Note: Descriptions are shown in the official language in which they were submitted.
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FOAMED BUILDIN~ PANE~ INCLUDING
AN INTERNALLY MOUNTED SIVD
This invention relates to construction panels for
structural support systems having high strength to wei~ht
ratios and excellent insulating properties~ The
construction panels are primarily for use as exterior walls
but may also be used for lnterior walls, partitions,
ceilings and the like.
Currently, buildings are being constructed frorn a wide
variety of materials. Among the more common are wood,
cinder block, brick, concrete, metal and glass. Each has
particular advantages and disadvantagesO Wood, while
relatively easy to work wlth, i5 flammable, requires the
}abor o~ skilled carpenters, and is becoming increasingly
e~pensive. Cinder block and brick, although quite durable
are quite heavy, thus requiring high transportation costs.
In addi~ionj working wlth brick and block requires the
attention of skilled masons over long periods of time.
Concrete is awkward to transport, comparatively expensive
and requires the use of special construc~ion techniques and
building eguipment. Metal panels ~re poor insulators and
require the services o~ welders, riveters or other personnel
to fasten the panels together and to t~e supporting
structure by bolts, rivets or the like. Glass is breakable,
hard to transport and is not a good insulatorO Because of
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~hese disadvantages, new materials have been and are being
developed to replace the traditional building materials.
RecQntly SDme state~ have passed new laws mandating
that new structures must meet certain ener~y efficiency
standards including high "R" value insula-tion stand rds.
Additionally, the cost of lumber is escalating and natural
rasources are being depleted. Proper insulation of a
building leads ~o conservation of both energy and natural
resources while at the same time meeting the new energy
efficiency standards being written into law.
Various prior art methods o insulating build:Lngs have
been proposed. The most common form of insulation is oil-
backed fiberglass. Rolls o~ this material having various
degrees of thicknesses are unrolled at a job site, cut to
size and then mounted between adjacent wall studs. For pre-
constructed structures, insulating matarial may be blown
between the outer facing and the inner walls of a building
to the desired density and R value.
Another technique of provlding adequate insulation for
buildings is to incorporate insulating material in
prefabricated building panels. These panels offer ~he
advantages of good insulating properties, mass production,
and each of on-site assembly of the panels, a~ong other.
These panels generally comprise a core of insulating
material surrounded by structurally rigid panels. The core
of insulating material may comprise balsa wood, glass wool,
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foamed or expanded polymeric materials such as polystyrene,
polyvinyl chloride~ polyure~hane, etc. Th~ core material
may be surrounded by panel members comprising first and
second major face members and side and end walls of such
materials as plywood, metal, rasin and resin reinforced with
fibrous glass rovings, etc. Generally, these panels are
strong, lightw,eight and provide proper insulatin~ proper~ies
while using less wall space.
These modular panels also have some disadvantages.
Since the foam used in forming the core is not elastic, once
it ls compressed, a space develops between the core and
facing member. This results in weakened structural
intagrity and may be responsible for such conditions as
warping, buckling and cracking of -the face member or of the
entire panel. An additional disadvantage is ~hat the major
~ace members generally cannot withstand a great amounk of
load-bParing pressure as may be encountered whan the panels
are used as load-bearing members. To make the panels
stronger, various reinforcing means have been incorporated
within them. U.S. Patent No. ~,078,348 (Rothman) includes a
discussion of patents that are representative of the way in
which the prior art has attempted to overcome the problems
and disadvantages associated-with foamed core sandwich-type
panels.
