US3258889A - Prefabricated stud panel with foam insulation connector - Google Patents

Prefabricated stud panel with foam insulation connector Download PDF

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Publication number
US3258889A
US3258889A US18770362A US3258889A US 3258889 A US3258889 A US 3258889A US 18770362 A US18770362 A US 18770362A US 3258889 A US3258889 A US 3258889A
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panel
plate
frame
studs
side
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Richard A Butcher
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Upson Co
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Upson Co
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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/38Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E04C2/386Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a frame of unreconstituted or laminated wood

Description

y 5, 1966 R. A. BUTCHER 3,258,889

PREFABRICATED STUD PANEL WITH FOAM INSULATION CONNECTOR Filed April 16, 1962 l2 23 2e I 28 W 2 2 r 155 F [G 4 INVENTOR. RICHARD A. BUTCHER HIS ATTORNEYS.

United States Patent Ofi ice 3,258,889 Patented July 5, 1966 York Filed Apr. 16, 1962, Ser. No. 187,703 3 Claims. (Cl. 52-309) This invention relates to prefabricated structural sections for the walls and ceilings or other partitions of building and residential structures generally, one object being to provide an improved and more efiicient prefabricated section of this nature and method of making the same.

Another object is the provision of such a section, including the frame and an interior facing or finishing panel, of a more rigid, strong and durable character.

Another object is to supply a section of the above character affording more complete insulation against the transmission of changes in temperature and humidity.

Another object is to provide a section of the above nature including means for securely attaching an interior finishing panel to the supporting frame without the use of nails, clips or other defacing parts.

A further object is to supply such a section having the same means for concomitantly uniting, insulating and sealing the section and its parts.

A further object is a section having the above advantages in a construction adapted to be manufactured readily and inexpensively of known material.

A further object is to supply a practical method for quantity production of such sections in a convenient and economical manner.

Still a further object is the provision of an efiicient method by which sections of the above nature, including supporting frame, interior finishing panel and exterior weather boarding, can be assembled and completely fastened together without turning over the section.

T these and other ends the invention resides in certain improvements and combinations of parts and method steps, all as will be hereinafter more fully described, the novel features being pointed out in the claims at the end of the specification.

In the drawings:

FIG. 1 is an elevation partly broken away of a prefabricated structural section embodying the present invention;

FIG. 2 is a sectional view on the line 22 in FIG. 1;

FIG. 3 is a sectional view on the line 33 in FIG. 1, and

FIG. 4 is a view similar to FIG. 3 but showing a modified construction.

The invention is embodied, in the present instance, in a prefabricated structural section for forming ceilings, walls, partitions and the like, of buildings and housings generally and comprises a supporting frame shown generally at (FIG. 1). Such frame preferably includes an upper or ceiling plate 12 and a lower or floor plate 14, of the usual 2 x 6 inch size, or smaller, as well understood in the art. These plates are connected by spaced studs 16 at the usual spacing of 16 inches between centers and these studs may be the usual 2 x 4 inch forms, or of lighter construction, as hereafter referred to. The studs are preferably nailed, as at 18, through the upper and lower plates. In the form of the invention shown in FIGS. 1 to 2, inclusive, studs 16 are assembled with one edge of each level with the edge of the associated plates so as to leave a space 20 (FIGS. 2 and 3) of about /2 inch between the other edges of the studs and the edges of the plates for a purpose hereafter described.

A frame such as the above is assembled or subsequently laid on an interior panel or finishing strip 22 of wallboard or other known and suitable material 22. A known and suitable liquid formulation, such as a polyurethane, is sprayed in the spaces of the frame and on the panel 22 to partially fill such spaces, including the spaces 20 between the studs 16 and the panel (FIG. 3). The plastic or polyurethane material is of a known character that can be sprayed and foamed in place to form a rigid, closed-cell body 24 which adheres tenaciously to the fram members and to panel 22, so as to firmly unite the same, without need for nails, clips or other means for securing the panel to the frame. The added rigidity enables the use of thinner panels and lighter frame members. The plastic is filled into the frame to the depth of about one half the height of th studs, leaving spaces in the frame conveniently available for the reception of piping, wiring and the like.

