WO1997044544A1

WO1997044544A1 - Composite wall panel system and components therefor

Info

Publication number: WO1997044544A1
Application number: PCT/US1997/008785
Authority: WO
Inventors: Steven W. Carlin; Robert M. Dresslar
Original assignee: Carlin Steven W; Dresslar Robert M
Priority date: 1996-05-21
Filing date: 1997-05-21
Publication date: 1997-11-27
Also published as: AU3285097A

Abstract

A structural, insulating, insect resistant, dimensionally stable composite wall panel for building construction comprising a rectangular tetragonal body of polymer foam (30) having two opposing primary wall surfaces (10) bounded on its sides by two parallel side walls (50) on its ends by two parallel end walls (38A, 38B); and at least from one end wall to the other end wall and parallel to the side walls of said body, the polymer foam extending into the center of the stud (50) to secure the stud to the body, at least one side wall of each stud forming a portion of the same primary wall surface of said body.

Description

COMPOSITE WALL PANEL SYSTEM AND COMPONENTS THEREFOR

Applicants claim the benefit of prior filed co-pending provisional patent application

Serial No. 60/018,050 on COMPOSITE WALL PANEL filed on May 21 , 1996, co-pending

U.S. Patent Applications Serial No. 08/683,670 filed July 17, 1996, and Serial No.

08/724,611 filed September 30, 1996. This is a continuation-in-part of said applications Serial Nos. 08/683,670 and 08/724,611.

Field of the Invention

The present invention is directed to wall systems and to polymer/metal composite wall panels, headers and posts used in the wall systems. In particular, lightweight, thermal and sound insulating, dimensionally stable, insect-resistant, polymer/metal composite wall panels, headers and posts, and to wall systems using such components..

The panels, optionally, and preferably, also constitute structural supporting members.

Background of the Invention Composite building panels are known to the art. Dickens U.S. Patent No.

4,953,334 discloses a building panel having an expanded cellular core with side edge reinforcing strips. The panels fit in a complementary manner with stepped core edges of different step widths to form rectangular troughs along the edges of mating panels for utility lines. Panels are used for renovation of existing building structures wherein the panels are applied on the existing building walls.

Gulur U.S. Patent No. 5,279,089 discloses an insulated wall system comprising tubular support members secured to footings and headers. The space between the tubular support members are filled with extruded polymer foam sheets in a three ply sandwich construction.

The panel of U.S. Patent No. 4,953,334 is made for applying to an existing wall structure and is not a structural supporting member. The reinforcement strips are a custom design and cannot be purchased off the shelf.

U.S. Patent No. 5,279,089 discloses a wall system which is built from scratch on site in the same manner that wood frame walls are constructed. Structural supporting panels are not used in 5,279,089 patent and the tubular framing must be accurately centered and secured to the headers and footers in order that the insulated polymeric foam panels can be inserted into the space between adjacent tubular support members with a minimum of cutting and "fitting".

The 5,279,089 patent discloses that a division of the Atlantic Richfield Company markets a wall system of expanded polystyrene and metal frame members under the trademark WALLFRAME and that NU-TECH Building Systems of Cleveland, Ohio markets a wall system of the same type under the trademark CANOTHERMO.

Summary of the Invention

One embodiment of the present invention is directed to a structural, insulating, insect resistant, dimensionally stable composite wall panel for building construction comprising a regular tetragonal body of polymer foam having two opposing primary wall surfaces bounded on its sides by two parallel side walls and on its ends by two parallel end walls; and at least one light metal gauge stud in the body, the stud having a hollow center cavity, a squared cross-section with a wide back wall extending the width of the stud, two parallel side walls, two narrow front walls parallel to the back wall and separated by an open slot extending into the central cavity, each light metal gauge stud extending at least from one end wall to the other end wall of said body and parallel to the side walls of said body, the polymer foam extending into the central cavity of the stud to secure the stud to the body, and at least one side wall of each stud forming a portion of the same primary wall surface of said wall panel.

The opposing primary wall surfaces are the major wall surfaces that will constitute room walls, exterior walls and the like. The studs employed in the present invention are the light metal gauge studs, which are employed throughout the United States and may other countries, which have a squared or regular tetragonal cross-section.

For composite wall panels employed in the interior of a building, the width of the panel between the two primary wall surfaces will normally be equal to the width of the studs and the side wall of the studs will form a portion of both the primary wall surfaces. In other words, the side walls of the studs will be visible as a portion of both primary wall surfaces of the panel prior to finishing off the panel as a wall surface with plaster, gypsum wall board, wood paneling and the like.

The top and bottom ends of the composite wall panels are adapted to be received by and secured in the open channel of light metal gauge building construction tracks to form a structural wall. The composite wall panels have a tongue adapted to be received and fastened in the open channel of the track. Other composite wall panels have a groove forming the tongue; other panels have a tongue formed in the panel or created by cutting the foam to form the end tongues. The panels are secured to the tracks by fasteners, such as self-tapping threaded fasteners, which extend through the wall of the track into the side wall of the studs. The bottom track is attached to the floor system of the building and the top track will support the ceiling, upper flooring and roofing members of the building.

In a preferred embodiment of the present invention, a stud will be one of the side walls of the body. Even more preferably, the back wall of a stud will be one of the side walls of the body. In the preferred embodiment of the present invention, the panels width will be equal to a standard center to center distance of studs for standard building construction or an integral multiple thereof. For example, 16 inches is a standard building construction stud center to center distance employed in the U.S. The panels can be 60 inches wide, 32 inches wide, or 48 inches wide, and the like. For some building construction, the center-to-center distance is 12 inches and for other applications, the center to center distance can be 24 inches. For exterior construction, the panel will preferably have at least two light metal gauge studs which are distanced apart from each other center to center a standard building construction center to center distance for studs, such as 12 inches, 16 inches or 24 inches or a multiple thereof.

When the composite wall panel is wider than the stud width, and a stud is positioned on the side wall of said body, the stud will only form a part of the side wall since is it not wide enough to cover the entire width of the side wall. For composite wall panels that are wider than the studs, the panel can have a tongue portion at each of its ends. The tongue portion will have a width equal to the width of the studs and the tongues will be adapted to be received by and secured in the open channel of light metal gauge building construction track to form a structural wall. Alternatively, and preferably, the panel will have a groove at each of its ends. The distance between the groove and one wall of the panel will be at least equal to the width of a stud and will permit the panel to be dropped into a bottom track with one wall of the track mating with the wall of the panel and the other wall of the track being received in the groove at the end of the stud.

A preferred composite panel of the present invention comprises a structural, insulating, insect resistant, dimensionally stable composite wall panel for building construction comprising a regular tetragonal body of polymer foam having two opposing wall surfaces bounded on its sides by two parallel side walls and on its ends by two parallel end walls; and one light metal gauge stud in the body, the stud having a hollow center cavity, squared cross-section with a wide back wall extending the width of the stud, two parallel side walls, two narrow front walls separated by an open slot extending into the central cavity, light metal gauge extending at least from one end wall to the other end wall of said body and parallel to the side walls of said body, the polymer foam extending into the central cavity of the stud to secure the stud to the body, the width of the panel between the two primary wall surfaces equal to the width of the stud and the side walls of the stud forming a portion of the primary wall surfaces, the back wall of the stud is one of the side walls of said body, and the ends of said body adapted to be received by and secured in the open channel of light metal gauge building construction track to form a structural wall

A further preferred embodiment of the present invention comprises a structural, insulating, insect resistant, dimensionally stable composite wall panel for building construction comprising a regular tetragonal body of polymer foam having two opposing primary wall surfaces bounded on its sides by two parallel side walls and on its ends by two parallel end walls, and at least two light metal gauge studs in the body, each stud having a hollow center cavity, a squared cross-section with a wide back wall extending the width of the stud, two parallel side walls, two narrow front walls separated by a open slot extending into the central cavity, each light metal gauge stud extending at least from one end wall to the other end wall of said body and parallel to the side walls of said body The polymer foam extending into the central cavity of the studs to secure the studs to the body, the width of the panel between the primary wall surfaces being greater than the width of the studs, at least one side wall of each stud forming a portion of the same primary wall surface of said body, the back wall of one stud being a part of one of the side walls of said body, said body having a tongue portion at each of its ends, the tongue portion having a width equal to the width of the studs, the tongue portion adapted to be received by and secured in the open channel of light metal gauge building construction track to form a structural wall.

The preferred wall panel system of the present invention a structural wall for building construction based on a light metal gauge stud, a channel and track construction, comprising a light metal gauge track with an open channel secured for building floor system and a second light metal gauge track with an open channel for receiving, securing and supporting a ceiling and roofing structural members, the tracks separated by, supported by and secured to each other with two or more structural, insulating, insect resistant, dimensionally stable composite wall panels for building construction, each panel comprising a regular tetragonal body of polymer foam having two opposing primary wall surfaces bounded on its sides by two parallel side walls and on its ends by two parallel end walls; at least two light metal gauge studs in the body, each stud having a hollow center cavity, a squared cross-section with a wide back wall extending the width of the stud, two parallel side walls, two narrow front walls parallel to the back wall and separated by an open slot extending into the central cavity, each light metal gauge stud extending at least from one end wall to the other end wall of said body and parallel to the side walls of said body, and polymer foam extending into the central cavity of the stud to secure the stud to the body, at least one side wall of each stud forming a portion of the same primary wall surface of said body, the distance between the studs, from center to center of the studs, is a standard building construction center to center distance for studs, studs of the panels being secured to the first and second tracks by self-threaded screws extending through the side walls of the tracks into the side walls of the studs.

The present invention is directed to a lightweight, thermal and sound insulating, polymer/metal composite wall panel. The wall panel is preferably a structural supporting member for the construction of a building. The panels can be utilized on the exterior walls and in the interior walls of the building. The invention is also directed to a wall system comprised of a plurality of assembled lightweight, thermal and sound insulating, polymer/metal composite wall panels as described herein.

The lightweight, thermal and sound insulating polymer/metal composite wall panels (hereinafter referred to as "composite wall panels") comprise a continuous panel of extruded or expanded closed cell, polymer foam having flat parallel exterior surface and interior surface, parallel longitudinal sides, parallel end sides and at least one light metal gauge stud embedded in the polymer foam panel with one side of each stud exposed on the interior side of the wall panel and extending the full longitudinal length of the wall panel. The wall panel is adapted to be received and fastened in a light gauge metal bottom track and top track for the construction of exterior and interior walls of a building.

The light gauge metal studs are positioned in the wall panel at equal distances so that when wall panels are assembled together they to form a wall system of two or more wall panels with the metal studs positioned equal distance from each other on centers, such as 12-inch, 16-inch, 24-inch and 48-inch centers.

