush surface at where the board 310 contacts a lateral edge of the stud 220 of the stud assembly 110 that may be more suitable for the application of additional layers of the weather protecting elements. In some embodiments, a silicone sealant may be applied on an inside of a window nail fin. In some embodiments, the coating (e.g., ProFab™ Platinum Coat) may be applied over an exterior of the nail fin to finish the moisture barrier system.
FIG. 7 shows a plan view of a wallboard and a building panel being attached to a stud assembly according to an embodiment of the present disclosure.
Referring to FIG. 7 , wallboard 710 (e.g., gypsum wallboard) may be added to one or more surfaces of the stud assembly 110 that face the window opening 130 and an interior of the structure. Additionally, a panel 720 (e.g., ProFab™ structural building panel) may be placed over the screws 620, the spacer 630, the board 310, and on an exposed surface of the stud assembly 110 that faces toward the exterior of the structure.
FIG. 8 shows a plan view of additional layers of coating and an additional mesh layer being added to the window assembly according to an embodiment of the present disclosure.
Referring to FIG. 8 , a base coating (e.g., ProFab™ Base Coat) 810 may be added to a surface of the panel 720. Next, a mesh 820 (e.g., e.g., ProFab™ mesh) may be added on the surface of the base coating 810, and a second base coating 830 (e.g., ProFab™ Base Coat) may then be added over the mesh 820.
FIG. 9 is a plan view of a finish layer and paint layer added to the window assembly according to an embodiment of the present disclosure.
Referring to FIG. 9 , a finish layer 910 may be added to a surface of the second base coating 830. In some embodiments, the finish layer 910 may include a green cork spray finish. Additionally, a wall paint 920 may be applied to the surfaces of the wallboard 710 that face the interior of the structure.

Claims

What is claimed is:

1. A wall assembly comprising:

a plurality of stud assemblies, each of the stud assemblies comprising a plurality of metal studs, the stud assemblies being spaced apart from each other and forming a window opening therebetween;

a sill wedge connected between the stud assemblies and forming a lower edge of the window opening; and

a board layer extending around a periphery of the window opening and being attached to the stud assemblies.

2. The wall assembly of claim 1, wherein the plurality of metal studs comprises three 2″×6″ metal studs and two 2″×4″ metal studs.

3. The wall assembly of claim 1, wherein the board comprises ProFab board.

4. The wall assembly of claim 1, wherein the sill wedge comprises ProFab board.

5. The wall assembly of claim 1, wherein the wall assembly further comprises a first mesh on the board layer.

6. The wall assembly of claim 5, wherein the wall assembly further comprises a coating layer on the first mesh.

7. The wall assembly of claim 6, wherein the coating layer comprises ProFab Platinum Coat.

8. The wall assembly of claim 6, wherein the wall assembly further comprises a panel is on the coating layer.

9. The wall assembly of claim 8, wherein the wall assembly further comprises a first base coating on the panel.

10. The wall assembly of claim 9, wherein the wall assembly further comprises a second mesh on the first base coating.

11. The wall assembly of claim 10, wherein the wall assembly further comprises a second base coating on the second mesh.

12. The wall assembly of claim 11, wherein the first and second base coatings comprise ProFab Base Coat.

13. The wall assembly of claim 11, wherein the wall assembly further comprises a finish layer on the second base coating.

14. The wall assembly of claim 13, wherein the finish layer comprises green cork layer.

15. A method for manufacturing a wall assembly, the method comprising:

forming a plurality of stud assemblies, each of the stud assemblies comprising a plurality of metal studs;

arranging the stud assemblies a distance from each other to form a window opening therebetween;

attaching a sill wedge between the stud assemblies to form a lower edge of the window opening;

attaching a board to the stud assemblies around a periphery of the window opening;

attaching a first mesh layer on the board, the sill wedge, and plurality of stud assemblies;

applying a coating layer on the mesh and the board;

attaching a window to the plurality of stud assemblies;

attaching a panel to the plurality of stud assemblies on the coating layer;

applying a first base coating layer to the panel;

attaching a second mesh layer to the panel on first base coating layer;

applying a second base coating layer on the second mesh layer; and

applying a finish layer on the second base coating layer.

16. A weather protection system for an exterior surface of a wall assembly, the weather protection system comprising

a plurality of stud assemblies, each of the stud assemblies comprising a plurality of metal studs, the stud assemblies being spaced apart from each other and having a surface that faces the exterior surface of the wall assembly;

a board layer being attached to the stud assemblies on the surface facing the exterior surface;

a first mesh on the board layer;

a coating layer on the mesh;

a panel on the coating layer;

a first base coating on the panel;

a second mesh on the first base coating;

a second base coating on the second mesh; and

a finish layer on the second base coating.

17. The weather protection system of claim 16, wherein the board comprises ProFab board.

18. The weather protection system of claim 16, wherein the coating layer comprises ProFab Platinum Coat.

19. The weather protection system of claim 16, wherein the first base and second base coatings comprise ProFab Base Coat.

20. The weather protection system of claim 16, wherein the finish layer comprises green cork layer.