WO2003027413A1 - Procede et systeme d'installation de conduits et de compartiments dans un systeme de mur ferme - Google Patents

Procede et systeme d'installation de conduits et de compartiments dans un systeme de mur ferme Download PDF

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Publication number
WO2003027413A1
WO2003027413A1 PCT/US2002/028946 US0228946W WO03027413A1 WO 2003027413 A1 WO2003027413 A1 WO 2003027413A1 US 0228946 W US0228946 W US 0228946W WO 03027413 A1 WO03027413 A1 WO 03027413A1
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WO
WIPO (PCT)
Prior art keywords
box
conduit
outward
insulation core
closed wall
Prior art date
Application number
PCT/US2002/028946
Other languages
English (en)
Other versions
WO2003027413A9 (fr
Inventor
William J. Plsek
Gregory S. Bergtold
Original Assignee
Dow Global Technologies Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dow Global Technologies Inc. filed Critical Dow Global Technologies Inc.
Publication of WO2003027413A1 publication Critical patent/WO2003027413A1/fr
Publication of WO2003027413A9 publication Critical patent/WO2003027413A9/fr

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
    • E04C2/521—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits serving for locating conduits; for ventilating, heating or cooling

Definitions

  • the invention relates to the building industry. More particularly, the invention relates to a method and system of providing various members within a closed wall system.
  • walls are fabricated by erecting on a foundation a structural frame that is usually formed from timber.
  • the frame is subsequently clad internally with a suitable material, which is usually finished to conceal the joints with a wall covering.
  • An exterior wall is usually made from concrete block, brick veneer, or a suitable cladding material that is fastened to the timber frame.
  • Common exterior cladding materials include wood, fiber-reinforced cement, and aluminum.
  • closed walls typically include one or more structural materials and one or more, typically two, surface materials, also known as “skins” that enclose the members therebetween.
  • Some closed walls include insulating board sandwiched or otherwise disposed between the skins with or without structural or other members.
  • the closed walls are made in relatively large sections, such as four feet by eight feet or larger. The closed walls can be brought to the building site, set in place, and fastened to rapidly erect walls or other portions of the building. Further, the materials used in the closed walls can be made from non-conventional materials and promote ecological conservation.
  • a subcategory of the closed wall system is known as a structural insulated panel (SIP).
  • SIP structural insulated panel
  • the SIP includes two outward layers of material and one or more layers of insulation material.
  • Insulation material is typically a rigid foam core such as polyurethane, polystyrene, EPS, XPS, and polyisocyanurate.
  • the conduit and box are installed in the insulation material.
  • IP '444 describes a structural panel having a polystyrene insulated material sandwiched between two wafer boards.
  • the disclosure provides a plurality of electric wiring holes installed in a criss-cross horizontal and vertical direction that can be aligned with horizontally or vertically adjacent panels.
  • the disclosure does not address conduits installed in the fabrication process, boxes installed that intersect the conduits, nor the ability to customize and vary the installation of the conduit and/or box for job-specific locations.
  • a closed wall system constructed in the manner of the disclosure of the JP '444 would still require the job site modifications and complexities described above.
  • the present invention provides an engineered closed wall system that includes one or more conduits installed during fabrication of the closed wall system and an associated box that is positioned to intersect the preinstalled conduit at a standard connection port of the box and in a predetermined location.
  • the location of the conduit and/or box can vary according to job-specific requirements.
  • the engineered closed wall system includes a first outward layer, an inside insulation core having a first and second face, the first face being coupled to the first outward layer, a second outward layer coupled to the second face of the inside insulation core, at least one preinstalled conduit installed in the insulation core during fabrication of the closed wall system, and at least one box installed in the insulation core and positioned to intersect the preinstalled conduit at the extended connection port of the box.
  • the location of the conduit and/or box can vary according to job-specific requirements.
  • the conduit and/or box can be engineered into the closed wall system during the fabrication.
  • the conduit can be installed equidistant from the first and second outward layers.
  • Specific boxes, and any ring extensions mounted to the boxes, can be sized to flexibly mount from either outward layer and be substantially flush with the face of the outward layer and still intersect the conduit at a standard connection port provided on the box.
  • the invention further provides a method of preparing an engineered closed wall system, comprising providing at least two outward layers of material and an insulation core, coupling the two outward layers with the insulation core, forming an elongated opening in the insulation core, installing a conduit in the elongated opening, forming a second opening in the insulation core and an opening in at least one outward layer, the second opening from the insulation core being substantially aligned with the opening in the outward layer, installing a box in the second opening, and aligning a standard connection port of the box with the conduit.
  • Figure 1 is a perspective schematic view of a building having a closed wall.