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U.S. Patent No. 4,163,349 (Smith) shows an insulating
building panel including an insulating core and having an
exterior skin on one side and an interior skin on the other
side. The skins overlap the core about its periphery and,
at the sides of the panel, extend from the core a distance
to receive a portion of a bearing post to which adjacent
panels are connected. U.S. Patent No. 4,567,699
(McClellan) relates to a prefabricated building system made
up of a plurality of prefabricated panels. Each panel
includes a formed body of insulating material having a top,
a bottom, sides, a front face and a back face. At lea~t one
hollow tubular load-bearing member is embedded in the body
intermediate the sides and faces thereof and extends
vertically between the top and bottom. The tubular load-
bearing member has a slot in the top and bottom. The slotshave their axis generally parallel to the front and rear
faces of the body. A bottom member is provided along the
floor and has an upstanding flange e~tending into the slot
o~ the bottom of the tubular member and a ~op member extends
~0 along ~he top o~ the panels and has a flange extending
downwardly into the slots in the top of the tubular load-
bearing members. The load-bearing members have a len~th
greater than the leng~h of ~he body so that vertical loads
are not transmitted to the body.
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~dditional e~amples o modular wall sections employing
foam insulation are shown in U.S. Patents Nos. 3,828,502
(Carlsson); 3,791,912 (Allard); 3,562,985 (Nicosia~ and
3,449,879 (Bloom).
Despite the several alternatives for providing
prefabricated panels in building systemc;, there is still a
need for a construction panel and build:Lng system which is
less expensive to produce because of conservation of
materials, requires less labor for erection at the work
site, costs less to transport to the work site and minimizes
energy losses. The present invention is direated toward
~illing that need.
The present invention relates to an integral energy-
efflcient load-bearing exterior wall fabricated of
lightwei~ht foam surrounding plastic load-bearing columns.
The present invention includes both the prefabricated
modular wall panels as individual elements and as part of an
integrated building system.
In a preferred embodiment of the sub~ect invention, a
prefabricated modular wall panel is made from a foam
material which is molded around a plurality of ~ertically
oriented hollow support columns. Each of the columns
contains a pair of vertically disposed T-shaped fastening
supports extending along the full length of the support
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column. The fastening supports are arranged to form part of
the interior and exterior suraces of the foam wall. The
hollow support columns, which are preferably ma~e of a vinyl
plastic, are set onto locking base plates that are mounted
on a wood or concrete deck system. Locking top plates are
also mounted on wood are then placed on top of the colu~ns.
In alternative embodiments, the hollow support columns
are shaped in cross-section in the form of a rectangle, a
square, a diamond, an oval and a circle. The hollow columns
are designed to be used as conduits for electrical wiring,
watar pipes and in certain cases can be fabricated to act as
heat or air conditioning ducts.
~ n the accompanying drawings which illustrate a speci~ic
pre~erred embodiment o~ the invention:
Figure 1 is a perspective view, partially cut away, of
a portion of a building made up of pre-fabricated wall
panels forming part oP the inventive integra~ed building
system.
Figure 2 is a perspective view, partially cut away,
showing ~he details of a vertically disposed hollow column
incorporating the teachings of the present invention.
Figure 3 is an exploded perspective view of the
elements constituting the inventive integrated building
system.
Figure 4 is a view taken along lines 4-4 o~ Figure 1.
Figure 5 is a view taken along lines 5-5 of Flgure 4.
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Figure 6 is a view ~aken alony lines 6~6 of Figure 4.
Figure 7 is a perspective view, partially cut away,
showing the details of another embodiment of the hollow
column of Fisure 2.
Figure 8 îs a perspecti~e view, partially cut away,
showing the details of yet another embodiment of the hollow
column of Figure 2.
Figure 9 is a persp~ctive view, partially cut away,
showing the details of still another embodiment o:E the
hollow column of Figure 2.
Figure 10 is a perspective view, par~ially cut away,
showing an electrical box and wiring inserted into a
vertically disposed hollow column.
Figure 11 is a perspective view, partially cut away,
showing the incorporation of an air duct into a vertically
disposed hollow column having dovetail sides~
In describing the pref~rred embodiments of the subject
invention illustra~ed in the drawings, specific terminology
will be resorted to for the sake of clari~y. However, the
invention is not intended to be limi-ted to the specific
terms so selected, and it is to be understood that each
specific term includes all technical equi~alents which
operate in a similar manner to accomplish a similar purpose.