Instead of a polyurethane, I may employ other formulations of plural component resins which react and foam to form rigid, closed cell materials, having a density of, say, 2.1 pounds per cubic foot, a tensile strength of 44 pounds per square inch and of its volume formed by closed cells, as well understood in the art.

Besides uniting the parts, as described, to form a rigid, strong section, the plastic provides the section with a high degree of continuous insulation against changes in temperatures and moisture, as well as completely sealing the section parts together, in a construction which is rot proof, shock absorbing and acoustically sealed.

While the parts are in the above described position, weather boarding 26 of any known and suitable character is readily nailed to the side of the studs opposite the panel 22 to complete the section.

In a somewhat modified construction (FIG. 4), studs 28 are employed having the same height as the plates 12 and 14 with the same results that the parts are effectively united, insulated and sealed by the application of the plastic.

The invention provides also an improved and practical method for quantity production of the sections. The unita-ry panel 22 is laid on the bed of a mailing machine of known and suitable character by means of which the frame parts are assembled and nailed together. The plastic is then sprayed in place as described and quickly forms the rigid bond between the frame parts and panel 22. The weather boarding is then assembled and nailed or otherwise fastened to the opposite sides of the studs and the door and window frames installed to complete the section without requiring it to be lifted and turned while being so formed, thus providing for manufacture of the sections in a convenient and economical manner.

The invention affords a wide range of component sizes up to 10 or '12. feet in width and 50 to 60 feet in length, and adapted to form a complete ceiling or side wall unit for a mobile home.

The invention thus provides a construction and method of making the same by which the same means of plastic filling concomitantly unites, insulates and seals the parts to produce an exceedingly rigid, effective and economical section.

It will thus be seen that the invention accomplishes its objects and while it has been herein disclosed by reference to the details of preferred embodiments, it is to be understood that such disclosure is intended in an illustrative, rather than a limiting sense, as it is contemplated that various modifications in the materials and method steps will readily occur to those skilled in the art, within the spirit of the invention and the scope of the appended claims.

I claim:

1. A prefabricated structural section comprising:

(1) a frame comprising, transversely, a wooden ceiling plate and a wooden floor plate longitudinally 3 4 spaced from said ceiling plate and, longitudinally, 3. A prefabricated structural section according to wooden studs transversely spaced from one another, claim 1 wherein said panel is an interior face panel and extending from said ceiling plate to said floor plate said section further comprises exterior weather boardand fastened to said plates by fasteners extending ing on said other side of said frame, and means fastenthrough said plates into said studs; 5 ing said boarding to said frame. (2) a panel on one side of said frame, extending longitudinally from said ceiling plate to said floor plate References Clted y the Exfimmel' with one side of said panel being disposed adjacent UNITED STATES PATENTS ff g zgi igg id 1161 t mm 1,728,837 9/1929 Slayter 52-743 S g Pa Sal S 1 10 1,805,069 5/1931 Ashenhurst 52 745 means consisting of rigid, cellular, polyurethane ma- 1,825,346 9/1931 Foster 52-238 XR terial tenaciously adhering to said ceiling plate, floor 2,200,713 5/1940 EIlCSOIl et al. 5 2-743 plate, studs and sald side of said panel, extendmg 2226617 12/1940 Kuenzli from one stud to the next and from said ceiling 2268251 12/1941 Haux 52 405 plate to said face plate, and extending from said side 15 2,744,042 5/ 1956 Pace 52309 XR of said panel. toward the other side of said frame 3 000144 9/1961 Kitson sufiiciently to substantially rigidify said section, but

3,029,172 4/1962 Glass 52-309 XR only part way to said other side of said frame, 041785 7/1962 Macdonald et a1 52*309 whereby between each pair of studs a substantial space extending from said ceiling plate to said face FRANK L ABBOTT, Primary Examiner.

plate is provided for piping and wiring. 2. A prefabricated structural section according to claim JACOB NACKENOFF HENRY E' L xammers.

1 wherein said side of said panel is spaced from said studs and said polyurethane material fills the spaces between said side of said panel and said studs.

