Note: Descriptions are shown in the official language in which they were submitted.
CA 02618416 2008-01-17
WALL SYSTEM
Backlzround of the Invention
Field of the Invention
The present invention is directed to a wall system and in particular to a wall
finishing system providing combined.insulation and mounting onto a masonry
wall.
Description of the Prior Art
Conventional wall systems for basements and other applications wherein a
masonry wall is used have traditional wood frame construction with wood studs
and
fiberglass insulation placed against the concrete block or other masonry
between the
studs. Such construction systems are well known and utilized widely.
Although such systems are proven to be suitable and often provide
satisfactory finishing, such systems have several drawbacks. Installation may
be
difficult with wood studs mounting to a masonry wall. The studs may warp or
twist
and may cause the nails to protrude back through sheetrock. The wood studs are
prone to mold, moisture damage and rot and require an additional vapor
barrier.
Although insulation may be placed between the studs, the studs themselves are
still a
thermal conductor. Steel studs are an alternative, but generally prove
difficult for
the average homeowner to install and require special mounting.
Fiberglass insulation is also susceptible to water damage and mold if
moisture is present. The thickness required for adequate insulation may
decrease the
overall size of the room due to the added depth of the wall. Fiberglass
insulation is
difficult to handle and requires special gloves and a respirator. Foani types
of
insulation are often open cell material that allows moisture to pass through.
Common stud and rolled insulation systems also suffer from difficult
installation for wiring, switches, tubing and other componeiits. Conventional
construction requires drilling tlu=ough the studs for routing wiring and/or
tubing
along the wall.
To overconie the problenis associated with common wood stud construction,
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systems have been developed to provide an insulation layer. Such systems
typically
use panels that may attach to one another. Some panels may include metal studs
formed therein to allow for mounting. Although such systems do provide
advantages in many applications over traditional construction, these systems
suffer
from their own disadvantages. Such systems require unwieldy, large panels and
do
not provide aligninent along all edges. In addition, such systems do not
provide for
quick and simple mounting using traditional tecluliques such as screws or glue
strips. Moreover, such systems do not provide for drains or chaiulels to allow
water
to easily drain witliout passing through to the inner side of the panels. Such
systems
also do not provide for easily routing wiring, tubing and other elements that
are
installed.
It can be seen then that a new and improved wall finishing system is needed.
Such a wall finishing system should provide simple, inexpensive and easy to
install
construction. In addition, such a system should provide for easily routing
tubing,
wiring and other components into the wall. Such a system should provide for
improved insulation and mounting of sheetrock, paneling or other innermost
layers.
The present invention addresses these, as well as others associated with wall
systenls.
Summarv of the Invention
The present invention is directed to a wall system and in particular to a wall
finishing system suitable for masonry and other similar wall construction. The
present invention utilizes foani insulating panels that are coiulected to form
an
intermediate wall layer. The panels include mounting stud type elements molded
into the panels to reduce cost and to eliminate problems associated with
traditional
wood frame construction with rolled fiberglass insulation.
According to the present invention, a load bearing or structural wall portion
such as concrete blocks or other masonry as is often found in basements of
many
homes is covered by an insulating layer and then an inner finishing layer that
may be
painted, wallpapered, paneled or finished in other well known techniques. The
panels have molded in mounting elements that are spaced apart the same
distance as
standard wood studs and allow for fastening with glue and conventional
hardware to
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the structural wall. The mounting elements also provide for attaclunent of
sheetrock, wood paneling and other inner finishing type layers to the
insulating
panel layer.
The panels are generally made of water impervious foam material so that the
panels are lightweight and easily transported. In typical embodiments, the
panels
are 2 feet x 4 feet or 16 inches by 4 feet, allowing for easily carrying the
panels
down stairways. The panels have a tongue and groove configuration along the
edges
for connecting to adjacent panels both vertically and horizontally to create a
continuous insulating layer for an entire wall. The panels include alignment
tabs
and complementary notches along the top and bottom edges to ensure a proper
engagement and placement.
