Frame unit and method
First Claim
1. An insulated frame unit for use in constructing an exterior wall of a building that has an exterior finish member for the exterior of the building and an interior finish member for the interior room that is defined by the wall, the wall including a plurality of spaced apart generally vertical studs, the studs having an exterior side facing the exterior of the building and an opposed interior side facing the interior room, and the studs having a generally predetermined thickness, predetermined width, and spacing between the studs of at least about 12 inches, the frame unit comprising:
- a panel composed substantially of a rigid foam insulating material, the panel having first and second generally opposed ends, and third and fourth generally opposed ends, an inner side and an outer side; and
at least two stud-receiving openings in the inner side of the panel, the stud-receiving openings generally parallel to each other and extending between the first and second ends of the panel, the stud-receiving openings having a width that is sufficient to allow a stud to be mounted within the stud-receiving openings, and the stud-receiving openings having a depth that is less than the predetermined width of the stud, so that when the exterior side of the stud has been fully inserted into the stud-receiving opening the interior side of the stud is spaced away from the inner side of the panel for providing a service chamber between the inner side of the panel and an interior finish member secured to the interior side of the studs, and whereby an exterior finish member can be secured proximate to the outer side of the panel; and
the third end of the panel having a first flange and first recess, and the fourth end of the panel having a second flange and a second recess whereby the first flange of the panel of the insulated frame unit is adaptable to be positioned in the second recess of a second insulated frame unit substantially identical to the insulated frame unit to thereby provide a stud-receiving channel.
1 Assignment
0 Petitions
Accused Products
Abstract
An insulated frame unit for enclosing a wall to provide a highly insulated and airtight wall is provided. The frame unit includes a panel that is formed from a rigid insulated composition such as an expanded foam composition. The panels can be mounted to a wall frame in rows and columns to enclose the wall, and may include outwardly extending flanges that can cooperate with a flange of an adjacent frame unit to provide a stud-receiving opening into which a stud is inserted when mounting the frame units to the frame of the building. The frame unit is mountable to the frame with the interior side of the stud extending from the inner side of the frame unit so that adequate space is provided between the inner side of the frame unit and an interior finish member mounted to the interior side of the studs.
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Citations
18 Claims
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1. An insulated frame unit for use in constructing an exterior wall of a building that has an exterior finish member for the exterior of the building and an interior finish member for the interior room that is defined by the wall, the wall including a plurality of spaced apart generally vertical studs, the studs having an exterior side facing the exterior of the building and an opposed interior side facing the interior room, and the studs having a generally predetermined thickness, predetermined width, and spacing between the studs of at least about 12 inches, the frame unit comprising:
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a panel composed substantially of a rigid foam insulating material, the panel having first and second generally opposed ends, and third and fourth generally opposed ends, an inner side and an outer side; and at least two stud-receiving openings in the inner side of the panel, the stud-receiving openings generally parallel to each other and extending between the first and second ends of the panel, the stud-receiving openings having a width that is sufficient to allow a stud to be mounted within the stud-receiving openings, and the stud-receiving openings having a depth that is less than the predetermined width of the stud, so that when the exterior side of the stud has been fully inserted into the stud-receiving opening the interior side of the stud is spaced away from the inner side of the panel for providing a service chamber between the inner side of the panel and an interior finish member secured to the interior side of the studs, and whereby an exterior finish member can be secured proximate to the outer side of the panel; and the third end of the panel having a first flange and first recess, and the fourth end of the panel having a second flange and a second recess whereby the first flange of the panel of the insulated frame unit is adaptable to be positioned in the second recess of a second insulated frame unit substantially identical to the insulated frame unit to thereby provide a stud-receiving channel. - View Dependent Claims (2, 3, 4, 5, 6)
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7. An insulated frame unit for use in constructing an exterior wall of a building that has an exterior of the building and an interior room that is defined by the wall, the wall including a plurality of spaced apart generally vertical studs, the studs having an exterior side facing the exterior of the building and an opposed interior side facing the interior room, and the studs having generally predetermined thickness, predetermined width, and spacing between the studs greater than about twelve inches, the frame unit comprising:
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a panel composed substantially of a rigid insulating material, the panel having a body with first and second generally opposed ends, and third and fourth generally opposed ends, the panel having an inner side and an outer side; at least first and second stud-receiving openings in the inner side of the panel, the first stud-receiving opening being a slot in the inner side of the panel that is spaced from the third and fourth sides of the body of the panel, the second stud-receiving opening being located along the fourth end of the panel, the stud-receiving openings being generally parallel to each other and extending between the first and second ends of the panel, the stud-receiving openings having a width that is sufficient to allow a stud to be mounted within the stud-receiving openings, a first flange extending outwardly from the third end of the body of the panel adjacent the inner side of the panel, and a second flange extending outwardly from the fourth end of the body of the panel adjacent the outer side of the panel, the length of the second flange being greater than the length of the first flange. - View Dependent Claims (8, 9, 10, 11, 12)
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13. An exterior wall construction for a building comprising:
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a frame having a plurality of spaced apart generally parallel studs, the studs having an exterior side facing the exterior of the building and an opposed interior side facing an interior of the building, and the studs having a generally predetermined thickness, predetermined width, and spacing between the studs of at least about 12 inches; first and second insulated frame units, each insulated frame unit comprising a panel composed substantially of rigid insulating material, the panel having first and second generally opposed ends, and third and fourth generally opposed ends, an inner side and an outer side, the panel including a stud-receiving opening in the inner side of the panel, the stud-receiving opening having a stud positioned therein with the interior side of the stud spaced inwardly from the inner side of the panel, the first insulated frame unit positioned adjacent the second insulated frame unit; an interior finish member secured to the interior side of the stud, the interior finish member spaced from the inner side of the panel to provide a service chamber between the inner side of the panel and the interior finish member; and each of the first and second insulated frame units having a first flange extending outwardly from the third end of the panel adjacent the inner side of the panel, and a second flange extending outwardly from the fourth end of the panel adjacent the outer side of the panel, the length of the second flange being greater than the length of the first flange, the first insulated frame unit positioned adjacent the second insulated frame unit so that the third side of the panel of the first insulated frame unit is adjacent the fourth side of the panel of the second insulated frame unit, and the second flange of the second insulated frame unit overlaps the first flange of the first insulated frame unit to thereby provide the stud-receiving opening.