In another embodiment of the present invention, the metal studs are rectangular in cross-section having an open slot running the length of the stud. The studs optionally have one or more holes in their back wall. The central cavity of each stud is filled with the polymeric foam of the wall panel. One of the studs is preferably positioned to form part of one of the longitudinal side of the wall panel. In one embodiment of the present invention, the stud is positioned so that its open slot is exposed on the longitudinal side of the composite wall panel. In this embodiment, some of the polymeric material is removed from the open slot of the stud to form a groove. The other longitudinal side of the composite wall panel is formed with a tongue so that when the composite wall panels assembled together, the tongue of one wall panel will engage the groove of the adjacent wall panel to form a continuous wall system having planar, non-stepped, exterior surfaces and interior surfaces

In another embodiment of the present invention, the light gauge metal studs are positioned inwardly from the longitudinal sides of the composite wall panel so that only one side of each stud is exposed on the interior surface of the composite wall panel In a further embodiment of the present invention, such wall panel is fabricated with a groove in the panel body along one longitudinal side and a tongue in the panel body along the opposing longitudinal side so that when adjacent composite wall panels are assembled together to form a wall system, the tongue and groove come together and mate to increase the strength of the resulting wall system panel and to minimize draft through the joint of the adjacent panels and the loss of insulating value for the resulting wall system

In another embodiment of the present invention, an interior composite wall panel having a single light metal gauge stud with a wall panel body of polymer foam The wall panel has two opposing flat surfaces forming interior room walls, two parallel and opposing longitudinal sides and two parallel end sides, that is, a top and bottom The stud can be placed along the edge of a composite wall panel, that is, it can constitute one of the longitudinal sides or the stud can be positioned within the middle of the composite wall panel so that polymer foam forms the longitudinal sides The stud extends the full length of the wall panel and the depth of the wall panel from building wall surfaces is the same distance as the greatest dimension of the light metal gauge stud The interior composite wall panel can also be formed with tongue and grooves as described above

The composite wall panels of the present invention can be prepared in a mold employing conventional light gauge metal studs which can be purchased off the shelf Several of the composite wall panels of the present invention are prepared from a pre- formed block of polymer foam and conventional light gauge metal studs as described herein Utilities, such as electrical lines, water pipes, sewage pipes, cables, and the like, can be run up from the floor or down from the ceiling of a building down through the composite wall panels or they can be passed horizontally through the wall panels optionally through holes and apertures in the metal studs. The positions of the holes and apertures in the metal studs can be marked on the exterior major surfaces of the wall panels. However, longitudinal runs of utilities such as wiring and piping through the studs may require that the foam material be worked out of the central cavity and holes or apertures of the studs in the interior wall panels and, for that reason, it is easier, quicker, and more economical to run the utilities from the top or from the bottom of the interior wall panel Runs or channels for the utilities can be cut into the polymer foam of the panel body using heat guns which are readily available on the market Holes, cut or pre¬ punched, in the light gauge metal top, or bottom track permit the utilities to be run through the tracks into the panel The runs or channels can be cut in the panel to intercept such holes Once the utility is placed in the run or channel, the channel can be back filled with foam from a foam gun or it can be left open because the surface of the composite wall panel is normally dressed The interior surface of the wall panels can be dressed with gypsum board, or lathe and plaster construction, or with composite panels, or the like and the exterior surface of the wall panels can be dressed with Tyvek or an equivalent membrane or tar paper and then stucco, paneling, shingles, brick, masonry, composite paneling, elastomeric coating or the like. Some back filling of the utility run or channel with polymer foam is desired to prevent freedom of movement of the utility in the channel which can create noise, to provide fire blocks and to provide blocks to air drafts

The studs must be exposed on one of the primary wall surfaces of the wall panel in order to thoroughly fasten gypsum board or other wall covering to the surface of the composite wall panel and to permit the installation of earthquake straps which are required in earthquake prone geological areas and high wind areas The composite wall panel cannot be properly strapped with earthquake straps if the studs are fully encapsulated by the polymer foam more than a ^ΛA inch thick

A wall system utilizing the composite wall panels is made by securing a u-shaped open light gauge metal track to the exterior perimeter of a floor, or the exterior perimeter of a building slab, or a floor system The panels are dropped into the track positioned side by side and the metal studs of each panel are fastened to the side walls of the track using self tapping metal screws The position of the studs covered by polymer foam is indicated by a stud marker on the exterior surface side of the wall panel

The present invention also is directed to a lightweight, structural, insulating, insect-resistant, dimensionally stable composite header for building construction The wall system of the present invention comprises a header frame, comprising first and second light metal gauge C-channel beams, each C-channel beam having a rectangular cross-section with a central cavity, a back wall, two side walls, and two front walls, separated by a wide slot in communication with the central cavity The two C-channel beams are mounted back-to-back on their back walls, two light metal gauge L-brackets, first and second plates perpendicular to one another, the two L-brackets are mounted to the opposing longitudinal ends of the header frame, a first rectangular polymer foam block mounted in the central cavity of one of the C-channel beams and extending the full longitudinal length of the C-channel beam, the front surface of the polymer foam block being approximately coplanar with the plane of the front walls of the C-channel beam, and a second rectangular polymer foam block mounted in the central cavity of the second C-channel beam and extending the longitudinal length of the C-channel beam, the front wall of the second block of polymer foam extending beyond the plane of the front walls of the second C-channel beam so that the distance between the front surface of the first block of polymer foam and the front surface of the second block of polymer foam is the width of a nominal 6-ιnch building wall (actual width about 5 ¹/₂ inches) Conveniently, the two C-channel beams are mounted to one another with self- tapping metal screws. However, the C-channel beams can be spot-welded, bolted, or attached to one another by means known in the art. The L-brackets are also conveniently secured to the inner surface of the back wall of a C-channel beam with self- tapping metal screws. However, the L-brackets can be spot-welded, bead-welded, bolted and the like to the inner surface of the back wall of a C-channel beam.

The header is secured to the vertical framing studs of the window opening or door opening of the wall system before the first and second polymer foam blocks are inserted. The first polymer foam block is adapted to be inserted upwardly by moving the top side of the blocks into the central cavity through the slot in the front of each C-channel beam and swinging the bottom of the polymer foam block through the slot, clearing the bottom front wall of the C-channel beam, and then allowing the block to drop in the central cavity with the bottom side of the block resting on the inner surface of the bottom side wall of the C-channel beam. In similar fashion, the second polymer foam block, the block wider than the width or depth of the C-channel beam, has a front portion having a height equivalent to the height of the C-channel beam, a rear portion having a height equivalent to the width of the open slot and the bottom front wall of the C-channel beam and longitudinal slots separating the two portions, the slots having a depth at least equivalent to the height of either front wall of the beam. The top side of the block is inserted into the central cavity of the C-channel beam through the open slot with a top longitudinal slot in the topside of the block receiving the upper front wall of the C-channel beam. The bottom side of the polymer foam block is swung into the central cavity through the open slot, and the polymer block is allowed to drop so that the bottom front wall of the C-channel beam is received in the bottom longitudinal slot in the bottom side of the polymer foam block, and the bottom side of the rear portion of the polymer foam block rests on the interior surface of the bottom side wall of the C-channel beam. The most unexpected property of the header is the fact that an individual C-channel beam can be easily twisted, however, when joined, the two C-channel beams are secured back-to-back on their back walls, and they form an unexpectedly rigid header frame Even more surprisingly, the addition of the L-brackets to the ends of the header frame further increases the rigidity of the header frame A header frame is difficult to twist The front surfaces of the polymer foam blocks form the surfaces of the header frame to which can be attached gypsum board, plywood, and other building construction materials for the exterior wall surfaces of a building and for the interior wall surfaces of a building The present invention is also directed to a lightweight, structural, insulating, insect-resistant, dimensionally stable composite post for light metal gauge framing for building construction for use in the wall system of the present invention, comprising a post frame comprising first and second light metal gauge C-studs, each stud having a central cavity, a back wall, two side walls, and two front walls separated by an open slot in communication with the central cavity, the two C-studs are positioned back-to-back on their back walls with their open slots facing outwardly and in opposite directions, and a polymer foam block having a rectangular cross-section, two opposing wall surface sides and two opposing inner wall sides, one side wall of each C-stud positioned on the surface of one wall surface side of the polymer foam block, the other side wall of each C-stud positioned within the polymer foam block parallel to the other wall surface side of the foam block, the polymer foam block extending the full longitudinal length of the C-studs, each longitudinal end of the polymer foam block having a slot extending from one inner wall side to the other inner wall side, parallel to the other wall surface side and adjacent to the other side wall of each C-stud The post is adapted to be received, mounted and secured in the bottom track of a wall system and secured therein with threaded self- tapping metal screws which are secured through the side walls of the bottom track into the side walls of the C-studs. The depth of the polymer foam block from one wall surface side to the other wall surface side is the width or depth of a nominal 6-inch building wall (actually 5 ^ΛA inches thick).

Brief Description of the Drawings

Fig. 1 is a prospective view of the wall system of the present invention employing the composite wall panels of the present invention;

Fig. 2 is a bottom view of the composite wall panel shown in Fig. 1 ; Fig. 3A is a plan end view of a longitudinal side of the composite wall panel of Fig. 1 ;

Fig. 3B is a plan view of the other longitudinal side of the composite wall panel of Fig. 1 ;

Fig. 4 is a plan view of a primary wall surface of the composite wall panel of Fig. 1 ; Fig. 5 is a plan view of the opposing primary wall surface of the composite wall panel of Fig. 1;

Fig. 6 is a prospective view of another embodiment of the wall system of the present invention employing another embodiment of the composite wall panel of the present invention; Fig. 7 is a bottom plan view of the composite wall panel of Fig. 6;

Fig 8A is a plan view of a longitudinal side of the composite wall panel of Fig. 6; Fig. 8B is a plan view of the other longitudinal side of the composite wall panel of Fig. 6;

Fig. 9 is a plan view of a primary wall surface of the composite wall panel of Fig. 6; Fig. 10 is a plan view of the exterior primary wall surface side of the composite wall panel of Fig. 6;

Fig. 11 is a top view of another embodiment of the composite wall panel of the present invention; Fig. 12A is a plan view of a longitudinal side of the composite wall panel of

Fig. 11 ;

Fig. 12B is a plan view of the other longitudinal side of the composite wall panel of Fig. 11 ;

Fig. 13 is a plan view of a primary wall surface of the composite wall panel of Fig. 11 ;

Fig. 14 is a plan view of the opposing primary wall surface of the composite wall panel of Fig. 11 ;

Fig. 15 is a top view of another embodiment of the composite wall panel of the present invention; Fig. 16A is a plan view of a longitudinal side of the composite wall panel of

Fig. 15;

Fig. 16B is a plan view of the other longitudinal side of the composite wall panel of Fig. 15;

Fig. 17 is a plan view of a primary wall surface of the composite wall panel of Fig. 15;

Fig. 18 is a plan view of the opposing primary wall surface of the composite wall panel of Fig. 15;

Fig. 19 is a top view of another embodiment of the composite wall panel of the present invention; Fig. 20A is a plan view of a longitudinal side of the composite wall panel of

Fig. 19; Fig. 20B is a plan view of the other longitudinal side of the composite wall panel of

Fig. 19;

Fig. 21 is a plan view of a primary wall surface of the composite wall panel of Fig. 19; Fig. 22 is a plan view of the opposing primary wall surface of the composite wall panel of Fig. 19;

Fig.23 is a top view of another embodiment of the composite wall panel of the present invention;

Fig. 24A is a plan view of a longitudinal side of the composite wall panel of Fig. 23;

Fig. 24B is a plan view of the other longitudinal side of the composite wall panel of Fig. 23;

Fig. 25 is a plan view of a primary wall surface of the composite wall panel of Fig. 19; Fig. 26 is a plan view of the opposing primary wall surface of the composite wall panel of Fig. 23;

Fig. 27 is a top view of an interior composite wall panel of the present invention; Fig. 28A is a plan view of a longitudinal side of the composite wall panel of Fig. 27; Fig. 28B is a plan view of the other longitudinal side of the composite wall panel of

Fig. 27;

Fig. 29 is a plan view of one of the primary wall surfaces of the composite wall panel of Fig. 27;

Fig. 30 is a top view of another embodiment of the composite wall panel of the present invention; Fig. 30A is a partial perspective view of the back side of the light metal gauge stud of the panel of Fig. 30.