The panels also have ridges formed on at least one face that define channels
or chases for routing wiring, tubing or other elements. The parallel ridges
extend
vertically substantially across the height of the panels leaving only a small
strip
along the edges so that when panels are connected in an edge to edge
relationship, a
chaiunel or chase is formed horizontally along adjacent panels between the
ends of
the ridges of adjacent panels. With this configuration, wiring and other
elements
may be routed both horizontally and vertically along the width and heiglit of
a wall
without having to modify the panels. The panels also include cutting charuzels
so
that clean, straight cuts may be simply and quickly made so that the panels
have
clean straight edges.
The mounting elements are molded into the panels in an embedded
configuration in one embodiment. In one embodiment, the mounting elements are
generally elongate members with a somewhat "H" shaped cross-sectional profile.
The first portion extends perpendicularly outward both its center, whicll
abuts a
series of center connectiiig ribs. The second portion extends from an opposite
end of
the coiinecting ribs in a substantially perpendicular configuration with a
very slight
obtuse "V" shaped profile. The first portion extends to a first face of the
panel and
includes a glue channel for receiving a bead of glue to mount the panel to an
adjacent wall layer. The second portion also extends to a second face of the
panel
and includes glue channels on each outward extending leg and a center chaiuiel
and
also provides for receiving adhesive type materials. The mounting elements are
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CA 02618416 2008-01-17
preferably molded of plastic material that is impervious to rusting and other
deterioration and that can provide a foundation for attaching mounting
hardware and
also provide support for the panel.
The wall system is easily installed. Preparations may require upgrading the
floor to ensure that there is adequate drainage.. The panels are then
installed by
gluing to the load bearing masoiuy wall. Panels are placed starting in one
corner
and working horizontally across the width of a wall. The tongues and grooves
form
connections between adjacent panels so that a continuous nearly water
impervious
layer is achieved. The panels are typically offset relative to adjacent panels
above
and below, but are correctly positioned and spaced with the alignnient tabs
and
notches. Construction of the insulating layer continues in a row by row
configuration until reaching the top of the wall. The panels are trimmed to
remove
the tongue and grooves from the edges abutting the floor, ceiling and corners
for
continuous total coverage of the masonry wall. After the glue dries, further
hardware may be used for mounting to the load bearing wall. Sheetrock or other
layers inay then be connected using conventional hardware to the mounting
elements. It can be appreciated that no special skills or special tools are
needed for
installation. Electrical boxes and other devices may be installed by simply
cutting
out the portions of a panel and coimecting to the wiring or other elements
extending
through the chaiuiels formed by the panels.
The present invention is lightweight, durable, easy to install, long lasting,
has
improved insulation attributes, is inexpensive, can be retrofit and minimizes
common drawbacks of traditional construction such as mold, water damage and
other problems associated with the prior art.
These features of novelty and various other advantages that characterize the
invention are pointed out with particularity in the claims arulexed hereto and
forming a part hereof. However, for a better understanding of the invention,
its
advantages, and the objects obtained by its use, reference should be made to
the
drawings that form a further part hereof, and to the accompanying descriptive
matter, in which there is illustrated and described a preferred embodiment of
the
invention.
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Brief Description of the Drawings
Referring now to the drawings, wherein like reference numerals and letters
indicate corresponding structure throughout the several views:
Figure 1 is a perspective view of a wall system with portions removed for
clarity according to the principles of the present invention;
Figure 2 is a perspective view of a panel for the wall system shown in Figure
l;
Figure 3 is a front elevational view of the panel shown in Figure 2;
Figure 4 is an end view of the panel shown in Figure 2;
Figure 5 is a rear elevational view of the panel shown in Figure 2;
Figure 6 is a perspective view of a mounting element that is embedded in the
panel shown in Figure 2;
Figure 7 is an opposite perspective view of the mounting element shown in
Figure 6;
Figure 8 is a side elevational view of the mounting element sliown in Figure
6; and
Figure 9 is an end view of the mounting element shown in Figure 6.