  • Figure 2 is a perspective schematic view of a closed wall with a conduit and box installed therein.
  • Figure 3 is a cross-sectional schematic view of a closed wall system having a conduit and box installed therein.
  • Figure 4 is partial cross-sectional schematic view of another embodiment of the box and/or extension ring installed in a closed wall system.
  • Figure 1 is a perspective schematic view of a building having a closed wall.
  • a building 10 is representative of any building upon which a closed wall may be installed.
  • Building 10 can include residential, commercial, industrial, and other types of structures.
  • the building can include any shape that can be constructed such as rectangular, square, multi-story, single-story, geodesic, or any other surface shape in which a building may be made.
  • a building will include a foundation 12, walls 14, and roof 16.
  • the foundation 12 can be any typical foundation, such as but not limited to, a slab, wood, beam, steel, raised platform, and other types of underlying supports. Further, the foundation can be the upper level of a lower story in a multi-story building. Generally, one or more walls 14 form a supporting surface between the foundation and a roof.
  • the term "wall,” “walls,” and like terms are used broadly herein and can include exterior or interior walls that may be vertical, horizontal, or at angles to the foundation, as is appropriate to the particular building design.
  • the roof 16 is shown to be an angled roof as would generally exist in many buildings. However, it is to be understood that the roof can have any shape as is appropriate, including a flat roof. Further, the building 10 can have one or more doors 18 and one or more windows 20.
  • An exterior 22 of the building 10 generally includes an exterior medium such as brick, stone, metal, wood, fiberglass, composites, and other materials to protect from weather, theft, and other aspects known to those with ordinary skill in the art.
  • a closed wall shown in more detail in Figure 2, can be installed inwardly of the building exterior 22.
  • the closed wall generally is a composite wall containing a first outward layer 24 and a second outward layer 26 with one or more inside members enclosed or otherwise disposed therebetween.
  • One or more of the outward layers 24, 26 can include a variety of structural or nonstructural material.
  • the outward layers can include materials made from sheetrock, plywood, particle board, oriented strand board (OSB), laminates, fiberboard, insulation boards and other insulating materials, films, plastics, metals, and other building materials.
  • the second outward layer can be made of similar materials.
  • inside member is intended to include any member(s) or feature(s) that can be disposed or formed at least partially between the first and second outward layers 24, 26.
  • some inside members can be studs, insulation, headers, elements of the plumbing or electrical systems, such as pipes, vents, conduits, wires, and rigid and flexible insulation, or other elements as can exist between the two outward members in a building.
  • the inside members can include openings, such as holes of various sizes and shapes, access ports, and other void areas.
  • a standard closed wall thickness can be formed from 7/16 inch thick outward layers and each 3-1/2 inches thick inside members, although the thicknesses can vary depending on the building and materials used. Insulative, plumbing, electrical, and other elements can be installed therein.
  • one or more of the outward layers can be laminated or otherwise coupled to the inside member, such as a foam core, during the fabrication process.
  • the term "coupling” is used broadly herein and is intended to include any method of securing, binding, bonding, fastening, attaching, joining, inserting therein, forming thereon or therein, or otherwise associating one or more of the layers and members together.
  • the outward members can be provided and the foam core or other inside member can be formed or disposed between the outward layers.
  • Full-length studs 28 generally known as kings studs, are used to support the wall along its length.
  • Shorter supports 34 may be used to support other headers 36 below building structures, such as the window 20.
  • a structure supporting the roof 16, generally termed herein upper structure 38 can include joists, rafters, braces, and other supports. Further, the upper structure 38 can include girders, beams, and other supports for multi-story building structures.
  • inside members disposed between the outward layers 24, 26 can include elements of the plumbing system 40.
  • such elements can include pipes, vents, drains, and other plumbing elements.
  • the inside members disposed in the space between the outward layers 24, 26 can include elements of an electrical system 42.
  • Such elements can include conduits, wires, boxes, switches, and other typical electrical elements.
  • FIG. 2 is a perspective schematic view of a closed wall with a conduit and box installed therein.
  • a closed wall 50 includes a first outward layer 24 and a second outward layer 26.
  • An inside member 51 can include elements such as studs 52, 58, and 60 and other structural elements, insulation core 54, conduit 56, features, such as openings, and other members as would be generally be found in a building structure.
  • the insulation core 54 can include any insulation material generally used in closed wall systems, including relatively rigid foam cores, polyurethane, polystyrene, EPS, XPS, and polyisocyanurate, more flexible materials, such as fiberglass batting, or other materials known to those with ordinary skill in the art.
  • conduit 56 is used broadly herein and can include any shaped tubing used for any variety of general building purposes.
  • such conduits commonly include metal, such as copper, aluminum, and steel, polyvinyl chloride (PNC), and other structural materials.
  • PNC polyvinyl chloride