J. L. RIDGILL, Assistant Examiner.

Claims (1)

1. A PREFABRICATED STRUCTURAL SECTION COMPRISING: (1) A FRAME COMPRISING, TRANSVERSELY, A WOODEN CEILING PLATE AND A WOODEN FLOOR PLATE LONGITUDINALLY SPACED FROM SAID CEILING PLATE AND, LONGITUDINALLY, WOODEN STUDS TRANSVERSELY SPACED FROM ONE ANOTHER, EXTENDING FROM SAID CEILING PLATE TO SAID FLOOR PLATE AND FASTENED TO SAID PLATES BY FASTENERS EXTENDING THROUGH SAID PLATES INTO SAID STUDS; (2) A PANEL ON ONE SIDE OF SAID FRAME, EXTENDING LONGITUDINALLY FROM SAID CEILING PLATE TO SAID FLOOR PLATE WITH ONE SIDE OF SAID PANEL BEING DISPOSED ADJACENT SAID STUDS; AND (3) MEANS FASTENING SAID PANEL TO SAID FRAME, SAID MEANS CONSISTING OF RIGID, CELLULAR, POLYURETHANE MATERIAL TENACIOUSLY ADHERING TO SAID CEILING PLATE, FLOOR PLATE, STUDS AND SAID SIDE OF SAID PANEL, EXTENDING FROM ONE STUD TO THE NEXT AND FROM SAID CEILING PLATE TO SAID FACE PLATE, AND EXTENDING FROM SAID SIDE OF SAID PANEL TOWARD THE OTHER SIDE OF SAID FRAME SUFFICIENTLY TO SUBSTANTIALLY RIGIDIFY SAID SECTION, BUT ONLY PART WAY TO SAID OTHER SIDE OF SAID FRAME, WHEREBY BETWEEN EACH PAIR OF STUDS A SUBSTANTIAL SPACE EXTENDING FROM SAID CEILING PLATE TO SAID FACE PLATE IS PROVIDED FOR PIPING AND WIRING.
US3258889A 1962-04-16 1962-04-16 Prefabricated stud panel with foam insulation connector Expired - Lifetime US3258889A (en)

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Cited By (57)