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Figures 1 through 6 illustrate a portion of a building
incorporating modular wall sections 10 embodying the
teachings of tha present inventionO One modul~r wall panel
10 basically comprises a wall member 12 made from a foamed
plastic material so that the member is principally designed
for use as an exterior wall and th~s hzls an exterior wall
surface 14 and an interior wall sur:Eace 16 which are
arranged parallel to each other. As oriented in Figures 1
and 3, each wall panel has a predetermined vertical height
which approximates the height of an exterior wall normally
~ound in industrial, commercial and residential buildings.
Because the panels are made from foamed plastic, the panel
size may be easily altered by workmen at the cons-truction
site.
Vertically disposed within the foamed wall panel 12 are
a series of spaced, hollow studs or support columns 20.
With reference to Figures 2 and 3, a hollow stud 20 is
fabricated from a plastic vinyl such as PVC through an
extrusion process. The stud basically comprises an
elongated, hollow member. In a preferred embodiment as
shown in Figures 2 and 3, the hollow member when viewed in
cross-section is in the shape of a rectangle 22 that is
defined as having a pair of opposed elonga~ed walls 24 and
26 which are arranged to be generally parallel with the
exterior and interior wall surfaces 14 and 16 when the
column is in its position of intended use within wall panel
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12. The cross-section is completed by a pair of opposed
shorter walls 28 and 30 which are opposecl from each other in
a generally parallel relationship. Together the interior
surfaces of the four walls 24, 25, 28 and 30 define an
interior space or volume 32 that exists throughout the
entire length of the column. Wall 24 contains an outside
face 34 and wall 26 contains an outside face 36. Each of
these faces contains the same structure which is described
as follows. Using face 34 as exemplary, emanating from an
area 38 def~ned vertically along the mid-point of face 24
are a pair of outwardly extending legs 40 and 42 which are
arranged generally parallel to each other. These legs each
define an elongated planar wall that is generally
perpendicular to surface 24 and extends vertically along the
entire length of the column. Each of legs 40 and 42
terminate a predetermined transverse distance from surface
24. Positioned at the termination of legs 40 and 42 is a
planar strip 44 that is generally parallel to surface 24
along the full length of the column. Plan2r strip 44
terminates a~ its longitudinal side in two inwardly directed
side fingers 46 and 48. An inside vertical strip 50 is
positioned generally parallel and spaced from strip 44 and
acts to join portions of fingers 46, 48 and legs 40 and 42
together. When viewed in cross-section as shown in Figure
2, the structure just described resembles a T with ~he head
44 of the T defining a portion of the outer surface 14 of
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the wall panel and the base of the T heing secured to the
vertical surface 24 of the hollow column. A similar
structural element is defin0d on face 26 in appro~imately
the same place as the element defined on face 24 and thus
contain the same reference numerals~
With reference to its ori~ntation in Figures 1 and 3,
the wall member 12 terminates at its top in a planar face 52
and at its bo~tom in planar face 54. The distance between
planar face 52 and 54 as measured vertically along one of
13 the columns Z0 is approximately equal to the intended height
of the finished wall. To complete the construction of the
wall member 10, a plurality of locking base plates 56 are
secured along a base stud 58 that is made of wood. In a
preferred embodiment, the base stud 58 has a width that is
substantially equal to the thickness of wall 12.
As shown ln Figure 3, each of the base plates is
defined by four walls 61 through 64 that are ~oined together
in a figure with an outer periphery that is slightly smaller
and mating with ths interior configuration of the hollow
member 20 so that the hollow member may be placed on top of
and receive the locking base plate 56 as shown in Figures 5
and 6. Surrounding the bo~tom periphery of each base plate
is a flange 66. The flange contains a number of apertures
68 for a receiving fastening device such as nails 70 in
order to secure the locking base plate at a predetermined
position alon~ the surface 72 of stud 58.
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As can be seen with referencP. to Figures 3 and 5,
locking base plates 56 are spacsd along the surface of stud
58 so that surface 72 may be placed in intimate contact with
surface 54 of wall section 12. The top of wall sec~ion 12
is completed through the use of spaced 1OGking top plates 76
and wooden stud 78 in a manner similar -to that described
with reference to the locking base plate 56 and the bottom
stud 58.