  • Such conduit can be used for plumbing, electrical, air conditioning, and other systems using the construction of building 10.
  • a conduit that is particularly useful in the electrical trade is known as "electrical metallic tubing" (“EMT”) in which electrical wiring is placed.
  • EMT electrical metallic tubing
  • the conduit 56 can be placed at predetermined locations in the insulation core 54, for example, by drilling, machining, routing, or otherwise forming a pathway through the core 54 for the conduit during fabrication of the closed wall, for example, at a manufacturing facility.
  • the conduit 56 can extend sufficiently beyond the closed wall system, and particularly the insulation core 54.
  • a connector such as connector 64, can be attached to the conduit 56 at the extension.
  • the connector 64 can allow another conduit 66 to be attached thereto to continue the conduit path.
  • the conduit 56 is shown extending above the closed wall 50, it is to be understood that the conduit can extend in any direction, such as through the top, sides, or bottom of the closed wall, or at a variety of angles to the closed wall, as is appropriate to the particular installation.
  • a box 68 can be installed in the closed wall 50 at a predetermined position. Generally, the box or some member coupled to the box, such as an extension ring, will extend through one of the outward layers 24, 26 and into the insulation core 54. The box 68 can be coupled to the conduit 56.
  • box is used broadly and includes not only boxes in which electrical devices, such as switches and outlets, can be installed but also includes junction boxes, conduit bodies, load sensors, fixture boxes, breaker boxes, fuse boxes, plumbing drain pans, access ports, and any other boxes used in building trades associated with constructing the building 10, shown in Figure 1.
  • the box 68 can be made of any metallic, plastic, foam, or other structural material. Further, the box can be octagonal, round, square, or any geometric shape. Generally, the box 68 includes an open face 72 for access to an inside volume of the box. The open face 72 may be closed by a cover (not shown) after access to the box 68 is complete.
  • the box can be attached to a structural member, such as stud 52 or the insulation core 54, if the box is located adjacent the member. Openings 76 formed in the box 68 provide access for attaching the box to a structural member with a fastener, such as a nail or screw or other known fastener.
  • the box 68 can be mounted substantially "flush,” that is, substantially even, or below the outer face 73 or 77 of the corresponding outward layer 26 or 24. The flush mounting or below surface mounting allows the closed walls to be shipped without excess shipping materials or dunnage interposed between adjacent closed walls that increases packing and shipping costs to avoid damage to adjacent walls.
  • an opening for the box can be formed in the core 54 and the outward layer through which the box extends.
  • the opening for the box can be formed either in core 54 prior to installation of the outward layer with the core, or can be done after installation of the outward layer with the core.
  • the present invention provides that the conduit and box are preinstalled, that is, installed during fabrication of the closed wall. Generally, the installation occurs at predetermined positions.
  • the closed wall can be fabricated as a system having the conduit and box preinstalled. An engineer, designer, or other person associated with the fabrication process determines prior to fabrication the desired location of the conduit and/or box.
  • the conduit and/or box is installed at the predetermined positions during the fabrication process.
  • the location of the box 68 and associated conduit(s) can vary depending on the specific requirements of the job. For example, if the closed wall 50 is used in residential construction, such as in a kitchen, the box 68 may be positioned at a particular height above countertops. As a further example, the horizontal spacing between adjacent boxes can vary in the closed walls of the present invention to accommodate different rooms in the building. The flexibility in job-specific predetermined locations appears to address part of the reason that acceptance of closed wall systems has been limited.
  • the present invention allows the boxes to be installed at job-specific locations, for example, at a manufacturing facility where a closed panel is engineered and fabricated. Thus, a manufacturing facility can review a set of architectural plans, engineer the specific locations of the boxes to accommodate the building design, and construct the closed walls with the conduit and boxes preinstalled for the particular placement of that closed wall on that job site.
  • the boxes and/or conduit can be located at standard positions in multiple categories of closed walls.
  • a building 10 could have one category of standard closed walls without a box, another category of closed walls with boxes installed at certain predetermined positions, and other categories with boxes installed at yet other positions.
  • Each of the closed walls could be installed in a selected position relative to the building design at the job site.
  • the present invention allows such flexibility in coordinating and designing the locations of the boxes. For example, an engineer/designer could select one category of closed walls having a box in one position for some areas of the house and another category of closed walls having a box in another position for other parts of the building 10, shown in Figure 1. Still other panels could have no electrical box and could be interspaced between those panels having electrical boxes.
  • the present invention allows such modular concepts, where the closed walls can be selected depending on the specific requirements of the job site.
  • FIG. 3 is a cross-sectional schematic view of a closed wall system having a conduit and box installed therein.