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Publication number Priority date Publication date Assignee Title
US3327442A (en) * 1964-06-23 1967-06-27 Gail Internat Prefabricated synthetic resin bonded tile wall unit
US3462897A (en) * 1966-02-07 1969-08-26 Urethane Structures Inc Building construction and residential building and method of fabricating thereof on construction site
US3641724A (en) * 1969-03-29 1972-02-15 James Palmer Box beam wall construction
US3643394A (en) * 1969-10-24 1972-02-22 Bobby G Johnson Insulated prefabricated building module
US3885008A (en) * 1969-11-26 1975-05-20 Robert E Martin Method for producing prefabricated wall section with molded panels
US3904524A (en) * 1973-06-11 1975-09-09 Advanced Fibre Glass Ltd Container structure
US3979867A (en) * 1975-06-20 1976-09-14 National Gypsum Company Nailable foam faced board
FR2307653A1 (en) * 1975-04-19 1976-11-12 Moban Bv Flat surfaced building units for walls, partitions, etc. - consists of thin boards with foam bonded structural details
US4050215A (en) * 1972-04-13 1977-09-27 John Sergio Fisher Premanufactured modular housing building construction
US4069632A (en) * 1972-11-06 1978-01-24 Monsanto Limited Shuttering member
US4244901A (en) * 1978-08-31 1981-01-13 Foamseal, Inc. Method of bonding structural support members to flat sheets
US4260569A (en) * 1978-09-01 1981-04-07 Hurst Aubrey J Method of making a foamed polystyrene building panel
US4284673A (en) * 1978-06-09 1981-08-18 Markomark B.V. Method of manufacturing a panel, provided with a frame foamed of synthetic material at least at one lateral face thereof, as well as a panel obtained through the method
US4471591A (en) * 1983-08-08 1984-09-18 Jamison Walter E Air impervious split wall structure
US4554124A (en) * 1983-03-07 1985-11-19 Fibrestone Incorporated Horizontally poured Fibrestone building construction
US4571909A (en) * 1984-09-07 1986-02-25 Keller Structures, Inc. Insulated building and method of manufacturing same
US4671032A (en) * 1986-03-31 1987-06-09 Philip W. Reynolds Thermally insulating structural panel with load-bearing skin
US4748781A (en) * 1986-10-22 1988-06-07 Foamseal, Inc. Method of bonding structural support channels to a panel and structural building module formed
US4841710A (en) * 1987-07-23 1989-06-27 The Original Lincoln Logs Ltd. Structural wall panel, method of manufacture and assembly system for a housing unit
US4914883A (en) * 1986-10-22 1990-04-10 Foamseal, Inc. Method of bonding structural support channels to a panel
US5069961A (en) * 1988-12-12 1991-12-03 Style-Mark, Inc. Pre-formed millwork article
US5106547A (en) * 1988-12-12 1992-04-21 Style-Mark, Inc. Method for making a pre-formed millwork article
US5389167A (en) * 1992-04-28 1995-02-14 Sperber; Henry Method for insulating a cavity
US5765330A (en) * 1996-07-29 1998-06-16 Richard; Michel V. Pre-insulated prefab wall panel
US6314696B2 (en) 1999-03-25 2001-11-13 Fust, Iii John W. Reinforced concrete walls having exposed attachment studs
US20010039777A1 (en) * 1998-10-08 2001-11-15 Meho Karalic Building components and method of making same
US20050188649A1 (en) * 2003-06-06 2005-09-01 Hans T. Hagen, Jr. Insulated stud panel and mehod of making such
EP1570969A2 (en) 2004-03-04 2005-09-07 Fahrzeugwerk Bernard Krone GmbH Method for the production of panels divided into sections
