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Patent 2019852 Summary

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Claims and Abstract availability

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(12) Patent: (11) CA 2019852
(54) English Title: FOAMED BUILDING PANEL INCLUDING AN INTERNALLY MOUNTED STUD
(54) French Title: PANNEAU DE CONSTRUCTION DE MOUSSE A MONTANTS INCORPORES
Status: Deemed expired
Bibliographic Data
(52) Canadian Patent Classification (CPC):
  • 20/23
(51) International Patent Classification (IPC):
  • E04C 3/30 (2006.01)
(72) Inventors :
  • RAYMOND, HARRY W. (United States of America)
(73) Owners :
  • RAYMOND, HARRY W. (United States of America)
(71) Applicants :
(74) Agent: MCCARTHY TETRAULT LLP
(74) Associate agent:
(45) Issued: 1995-08-01
(22) Filed Date: 1990-06-25
(41) Open to Public Inspection: 1990-12-23
Examination requested: 1992-06-19
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data:
Application No. Country/Territory Date
370,988 United States of America 1989-06-23

Abstracts

English Abstract






An integral energy efficient load-bearing exterior
wall fabricated of light-weight foam surrounding plastic
load-bearing columns. The invention relates to pre-
fabricated modular wall panels as individual building
elements and as part of an integrated building system. In
a preferred embodiment, a prefabricated modular wall panel
is made from a foamed material that is molded around a
plurality of vertically disposed hollow support columns.
Each of the columns contains a pair of opposed and
vertically disposed T-shaped fastening supports which are
arranged to form part of the interior and exterior surfaces
of the foamed wall. The hollow columns are set onto
locking base plates which are mounted on a wood or concrete
deck system. Locking top plates are also mounted on wood
and are then placed on top of the columns. The tubular
columns are made of a plastic material and are shaped in
cross-section in the form of a rectangle, square, diamond,
oval or circle. The hollow columns may be used as conduits
for electrical wiring, water pipes and in certain cases can
be fabricated to act as heat or air-conditioning ducts.


Claims

Note: Claims are shown in the official language in which they were submitted.




- 22 -

WE CLAIM:

1. A construction column for use as a structural support element in a
modular wall having an exterior surface and an interior surface, said
column comprising:
an elongated, hollow sleeve having a longitudinal axis and a
rectangular transverse cross-section, said sleeve having a pair of opposed
planar side walls and a pair of opposed planar end walls, said side walls
being arranged to be generally parallel with the exterior and interior
surfaces of said modular wall, each of said side walls having an inside
face and an outside face, each of said outside faces having a pair of
parallel, spaced-apart primarily legs extending outwardly thereform, each
of said primary legs defining an elongated planar wall generally
perpendicular to said outside face and having a termination at a
predetermined transverse distance from said outside face, a pair of
parallel planar outside vertical strips, each of said outside vertical strips
having a pair of opposed free ends and terminating along said free ends in
respective inwardly directed fingers, each of said outside vertical strips
being positioned at said terminations of one of said pairs of primary legs
generally parallel to said outside face along the full length of said
structural columns and having a pair of opposed free ends, and a pair of
parallel planar inside vertical strips, each of said inside vertical strips
being positioned generally parallel to and spaced from one of said outside
vertical strips and having a pair of opposed free ends, said inside and
outside vertical strips being joined at their free ends by said inwardly
directed fingers, extending from said free ends to said outside vertical
strip.

2. The construction column of claim 1, wherein said column is made
from plastic.

3. The construction column of claim 2, wherein said plastic is PVC.




- 23 -

4. The construction column of claim 1, wherein said hollow sleeve
when viewed in cross-section is in the form of a rectangle.

5. The construction column of claim 1, wherein said hollow sleeve
comprises two separable portions, and wherein said construction column
further comprises insert means for insertion into said hollow sleeve for
securing said separable portions of each other

Description

Note: Descriptions are shown in the official language in which they were submitted.