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14. An exterior wall construction for a building comprising:
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a frame having a plurality of spaced apart generally parallel studs, the studs having an exterior side facing the exterior of the building and an opposed interior side facing an interior of the building, and the studs having a generally predetermined thickness, predetermined width, and spacing between the studs of at least about 12 inches; and first and second insulated frame units, each of the insulated frame units comprising a panel composed substantially of rigid insulating material, the panel having a body with first and second generally opposed ends, and third and fourth generally opposed ends, the panel having an inner side and an outer side, a first flange extending outwardly from the third end of the body of the panel adjacent the inner side of the panel, and a second flange extending outwardly from the fourth end of the body of the panel adjacent the outer side of the panel, the length of the second flange being greater than the length of the first flange, the first insulated frame unit positioned adjacent the second insulated frame unit so that the third side of the panel of the first insulated frame unit is adjacent the fourth side of the panel of the second insulated frame unit, and the second flange of the second insulated frame unit overlaps the first flange of the first insulated frame unit to thereby provide a stud-receiving opening, and the stud-receiving opening having a stud positioned therein. - View Dependent Claims (15)
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16. A method of constructing an exterior wall of a building having a frame having a plurality of spaced apart generally parallel studs, the studs having an exterior side facing the exterior of the building and an opposed interior side facing an interior of the building, and the studs having a generally predetermined thickness, predetermined width, and spacing between the studs of at least about 12 inches comprising:
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providing a plurality of insulated frame units, each insulated frame unit comprising a panel composed substantially of rigid insulating material, the panel having first and second generally opposed ends, and third and fourth generally opposed ends, an inner side and an outer side, the panel including a stud-receiving opening in the inner side of the panel, providing a first flange extending outwardly from the third end of the panel adjacent the inner side of the panel, and a second flange extending outwardly from the fourth end panel adjacent the outer side of the panel, the length of the second flange being greater than the length of the first flange; installing the plurality of insulated frame units onto the frame to enclose the frame by installing an insulated frame unit onto the frame by positioning the exterior side of the stud within the stud-receiving opening in the inner side of the panel and with the interior side of the stud spaced from the inner side of the panel; installing a first insulated frame unit adjacent a second insulated frame unit so that the third side of the panel of the first insulated frame unit is adjacent the fourth side of the panel of the second frame unit and the second flange of the panel of the second insulated frame unit overlaps the first flange of the panel of the first insulating frame unit whereby the overlapping of the second flange of the second insulated frame unit with the first flange of the first frame unit forms the stud-receiving opening; and installing an interior finish member to the interior side of the stud with the interior finish member spaced from the inner side of the panel to provide a service chamber between the inner side of the panel and the interior finish member.
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17. A method of constructing an exterior wall of a building having a frame having a plurality of spaced apart generally parallel studs, the studs having an exterior side facing the exterior of the building and an opposed interior side facing the interior of the building, and the studs having a generally predetermined thickness, predetermined width, and spacing between the studs of at least about 12 inches comprising:
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providing a plurality of insulated frame units, each insulated frame unit comprising a panel composed substantially of rigid insulating material, the panel having a body with first and second generally opposed ends, and third and fourth generally opposed ends, the panel having an inner side and an outer side, a first flange extending outwardly from the third end of the body of the panel adjacent the inner side of the panel, and a second flange extending outwardly from the fourth end of the body of the panel adjacent the outer side of the panel, the length of the second flange being greater than the length of the first flange; positioning a first insulated frame unit adjacent a second insulated frame unit so that the third side of the panel of the first insulated frame unit is adjacent the fourth side of the panel of the second frame unit and the second flange of the panel of the second insulated frame unit overlaps the first flange of the panel of the first insulating frame unit whereby the overlapping of the second flange of the second insulated frame unit with the first flange of the first frame unit forms a stud-receiving opening; positioning a stud within the stud-receiving opening; and securing at least one of the first and second insulated frame units to the stud. - View Dependent Claims (18)
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Specification