Detailed Description of the Preferred Embodiment
Referring now to the drawings and in particular to Figure 1, there is shown a
wall system, generally designated 100. The wall system 100 is especially
suited for
masonry type walls, commonly found in basements and other areas where concrete
block or similar construction is utilized. It can be appreciated however that
the
system 100 of the present invention may be adapted to many other types of
applications.
The wall system 100 generally includes a first layer or section, often a load
bearing or structural masonry wall 102 formed of concrete block or other
similar
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building materials. An insulation layer 104 fornied of interconnected panels,
described hereinafter, mounts to the masonry wall layer 102 with glue or
fasteners
112. A finishing iiuler layer, such as paiieling, sheetrock or other finishing
type
material 106 mounts with fasteners 112, glue or other conventional mounting
tecluniques to the insulating layer 104. A coating 108 such as paint,
wallpaper or
other final, exposed material that is visible covers the ituier layer 106. The
technique of the present invention provides for elimination of the
conventional stud
framing and roll-type insulation and provides improved R-value in a thinner
layer,
adding floor space and volume to the finished room. In addition, the present
invention is less expensive and easier to install than prior conventional
building
systems and tecluiiques.
The insulating layer 104 is formed from a number of rectangular insulating
panels 120 mounted in an edge-to-edge relationship. The panels are generally
rectangular and include tongues 130 and complementary grooves 132, such as
shown most clearly in Figures 2 and 4, along the cdges of the panel 120. The
tongues and grooves 130 and 132 provide for alignment and connection along
both
the horizontal and vertical edges so that the panels 120 may be connected to
extend
horizontally and vertically in a continuous insulating layer. The panels 120
also
include alignment tabs 134 and complementary notches 136 along the top and
bottom edges that aid in aligning the panels for final orientation. In one
embodiment, the panels 120 are made of a closed cell expanded polystyrene
material. Such a material is lightweight, provides excellent insulation
performance
and is impervious to water. Moreover, such material may include a fire
retarder.
Althougli a vapor barrier niay also be added to the system, it can be
appreciated that
with the insulating layer 104 made of a water impervious material and with
interlocking edges, the need for a separate vapor barrier used in many
applications
may be eliminated.
Referring again to Figures 4-5, the panels 120 include a series of parallel
ridges 122 formed on one face of the panel. The ridges 122 extend vertically
when
the panels 120 are nlounted and provide 1irst cliannels 124 that may serve as
a
wiring chase or for running tubing, fiber optics or other elements through the
insulating layer without requiring cutting into the panels 120. The channels
124 also
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allow for water to drain. In addition, some of the channels are deeper,
forniing
wiring chases 128. The ridges 122 extend substantially along a large part of
the
height of the panel 120, but stop short of one edge so that when the panels
120 are
attached, horizontally extending channels 126 are formed. The horizontal
channels
126 intersect with the vertical chaiuiels 124 providing for easy insertion and
routing
of wiring, tubing and other elements that are typically placed inside a wall.
A
cutting guide 138 also provides for trimming the panels 120 to a common size
and
provides a guide for forming a straight edge. It can be appreciated that in
one
embodiment, the panels are approximately 48 inches wide and 24 inches high
(122 x
61cm). A typical depth for a panel 120 is two inches (5cm). Such a size
provides
for standard alignment and easily transporting the panels 120 down narrow
staircases such as often lead to a basement.
The panels 120 also include mounting elements 150 that serve as studs
embedded into the panels. In one embodiment, each panel 120 includes three
etnbedded niounting elements 150. The mounting elements 150 extend vertically
when the panels 120 are installed. The mounting elements 150 are placed at 16
inch
(41 cm) centers as is typical with wood stud construction. The mounting
elements
150 extend to a first face of the panels 120 and provide a surface for gluing
as well
as receiving conventional fasteners such as bolts, screws and/or nails. The
mounting
elements 150 are lightweight, but provide rigidity and strength to the panels
120.