2~l9~5~2




FOAMED BUILDING PANBL INCLUDING
AN INT~PN~T.T.y NOUNTED 8TUD

This invention relates to construction panels for
structural support systems having high strength to weight
ratios and excellent insulating properties. The
construction panels are primarily for use as exterior walls
but may also be used for interior walls, partitions,
ceilings and the like.
Currently, buildings are being constructed from a wide
variety of materials. Among the more common are wood,
cinder block, brick, concrete, metal and glass. Each has
particular advantages and disadvantages. Wood, while
relatively easy to work with, is flammable, requires the
labor of skilled carpenters, and is becoming increasingly
expensive. Cinder block and brick, although quite durable
are quite heavy, thus requiring high transportation costs.
In addition, working with 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 construction techniques and
building equipment. Metal panels are poor insulators and
require the services of welders, riveters or other
personnel to fasten the panels together and to the
supporting structure by bolts, rivets or the like. Glass
is breakable, hard to transport and is not a good
insulator. Because of these disadvantages, new materials
have been and are being developed to replace the
traditional building materials. ~

201 q852


Recently some states have passed new laws mandating
that new structures must meet certain energy efficiency
standards including high "R" value insulation standards.
Additionally, the cost of lumber is escalating and natural
resources are being depleted. Proper insulation of a
building leads to 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 of insulating buildings have
been proposed. The most common form of insulation is foil-
backed fiberglass. Rolls of 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 material may be
blown between the outer facing and the inner walls of a
building to the desired density and R value.
Another technique of providing adequate insulation for
buildings is to incorporate insulating material in
prefabricated building panels. These panels offer the
advantages of good insulating properties, mass production,
and ease of on-site assembly of the panels, among 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,
foamed or expanded polymeric materials such as polystyrene,
polyvinyl chloride, polyurethane, etc. The core material
may be surrounded by panel members comprising first and
second major face members and side and end walls of such


2019852




materials as plywood, metal, resin and resin reinforced
with fibrous glass rovings, etc. Generally, these panels
are strong, lightweight and provide proper insulating
properties 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 is compressed, a space develops between the core
and facing member. This results in weakened structural
integrity 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 that the major
face members generally cannot withstand a great amount of
load-bearing pressure as may be encountered when 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. 4,078,348 (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.
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

2 0 ~ 2




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 least
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 slots
have 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 extending into the slot
of the bottom of the tubular member and a top member
extends along the top of 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 length greater than the length of the body so that
vertical loads are not transmitted to the body.
Additional examples of 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 systems, there is still a
need for a construction panel and building 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 directed
toward filling that need.

201~85~




The present invention relates to an integral energy-
efficient load-bearing exterior wall fabricated of
lightweight 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 subject invention, a
prefabricated modular wall panel is made from a foam
material which is molded around a plurality of vertically
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
column. The fastening supports are arranged to form part
of the interior and exterior surfaces of the foam wall.
The hollow support columns, which are preferably made 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 columns.
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, water pipes and in certain cases can be fabricated
to act as heat or air conditioning ducts.

21)1~85~




The present invention provides a one-piece exterior
wall construction which is fabricated from lightweight foam
and includes plastic load-bearing columns. It also
provides an internally mounted stud for use in a
prefabricated wall system. Further, it provides a
prefabricated construction panel having a high strength to
weight ratio; a prefabricated insulated construction panel
exhibiting excellent insulating properties; a prefabricated
construction wall and building system capable of easy on-
site assembly; a modular wall system which is capable of
easy mass production; a modular wall system resistant to
rot, decay, termites, woodbores, etc.; and a modular wall
system that is warp-resistant and free of knots.
Figure 1 is a perspective view, partially cut away, of
a portion of a building made up of pre-fabricated wall
panels forming part of the inventive integrated building
system.
Figure 2 is a perspective view, partially cut away,
showing the 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 of Figure 1.
Figure 5 is a view taken along lines 5-5 of Figure 4.
Figure 6 is a view taken along lines 6-6 of Figure 4.
Figure 7 is a plan view showing the details of another
embodiment of the hollow column of Figure 2.