Fig. 31 is a top view of another embodiment of the composite wall panel of the present invention; and Fig. 32 is a top view of another embodiment of the composite wall panel of the present invention.

Fig. 33A is a perspective view of a block of polymer foam used in some embodiments of the composite wall panel of the present invention;

Fig. 33B is a perspective view of the channel cut polymer foam block of Fig. 33A; Fig. 33BB is an enlarged sectional view of one end of the polymer foam block of

Fig. 33B;

Fig. 33C is a perspective view of the grooved block of polymer foam of Fig. 33B;

Fig. 33D is a perspective view of the polymer foam block of Fig. 33C receiving light metal gauge studs to yield the composite wall panel of Figs. 35A and 35B; Fig. 34 is an enlarged fragmentary perspective view of the completed composite wall panel of Fig. 33D;

Fig. 35A is a plan view of one primary wall surface of the completed composite wall panel of Fig. 33D,

Fig. 35B is a plan view of the opposing primary wall surface of the completed composite wall panel of Fig. 33D;

Fig. 36 is an enlarged plan end view of a longitudinal side of the completed composite wall panel of Fig. 33D;

Fig. 37 is a plan end view of the other longitudinal side of the completed composite wall panel of Fig. 33D; Fig. 38 is a top view of the completed composite wall panel of Fig. 33D;

Fig. 38A is another top view of the completed composite wall panel of Fig. 33D; Fig. 39 is a cross-sectional view of the completed composite wall panel of Fig. 33D taken along lines 39-39 of Fig. 35A;

Fig. 40 is a bottom view of the complete composite wall panel of Fig. 33D;

Fig. 41 is a fragmentary plan view of an alternative embodiment of the completed composite wall panel of Fig. 35A;

Fig. 42 is a fragmentary cross-sectional view taken along lines 42-42 of Fig. 41 ;

Fig. 43 is a plan view of a primary wall surface of an alternative embodiment of the completed composite wall panel of Fig. 33D;

Fig. 44 is an enlarged plan end view of a longitudinal side of the alternative embodiment of the completed composite wall panel of Fig. 33D;

Fig. 45 is a plan end view of the other longitudinal side of the alternative embodiment of the completed composite wall panel of Fig. 33D;

Fig. 46 is an enlarged top view of the alternative embodiment of the completed composite wall panel of Fig. 33D; Fig. 47 is a cross-sectional view taken along lines 47-47 of Fig. 43;

Fig. 48 is a bottom view of the completed composite wall panel of Fig. 43;

Fig. 49 is a plan view of another embodiment of the wall system of the present invention employing the completed composite wall panels of Fig. 33D;

Fig. 50 is a cross-sectional view taken along lines 50-50 of Fig. 49; Fig. 51 is a plan top view showing the assembly of two light metal gauge bottom tracks on a floor system;

Fig. 51A is a fragmentary top view of the completed composite wall panel of Fig. 33D;

Fig. 51 B is a fragmentary top view of a modified version of the completed composite wall panel of Fig. 51A; Fig. 51 C is a fragmentary top view of a completed composite panel of Fig. 51 A that has been turned upside down;

Fig. 51 D is a fragmentary top view of a corner constructed from the composite wall panels of Fig. 51 B and 51C; Fig. 52A is a perspective view of a polymer foam block used in some embodiments of the composite wall panels of the present invention;

Fig. 52B is a perspective view of the channel cut polymer foam block of Fig. 52A;

Fig. 52BB is an enlarged sectional view of one end of the polymer foam block of Fig. 52B; Fig. 52C is a perspective view of the block cut polymer foam block of Fig. 52B;

Fig. 52D is a perspective view of the polymer foam block of Fig. 52C receiving light metal gauge studs to form an alternative embodiment of the composite wall panel of the present invention;

Fig. 53 is a plan view of a primary wall surface of the completed composite wall panel of Fig. 52D;

Fig. 54 is a plan view of the other primary wall surface of the completed composite wall panel of Fig. 52D;

Fig. 55 is a plan end view of a longitudinal side of the completed composite wall panel of Fig. 52D; Fig. 55A is a plan end view of the other longitudinal side of the completed composite wall panel of Fig. 52D;

Fig. 55B is a cross-sectional view along lines 55B-55B of Fig 54;

Fig. 56 is a top view of the completed composite wall panel of Fig. 52D;

Fig. 56A is a cross-sectional view taken along lines 56A-56A of Fig. 54; Fig. 57A is a perspective view of the composite header of the present invention;

Fig. 57B is a perspective view of the header frame of the header in Fig. 57A; Fig. 58 is an end view of a C-channel beam of the header frame of Fig. 57B

Fig. 59 is a front view of a door opening in a wall system of the present invention employing the header of Fig. 57A;

Fig. 60 is a horizontal cross-sectional view taken along lines 60-60 of Fig. 59; Fig. 61 is a vertical cross-sectional view taken along lines 61-61 of Fig. 59;

Fig. 62 is a cross-sectional view of the header of Fig. 57;

Fig. 63 is a cross-sectional view showing the installation of the polymer foam blocks into the header frame in Fig. 57B;

Fig. 64 is a perspective view of the composite post of the present invention; Fig. 65 is a bottom view of the post of Fig. 64;

Fig. 66 is a perspective cutaway view of the post of Fig. 64 secured to a bottom track of a wall system of the present invention;

Fig. 67A is a top view of the post of Fig. 64;

Fig. 67B is a top view of a modified post of Fig. 64; Fig. 67C is a top view of modified C-studs of the present invention;

Fig. 67D is a top view of another modified post of Fig. 64;

Fig. 67E is a top view of a modified post of Fig. 67D;

Fig. 67F is a top view of another modified post of Fig. 67D;

Fig. 68A is a perspective view of a block of polymer foam; Fig. 68B is a perspective view of a pre-grooved polymer foam block of Fig. 68A;

Fig. 68C is a perspective view of a further grooved polymer foam block of Fig. 68B; and

Fig. 68D is a perspective view showing the insertion of C-studs into the grooved polymer foam block of Fig. 68C to obtain the post of Fig. 64. Detailed Description of the Invention

Referring to Fig. 1 , the wall system of the present invention comprises a top track or plate 12A, a bottom track or plate 12B, composite wall panels 10 and horizontal filler pieces 20. The tongue of the bottom end 38B of the composite wall panels 10 are dropped into the open channel 18 of the bottom track 12B. The panels are aligned together to form a continuous wall system 9 having planar exterior and interior surfaces. The composite wall panels are secured to the bottom track by self tapping metal screws 24 which extend through the side walls 14 of the track into the side walls 50 of the studs 32. After the composite wall panels have been assembled together and secured to the bottom track, the top track 12A is dropped onto the top tongue 38A at the top end of the panels. The top track is secured to the wall panels by screwing the side walls 14 into studs 32 with self tapping metal screws 24.

Doors (not shown) for wall structures are made in the usual way with lightweight gauge metal studs and tracks. The transverse width, that is the width from one longitudinal side 40A of the panel 10 to the other longitudinal side 40B (side to side width), can be cut to size with a heat gun down to a size to fit where a door is to be situated. Similarly, windows (not shown) can be constructed in the usual manner that they are constructed with light metal gauge studs and track and, optionally, the panel can be cut with a heat gun to accommodate smaller windows within the space between two studs.

For light gauge metal studs, the "on centers" for the studs is normally 24 inches compared to 16 inches for wood studs. A building fabricated from light metal gauge studs and tracks are far stronger than a building constructed from wooden "2X4" frame construction. The gauge of the metal used in the light gauge metal studs can be varied for a particular application. Gauges range from 12 to 25, although other gauges are available. It is difficult to determine the gauge of a light gauge metal stud when the panels are formed. Accordingly a marker or legend 46 is placed on the interior or exterior surface, optionally on both surfaces, to identify the metal gauge. Such a marker is shown in Fig. 1 as element 46. The position of the studs on the primary wall surface 36 is indicated by marker 44 which can be a score line, dimples, small depressions, diamond marks, paint marks or the like. This permits the carpenters and installers to determine the position of stud in the panel for purposes of fastening the tracks to the panels and attaching elements, such as wall board, to the studs. Since one of the studs in the composite wall panel 10 is situated at one of the longitudinal sides of the wall panel, the marker 44 can be omitted for the end stud because carpenters and installers know that studs are centered ³λ inch in from the longitudinal side of a wall panel. However, wall panels can optionally have a marker also showing the end stud. After the wall panels have been assembled and fastened to the bottom track and top track with fasteners 24 as described above, the space partially formed by shoulders 42A and 42B is filled with horizontal filler pieces 20. This provides that the primary wall surface 36 of the wall system 9 is flat, smooth and continuous from the top to bottom and side to side of the joined panels.

Referring to Figs. 2 - 5, the composite wall panel 10 has a single piece, continuous polymer foam body 30 and two light gauge metal studs 32 partially embedded in the polymer foam body. The studs at least extend from one end 38A to the other end 38B of the panel. The studs and length of the body 30 can be the same. Shrinkage of the polymer foam during the manufacture of the panels may render the body 30 slightly shorter and narrower than the studs 32. This slight size difference is not detrimental to the panel, its use or the wall system fabricated from the panel. The panels can be manufactured in a mold by injection, extrusion, or the like of the polymer or polymer foam. The polymer foam flows into the central cavity of the stud through holes 58 in the back wall 52 and/or through open slot 56 of the studs 32. It is easier to fill the central cavity 57 with polymer foam through the open slot than the holes 58 during the manufacturing process. Thus in the preferred embodiment, the open slots of the studs face to the interior of the polymer foam body 30 as shown in panel 10 of Figs. 1 - 5 to insure filling the central cavity of the stud with polymer foam. The filling of the central cavity with polymer foam strengthens the stud and prevents deflections of the stud side walls 52 during the fastening of the panel studs to the tracks with threaded fasteners or the like. The panels can also be made from blocks of polymer foam as described below.

The panel can have more than two studs, for example, it can have three studs on equal centers, such as 16 inch centers for a 48 inch wide panel. The body is a continuous piece of polymer foam and the foam extends into the central cavity 57 of the studs through open slot 56 and, in some embodiments, through holes 58 in the stud to securely fasten the stud and body together. Optionally the stud sides can be treated with an adhesive or primer to aid in cementing the polymer foam to the walls of the stud.

The studs have two narrow side walls 50, a back wall 52 running the width of the stud and two small front walls 54 parallel to the back wall and separated by slot 56 which is in communication with the central cavity 57. One of the narrow walls 50 of the studs 32 is exposed on the surface 34 of the panel. The body 30 of the panel shields the other walls of the studs to prevent corrosion from water and chemicals. In this embodiment, one stud, situated on one of the longitudinal sides of 40A of the panel, has one side wall 50 and its back wall 52 also exposed to the exterior. The light gauge metal studs are normally galvanized coated steel optionally painted with a corrosive resistant paint. The back wall of the studs normally have one or more openings 58 which can be used for running utility lines and the like through the panel (see Fig. 3B). The top of each panel has a shoulder 42A and the bottom of each panel has a shoulder 42B. These shoulders provide large tongues at the top 38A and at the bottom 38B of the panel. The tongues are the width of the studs and fit into the open channels 18 of the top and bottom tracks as described above. One side of each stud is exposed on the interior surface 34 of the panel. It is easier to assemble panels with the studs exposed on one primary wall surface, such as primary wall surface 34. However, since the stud is only expose on the one wall surface, the polymer foam of the body 30 protects the other sides of the studs from corrosion as discussed above. A side wall 50 of each studs is exposed. If the studs are positioned on the sides 40A and 40B with the back walls 50 facing out, these walls are also exposed. As shown in Fig. 5, the exterior surface bears stud markers 44 to indicate the center of the narrow wall 50 of each stud so that the installer will know where to attach paneling, lathe board, etc. to the studs of the wall panel with threaded fasteners (not shown). The exterior surface can also bear at least one legend 46 indicating the gauge of the light gauge metal stud. Optionally, the legend can appear on the interior surface of the wall panel or on both surfaces. The legend can be embossed, painted or inked on the surface of the panel polymer foam.