The locking base and top plates 56 and 76 are secured
within hollow column 20 through use of an appropriate
adhesive such as that commonly used to secure PVC articles
or with a mechanical fastener, such as a screw or nail.
With reference to Figures 3 and 4, the way in which the
ends o~ two panels 10 are ~oined together is graphically
illustrated. Each of the wall sections 12 terminate at its
vertical edges in end columns 120 and 121. As shown in
Figure 4, each of the end columns when viewed in cross-
section generally resembles one-half of the T member cross-
section of column 20. When viewed in cross-section, end
20 column 120 has a pair of opposed planar walls 122 and 124
which are arranged to he generally parallel with the
exterior and interior wall surfaces 14 and 16 when the
column is its position of intended use at the edge of wall
panel 10. The cross-section is completed by planar wall 126
25 which ~oins the ends Qf walls 122 and 124 into a generally
U-shaped member. Wall 122 contains an outside face 128 and
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wall 124 contains an outside face 130. ~ach of these faces
contains the same s~ructure which 1~ described as follows.
Using face 128 as exemplary, emanating rom the free end of
leg 122 of the U-shaped section is an outwardly e~tending
leg 132. The leg defines and elongated planar wall that is
generally perpendicular to surface 128 and extends
vertically along the entire length of the column. Leg 132
terminates a predetermined transverse distance from surface
128. Positioned at the termination of leg 132 is a planar
strip 134 that is generally parallel to surface 128 along
the full length of the column. Planar strip 134 terminates
along its free end in an inwardly directed finger 136. An
inside vertical strip 138 is positioned generally parallel
and spaced from strip 134 and acts to ~oin leg 132 to finger
15 136. A similar complimentary structure is defined for edge
column 121 and noted by the same reference numerals.
When the planar ~urfaces of legs 132 of edge columns
120 and 121 are placed into intimate contact with each
other, the two edge columns define an interior space 140
that is of the same size and configuration at the interior
space 32 of one-piece column 20.
In order to secure the edge columns 120 and 121 to each
other, a U-shaped insert 142 is employed. The insert, which
in a preferred embodiment, is extruded from a plastic such
as PVC extends throughou~ ~he entire length of the edge
columns with the exception of a predetermined space near the
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bottom and top of the ~olumn to leave room for inser~ion of
the base and top pla~es 56 and 76. When viewed in cross-
section, the generally U-shaped member 142 con-tains two
elongated planar wall sections 144 and 145 which are
arranged generally parallel and spaced from each other. The
two walls are joined together to form the U-shape by a
shorter wall 146 which is perpendicular to the other two
walls.
The U-shaped insert 142 ls sized to fit snugly within
10the interior area of the edge columns 120 and 121. As shown
in Figure 5, the U-shaped insert ~acilitates securing and
~oining o~ the two wall sections 12. The U-shaped wall
member may either be glued within the edge columns or
fastened through the use of screws 17 or nails 19.
15Figures 3, 4 and 6 generally show the way that wall
sections 10 are joined together at corners. A ver~ically
oriented corner column is shown and designated as 152. In a
preferred embodiment, ~he corner column 152 is extruded as a
one-piece plastic unit incorpora~ing three basic sections.
At the heart of the corner column is a column definin~ area
154 which contains several vertically oriented walls 161
through 164 that are joined together in order to deflne an
opening 156 that is the same si~e and shape as the opening
32 defined in vertical column 20. This is done so -that the
25column 156 is able to receive the base and top plates 56 and
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76 in a manner described hereinbefore with reference to
space 3Z of vertical column 20.
Spaced from wall 161 is an exterior corner wall 166
that is intended to lie in the same plane and define a
portion of exterior wall 14. In a similar manner, spaced
from wall 162 is another planar wall 168 that contributes ~o
defining the other corner wall and lias in the same plane as
exterior surface 14 for an adjacent wall member 12.