7 ~ 2
Figure 8 is an exploded perspective view of another
embodiment of the elements of Figure 3 used to join the
ends of two panels.
Figure 9 is plan view showing the details of the
elements of Figure 8.
Figure 10 is a perspective view, partially cut away,
showing the details of another embodiment of the hollow
column of Figure 2.
Figure 11 is a perspective view, partially cut away,
showing the details of yet another embodiment of the hollow
column of Figure 2.
Figure 12 is a perspective view, partially cut away,
showing the details of still another embodiment of the
hollow column of Figure 2.
Figure 13 is a perspective view, partially cut away,
showing an electrical box and wiring inserted into a
vertically disposed hollow column.
Figure 14 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 preferred embodiments of the subject
invention illustrated in the drawings, specific terminology
will be resorted to for the sake of clarity. However, the
invention is not intended to be limited to the specific
terms so selected, and it is to be understood that each
specific term includes all technical equivalents which
operate in a similar manner to accomplish a similar
purpose.


8 2Q19~2
Figures 1 through 6 illustrate a portion of a building
incorporating modular wall sections 10 embodying the
teachings of the present invention. One modular 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 thus has an exterior wall
surface 14 and an interior wall surface 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
found 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 construction
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 elongated 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
12. The cross-section is completed by a pair of opposed
shorter walls 28 and 30 which are opposed from each other


~19852




in a generally parallel relationship. Together the
interior surfaces of the four walls 24, 26, 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 defined 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.
Planar strip 44 terminates at 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 the head 44 of the T defining a portion
of the outer surface 14 of the wall panel and the base of
the T being secured to the vertical surface 24 of the
hollow column. A similar structural element is defined on
face 26 in approximately the same place as the element


2~$~2

defined on face 24 and thus contain the same reference
numerals.
With reference to its orientation in Figures 1 and 3,
the wall member 12 terminates at its top in a planar face
52 and at its bottom in planar face 54. The distance
between planar face 52 and 54 as measured vertically along
one of the columns 20 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 in Figure 3, each of the base plates is
defined by four walls 61 through 64 that are joined
together in a figure with an outer periphery that is
slightly smaller and mating with the 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 bottom 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 along the surface 72 of stud
58.

201~i2
11
As can be seen with reference to Figures 3 and 5,
locking base plates 56 are spaced 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
section 12 is completed through the use of spaced locking
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 of two panels 10 are joined 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 column 120 has a pair of opposed planar walls
122 and 124 which are arranged to be 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 which joins the ends of walls 122 and 124 into a
generally U-shaped member. Wall 122 contains an outside
face 128 and an inside face 129 and wall 124 contains an
outside face 130 and an inside face 131. Each of outside

12 2 ~ 5 2
faces 128 and 130 contains the same structure which is
described as follows. Using face 128 as exemplary,
emanating from the free end of wall 122 of the U-shaped
section is an outwardly extending leg 132. The leg defines
an 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
lo 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 join leg 132 to finger 136. A
similar complementary structure is defined for end column
121 and noted by the same reference numerals.
When the planar surfaces of legs 132 of end columns
120 and 121 are placed into intimate contact with each
other, the two end 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 end 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 throughout the entire length of the end
columns with the exception of a predetermined space near
the bottom and top of the column to leave room for
insertion of the base and top plates 56 and 76. When


13 20~ 5~
viewed in cross-section, the generally U-shaped member 142
contains 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 is sized to fit snugly within
the interior area of the end columns 120 and 121. As shown
in Figure 5, the U-shaped insert facilitates securing and
joining of the two wall sections 12. The U-shaped wall
member may either be glued within the end columns or
fastened through the use of screws 17 or nails 19.
In an alternative embodiment, shown in Figures 8 and
9, a second leg 133 is provided parallel to leg 132 and
offset from the free end of wall 122 or 124. Also, inside
faces 129 and 131 of end columns 120 and 121 are each
provided with longitudinal barbs 147 angled towards the end
walls 126. End columns 120 and 121 are secured to each
other by an insert 142 having an ellipsoidal transverse
cross-section. Insert 142 has an outer surface 148 having
substantially planar, parallel side sections 149 and 150.
These sections 149 and 150 are provided with longitudinal
barbs 151 angled towards the minor transverse axis of
insert 142. Barbs 147 extend the entire length of end
columns 120 and 121, and barbs 151 extend the entire length
of insert 142. The inside end-to-end dimensions of end
columns 120 and 121 when joined together is somewhat
smaller than the outside end-to-end dimension of insert