  • a closed wall 50 can include the previously described first and second outward layers 24, 26 and an inside member such as the insulation core 54.
  • the inside member, such as the core 54 can include a first face 23 and a second face 25, where the first face can be coupled to the first outward layer 24 and the second face 25 can be coupled to the second outward layer 26.
  • a conduit 56 can be installed in the core 54 at some predetermined position. The conduit 56 may extend beyond the core 54 to allow attachment of a connector 64. Another conduit 66 may be attached to the connector 64 to continue the conduit path.
  • One or more boxes 68, 86 can be installed in the wall and directly or indirectly coupled to the conduit 56.
  • the conduit 56 can be installed in the closed wall 50, so that the conduit intersects the boxes, such as box 68, at a standard connection port 70a.
  • Standard connection ports are generally meant to include those connection openings that are preformed prior to installation of the box. Generally, such connection ports are formed by the box manufacturer.
  • the conduit can extend slightly into the box at conduit end 82.
  • the box 68 and conduit 56 can be coupled together, for example, by a retainer 84 attached to the conduit.
  • the conduit can be installed in a centrally disposed location through the closed wall 50, so that the conduit is equidistant from the outward layers 24, 26.
  • This location provides an advantageous setup in the fabrication of the closed wall 50, in which boxes, such as box 68 and box 86, can be installed from either side of the closed wall and still be aligned with the conduit 56.
  • the equidistant spacing can allow alignment from box to box.
  • box 68 can be aligned with box 86, where both can be aligned with the conduit 56 at a standard connection port.
  • the conduit 56 is aligned with a standard opening 70a in box 68.
  • Box 86 is aligned with box 68 through a standard connection port 70b in box 68 and port 70c in box 86.
  • the boxes 68, 86 can be coupled to each other, for example, by a short conduit 88, sometimes called a "chase nipple.”
  • the chase nipple can be secured to each box by a retainer 90 in box 68 and a retainer 92 in box 86, if appropriate.
  • the box 68 and/or 86 may be insufficiently deep to extend outward the outward layers 24, 26.
  • the extension ring can be coupled to the respective box by screws, fasteners, and other devices (not shown).
  • Figure 4 is partial cross-sectional schematic view of another embodiment of the box and/or extension ring installed in a closed wall system.
  • the box and/or extension ring can include one or more tabs 74.
  • the tabs 74 can allow attachment of the box and/or extension ring to an outward layer, such as outward layers 24, 26.
  • One or more fasteners 75 can be disposed through the tabs and into the outward layer and/or core 54 to secure the element(s).
  • the extension by the tabs above the face 73 of the outward layer is greater than a flush mounted box without the tabs.
  • the amount of extension is minimal and is to be substantially flush with the surface of the outward layer. It has been discovered by the inventors, once the concepts of the invention were
  • the closed wall system includes two outward layers made from 7/16 inch thick oriented strand board (OSB) and an insulation core disposed therebetween.
  • OSB is a laminate of fibers and other materials that are mixed with a binder and formed into panels.
  • the insulation core was a foam core of 3-1/2 inches thick and made from either polyurethane or polyisocyanurate foam.
  • the OSB was laminated onto the foam core on both sides to form the outward layers.
  • the OSB can be formed or otherwise supplied and the foam can be formed between the OSB outward layers.
  • At least one opening was drilled with an elongated drill, commonly called a "chase drill," during fabrication of the closed wall and electrical conduit inserted therethrough.
  • a jig or other setup device could be used to help assist accuracy of the placement of the opening(s) formed in the closed wall, as would be known to those with ordinary skill in the art.
  • a location for an electrical box was chosen and an opening formed through the outward layer and into the insulation core.
  • the opening for the electrical box could have been formed in the core separately from a corresponding opening formed in an unattached outward layer. The openings are designed to align upon coupling of the outward layer with the core.
  • the conduit was installed so that it would be centrally spaced, that is, equidistant from the outer surface.
  • the opening for the box was made 3 inches deep from the outward face of the outward layer.
  • An electrical box of 4 inches square and 1-1/2 inches deep was inserted into the opening.
  • An electrical box from Raco, Inc. of South Bend, Indiana, USA, Model 190 or a similarly-styled box was used.
  • An extension ring, Raco Model 201, of approximately the same cross-sectional area and also 1-1/2 inches deep was coupled to the box. The combination of the box and the extension ring allowed the assembly to extend approximately flush with the outer face of the outward layer through which the box and/or extension extended.
  • this selection of component dimensions for this wall allowed a standard connection port formed in the box by the manufacturer to be aligned with the centrally disposed conduit. Also, this selection of component dimensions allowed the same type of box and extension ring to be installed from the other outward layer and still align with the centrally disposed conduit, the box installed from the first outward layer, or both. Naturally, other components could be used as well as other dimensions of various elements, such as outward layers, inside members, and other components of the closed wall system.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Installation Of Indoor Wiring (AREA)