As shown in Figures 6-9, each mounting element 150 is a substantially
elongate, molded plastic element with a generally "H" shaped cross-sectional
profile. The mounting element 150 includes a first mounting portion 152, a
second
opposed mounting portion 160, and a series of central ribs 154 connecting the
first
portion 152 and the second portion 160. The first portion 152 extends
laterally
outward from the ribs 154 at a generally right angle. A first face of the
first portion
152 includes a glue channel 153 or glue charuiels transverse to the
longitudinal
direction. The ribs 154 include a first ridge poi-tion 156 connecting to the
first
portion 152 and a second ridge portion 158 connecting to the second portion
160.
The second mounting poi-tion 160 includes leg sections 162 extending from
either
side of the center ribs 154 and extending slightly outward along the direction
of the
ribs. The leg sections 162 each include an outer chaiulel 166. The second
portion
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also includes a center channel 164 substantially aligned with the ribs 154.
The
chamiels 164 and 166 aid in anchoring the mounting element 150 into the panel
120.
The outer channels 166 also serve as glue channels for mounting.
The mounting elements 150 are spaced apart generally in the same spacing
as wood studs or other common spacing such as 8 inch or 12 inch intervals and
provide a lightweight yet durable surface for receiving mounting hardware, as
discussed above. The mounting elements 150 are also lightweight and molded and
impervious to water for durable and inexpensive construction. It can be
appreciated
that the system of the present invention reduces the likelihood for water
damage,
mold and other problems that conventional building tecluiiques are prone to,
especially when set in a damp environnlent, such as a basement. It can
furtlier be
appreciated that the present invention provides for easy trimming and cutting
with a
hand saw or simple knife. The materials used are not irritating to skin or
eyes and
do not require special gloves for handling as is needed for fiberglass
systems. The
materials are liglitweight and of a size that is easier to handle than typical
long wood
studs and 4 feet by 8 feet sheets of sheetrock. Drywall does not need to be
aligned
with studs as in a convention techniques. Installation is much quicker and
does not
require special skills or tools. Moreover, the present invention can be
retrofit to
existing wall systems and provide improved insulating characteristics.
The wall system 100 of the present invention is also easy to install. Little
preparation is needed but drain tile, if necessary, is installed before the
system is in
place. A bead of construction adhesive is placed in the gluing channel 160 on
all
tliree of the studs 150 on each panel 120. Installation generally starts in a
lower
corner of the wall with the panel 120 simply pressed onto the inner masonry
wall
102. The panel 120 is tlien secured with a power fastening device or other
conventional mounting hardware. Installation continues with the panels 120
being
aligned and vertically extending tongues 130 inserting into corresponding
grooves
132 until a bottom row of panels 120 extends across the wall. The panels 120
of the
next row are generally offset from the previous row and placed starting along
one
edge and working along the row in a similar manner. The mounting elements 150
are aligned by the aligiunent tabs 134 inserting into the corresponding
notches 136.
Construction continues along horizontal rows until the entire wall is covered.
The
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corners are accommodated by cutting off the tongues and/or grooves and butting
the
panels 120 together.
Spaces for receiving electrical boxes can be cut into the panels 120 using a
standard drywall keyhole saw. Wiring and other elements can be run through the
wall 100 by leading the wiring tluough the channels 124 and 126. When the
panels
120 have been installed, the glue is generally allowed to dry for a period of
time
such as 24 hours. Once the glue sets, the slieetrock can be applied by using
standard
drywall screws attaching to the mounting elements 150. The wall 100 is
finished in
the same manner as conventional walls with mud and tape used with the drywall
and
an inner layer such as paint or wallpaper applied over the sheetrock. In some
applications, paneling or other materials may be used rather than sheetrock.
The
method is typically faster and easier with less skill and fewer tools required
than
conventional construction tecluiiques.
It is to be understood, however, that even though numerous cliaracteristics
and
advantages of the present invention have been set forth in the foregoing
description,
together with details of the structure and function of the invention, the
disclosure is
illustrative only, and changes niay be made in detail, especially in matters
of shape,
size and arrangement of parts within the principles of the invention to the
full extent
indicated by the broad general meaning of the tenns in which the appended
claims are
expressed.
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