The body 30 of the panel is one continuous piece of polymer foam. The foam as well as the light metal gauge studs are dimensionally stable and are not effected by humidity, dampness or moderate temperature changes. Preferably the polymer foam is preferably closed cell which is waterproof. Thus the panels can be used in desert, tropical, sub-tropical, arctic and temperate environments and climates.

The panels can be designed for different seismic zones, wind loads, live loads, dead loads and axial loads prescribed by building codes and/or structural engineers. The polymer foam, especially expanded polystyrene, has good compressive strength and provides substantial shear resistance and inhibits twisting of the studs.

Fig. 6 shows another embodiment of the wall system of the present invention. Common elements between the wall system 9A of Fig. 6 and wall system 9 of Fig. 1 bear the same number and the same description as set forth above. The wall system of 9A of Fig. 6 employs another embodiment of the composite wall panel 10A of the present invention This wall panel has a longitudinal shoulder 43 running the length of the panel along one of the longitudinal sides 40 of the panel When the panels 10A are assembled together, a slot 26 is created which is filled with vertical filler piece 22 as shown in Fig 6 In all other respects, the wall system of Fig 6 is similar to the wall system of Fig 1 Referring to Figs 7 - 10, the composite wall panel 10A has a shoulder 43 when two panels 10A are abutted against each other with longitudinal side 40A meeting with longitudinal side 40B of the adjacent panel, a slot 26 is created as described above which is filled after assembly of the wall system with a vertical filler piece 22 as descnbed above In all other respects, panel 10A is similar to panel 10 The back sides 52 of the light gauge metal studs 32 have rectangular 58A or holes of other shapes The polymer foam extends into the holes 58 and open slot 56 to fill the central cavity 57 of the studs

Referring to Fig 11 , the composite wall panel 10B has both light gauge metal studs 32 positioned between the longitudinal side walls 40A and 40B of the panel A stud is not positioned on a side wall 40 as in panel 10 In all other respects, the composite wall panel 10B is similar to the composite wall panel 10A

Referring to Fig 15 - 18, the composite wall panel 10C has a stud 32 positioned at one of the longitudinal side walls 40A of the panel with its open channel 56 facing outwardly In contrast the composite wall panel of 10 has the open channel 56 of the light gauge metal stud 32 positioned on one longitudinal side 40A of the panel facing inwardly into the body 30 As in all the composite wall panels, the central cavity 57 of the studs is filled with polymer foam The polymer foam extends from body 30C into the central cavity through the holes 58 in the back wall 52 of the stud to securely bind the body and studs The central cavity may however, not be completely filled with polymer foam However, the end stud 32 of panel 10C having its open channel exposed to the exterior, has a portion of the polymer foam of the central cavity cut away to form a groove 49. The other longitudinal side 40B of the panel 10C is formed with a tongue 48 which is adapted to engage the groove 49 of an adjacent panel 10C (not shown) when the panels are positioned and placed and abutted together to form a wall system. This tongue and groove construction increases the strength of the wall system since it helps bind the panels together and inhibits drafts and air leakage through the joint formed by side walls 40A and 40B between adjoining panels. In all other respects, panel 10C is similar to panel 10.

Referring to Figs. 19 - 22, the composite wall panel 10D is similar to the composite wall panel 10B with the exception that the panel has a groove 49A molded into the body 30D on longitudinal side wall 40A and a tongue 48A molded into the body 30D on the other longitudinal side wall 40B. When adjacent panels 10D are abutted or joined together in tracks 12A and 12B, the groove 48A mates with the tongue 48A of the adjoining panel to form a strong interlocking wall system of the composite wall panels. The tongue and groove construction helps bind the individual panels together and inhibits drafts between the joints or seams of adjacent panels.

Referring to Figs. 23 - 26, the composite wall panel 10E is similar to the composite wall panel 10 with the exception that the composite wall panel 10E is formed with a lip 41 on the primary wall surface 36 of the panel on longitudinal side wall 40A and with a shoulder 43 on the primary wall surface 36 at the other longitudinal side wall 40B of the panel. The lip 41 is designed to engage shoulder 43 of an adjacent panel to form an overlap joint when the panels are abutted and joined next to each other in light metal gauge tracks 12A and 12B. The overlap joint prevents drafts between the joint or seam of adjacent panels. Some studs 32 available on the market have round holds, rectangular holes 58 square holes or other shaped holes in their back walls 52. In all other respects, the composite wall panel 10E is similar to the composite wall panel 10. Referring to Fig 27, a wall composite wall panel 70 is shown which is normally half the transverse width of the composite wall panels 10A through 10E It is envisaged that panel 70 will be used primarily in interior wall systems However, it can be used in the exterior wall systems Preferably the composite wall panels 10 - 10E are used for exterior walls Conveniently, the transverse width of panel 70 between the longitudinal side walls 74A and 74B is a standard building construction distance between the studs, center-to-center, required for the wall structure Typically, this is 24" or 16" Interior composite wall panel 70 comprises a body 72 of polymer foam and a light gauge metal stud 32 secured at one end of the body The polymer foam extends into the central cavity 57 of the stud The width of the panel between the primary wall surfaces 76A and 76B is the width of the stud 32 The interior composite wall panel 70 is thinner than composite wall 10 - 10E panels because the insulation demands of interior walls is much less than exterior walls The panels 70 are utilized and assembled in the same manner as panels 10 - 10E Referring to Figs 28A, 28B and 29, a bottom track 12B is attached to a flooring system 17 The bottom sides of 78B of one or more panels 70 are inserted into the open channels 18 The lower track 12B and upper track 12A are shown in phantom in Fig 29 A plurality of panels are inserted into the track and abutted up against each other to form a continuous, smooth interior wall (not shown) In this manner, studs 32 of each panel will be "on center" as required by the building codes After the panels are assembled in the bottom track, the top track 12A is lowered onto the upper side 78A of the panels 70 with the open channel extending over and onto the upper side 78A Side walls 14 of the upper track and lower track keep the walls aligned to form a smooth continuous wall surface on each side of the panels The panels are screwed into the tracks by screwing in self tapping meal screws 24 through the side wall 14 of the tracks into the side walls 50 of the studs 32 of the panel The panel surfaces 76A and 76B can be plastered, covered with sheet rock, tiled or the like. The sheet rock or other paneling can be adhesively attached to the panels or screwed into the studs of the panels.

Doors and other elements in walls can be made with light metal gauge studs and light metal gauge track in the conventional manner. Utilities are brought down from above or up from below through holes in the tracks and runs or channels in the polymer foam of the body cut with heat knives. Alternatively, the utilities can be run horizontally through the panels.

Referring to Fig. 30, an alternative embodiment of the interior composite wall panel 70A has the light metal gauge stud 32 positioned in the body 72A of the panel between the longitudinal walls 74A and 74B. The body 72A of the panel extends on both sides of the stud and the polymer foam of the body extends into the central cavity 57 of the stud. The back wall of stud 52 has a plurality of apertures 58 (see Fig. 30A) which can be circular, rectangular, square, diamond shaped, oval shaped. The polymer foam extends into the central cavity through the open slot 56 and through the holes 58 to securely bind the stud with the polymer foam body.

Referring to Fig. 31 , another embodiment of the interior composite wall panel 70B comprises a body 72B and a stud 32. The body 72B is composed of polymer foam as the other composite wall panels of the present invention and the polymer foam extends through the apertures 58 (not shown) in the back wall 52 of the stud 32 into the central cavity 57 of the stud. The polymer foam extending through the aperture 58 between the central cavity and the body 72 binds the stud 32 securely with the body.

Referring to Fig. 32 a composite wall panel 100 having a large, i.e., wide stud 32A and a thick body 30F is shown. Such large dimensional panels can be easily made and used. Such panels would find use for heavy construction were the ceiling, upper floor or roof loading would be substantially greater than found in typical 1-3 story framed buildings The polymer foam fills the body 30F and extends into the central cavity 57A of the stud through open slot 56A.

Referring to Fig 33A, in an alternative embodiment of the present invention, the panels can be made from a pre-formed rectangular block of polymer foam having the outer dimensions equivalent to a standard wall panel, such as a panel 4'x8' and 5/4" to 6" thick Preferably the panel width is 1/16" to 1/18" narrower than a standard width, such as 4' width to give a certain amount of play when assembling a wall system The block of polymer foam is channel cut with a conventional device such as hot wires or hot knives to form c-shaped channels 102 running the length of the polymer foam block 100 which are adapted to receive light metal gauge studs described above to form polymer foam block 100A The polymer foam block 100A is grooved with a hot knife or a hot wire to form a lateral groove 104 cut into the top end 106 and bottom end 108 of the block The groove 104 and the bottom primary wall surface 112 of the polymer block form a tongue 121 which is adapted to be received in the open channel 18 of a track 12 similar in fashion to the other composite wall panels described herein The top primary wall surface 110 of the panel is partially grooved with a hot knife or a hot wire to form lateral partial grooves 114A and 114B on the primary wall surface 110 at the longitudinal ends of the block, partial length longitudinal partial grooves 116 on the primary wall surface 110 of the polymer foam block at the longitudinal ends, a full length longitudinal partial groove 118 on surface 110 along one side of the polymer foam block and partial grooves for an access slot 120 The partial grooves only extend a short distance into the surface of the polymer foam block, such as Vβ" to Y₂" These grooves are guidelines for a construction worker to cut along when it is necessary to remove a foam piece as described herein A deep groove is cut along the end of each block 100C to the depth longitudinally co- extensive with lateral partial groove 114A A full length longitudinal deep groove 122 is cut into the side 124 of the polymer foam block 100C which extends laterally into the foam co-extensive with the full length longitudinal partial groove 118. Thus, when the polymer foam is cut along groove 118 to the depth of the deep groove 122 (see Fig. 35B) along the full length of longitudinal partial groove 118, the longitudinal strip of polymer foam 132 is released (see Figs. 46-48 and 51 B). When the polymer foam is cut along grooves 114A or 114B and 116 to the depth of the deep groove 123 (see Fig. 37), a strip of polymer foam (shown in phantom in Fig. 42) is released to yield a recess (see Figs. 41 , 42, 49 and 50).

Referring back to Fig. 33, light metal gauge studs 32 are inserted into the c- shaped grooves 102 and pushed along the longitudinal length of the polymer foam block. The c-shaped channel extends the full length of the block. The studs are the same length as the polymer foam block and extend from one end 106 to the other end 108.

Referring to Fig. 34, the top portion of the completed composite wall panel 100D is shown showing the studs 32 fully inserted into the polymer foam body 100C, and showing how the lateral partial grooves 114A and 114B, the partial length longitudinal partial groove 1 16 and the full length longitudinal partial groove 118 only extend a short distance into the primary wall surface 110 of the polymer foam. The partial grooves for the access slots 120 extend deeper into the polymer foam. This permits the workmen to easily remove the access slots in order to expose and fasten the side wall 14 or a bottom track 12B or top track 12A to the studs 32 of the completed composite wall panel 100D when they are installed into the tracks. The lateral groove 104 is wider than the other grooves in order to permit one side wall 14 of the track to be easily inserted into groove 104 as tongue 121 is dropped into the open channel of a track.