US20050210827A1 (en) * 2004-03-11 2005-09-29 Schwartz Joel A Rigid insulation product
US7127856B2 (en) 2003-06-06 2006-10-31 Hans T. Hagen, Jr. Insulated stud panel and method of making such
WO2007021497A2 (en) * 2005-08-11 2007-02-22 Platinum Advanced Technologies, Inc. Poly-bonded framed panels
US20080127601A1 (en) * 2006-12-04 2008-06-05 Custom Components Of Eagle River, Inc. Building, building walls and other structures
US20080168741A1 (en) * 2007-01-11 2008-07-17 The Mattamy Corporation Wall fabrication system and method
US20090165411A1 (en) * 2006-12-04 2009-07-02 Schiffmann Gerhard P Method of fabricating building wall panels
WO2009086617A1 (en) 2008-01-08 2009-07-16 Ano Leo Prefabricated building components and assembly equipments
US20090260310A1 (en) * 2008-04-17 2009-10-22 Den Adel Duane G Method and system for providing an insulative wall structure
US20100107514A1 (en) * 2008-11-04 2010-05-06 Integrated Structures, Inc. Methods and apparatus for a building roof structure
US20100281784A1 (en) * 2008-01-08 2010-11-11 Ano Leo Prefabricated building components and assembly equipments
US20120011792A1 (en) * 2010-07-15 2012-01-19 Dewildt Dean P High strength light-framed wall structure
US20130008110A1 (en) * 2008-08-19 2013-01-10 Jordan Byron Rothwell Insulated panel
US8534028B2 (en) 2010-10-08 2013-09-17 Composite Panel Systems, Llc Building panels
US20130280467A1 (en) * 2011-11-01 2013-10-24 Johns Manville Methods and systems for insulating a building
US8567153B1 (en) 2011-04-21 2013-10-29 Spray Rock Llc Composite concrete and framing system and method for building construction
US8607531B2 (en) 2008-12-18 2013-12-17 Composite Panel Systems, Llc Building panel assemblies and methods of use in wall structures
US20140059963A1 (en) * 2012-08-29 2014-03-06 Emercor Ltd. Insulated sheathing and method
US20140115989A1 (en) * 2011-06-17 2014-05-01 Basf Se Prefabricated Wall Assembly Having An Outer Foam Layer
US20140115988A1 (en) * 2011-06-17 2014-05-01 Basf Se Prefabricated Wall Assembly Having An Insulating Foam Layer
US20140290168A1 (en) * 2011-10-03 2014-10-02 Johns Manville Methods and systems for sealing a wall
US8904737B2 (en) 2008-12-18 2014-12-09 Composite Panel Systems, Llc Building panel assemblies and methods of use in wall structures
US20150093535A1 (en) * 2013-09-27 2015-04-02 Bayer Materialscience Llc Foam wall structure
US20150135619A1 (en) * 2010-08-13 2015-05-21 Knauf Insulation Gmbh Insulative sealing system and materials therefor
US20150275502A1 (en) * 2014-03-31 2015-10-01 Ping Guo Cold-formed steel above ground tornado shelter
US9151046B1 (en) 2011-04-21 2015-10-06 Precision Design Llc Concrete slab having integral wall base forms and wall base plates for automated construction and system thereof
US20150354211A1 (en) * 2014-06-09 2015-12-10 Johns Manville Wall insulation boards with non-halogenated fire retardant and insulated wall systems
WO2016176762A1 (en) * 2015-05-02 2016-11-10 Start Michael Construction assembly and construction panels for use therewith
US9493938B2 (en) 2008-12-18 2016-11-15 Composite Panel Systems, Llc Building panel assemblies and methods of use in wall structures
US9919499B2 (en) * 2014-06-28 2018-03-20 Kenneth Robert Kreizinger Stiffened frame supported panel