14 201~5~2
142. End columns 120 and 121 can thus be press-fit over
the ends of insert 142, causing sections 149 and 150 to bow
outwardly and barbs 151 to bite into and lockingly engage
barbs 147 to secure end columns 120 and 121 together.
Glue, screws, nails, or other extraneous fastening means
are thus unnecessary, although they can be used if desired.
End columns 120 and 121 and insert 142 are extruded
from a plastic such as PVC. End columns 120 and 121 can be
extruded individually. Alternatively, a hollow column 20
as shown in Figure 7 can be cut in half and the inner edges
trimmed to form end columns 120 and 121. Column 20 as
shown in Figure 7 is similar to column 20 shown in Figures
1-6 except for the provision of barbs 51 and outer legs 43,
and an interruption in vertical strip 50 between legs 40
and 42, and is also formed from an extruded plastic such as
PVC .
Figures 3, 4 and 6 generally show the way that wall
sections 10 are joined together at corners. A vertically
oriented corner column is shown and designated as 152. In
a preferred embodiment, the corner column 152 is extruded
as a one-piece plastic unit incorporating three basic
sections. At the heart of the corner column is a column
defining area 154 which contains several vertically
oriented walls 161 through 164 that are joined together in
order to define an opening 156 that is the same size and
shape as the opening 32 defined in vertical column 20.
This is done so that the column 156 is able to receive the
base and top plates 56 and 76 in a manner described


2019~S~
hereinbefore with reference to space 32 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
to defining the other corner wall and lies in the same
plane as exterior surface 14 for an adjacent wall member
12.
Corner column 152 terminates at each end in an end
column defining portion 168. The portion is constructed to
define an interior area 170 that is of the same size and
shape as the interior wall defined by edge members 120 and
121 so that when the corner column 152 is joined into
operative 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 intended 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 facilitate
attachment of each wall member 10 to the building under
construction. The wall is erected near the perimeter of
the structure so that the wall 14 defines an exterior wall
and the wall 16 defines and interior wall. The flat


16 2O ~g~ 2
surfaces 44 of each of the columns 20 define an area along
both surfaces 14 and 16 for receiving fastening devices
such 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 attachment of the skin. The same relationship
holds true for surface 134 of end 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 studs 78 and 58. To complete the
construction of the interior surface, drywall or paneling
21 is secured in a similar fashion.
Figures 10 through 12 show in cross-section
alternative configurations for the hollow column 20. In an
alternative preferred embodiment as shown in Figure 10, 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 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.
The cross-section is completed by a pair of walls 82 and 84
which are opposed from each other in a generally parallel

2Q.~g852
17
relationship. Together the interior surfaces of the four
walls 81, 82, 83 and 84 define the interior space 32. Wall
81 contains an outside face 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, emanating 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 surface 87. Leg 86 terminates a
predetermined transverse distance from surface 87. Defined
at the termination of leg 86 is a planar strip 88 that is
generally parallel to surface 87. Planar wall 88
terminates at its sides in two inwardly directed side
fingers 90. When viewed in cross-section as shown in
Figure 10, the structure just 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. In the several T-
structures, leg 92 resembles to leg 86, wall 94 resembles
to wall 88 and fingers 96 resemble to fingers 90.

18 201!~2
In still another preferred embodiment as shown in
Figure 11, 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 exterior and interior wall
surfaces 14 and 16. The cross-section is completed by a
pair of opposed walls 182 and 184 which are opposed from
each other in a generally parallel relationship. Together
the interior surfaces of 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. Similarly, a side of wall 182 meets with a side
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 wall 12. Leg 86
terminates a predetermined transverse distance from corner
101. Defined at the termination of leg 86 is a structure
similar to that shown in Figure 10. Inner corners 105 and
107 of the column include structural elements 92 and 94 as
previously described with reference to the embodiment in
Figure 10 without the fingers 96.
Finally, Figure 12, shows another embodiment of the
vertical columns which when viewed in cross-section
resembles the square embodiment of Figure 10 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