Referring to Figs. 35A, 35B, 36, 37, 38, 38A, 39 and 40, the completed composite wall panel of Fig. 33D is illustrated. The primary wall surface 110 of the composite wall panel 100D bears the partial grooves 114A, 114B, 116, and 118 described above. In its unaltered state, the studs 32 of composite wall panel do not show on primary wall surface 110 The other primary wall surface 112 of the panel shown in Fig 35B has the studs 32 positioned on the surface of the primary wall surface 112 The depths of deep grooves 104, 122 and 123 are shown in phantom in Fig 35B It can be seen in the top view, bottom view and cross-sectional views of Figs 38-40, the studs 32 only extend about 2/3 of the way through the thickness of the polymer foam block Thus the walls of the studs cannot be seen on the primary wall surface 110 Primary wall surface 110 is normally the interior wall surface because it permits easier installation of utilities that will be described herein Primary surface 112 is the surface normally facing the exterior and the visibility of the studs gives the construction worker guidance in securing the wall surface, whatever it is, paneling, lathe, wire for stucco, and the like, to the studs

The lateral groove 104 is wide enough to receive the side wall 14 of a track 12 (the channel tracks are illustrated in Figs 1 , Figs 6 and the like above and as shown at the bottom of Fig 36 with the track shown in phantom) The groove 104 only extends a short distance into the ends of the composite wall panel, just far enough to easily receive the side wall 14 of a track (see Fig 35B)

The full length longitudinal deep groove 122 extends the full length of the composite wall panel and extends inwardly from the side 124 of the wall panel as far as the full length longitudinal partial groove 118 as can be seen in Figs 35B and 39 The depth of groove 122 is shown in phantom in Fig 39 When the full length partial groove 118 is cut with a hot wire or knife down to the deep groove 122, a strip of polymer foam 132 is freed from the composite wall panel (see Fig 51 B)

Referring to Figs 41 and 42, the composite wall panel 100D has had a portion of the primary wall surface 110 removed in area 134 by having polymer foam cut with a knife or with a hot wire or hot knife along partial length longitudinal partial grooves 116 and partially along the lateral partial groove 114A down to a depth of deep groove 123 The panel is dropped into and mounted on a bottom track 12B (shown in phantom) The side wall 14 of the track is secured to the side wall of stud 32 with a fastener 24 (shown in phantom) Normally, this type of cut would not be made in the panel for purposes of securing the panel to a track To secure the panel to the track, the partial grooves for access slots 120 are cut down to the depth of the lateral deep grooves 123 to remove the foam and expose the side wall of the track (see Fig 40 which shows the access slot and

Fig 41 which shows the access slot removed and a fastener 24 positioned to secure the side wall of the track to stud 32) Fig 42 shows the stud 32 fitted into track 12 and secured with fasteners 24 (the track is shown in phantom) As shown in Fig 42, a portion of the polymer foam has been cut away along the original groove line 114A down to the deep lateral groove 123 to form open area 134

Referring to Figs 49 and 50, an alternate embodiment of the wall system of the present invention is illustrated employing the composite wall panels 100D Composite wall panels 110D have been modified by cutting along the length of the lateral partial groove 114A at the bottom 108 of the composite wall panel down to the deep lateral groove 123 to expose the side wall 50 of the studs 32 This cut frees a strip of polymer foam from the panel The longitudinal depth of deep lateral groove 123 is shown in phantom in Fig 35B The strip of polymer foam can be removed before the composite wall panel is assembled into the bottom track 12B or after it is actually fastened and secured into track 12B In either case, after the composite wall panel is fitted into the bottom track 12B, the space occupied by the polymer foam strip cut out along the groove line 114B and the lateral deep groove 123 is replaced with an anchor base 130 normally made of wood, such as a 2x4 or the like The anchor base is secured to a side wall 14 of the bottom track 12B by long self-tapping threaded fasteners, such as 2%" fasteners The fastener extends through the side wall 14 and side wall 50 of the stud and secures the side wall 14 of the bottom track 12B to the side wall 50 of the stud 32 An anchor base can also be installed at the top 106 of the wall panel 100D in a similar fashion to the anchor base illustrated in Figs. 49 and 50. The anchor base at the bottom of the panel can be used as a base to install molding, secure cabinets, bookshelves, and the like.

The wooden anchor base provides a convenient medium to nail or screw the molding to.

Similarly, an anchor base at the top of the panel can be used to secure ceiling molding, crown molding, or hanging cabinets or the like.

The wall system is anchored at the top with the top track 12A which is fitted over the tongue 121 of wall panels with one side wall 14 inserted into the groove 104 of the composite wall panel and the other side wall adjacent the primary wall surface 112 (see

Fig. 50). The top track 12A is secured to the composite wall panel by fasteners 24 as described above.

Referring to Figs. 43, 44, 45, 46, 47 and 48, modification is shown to the composite wall panel 100D which is made by construction workers to prepare wall panels for the creation of a corner. The construction worker cuts along the entire length of the longitudinal partial groove 118 down to the full length longitudinal deep groove 122 to free a strip of polymer foam 132 (see Fig. 33D) leaving along the length of the composite wall panel exposing one side wall 50 of the end stud 32 of the composite wall panel. In all other respects, the composite wall panel 100E is identical to composite wall panel 100D.

A corner can be easily assembled for the construction of a building employing the composite wall panels 100D in combination with composite wall panels 100E, using one of each for each corner.

Referring to Fig. 51 , bottom track 12B' is secured to the floor with fasteners 140. Track 12B" is then butted up against the end of track 12B' at right angles to form the corner as shown. Now referring to Figs. 51 A through 51 D, composite wall panel 100E is prepared from composite wall panel 100D as described above to remove the polymer foam strip 132 as shown in Fig. 51 B. Composite wall panel 100E is fitted into bottom track 12B' with the side 124 of the composite wall panel 100E contiguous with the end 142 of the bottom track 12B'. Composite wall panel 100D is then dropped into bottom track 12B" and the end 124 of the composite wall panel is butted up against the exposed grooved surface of the full length longitudinal deep groove 122. Composite wall panel

100E is secured to composite wall panel 100D by fastening the end studs of both wall panels as shown in Fig. 51 D with a long, such as 4¹/4", threaded, self-tapping fastener

24B.

Referring to Figs. 52A through 52D, an alternative embodiment of the composite wall panel of the present invention is shown. A polymer foam block 100 is grooved with a knife, hot knife or hot wire to form C-channel beams 102 which extend along the full length of the block. Tongues are formed at each end of the polymer foam block 100A by removing lateral strips 150 with a knife, hot knife or hot wire to yield a polymer foam block 100G. Studs 32 are inserted into the c-shaped channels 102 which are adapted to receive the light metal gauge studs. The studs are the same length as the polymer foam block and extend the full length thereof after the light metal gauge studs are inserted into the polymer foam block. The resulting composite wall panel is similar to composite wall panel 10A described above.

Referring to Figs. 53, 54, 55, 55A, 55B, 56 and 56A, the composite panel 10A is prepare from a single pre-formed polymer foam block 100 and is substantially identical to the composite wall panel 10A illustrated in Figs. 7, 8A, 8D, 9 and 10 above. The same numbers are used for the same elements.

Fig. 53 shows the composite wall panel mounted in a bottom or lower track 12B and secured at the top by top or upper track 12A. The side walls of track 14 are secured to the studs 32 of the composite wall panel with fasteners 24 as described above. The adjoining wall panels are not shown. With a hot wire tool, utility ducts 202, 204 and 206 have been cut into the inner surface 34 of the panel using a hot knife, a receptacle well 200 has been cut into the surface 34 to receive an electrical box or the like. The panels can be utilized in either direction. That is, the primary wall surface 34 can be positioned to the outside of a building or towards the inside of a building. Normally, it is positioned towards the inside of a building since it provides about 2" of foam between the inner side of the studs 32 and the wall surface 34 which can be easily cut with a hot wire, knife or device to form utility channels for plumbing, wiring, cabling, gas lines, and the like.

Referring to Figs. 57A, 57B and 58, the composite header 150 comprises header frame 151 , polymer foam block 154, and polymer foam body 156. The header frame 151 (see Fig. 57B) comprises two C-channel beams 152A and 152B. Each C-channel beam has a back wall 172, two side walls 174, and two front walls 176 separated by an open slot 178 which is in communication with the central cavity 180. The two C-channel beams are secured back-to-back on their back walls 172 by a plurality of fasteners 24 which are threaded self-tapping machine screws. At each longitudinal end of the header frame 151 (only one end shown), there is secured an L-bracket 164, each L-bracket having a side plate 166 and an end plate 168 which are positioned perpendicular to each other (the L-bracket is not shown in Fig. 57A for clarity). The side plate is secured to the inner surface 173 on the back wall of one of the C-channel beams conveniently by threaded self-tapping metal screws which extend through the back wall of both C-channel beams. The L-bracket can be positioned so that the end plate 168 extends from the back wall 172 of C-channel beam 152A towards the open slot 178 of C-channel beam 152A, or can be positioned to extend around the ends of both C-channel beams and extend towards the open slot of the other C-channel beam 152B as shown in phantom. Optionally, two L-brackets can be secured to each end of the header frame; separate L-brackets can be attached to the inner surface of the back wall of each C-channel beam. Referring to Fig. 59, the wall system has an opening bounded by two vertical framing studs 32, a header 150, and the floor system 17. Two bottom tracks 12B are secured to the floor system. The door frame studs 32, the vertical framing elements of the opening are secured to the bottom tracks and the top track 12A. The header frame 151 is secured to the framing studs 32 by L-brackets 164 which are secured to the back walls 52 of the studs (see Fig. 60) by fasteners 24, such as threaded self-tapping metal screws. The top of the wall system is secured by the top track 12A. The side walls 14 of the top track can optionally be secured to the top front wall 176 at the header frame with fasteners 24. The ends of the header frame 151 shown in phantom in Fig. 59 may or may not engage the back wall 52 of the studs 32. The header frame is normally fabricated about ¹Λ inch less than the nominal size A of the opening. The L-brackets normally are not secured to the assembly of the two C-channel beams until the assembly of the C-channel beams is positioned in the opening. In this way, the end plates 168 of the L-brackets can be positioned against the back wall 52 of the studs and secured to the assembly of C-channel beams and the back wall of the studs with fasteners 24 as shown in Figs. 59 and 60. To achieve rigidity and strength, it has not been found necessary to have a tight fit of the assembly of the two C-channel beams with the vertical framing studs. However, it is important that the end plates of the L-brackets are positioned against the back wall of the studs, and that the side plates 166 of the L-brackets are positioned against the inner side of the back wall of the C-channel beams. The assembly of two C-channel beams can be installed in the opening before or after the top track 12A is assembled into the wall system.