Abstract

La présente invention concerne un système de mur fermé comprenant un ou plusieurs conduits pré-installés installés au cours de la fabrication du système de mur fermé et un compartiment associé positionné de manière à croiser le conduit pré-installé au niveau d'un orifice de connexion standard du compartiment et à un emplacement prédéterminé. L'emplacement du conduit et/ou du compartiment peut varier en fonction des exigences spécifiques du travail. Le conduit peut être favorablement installé de manière équidistante par rapport à la première et à la seconde couche extérieure. Les compartiments spécifiques, et toute extension annulaire montée dans les compartiments, présentent des dimensions leur permettant d'être montés flexiblement sur n'importe laquelle des couches extérieures tout en étant sensiblement alignés avec la surface de la couche extérieure et tout en croisant le conduit au niveau d'un orifice de connexion standard du compartiment.
PCT/US2002/028946 2001-09-26 2002-09-10 Procede et systeme d'installation de conduits et de compartiments dans un systeme de mur ferme WO2003027413A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US09/963,989 2001-09-26
US09/963,989 US20030056451A1 (en) 2001-09-26 2001-09-26 Method and system for providing conduit and boxes in a closed wall system

Publications (2)

Publication Number Publication Date
WO2003027413A1 true WO2003027413A1 (fr) 2003-04-03
WO2003027413A9 WO2003027413A9 (fr) 2004-04-15

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WO (1) WO2003027413A1 (fr)

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WO2007004526A2 (fr) 2005-07-01 2007-01-11 Oncotherapy Science, Inc. Methodes de modulation de smyd3 dans le traitement du cancer

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US9485917B2 (en) * 2006-12-15 2016-11-08 Ecovative Design, LLC Method for producing grown materials and products made thereby
US20090205277A1 (en) * 2008-02-19 2009-08-20 Gibson A David Construction Panel System And Method Of Manufacture Thereof
US8555574B2 (en) 2008-10-07 2013-10-15 Insulation Systems, Llc Pipe insulation system
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US11277979B2 (en) 2013-07-31 2022-03-22 Ecovative Design Llc Mycological biopolymers grown in void space tooling
US20150101509A1 (en) 2013-10-14 2015-04-16 Gavin R. McIntyre Method of Manufacturing a Stiff Engineered Composite
PL3423561T5 (pl) 2016-03-01 2024-06-03 The Fynder Group, Inc. Biomaty grzybów strzępkowych, sposoby ich wytwarzania i sposoby ich zastosowania
JP7161489B2 (ja) 2017-03-31 2022-10-26 エコベイティブ デザイン リミテッド ライアビリティ カンパニー 菌類生体高分子材料の溶液系後処理方法及びそれにより作製された菌類由来製品
US11266085B2 (en) 2017-11-14 2022-03-08 Ecovative Design Llc Increased homogeneity of mycological biopolymer grown into void space
US11920126B2 (en) 2018-03-28 2024-03-05 Ecovative Design Llc Bio-manufacturing process
US11293005B2 (en) 2018-05-07 2022-04-05 Ecovative Design Llc Process for making mineralized mycelium scaffolding and product made thereby
US11343979B2 (en) 2018-05-24 2022-05-31 Ecovative Design Llc Process and apparatus for producing mycelium biomaterial
EP3860370A4 (fr) 2018-10-02 2022-10-12 Ecovative Design LLC Paradigme de bioréacteur servant à la production de matrices hyphales extraparticulaires secondaires
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US3707165A (en) * 1970-08-10 1972-12-26 Joel S Stahl Plastic plumbing wall
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Publication number Priority date Publication date Assignee Title
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US20030056451A1 (en) 2003-03-27
WO2003027413A9 (fr) 2004-04-15

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