Corner column 152 terminates at each end in an edge
column defining portion 168. The portion is construc-ted to
define an interior area 170 that is of the same si~e and
shape as the interlor wall defined by edge member3 120 and
121 so that when the corner column 152 i9 Joined lnto
operatlve contact with one of those members an interior
space of proper size for receiving the bottom and top plates
56 and 76, as well as the U-shaped Joining member 142, is
provided.
Figures 1 and 3 show a number modular wall units 12
arrange in their position of in~ended use. As can be seen,
the wall units 12 are erected in vertical fashion with the
undersurface of base stud 58 in contact with the floor 55 or
foundation of the building or dwelling. The wooden
construction of the base and top studs 58 and 78 facilita-te
attachment of each wall member 10 to the building under
cons~ruction. The wall is erected near the perimeter o~ the
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structure so that the wall 14 defines an exterior wall and
the wall 16 defines and interior ~all. The flat surfaces 44
of each of the columns 20 define an area along both surf~ces
14 and 16 for receiving fastening de~ices sl~ch as nails or
screws 57 to secure the appropriate type of wall covering 59
or skin to complete the construction of the modular wall
member 10. The side surfaces 71 and 73 of top stud 78 and
the side surfaces 75 and 77 of bottom stud 58 also occupy
the same plane as faces 44 of columns 20 for facilitating
attac~nent of the skin. The same relationship holds true
for surface 134 of edge columns 120 and 121 and corner
surfaces 166 and 168 of corner column 152. As shown in
Figure 4, the exterior surface 14 receives a sheet of
plywood siding 15 which is fastened by chemical bond
(adhesive) or by mechanical fastener such as screws 17 or
nails 19 to the various faces 44, 134 and 168 of columns 20,
120, 121 and 152, respectively, and the side surfaces of the
top and bottom s~uds 78 and 58. To complete the
construction of the interior surface, drywall or paneling 21
is secured in a similar fashion.
Figures 7 through 9 show in cross-section alternative
configurations for the hollow column 20. In an alternative
preferred embodiment as shown in Figure 7, the hollow member
when viewed in cross-section is generally shaped like a
square that is defined as having a pair of opposed walls 81
and 83 which ar~ arranged to be generally parallel with the
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exterior and interior wall surfaces 14 and 16 when the
column is in its position of intended use. The cross-
section is completed by a pair of walls 82 and ~4 which arP
opposed from each other in a generally parallel
relationship. Together the interior surfaces of the four
walls 81, 82, 83 and 84 define the inter:ior space 32. Wall
81 contains an outside ace 85 and wall 83 contains an
outside face 87. Each of these faces contains the same
structure which is described as follows. Using face 83 as
exemplary, emana~ing from an area 38 defined vertically
along the mid-point of face 83 is a vertically extending leg
86. The leg defines a planar wall that is generally
perpendicular to surace 87. Leg 86 terminates a
predetermined transverse distance from surface 87. Defined
at the termination of lag 86 is a planar strip 88 tha~ is
generally parallel to surface 87. Planar wall 88 ~erminates
at its sides in two inwardly directed side fingers 90. When
viewed in cross-section as shown in Figure 7, the structure
~ust described resembles a T with the head 88 of the T
defining a portion of the outer or inner surface 14 or 16 of
the wall panel 12 and the base of the T being secured to the
vertical surface 87 of the hollow column. A similarly
configured element is defined on face 85 in approximately
the same place as the element defined on surface 87. The
outer face of walls 82 and 84 contain T structures 95 that
are smaller than the T-structure emanating from surface 85.
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In the several T-struc~ures, leg 92 resembles to leg
86, wall 94 resembles to wall 88 and fingers 96 resemble to
fingers 90.
Tn still another preferred embocliment as shown in
Figure 8, the hollow member when viewed in cross-section is
in the shape of a diamond that is defined as having a pair
of opposed walls 181 and 183 which are arranged at about a
45 angle with the e~terior and ln~erior wall surfaces 14
and 16~ The cross-section is completed by a pair of opposed
10 walls 182 and 184 which are opposed from each other in a
generally parallel relationship. Toget,her the interior
surfaces o~ the four walls 181, 182, 183 and 184 define the
interior space 32. A side of wall 181 meets with a side of
wall 184 at a corner 101 near surface 14 of wall 12.