After the header frame 151 is installed in the opening, as shown in Fig. 59, the polymer foam block and body 154 and 156 are inserted into the frame. The polymer foam block 154 has a height a little less than the width of the open slot plus the height of the bottom front wall 176. The bottom side 155B of the polymer foam block is inserted through the open slot onto the interior surface of the bottom side wall 174 of the C-channel beam, and then the top side 155a of the polymer foam block can be rotated through the open slot into the central cavity of the C-channel beam. As can be seen in Fig. 62, when the polymer foam block 154 has been inserted into the central cavity 180 of the C-channel beam, the front surface 155C of the block is substantially coplanar with the plane defined by the front walls 176 of the C-channel beam. The polymer foam body 156 on its inner side has a height approximately the width of the open slot and the top front wall of the other C-channel beam. The front side of the polymer foam body 156 has a height equivalent to the height of the C-channel beam. There is a groove 160 on the top side of the block separating the front side from the back side of the polymer foam body. The top 158 of the polymer foam body 156 is pushed up into the central cavity 180 with the side walls of the top front wall of the C-channel beam engaging the top groove 160. The bottom of the polymer foam body is then swung into the central cavity of the beam and lowered so that the bottom front wall 176 of the beam engages the bottom channel 162 of the polymer block, permitting the polymer foam body to slide down and become supported on the interior surface of the side wall 174 of the beam, as shown in Figs. 62 and 63. Surprisingly, once the foam block and body are inserted into the C-channel beams, they remain in place without being secured in any manner. Optionally, although it is not necessary, the bottom sides 155B and 157B, respectively, can be coated with adhesive as well as the back sides 155D and 157D, respectively, can be coated with an adhesive material to bond the blocks to the inner surface of the C-channel beams. If desired, the bottom groove 162 and the space between the top side 155A and the top of the central cavity of the C-channel beam can be filled with a polymeric foam or the like to stop drafting through the assembled structure. Now referring to Fig. 64, one end of a vertical post 200 is shown in perspective.

The vertical post 200 comprises a block of a polymer foam 202 and two C-studs positioned back-to-back partially imbedded in the block of foam. The studs extend the full longitudinal length of the polymer foam. The post is made in nominal lengths such as eight feet, nine feet, ten feet, twelve feet. Each end of the block 202 has a groove extending from one side 210A to the other side wall 21 OB of the block 202 and parallel to the side 208 of the block. Although side 208 is normally the side that would be positioned interiorly into a building, there can be situations where side 208 would be an exterior face. Each end of the post is adapted to be fitted into and received by a top track 12A and a bottom track 12B, respectively, of a building system as described above. In Fig. 66, a post is shown received in and secured to the bottom track 12B. Side walls 50 of the C-studs 32 are received within the side walls 14 of the bottom track and secured thereto conveniently with threaded self-tapping screws 24. In order to expose the dry wall 14 of the bottom track on the interior side 208 of the post, a small amount of the foam is chipped away to form an access hole 212, as shown in Fig. 66, to expose the side wall 14 so that the side walls 50 of the C-studs can be joined with the side wall 14. Since the side walls 50 of the studs are exposed on the exterior side 206 of the post, an access hole is not required.

This type of post can be utilized in wall systems in places where a particularly strong vertical supporting framework is required, such as at the location where earthquake straps and the like are going to be positioned and/or secured. A post can also be utilized to form other post-like structures, as shown in

Figs. 67A through 67F.

The post 200 in Fig. 67A is similar to the post 200 in Fig. 65 with the exception that no access hole 212 was cut into the foam block. Applying a hot wire knife (not shown), the foam between the side walls 50 of the C-studs 32 and the wall surface 208 of the post is cut with the hot wire knife next to the side walls 50 to yield the post 200A shown in Fig. 67B. The cut-off piece of polymer foam 202C can be used as filler during the construction of a building or can be disposed of as waste The two C-studs are not joined together and thus are easily separated to form the C-studs 200B shown in Fig 67C These studs can be utilized in the construction of a building where isolated C-studs are required that contain foam insulation Alternatively, the post 200 can have a side of polymer foam cut with a hot wire knife along or adjacent to the front walls 54 of the studs to form the post 200C, as shown in Fig 67D In that case, the block of polymer foam 202F that is cut away can be used as filler in the wall system of the building or disposed of as waste The post 200C is comprised of post portions 202D and 202E The two portions are not secured together and can easily be separated as shown in Fig 67E Post portion 200E is a C-stud filled with foam This portion after being separated from portion 202D can be rotated 180° and positioned into post portion 202D to yield post 200F, as shown in Fig 67F The posts 200A, 200B, 200C, 200D, 200E and 200F can similarly be secured in the building system of the present invention, and they can be installed in the bottom track 12D and the top track 12A, as shown above for Post 200 Posts 202A and 202E can be inserted directly into the top or bottom track and the side wall 14 of the tracks can be secured to the side walls 50 of the C-studs, as described herein The posts 200C, 200D, and 200F can similarly be secured in the bottom track and top track 12B and 12A described above by inserting the C-studs of the posts onto the track with the groove 204 receiving one of the side walls 14 of the track with the side walls 50 of the C-studs seated between the side walls 14 of the track where they can be secured with fasteners such as threaded self-tapping screws Access holes, such as access hole 212 of post 200, must be chipped out of these posts to gain access to side walls 14 or the tracks to apply the fasteners These posts permit the assembler of the building system a great deal of freedom in organizing the studs in the manner required such as for an opening corner or strapping for earthquake straps The posts are pre- assembled and are filled with insulating foam All the assembler has to do is cut away the excess foam as required for the particular application, using a wire knife which is

available

The posts are assembled from conventional light metal gauge C-studs 32 and a block of polymer foam 210 As shown in Figs 68A-68D, the block of polymer foam 202 is pre-grooved with longitudinal shallow grooves 214 to receive the front walls 54 of the C-studs A deep T-shaped groove is run the length of the polymer foam to receive the back wall 54, one side wall 50, and one front wall 54 of each C-stud The grooves are made with hot wire knives or alternatively can be made with pre-formed hot-blade knives Each end of the foam is further grooved with a lateral groove 204 which is a groove adapted to receive the side wall 14 of the top track or bottom track, as described above The grooved two C-studs are then positioned back-to-back and slid into the grooves 214 and 216C with the front walls 54 being received in the shallow vertical grooves 214 and 216C, the bottom side walls 50 of the C-studs being received in the horizontal groove 216B and the back walls 52 of the C-studs being received in the deep vertical groove 216A, as shown in Fig 68D The friction between the surfaces of the C-studs and the surfaces of the polymer foam groove are sufficient to securely keep the C-studs within the polymer foam

The composite wall panels, composite headers, and composite posts of the present invention offer many advantages over the existing metal/polymer composite wall panels The composite wall panels, headers and posts are made from commercially available materials including the light metal gauge studs 32 and the polymer foam The header C-channel beams are custom made by Angeles Steel, Los Angeles, California Many types of polymer foams can be utilized including extruded polymer foams such as polystyrene, polyethylene, polyisocynauπte and polyurethane and expanded polymer foams such as polystyrene and polyurethane The panels, headers and posts are dimensionally stable and have flat continuous surfaces to provide a continuous smooth wall system having flat planar surfaces which can be easily covered with lathe and plaster, gypsum board, composite panels, tile and the like. The panels, headers and posts are lightweight and can be easily carried by a single man or woman even when they contain up to four studs and have dimensions as great as 4X12'. The composite wall panels, headers and posts will not support combustion. The polymer foam incorporates a fire resistant material known to the art such as halogenated phosphates, antimony oxide, and the like. The polymer foam is preferably a closed cell foam which prevents water saturation and offers a greater degree of thermal and sound insulation.

The panels, headers and posts are completely impervious to dry rot and completely resistant to termite damage. The passive interaction of the studs and beams with the polymer foam body, and the passive interaction of the assembled panels, headers and posts in a wall system secured with the top track and bottom track, provide an extremely strong and rigid wall which offers tremendous lateral stiffening and far greater vertical load bearing capacity than comparable wood framing walls. An additional advantage of the composite wall panels, headers and posts arises because they do not have to undergo extensive testing to obtain building and structural approvals from governmental agencies, ICBO, BOCCA, and the like, because light gauge steel construction is already accepted and widely used in the building industry.

The panels, headers and posts can be used to build a structure employing standard wood framing techniques. The wall/frame assembly using the panels can be carried out on the ground or on the floor and then the wall/frame assembly is raised as a complete wall system with detailing completed when the wall is up, such as plumb and line of the walls and completing the fastening of the tracks and studs.

The panels are squared and have straight flat walls. Thus the panels and tracks are assembled with a minimum of plumbing compared to straight wood or light metal framing. Yet the assembled wall system retains sufficient give to permit slight racking of the assembly to make the assembled wall system plumb when the floor system is not exactly level.

In conventional light metal framing, the stud's side walls 50 must be clamped to the track side walls prior to fastening because when the fasteners are screwed through the side wall 14 of the track 12 into the side wall 50 of the stud 32, the side wall of the stud can bend inwardly toward the open slot 56 of the stud causing a gap to form between the side wall of the track and the side wall of the stud This gap weakens the joinder of the stud and track, and, thus, the stud side wall is clamped to the side wall of the track to prevent such gaps This gap problem is avoided with use of the present panels because the polymer foam, which at least partially fills the central cavity 57 of the stud, prevents a side wall of the stud from flexing inwardly toward the open slot 56 Thus the tracks and panel studs can be fastened without the need for clamping.

The composite wall panels, headers and posts can be manufactured in molds to form a continuous body of polymer foam Studs can easily be positioned in the mold with one side wall 50 of the studs 32 positioned at the bottom of the mold in register with the interior surface of the wall panel The polymer foam can be injected, molded or extruded into the mold containing the studs to form the composite wall panels described herein, or the polymer foam can be formed into blocks which are cut to receive the studs.

Conventional light metal gauge studs, also known as light gauge steel studs, light weight, cold-formed steel members, cold-formed steel structural members, metal studs or steel studs, C-stud, joist, can be employed in the present invention including SHD, X SHD and XX SHD studs having various leg sizes such as 1% inch, VA inches, 2 inches and various web sizes, such as VA inches up to 8 inches The web size is the width of the stud and the leg size is the thickness of the stud The width of the back wall is equivalent to the web of the stud and the length of the side wall is the length of the leg of a stud. The light metal gauge studs employed in this invention preferably are engineered to meet the specifications of the 1986 Edition of the AISI (American Iron and Steel Institute) publication "Specification for the Design of Cold-Formed Steel Structural Members", including 1989 amendments and comply with the Uniform Building Code.

Claims

1 A structural, insulating, insect resistant, dimensionally stable composite wall panel for building construction comprising a regular tetragonal body of polymer foam having two opposing pπmary wall surfaces bounded on its sides by two parallel side walls and on its ends by two parallel end walls, and at least one light metal gauge stud in the body, the stud having a hollow central cavity, a squared cross-section with a wide back wall extending the width of the studs, two parallel side walls, two narrow front walls parallel to the back wall and separated by an open slot extending into the central cavity, each light metal gauge stud extending at least from one end wall to the other end wall and parallel to the side walls of said body, the polymer foam extending into the central cavity of the stud to secure the stud to the body, at least one side wall of each stud forming a portion of the same primary wall surface of said body

2 The composite wall panel according to claim 1 wherein the width of the panel between the two primary wall surfaces is equal to the width of the studs and the side walls of the studs forming a portion of the primary wall surfaces

3 The composite wall panel according to claim 2 wherein at least one stud is one of the side walls of said body

4 The composite wall panel according to claim 2 wherein the ends of said body are adopted to be received by and secured m the open channel of light metal gauge building construction tracks to form a structural wall 5. The composite wall panel according to claim 2 wherein the back wall of one stud is one of the side walls of said body.

6. The composite wall panel according to claim 1 wherein the composite wall panel has at least two light metal gauge studs.

7. The composite wall panel according to claim 6 wherein the distance between the studs, from center to center of the studs, is a standard building construction center to center distance for studs.