2 ~ 5 ~
19
88 is much wider in the oval embodiment than in the square
embodiment. Likewise, the inward fingers 96 are replaces
by fingers 190 that extend both inwardly and outwardly.
As shown in Figures 13 and 14, the hollow interior of
the vertical columns 20 provides usable space for use as a
conduit for electrical wiring, plumbing and, in certain
cases, heating or air-conditioning ducts.
Figure 13 shows an electrical box 190 inserted within
outside 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
that it 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
pass from location to location by entering and exiting
holes (not shown) defined in the bottom and top plates 58
and 78.
Figure 14 shows a vertical column 20 which has been
cut on one of its faces to receive a box 200 in order to
provide an exit point for air to pass through the vertical
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


2 ~ 5 ~

may be used in conjunction with equipment sold by Dunham
Bush, Inc. under the trademark SPACE PACK. Figure 14 also
shows an alternate construction for the side walls 30 of
the embodiment shown in Figure 2. In particular, an
elongated vertically extending mortis shape 202 is defined
along the outer faces 28 and 30. The mortis indentation
allows foam to form and act as a tenon, giving better bond
of foam to the stud.
Thus it can be appreciated that a construction system
employing the teachings of the present invention makes
optimum use of an exterior wall construction module and
assembly technique that includes a one-piece load-bearing
exterior wall fabricated from light-weight foam surrounding
load-bearing columns. The same construction technique may
be used to produce walls for interior construction.
The modular panels 10 made in accordance with the
teachings of the present invention enjoy several
advantages. The individual wall panels may be pre-cast and
molded in a factory setting away from the construction
site. The wall units may be delivered as light-weight
panels thus conserving both energy and transportation.
Because of the way the panels are constructed, they are
ready for easy erection using ordinary tools.
Each modular wall panel 10 includes a core 12 of
expanded or foamed polymeric material which exhibits a high
strength to weight ratio. The walls also exhibit super
insulating properties especially because of the use of a
continuous length and width of foamed material completely


~019852
21
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 significant
reduction in 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 of 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.


Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date 1995-08-01
(22) Filed 1990-06-25
(41) Open to Public Inspection 1990-12-23
Examination Requested 1992-06-19
(45) Issued 1995-08-01
Deemed Expired 2002-06-25

Abandonment History

There is no abandonment history.

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee $0.00 1990-06-25
Maintenance Fee - Application - New Act 2 1992-06-25 $50.00 1992-06-02
Maintenance Fee - Application - New Act 3 1993-06-25 $50.00 1993-04-22
Maintenance Fee - Application - New Act 4 1994-06-27 $50.00 1994-04-22
Maintenance Fee - Application - New Act 5 1995-06-26 $75.00 1995-06-06
Maintenance Fee - Patent - New Act 6 1996-06-25 $75.00 1996-04-04
Maintenance Fee - Patent - New Act 7 1997-06-25 $75.00 1997-06-04
Maintenance Fee - Patent - New Act 8 1998-06-25 $75.00 1998-06-25
Maintenance Fee - Patent - New Act 9 1999-06-25 $75.00 1999-06-22
Maintenance Fee - Patent - New Act 10 2000-06-27 $200.00 2000-06-21
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
RAYMOND, HARRY W.
Past Owners on Record
None
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
Documents

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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Cover Page 1995-08-01 1 16
Description 1995-08-01 21 791
Drawings 1995-08-01 6 218
Abstract 1995-08-01 1 32
Abstract 1995-08-01 1 32
Claims 1995-08-01 2 54
Representative Drawing 1999-07-30 1 11
Fees 1997-06-04 1 43
Fees 1998-06-25 1 39
Fees 1999-06-22 1 36
PCT Correspondence 1995-06-19 2 37
Examiner Requisition 1994-08-10 2 50
Prosecution Correspondence 1995-02-10 3 104
PCT Correspondence 1995-05-23 1 30
Office Letter 1992-07-21 1 43
Prosecution Correspondence 1992-06-19 1 28
PCT Correspondence 1991-09-26 2 57
Fees 1996-04-04 1 33
Fees 1995-06-06 1 32
Fees 1994-04-22 1 33
Fees 1993-04-22 1 26
Fees 1992-06-02 1 23