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US1825346A (en) * 1927-09-24 1931-09-29 Thomas J Foster Building slab and wall construction
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Cited By (98)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3327442A (en) * 1964-06-23 1967-06-27 Gail Internat Prefabricated synthetic resin bonded tile wall unit
US3462897A (en) * 1966-02-07 1969-08-26 Urethane Structures Inc Building construction and residential building and method of fabricating thereof on construction site
US3641724A (en) * 1969-03-29 1972-02-15 James Palmer Box beam wall construction
US3643394A (en) * 1969-10-24 1972-02-22 Bobby G Johnson Insulated prefabricated building module
US3885008A (en) * 1969-11-26 1975-05-20 Robert E Martin Method for producing prefabricated wall section with molded panels
US4050215A (en) * 1972-04-13 1977-09-27 John Sergio Fisher Premanufactured modular housing building construction
US4069632A (en) * 1972-11-06 1978-01-24 Monsanto Limited Shuttering member
US3904524A (en) * 1973-06-11 1975-09-09 Advanced Fibre Glass Ltd Container structure
FR2307653A1 (en) * 1975-04-19 1976-11-12 Moban Bv Flat surfaced building units for walls, partitions, etc. - consists of thin boards with foam bonded structural details
US3979867A (en) * 1975-06-20 1976-09-14 National Gypsum Company Nailable foam faced board
US4284673A (en) * 1978-06-09 1981-08-18 Markomark B.V. Method of manufacturing a panel, provided with a frame foamed of synthetic material at least at one lateral face thereof, as well as a panel obtained through the method
US4244901A (en) * 1978-08-31 1981-01-13 Foamseal, Inc. Method of bonding structural support members to flat sheets
US4260569A (en) * 1978-09-01 1981-04-07 Hurst Aubrey J Method of making a foamed polystyrene building panel
US4554124A (en) * 1983-03-07 1985-11-19 Fibrestone Incorporated Horizontally poured Fibrestone building construction
US4471591A (en) * 1983-08-08 1984-09-18 Jamison Walter E Air impervious split wall structure
US4571909A (en) * 1984-09-07 1986-02-25 Keller Structures, Inc. Insulated building and method of manufacturing same
US4671032A (en) * 1986-03-31 1987-06-09 Philip W. Reynolds Thermally insulating structural panel with load-bearing skin
US4748781A (en) * 1986-10-22 1988-06-07 Foamseal, Inc. Method of bonding structural support channels to a panel and structural building module formed
US4914883A (en) * 1986-10-22 1990-04-10 Foamseal, Inc. Method of bonding structural support channels to a panel
US4841710A (en) * 1987-07-23 1989-06-27 The Original Lincoln Logs Ltd. Structural wall panel, method of manufacture and assembly system for a housing unit
US5069961A (en) * 1988-12-12 1991-12-03 Style-Mark, Inc. Pre-formed millwork article
US5106547A (en) * 1988-12-12 1992-04-21 Style-Mark, Inc. Method for making a pre-formed millwork article
US5389167A (en) * 1992-04-28 1995-02-14 Sperber; Henry Method for insulating a cavity
US5765330A (en) * 1996-07-29 1998-06-16 Richard; Michel V. Pre-insulated prefab wall panel
US20010039777A1 (en) * 1998-10-08 2001-11-15 Meho Karalic Building components and method of making same
US7882666B2 (en) * 1998-10-08 2011-02-08 Meho Karalic Building components and method of making same
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US20050188649A1 (en) * 2003-06-06 2005-09-01 Hans T. Hagen, Jr. Insulated stud panel and mehod of making such
US7574837B2 (en) 2003-06-06 2009-08-18 Hans T. Hagen, Jr. Insulated stud panel and method of making such
US7127856B2 (en) 2003-06-06 2006-10-31 Hans T. Hagen, Jr. Insulated stud panel and method of making such
US7168216B2 (en) 2003-06-06 2007-01-30 Hans T. Hagen, Jr. Insulated stud panel and method of making such
US20060260267A1 (en) * 2003-06-06 2006-11-23 Hans Hagen Insulated stud panel and method of making such
EP1570969A3 (en) * 2004-03-04 2007-09-19 Fahrzeugwerk Bernard Krone GmbH Method for the production of panels divided into sections
EP1570969A2 (en) 2004-03-04 2005-09-07 Fahrzeugwerk Bernard Krone GmbH Method for the production of panels divided into sections
US8438792B2 (en) 2004-03-11 2013-05-14 Joel A. Schwartz Rigid insulation product
US20050210827A1 (en) * 2004-03-11 2005-09-29 Schwartz Joel A Rigid insulation product
WO2007021497A3 (en) * 2005-08-11 2007-11-08 Platinum Advanced Technologies Poly-bonded framed panels
WO2007021497A2 (en) * 2005-08-11 2007-02-22 Platinum Advanced Technologies, Inc. Poly-bonded framed panels
US20080127607A1 (en) * 2006-12-04 2008-06-05 Custom Components Of Eagle River, Inc. Building panels
US20080127604A1 (en) * 2006-12-04 2008-06-05 Custom Components Of Eagle River, Inc. Methods of manufacturing building panels
US20080127584A1 (en) * 2006-12-04 2008-06-05 Custom Components Of Eagle River, Inc. Support pads and support brackets, and structures supported thereby
US20080148659A1 (en) * 2006-12-04 2008-06-26 Custom Components Of Eagle River, Inc. Walls and wall sections
US8516777B2 (en) * 2006-12-04 2013-08-27 Composite Panel Systems, Llc Method of fabricating building wall panels
US20080127600A1 (en) * 2006-12-04 2008-06-05 Custom Components Of Eagle River, Inc. Buildings, building walls and other structures
US20090165411A1 (en) * 2006-12-04 2009-07-02 Schiffmann Gerhard P Method of fabricating building wall panels
US8393123B2 (en) 2006-12-04 2013-03-12 Composite Panel Systems, Llc Buildings, building walls and other structures
US20080127602A1 (en) * 2006-12-04 2008-06-05 Custom Components Of Eagle River, Inc. Methods Of Constructing Buildings And Building Appurtenances
US20130031858A1 (en) * 2006-12-04 2013-02-07 Composite Panel Systems, Llc Method of fabricating building wall panels
US8322097B2 (en) * 2006-12-04 2012-12-04 Composite Panel Systems, Llc Methods of constructing buildings and building appurtenances
US20080127601A1 (en) * 2006-12-04 2008-06-05 Custom Components Of Eagle River, Inc. Building, building walls and other structures
US8272190B2 (en) 2006-12-04 2012-09-25 Composite Panel Systems, Llc Method of fabricating building wall panels
US7905067B2 (en) 2006-12-04 2011-03-15 Composite Panel Systems, Llc Support pads and support brackets, and structures supported thereby
US7926233B2 (en) * 2006-12-04 2011-04-19 Composite Panel Systems, Llc Buildings, building walls and other structures
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