8. The composite wall panel according to claim 7 wherein at least one stud of one of the side walls of said body.

9. The composite wall panel according to claim 8 wherein the back wall of one stud is a part of one of the side walls of said body.

10. The composite wall panel according to claim 8 wherein the width of the panel between the primary wall surfaces being greater than the width of the studs.

11. The composite wall panel according to claim 10 wherein said body has a tongue portion at each of its ends, the tongue portion having a width equal to the width of the studs and adapted to be and received by and secured in the open channel of light metal gauge building construction track to form a structural wall.

12. The composite wall panel according to claim 10 wherein at least one stud is part of one of the side walls of said body. 13. The composite wall panel according to claim 10 wherein the back wall of one stud is part of one of the side walls of said body.

14. A structural, insulating, insect resistant, dimensionally stable composite wall panel for building construction comprising a regular tetragonal body of polymer foam having two opposing wall surfaces bounded on its sides by two parallel side walls and on its ends by two parallel end walls; and one light metal gauge stud in the body, the stud having a hollow center cavity, squared cross-section with a wide back wall extending the width of the stud, two parallel side walls, two narrow front walls separated by an open slot extending into the central cavity, light metal gauge extending at least from one end wall to the other end wall and parallel to the side walls, the polymer foam extending into the central cavity of the stud to secure the stud to the body, the width of the panel between the two primary wall surfaces equal to the width of the stud and the side walls of the stud forming a portion of the primary wall surfaces; the back wall of the stud is one of the side walls of said body, and the ends of said body adapted to be received by and secured in the open channel of light metal gauge building construction track to form a structural wall.

15. A structural, insulating, insect resistant, dimensionally stable composite wall panel for building construction comprising a regular tetragonal body of polymer foam having two opposing primary wall surfaces bounded on its sides by two parallel side walls and on its ends by two parallel end walls; and at least two light metal gauge studs in the body, each stud having a hollow center cavity, a squared cross-section with a wide back wall extending the width of the stud, two parallel side walls, two narrow front walls separated by a open slot extending into the central cavity, each light metal gauge stud at least extending from one end wall to the other end wall and parallel to the side walls of said body, the polymer foam extending into the central cavity of the studs to secure the studs to the body, the width of the panel between the primary wall surfaces being greater than the width of the studs, at least one side wall of each stud forming a portion of the same primary wall surface of said body, the back wall of one stud being a part of one of the side walls of said body, said body having a tongue portion at each of its ends, the tongue portion having a width equal to the width of the studs, the tongue portion adapted to be received by and secured in the open channel of light metal gauge building construction track to form a structural wall

16 The composite wall panel according to claim 1 wherein the width of the wall panel between its sides is equal to a standard building construction center to center distance for studs or a multiple integral multiple thereof

17 The composite wall panel according to claim 14 wherein the width of the wall panel between its sides is equal to a standard building construction center to center distance for studs or a multiple integral multiple thereof

18 The composite wall panel according to claim 15 wherein the width of the wall panel between its sides is equal to a standard building construction center to center distance for studs or a multiple integral multiple thereof

19 The composite wall panel according to claim 15 wherein the distance between the studs, from center to center of the studs is a standard building construction center to center distance for studs 20 A structural wall for building construction based on a light metal gauge stud, a channel and track construction, comprising a light metal gauge track with an open channel secured for building floor system and a second light metal gauge track with an open channel for receiving, securing and supporting a ceiling and roofing structural members, the tracks separated by, supported by and secured to each other with two or more structural, insulating, insect resistant, dimensionally stable composite wall panels for building construction, each panel comprising a regular tetragonal body of polymer foam having two opposing primary wall surfaces bounded on its sides by two parallel side walls and on its ends by two parallel end walls, at least two light metal gauge studs in the body, each stud having a hollow center cavity, a squared cross-section with a wide back wall extending the width of the stud, two parallel side walls, two narrow front walls parallel to the back wall and separated by an open slot extending into the central cavity, each light metal gauge stud extending at least from one end wall to the other end wall and parallel to the side walls of said body, and polymer foam extending into the central cavity of the stud to secure the stud to the body, at least one side wall of each stud forming a portion of the same primary wall surface of said body, the distance between the studs, from center to center of the studs, is a standard building construction center to center distance for studs, studs of the panels being secured to the first and second tracks by self-threaded screws extending through the side walls of the tracks into the side walls of the studs

AMENDED CLAIMS

[received by the International Bureau on 21 October 1997 (21.10.97); original claim 20 amended; new claims 21 - 42 added; remaining claims unchanged (15 pages)]

1 A structural, insulating, insect resistant, dimensionally stable composite wall panel for building construction comprising a regular tetragonal body of polymer foam having two opposing primary wall surfaces bounded on its sides by two 5 parallel side walls and on its ends by two parallel end walls; and at least one light metal gauge stud in the body, the stud having a hollow central cavity, a squared cross section with a wide back wall extending the width of the studs, two parallel side walls, two narrow front walls parallel to the back wall and separated by an open slot extending into the central cavity, each light metal gauge stud extending at 0 least from one end wall to the other end wall and parallel to the side walls of said body, the polymer foam extending into the central cavity of the stud to secure the stud to the body, at least one side wall of each stud forming a portion of the same primary wall surface of said body.

2. The composite wall panel according to claim 1 wherein the width of the panel between the two primary wall surfaces is equal to the width of the studs and the side walls of the studs forming a portion of the primary wall surfaces.

3. The composite wall panel according to claim 2 wherein at least one stud is one of the side walls of said body.

4. The composite wall panel according to claim 2 wherein the ends of said body are adopted to be received by and secured in the open channel of light metal gauge building construction tracks to form a structural wall.

5 The composite wall panel according to claim 2 wherein the back wall of one stud is one of the side walls of said body

6 The composite wall panel according to claim 1 wherein the composite wall panel has at least two light metal gauge studs

7 The composite wall panel according to claim 6 wherein the distance between the studs, from center to center of the studs, is a standard building construction center to center distance for studs

8 The composite wall panel according to claim 7 wherein at least one stud of one of the side walls of said body

9 The composite wall panel according to claim 8 wherein the back wall of one stud is a part of one of the side walls of said body

10 The composite wall panel according to claim 8 wherein the width of the panel between the primary wall surfaces being greater than the width of the studs

11 The composite wall panel according to claim 10 wherein said body has a tongue portion at each of its ends, the tongue portion having a width equal to the width of the studs and adapted to be and received by and secured in the open channel of light metal gauge building construction track to form a structural wall

12 The composite wall panel according to claim 10 wherein at least one stud is part of one of the side walls of said body

13. The composite wall panel according to claim 10 wherein the back wall of one stud is part of one of the side walls of said body.

14. A structural, insulating, insect resistant, dimensionally stable composite wall panel for building construction comprising a regular tetragonal body of polymer foam having two opposing wall surfaces bounded on its sides by two parallel side walls and on its ends by two parallel end walls; and one light metal gauge stud in the body, the stud having a hollow center cavity, squared cross section with a wide back wall extending the width of the stud, two parallel side walls, two narrow front walls separated by an open slot extending into the central cavity, light metal gauge extending at least from one end wall to the other end wall and parallel to the side walls, the polymer foam extending into the central cavity of the stud to secure the stud to the body, the width of the panel between the two primary wall surfaces equal to the width of the stud and the side walls of the stud forming a portion of the primary wall surfaces; the back wall of the stud is one of the side walls of said body, and the ends of said body adapted to be received by and secured in the open channel of light metal gauge building construction track to form a structural wall.

15. A structural, insulating, insect resistant, dimensionally stable composite wall panel for building construction comprising a regular tetragonal body of polymer foam having two opposing primary wall surfaces bounded on its sides by two parallel side wails and on its ends by two parallel end walls; and at least two light metal gauge studs in the body, each stud having a hollow center cavity, a squared cross section with a wide back wall extending the width of the stud, two parallel side walls, two narrow front walls separated by a open slot extending into the central cavity, each light metal gauge stud at least extending from one end wall to the other end wall and parallel to the side walls of said body, the polymer foam extending into the central cavity of the studs to secure the studs to the body, the width of the panel between the primary wall surfaces being greater than the width of the studs, at least one side wall of each stud forming a portion of the same primary wall surface of said body, the back wall of one stud being a part of one of the side walls of said body, said body having a tongue portion at each of its ends, the tongue portion having a width equal to the width of the studs, the tongue portion adapted to be received by and secured in the open channel of light metal gauge building construction track to form a structural wall

19 The composite wall panel according to claim 15 wherein the distance between the studs, from center to center of the studs is a standard building construction center to center distance for studs

20 A structural wall for building construction based on a light metal gauge stud, a channel and track construction, comprising a light metal gauge track with an open channel secured for building floor system and a second light metal gauge track with an open channel for receiving, securing and supporting a ceiling and roofing structural members, the tracks separated by, supported by and secured to each other with two or more structural, insulating, insect resistant, dimensionally stable composite wall panels for building construction, each panel comprising a regular tetragonal body of polymer foam having two opposing primary wall surfaces bounded on its sides by two parallel side walls and on its ends by two parallel end walls, at least one light metal gauge stud in the body, each stud having a hollow center cavity, a squared cross section with a wide back wall extending the width of the stud, two parallel side walls, two narrow front walls parallel to the back wall and separated by an open slot extending into the central cavity, each light metal gauge stud extending at least from one end wall to the other end wall and parallel to the side walls of said body, and the body of polymer foam filling the central cavity, at least one side wall of each stud forming a portion of the same primary wall surface

21 A structural, insulating, insect resistant, dimensionally stable composite wall panel for building construction comprising a regular tetragonal body of polymer foam having first and second opposing primary wall surfaces spaced apart by a first distance and bounded on its sides by two parallel side walls and on its ends by two parallel end walls, and at least one light metal gauge stud in the body, the stud having a hollow central cavity, a squared cross section with a wide back wall extending the width of the studs, first and second narrower parallel side walls, two narrow front walls parallel to the back wall and separated by an open slot extending into the central cavity, each light metal gauge stud extending the longitudinal length of the polymer foam body from one end wall to the other end wall and parallel to the side walls of said body, polymer foam filling the central cavity of each stud to secure each stud to the body, the first side wall of each stud forming a portion of the first primary wall surface of said body, each end wall of the polymer foam body having an end groove running its length and bordering the end portions of the second side wall of each stud, each end groove extending a first predetermined distance into the body of polymer foam from the end wall

22 The composite wall panel according to claim 21 wherein the back wail of one stud is coplanar with the first side wall of said body

23 The wall panel according to claim 22 wherein the second primary wall surface of the polymer foam body at each longitudinal end of the body has a first groove extending partially into the second primary wall surface, each groove parallel to the end walls and positioned a distance equivalent to the first predeter- mined distance from the closest end wall

24 The composite wall panel according to claim 23 wherein the second primary wall surface has a second groove extending partially into the second primary wail surface, the groove positioned between the closest end wall and the first groove and parallel thereto

25 The composite wall panel according to claim 23 wherein the second primary wall surface has a plurality of parallel grooves extending partially into the second primary wall surface and extending longitudinally from each end wall to the nearest first groove

26 The composite wall panel according to claim 22 wherein the first side wall of the polymer foam body has a longitudinal side groove extending the length of the body from one end wall to the other end wall, the groove extending into the polymer foam from the first side wall a second distance equivalent to the width of the composite wall panel, the longitudinal side groove bordering the end portions of the second side wall of each stud, and the second primary wall surface of the body of polymer foam having a longitudinal groove running the length of the body from one end wall to the other end wall and parallel to the side walls, the groove extending partially into the second primary wall surface, the groove positioned a distance equivalent to the second distance from the first side wall

27 The composite wall panel according to claim 22 wherein the second primary wall surface of the body at each longitudinal end of the body has a groove cutout extending partially into the wall surface opposite the end portion of the second side wall of each stud, the polymer foam of the groove cutout adapted to be cut out or knocked out to form a window in the second primary wall surface to the end groove

28 The composite wall panel according to claim 22 wherein the panel has one light metal gauge stud

29. The composite wall panel according to claim 22 wherein the panel has two light metal gauge studs, the transverse distance between the parallel studs from center to center of the studs is a standard building construction center-to- center distance for studs.