15 Similarly, a side of wall 182 meets with a sid~ of wall 183
at a corner 103 near surface 16 of wall 12. Emanating from
corner 101 as defined vertically along column 20 is leg 86.
The leg defines a planar wall that is generally
perpendicular to surface 14 of ~all 12. Leg 86 terminates a
predetermined transverse distance from corner 101. Defined
at the termina~ion of leg 86 is a structure similar to that
shown in Figure 7. Inner corners 105 and 107 of the column
include structural elements 92 and 94 as previously
described with reference to the embodiment in Fiyure 7
without the fingers 96.
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Finally, Figure 9, shows another embodiment of ~he
vertical columns which when viewed in cross-section
resembles the square embodiment of Figure 7 with rounded
corners 181 through 184. For this reason, like elements
contain like reference numerals. However, certain mirror
differences are noted. In particular, the fastener strip 88
is much wider in the oval embodiment than in the square
embodiment. Likewise, the inward fingers 96 are replaces by
ingers 190 that extend both inwardly and outwardly~
10As shown in Flgures 10 and 11, the hollow interi.or of
the vertical columns 20 provides usable space for use as a
conduit for electrical wiring, plumbing and, in certain
cases, heating or air-conditioniny ducts.
Figure 10 shows an electrical box 190 inserted within
15outside face 36 of column 20. A portion of box 190 is well
within the open space 32 defined in the vertical column~
Conventional household wiring 192 is shown passing through
the volume 32 in the vertical column 20 and then into the
interior of the electrical box for subsequent connection to
conventional receptacles and switches. The box may be made
of a PVC plastic and secured within the hollow column 20 so
~hat i-t actually becomes part of the stud conduit.
Alternatively, an opening may be cut on either side of the
vertical column at any height and a box may be then
introduced into the open space. The wire cables 192 may
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pass ~rom location to location ~y entering and exitiny holes
(not shown) defined in the bottom and top plates 58 and 78.
Figure 11 shows a vertical col~mn 20 which has been cut
on one of i-ts faces to receive a box 200 in order to provide
an exit point for air to pass through the ver~ical column.
In this way, the volume 32 defined in the vertical column
provides a duct work and the box 200 defines an air supply
outlet. It is contemplated that the hollow conduits may be
used ~n conjunction with equipment sold by Dunham ~ush~ Inc.
under the trademark SPACE PACK. Figure 11 also shows an
alternate construction for the side walls 30 of the
embodiment shown in Flgure 2. In particular, an elongated
vertically extending mortis shape 202 is defined along the
outer faces 2B and 30. The mortis indentation allows foam
to form and act as a tenon, giving better bond of oam to
the stud.
~ hus it can be appreciated that a construction system
employing the teachings of the present invention makes
optimum use of an exterior wall construction ~odule and
assembly technique that i~cludes a one-piece load-bearing
exterior wall ~abricated from light-weight foam surrounding
load-bearing columns. The same construction technique may
be used to produce walls for interior cons~ruction.
The modular panels 10 made ~n accordance with the
teachings of the present invention enjoy several advantages.
The individual wall panels may be pre-cast and molded in a
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factory setting away from the construction site. The wall
units may be delivered as light-weight panels thus
conserving both ener~y and transportation. Because of the
way the panels are constructed, they are ready for easy
erection using ordinary toolsO
Each modular wall panel 10 includes a core 12 of
expanded or foamed polymeric material which exhibits a high
strength to weight ratio. The ~alls also e~hibit super
insulating properties especially because of the use of a
continuous length and width o~ foamed material completely
surrounding and touching the vertically oriented support
columns 20. In addition, the hollow, vertical columns
provide an excellent way to conceal wiring, plumbing and
heating or cooling duct work. There is also a significan~
reduction ln the number of wooden studs used in the
construction.
From the above, it is apparent that many modifications
and variations of the present invention are possible in
light o~ the above teachings. It is therefore to be
understood that, within the scope of the appended claims,
the invention may be practiced otherwise than as
specifically described.
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