Composite wall panel

• US 5,822,940 A
• Filed: 09/30/1996
• Issued: 10/20/1998
• Est. Priority Date: 07/17/1996
• Status: Expired due to Term

• Current Assignee: Henry Varela
• Original Assignee: Robert M. Dresslar, Steven Carlin
• Inventors: Carlin, Steven, Dresslar, Robert M.
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): EDWARDS, WILLIAM GLENN
• Application Number:
  US08/724,611
• Time in Patent Office: 750 Days
• Field of Search: 52/309.4, 52/309.6, 52/309.11, 52/506.03, 52/481.1, 52/481.2, 52/478, 52/586.1, 52/783.1, 52/783.13, 52/459, 52/468, 52/541 , 52/731.2, 52/731.1, 52/479, 52/309.3, 52/309.7, 52/309.9, 52/609.15, 52/458, 52/591.4, 52/800.1, 52/242, 52/716.1, 52/762
• US Class Current: 52/479
• CPC Class Codes: E04B 2/7453 with panels and support posts, extending from floor to ceiling
• CPC Class Codes: E04C 2/384 with a metal frame

Abstract

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

Claims

1. A structural, insulating, insect resistant, dimensionally stable composite wall panel for building construction comprising a regular tetragonal body of polymer foam having two opposing primary wall surfaces bounded on its sides by two parallel side walls and on its ends by two parallel end walls;

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

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

3. The composite wall panel according to claim 1 wherein the distance between the studs, from center to center of the studs is a standard building construction center to center distance for studs.

4. A structural, insulating, insect-resistant, dimensionally stable composite wall panel for building construction comprising:

a rectangular, tetragonal body of polymer foam having two opposing primary wall surfaces bounded on its side by two parallel side walls and on its ends by two parallel end walls;

two light metal gauge studs in the body, each stud having a hollow central cavity, a squared cross-section with a wide back wall extending the width of the studs, two parallel side walls, two narrow front walls parallel to the back wall and separated by an open slot extending into the central cavity, each light metal gauge stud extending at least from one end wall to the other end wall of the polymer foam body and parallel to the side walls of said body, the polymer foam extending into the central cavity of the stud to secure the stud to the body, at least one side wall of each stud forming a portion of the same primary wall surface of said body, the distance between the studs, center to center of the studs, being a standard building construction center-to-center distance for studs, at least one stud forming a portion of one of the side walls of said polymer foam body, the width of the polymer foam body between the primary wall surfaces being greater than the width of the studs, said polymer foam body having a tongue portion at each of its parallel end walls, the tongue portion having a width equal to the width of the studs and adapted to be received by and secured in the open channel of light metal gauge building construction track to form a structural wall.