30. A method of producing a composite wall panel comprising the steps of forming a block of polymer foam into a regular tetragonal body having first and second opposing primary wall surfaces spaced apart a first distance and bounded on its sides by two parallel side walls and on its ends by two parallel end walls, cutting an L-shaped groove into the polymer foam body on one of the side walls the full length of the body, cutting a straight groove on the first primary wall surface the full length of the body parallel to the first end wall, inserting into the L-shaped groove and straight groove a light metal gauge stud, the stud having a hollow central cavity, a square cross section with a wide back wall extending the width of the studs, first and second narrower parallel side walls, narrow first and second front walls parallel to the back wall separated by an open slot extending into the central cavity, the second side wall and its contiguous narrow second front wall being inserted into the L-shaped groove and the narrow second front wall of the stud being inserted into the straight groove, the stud being inserted the full length of the polymer foam body so that the central cavity of the stud is filled with polymer foam and the wide back wall of the stud forms a portion of the side wall of the composite wall panel and the first side wall of the stud forms a portion of the first primary wall surface of the body; cutting end grooves into the end walls of the polymer foam body, the end grooves being parallel to the primary wall surfaces and adjacent to the end portions of the L-shaped grooves, the end grooves extending into the polymer foam body, the end grooves adapted to receive the side walls of the bottom and top tracks of a wall panel system

31 The method according to claim 30 wherein a J-shaped groove is cut into the polymer foam block from one end wall to the other end wall, the J-shaped groove extending into the polymer foam block from the first primary wall surface, cutting a second straight groove into the first primary wall surface parallel to the J groove, the J groove and the second straight groove adapted to receive a second light metal gauge stud, the back wall, second side wall and the contiguous narrow second front wall of the stud being inserted into the J groove and the first front wall of the stud being inserted into the second straight groove, the stud being inserted the full length of the polymer foam block

32 A composite panel header for a panel wall system employing composite polymer foam-light metal gauge stud panels, the header comprising a header frame and first and second polymer foam blocks, the header frame having opposing longitudinal ends and opposing parallel top side and bottom side, and opposing parallel front side and back side, the header frame comprising first and second light metal gauge C-channel beams and at least two L brackets, each beam having a central cavity, a rectangular cross section, a wide back wall, two narrower first and second side walls, narrow first and second front walls parallel to the back wall and separated by a wide open slot, the two C-channel beams secured back-to- back on their back walls, the first side walls of the two beams forming the top side of the header frame, the two second side walls of the beams forming the bottom side of the header frame, the two front walls and open slot of the first C-channel beam forming the front side of the header frame and the two front walls and open slot of the second C-channel beam forming the back side of the header frame, each L bracket having a first plate and a perpendicular second plate, each longitu¬ dinal end of the header frame having an L bracket, the first plate of each L bracket secured to the inner surface of a C-channel beam with the second plate of each L bracket positioned at the longitudinal end of the header frame and used to secure the header frame to light metal gauge C studs of a panel wall system; the first polymer foam block extending the length of the header frame, having a thickness equal to the depth of the first C-channel beam between the inner side of the back wall and the inner side of a front wall, and having a height equal to the height of a front wall and the open slot of the first C-channel beam, the first polymer block located in the central cavity of the first C-channel beam and adapted to be inserted and removed through the open slot; and the second polymer foam block extending the length of the header frame, having a rear section and front section separated by upper and lower longitudinal grooves, the rear section having a thickness equal to the depth of the second C-channel beam between the inner sides of the back wall and the front wall, and a height equal to the height of a front wall and the open slot of the beam, the longitudinal grooves extending from the top and bottom of the polymer foam block a distance equivalent to the height of the front walls of the beam, the first section located in the central cavity of the second C-channel beam and adapted to be inserted into and removed through the open slot, the height of the second section equal to the height of the header frame and the thickness of the second section equal to the difference between the width of the header frame and the width of a polymer foam-light metal gauge stud wall panel.

33. The composite header of claim 32 wherein the two C-channel beams are secured back-to-back by a plurality of threaded fasteners.

34. The composite header of claim 32 wherein the two C-channel beams are secured by welding.

35. The composite header of claim 32 wherein the L brackets are secured to the header frame by a plurality of threaded fasteners.

36. The composite header of claim 32 wherein the header frame is crowned with a top track of a panel wall system, the side walls of the top track extending partially over the front side and back side of the header frame and the web of the top track on the top side of the header frame.

37. The composite header of claim 36 wherein the web of the top track is secured to the header frame by threaded fasteners extending through the web into the first side walls of the two C-channel beams.

38. The composite header of claim 36 wherein the side walls of the top track are secured to the header frame by threaded fasteners extending through the side walls of the top track into the first front walls of the two C-channel beams.

39. A method of constructing a composite panel header for a composite panel wall system employing polymer foam-light metal gauge stud panels comprising fabricating a header frame and first and second polymer foam blocks, the header frame having opposing longitudinal ends, opposing top and bottom sides, and opposing front and back sides, the header frame assembled by securing first and second light metal gauge C-channel beams back-to-back on their back walls, each C-channel beam having a central cavity, a rectangular cross section, a wide back wall, narrower parallel first and second side walls, narrow first and second front walls parallel to the back wall separated by a wide open slot, the first side walls of the two channel beams constituting the top side of the header frame, the two second side walls of the beams creating the bottom side of the header frame, the two front walls and open slot of the first light metal gauge C-channel beam constituting the front side of the header frame and the two front walls and open slot of the second C-channel beam constituting the back side of the header frame, securing an L bracket to each longitudinal end of the header frame, each L bracket having a first plate and perpendicular second plate, the first plate secured to the inner surface of the back wall at a longitudinal end of the beam with the second plate positioned at the longitudinal end of the header frame for securing the header frame to a C stud of a polymer foam-light metal gauge stud panel of the composite wall panel system, forming a first polymer foam block which extends the length of the header frame, the polymer foam block being rectangular in shape and having a thickness equal to the depth of the first C-channel beam between the inner side of the back wall and the inner side of the front wall and having a height equal to the height of a front wall and the open slot of the first beam, inserting the first polymer block into the central cavity of the first beam through the open slot, forming a second polymer foam block having a rectangular shape and extending the length of the header frame, the second polymer foam block having a rear section and a front section separated by an upper longitudinal groove and a lower longitudinal groove, the groove extending from the top surface of the second block a distance equivalent to the height of a front wall of a beam, and the bottom groove extending from the bottom side of the second block into the polymer foam a distance equivalent to the height of a front wall of a beam, the rear section having a thickness equal to the depth of the second C-channel between the inner sides of the back wall and the front wall and a height equal to the height of the front wall and the open slot, inserting the first section into the central cavity of the second C-channel beam through the open slot, the height of the second section equal to the height of the header frame and the thickness of the second section equal to the difference between the width of the header frame and the width of a polymer foam- light metal gauge stud wall panel

40 A composite vertical post for a composite panel wall system employing top tracks and bottom tracks having a web and side walls, the width of the web being equal to the width of a light metal gauge stud employed in the composite polymer foam-light metal gauge stud wall panel, the composite vertical post comprising a pier and a polymer foam block, the pier comprising first and second light metal gauge C studs, each stud having a central cavity, a square cross section with a wide back wall extending the width of the stud, narrower first and second parallel side walls, two narrow front walls parallel to the back wall separated by an open slot extending into the central cavity, the two C studs secured back-to- back on their back walls the first side walls of the two C studs constituting the first side of the pier and the second side walls of the two C studs constituting the second side of the pier, the front walls and open slots of the first C stud constituting one side of the pier and the front wall open slot of the second C stud constituting the other side of the pier, and a polymer foam block extending the full length of the pier and having opposing end walls, parallel and opposing front and back walls, and parallel and opposing side walls, the front wall of the pier and the front wall of the polymer foam block being coplanar and constituting the front wall of the composite vertical post, the polymer foam block surrounding the back wall and the two sides of the pier, the polymer foam filling the central cavity of each C stud, each end wall having a groove running its length from one side wall to the other side wall of the polymer foam block and bordering the end portions of the side of the pier, each groove being parallel to the front and rear walls of the block, each groove extending from the end wall of the block into the polymer foam a distance at least equivalent to the height of the side wall of the top track and bottom track of the composite wall panel system, the pier adapted to be inserted into the top track and bottom track by inserting the front wall of the composite vertical post and the end groove between the two side walls of the track with the front wall and back wall of the pier within the track so that the side walls of the track can be secured to the front wall and back wall of the pier

41 The composite vertical post according to claim 40 wherein the first and second light metal gauge C studs are secured back-to-back by threaded fasteners to form the pier

42 A method of producing a composite vertical post for a composite panel wall system employing polymer foam-light metal gauge C-stud panels and top tracks and bottom tracks having a web and two side walls, the composite vertical post comprising a pier and a polymer foam block, the method comprising forming a polymer foam block having opposing end walls, parallel and opposing front wall and back wall, and parallel and opposing side walls, cutting a first groove the length of the polymer foam block from one end wall to the other end wall, the groove extending from the front wall of the block into the polymer foam, the first groove cross section having the shape of two J grooves joined back-to-back, cutting two parallel grooves the length of the block in the front side of the block from one end wall to the other end wail, the two grooves being parallel to the first groove, the distance of the first and second grooves from the first groove being equivalent to the distance between the inner sides of the front wall and back wall of a light metal gauge C stud; forming a pier having parallel and opposing front and back walls and parallel and opposing sides, the pier assembled by securing first and second light metal gauge C studs back-to-back on their back side, each stud having a central cavity, a squared cross section with a wide back wall extending the width of the stud, narrower first and second and parallel side walls, two narrow front walls parallel to the back wall and separated by an open slot extending into the central cavity; and inserting the pier into the polymer foam block, the back wall of the two C studs of the pier, the second side walls of the two C studs of the pier, and the two second front walls of the C studs of the pier are inserted into the first groove and the first front walls of the studs of the pier are inserted into the second and third grooves in the polymer foam block and the pier is inserted through the polymer foam block along its entire length to create the composite vertical post.

STATEMENT UNDER ARTICLE 19 (1)

Attached hereto are replacement pages 43 - 57 including amended claim 20 and new claims 21 through 42 Claims 21 through 29 show the composite wall panel illustrated in Figures 34 through 51 D described on pages 29 - 33 of the specification New claims 30 and 31 describe the method of making the panel of claims 21-29 illustrated in Figures 33A through 33D and 52A through 52D described on pages 28, 29 and 33 of the specification Claims 32-39 cover the composite header and its method of assembly shown in Figures 57A - 63 described on pages 34 through 36 of the specification Claims 40 and 41 are directed to the composite post and the method of making it illustrated in Figure 64-68D of the

drawings and described on pages 36-39 of the specification Claim 20 has been redrafted to cover all the composite wall panels of the application

These claims were inadvertently omitted from the parent priority application This is the first opportunity presented to present the claims in the international patent application The claims are also being added to the parent priority application