# US 11,441,309 B1 · Wall system > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,441,309 B1 - Document ID: US11441309B1 - Status: Granted - Kind: B1 - Application number: 17/702,950 - Filed: 2022-03-24 - Published: 2022-09-29 - Granted: 2022-09-13 - Earliest claimed: 2021-03-26 - Assignees: Signature Wall Solutions, Inc. - Applicants: Signature Wall Solutions, Inc. - Inventors: Wiljo E. Asiala, Jr.; Kenneth Staten - Web page: https://patentgrep.com/patent/US11441309B1 ## CPC - E04B 1/6125: {with protrusions on the one frontal surface co-operating with recesses in the other frontal surface} - E04B 1/6133: {the connection made by friction-grip} - C08J 9/34: Chemical features in the manufacture of articles consisting of a foamed macromolecular core and a macromolecular surface layer having a higher density than the core - C08J 9/365: {Coating} - E04B 2/00: Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls (connections for building structures in general E04B1/38; insulation for buildings in general E04B1/62; building elements of relatively thin form for parts of buildings E04C2/00) - E04C 1/39: characterised by special adaptations, e.g. serving for locating conduits, for forming soffits, cornices, or shelves, for fixing wall-plates or door-frames, for claustra - E04C 1/40: built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts - E04C 2/02: characterised by specified materials (translucent E04C2/54) - E04C 2/049: {completely or partially of insulating material, e.g. cellular concrete or foamed plaster} - E04C 2/205: {of foamed plastics, or of plastics and foamed plastics, optionally reinforced} - E04C 2/243: {one at least of the material being insulating} - E04C 2/292: composed of insulating material and sheet metal - E04C 2/296: composed of insulating material and non-metallic or unspecified sheet-material (E04C2/288 takes precedence) - E04C 2/46: {specially adapted for making walls (E04C2/52, E04C2/54 take precedence; structure of slab-shaped elements E04B1/02; walls of elements of relatively thin form E04B2/72)} - C08J 2205/10: Rigid foams - C08J 2207/00: Foams characterised by their intended use - C08J 2325/06: Polystyrene - E04B 2002/0202: {Details of connections} - E04C 2002/004: {Panels with profiled edges, e.g. stepped, serrated} - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) ## Abstract A wall panel includes a first and second planar skins and a core disposed therebetween. A first and second lateral edge extends between the skins. The second lateral edge comprises a female receiver. The first lateral edge comprises a male extension extending therefrom. The female receiver is formed in the core and has a depth equal to or greater than a length of the male extension. The male extension is formed from the core comprises a first parallel surface extending parallel to and offset from the first planar skin and a second parallel surface extending parallel to and offset from the second planar skin. A first tapered portion comprises a first tapered surface extending at an angle relative to a longitudinal axis from the first parallel surface to a rounded end, and a second tapered surface extending at the angle from the second parallel surface to the rounded end. ## Claims ### Claim 1 A wall panel comprising: a first planar skin; a second planar skin; a core disposed between the first planar skin and the second planar skin; a first lateral edge extending between the first planar skin and the second planar skin; a second lateral edge extending between the first planar skin and the second planar skin parallel to the first lateral edge, the second lateral edge comprises a female receiver disposed therein; the first lateral edge comprises a male extension extending therefrom, said female receiver is formed in the core and has a depth equal to or greater than a length of the male extension; the male extension formed from the core comprising a first parallel surface extending parallel to and offset from the first planar skin and a second parallel surface extending parallel to and offset from the second planar skin; and a first tapered portion comprising a first tapered surface extending at an angle relative to a longitudinal axis from the first parallel surface to a rounded end, and a second tapered surface extending at the angle from the second parallel surface to the rounded end. ### Claim 2 (depends on 1) The wall panel of claim 1 wherein the depth of the female receiver is less than the length of the male extension so that a gap is formed between a lateral wall of the female receiver and the male extension. ### Claim 3 (depends on 2) The wall panel of claim 2 wherein the female receiver is formed by the lateral wall and a pair of longitudinal walls, said lateral wall coupled each of the longitudinal walls with a radius. ### Claim 4 (depends on 1) The wall panel of claim 1 wherein said female receiver formed between a first female hip and a second female hip, said female receiver comprising a second thickness. ### Claim 5 (depends on 4) The wall panel of claim 4 wherein said first lateral edge comprising a first male hip disposed between the first planar skin and the male extension and a second male hip disposed between the second planar skin and the male extension. ### Claim 6 (depends on 5) The wall panel of claim 5 wherein the first female hip and the second female hip comprise a first thickness the same as or less than the first male hip and the second male hip. ### Claim 7 (depends on 1) The wall panel of claim 1 wherein a thickness of the female receiver is greater than or equal to a distance between the first parallel surface and the second parallel surface. ### Claim 8 (depends on 1) The wall panel of claim 1 wherein a thickness of the female receiver is between about 1.5 percent and 3.5 percent greater than a distance between the first parallel surface and the second parallel surface. ### Claim 9 (depends on 1) The wall panel of claim 1 wherein a thickness of the tapered portion is reduced between the first parallel surface and the second parallel surface and the rounded end. ### Claim 10 (depends on 1) The wall panel of claim 1 wherein the first tapered surface and the second tapered surface are disposed between 20 degrees and 30 degrees from a longitudinal axis of the wall panel. ### Claim 11 (depends on 1) The wall panel of claim 1 wherein the first planar skin and the second planar skin are composed of polymer. ### Claim 12 (depends on 1) The wall panel of claim 1 wherein the core is composed of a high-density foam. ### Claim 13 (depends on 12) The wall panel of claim 12 wherein the high-density foam is between 2 and 4 pounds per cubic feet. ### Claim 14 (depends on 12) The wall panel of claim 12 wherein the high-density foam is composed of expanded polystyrene. ### Claim 15 (depends on 1) The wall panel of claim 1 wherein the rounded end has a width of about 55 percent to 70 percent of a width of the female receiver. ### Claim 16 (depends on 1) The wall panel of claim 1 wherein the first parallel surface and the second parallel surface comprises a first length and the male extension comprises a second length, said first length is about 25 percent to about 33 percent of the second length. ### Claim 17 (depends on 1) The wall panel of claim 1 wherein the first parallel surface and the second parallel surface comprise a first length between about 25 percent and about 33 percent of a second length of the male extension. ### Claim 18 (depends on 1) A wall system comprising: a plurality of wall panels formed according to claim 1; wherein the male extension of a first wall panel of the plurality of wall panels is inserted into the female receiver of a second wall panel of the plurality of wall panels so that the male hips of the first wall panel are adjacent to female hips of the second wall panel. ### Claim 19 A wall panel comprising: a first planar skin; a second planar skin; a core disposed between the first planar skin and the second planar skin; a first lateral edge extending between the first planar skin and the second planar skin; a second lateral edge extending between the first planar skin and the second planar skin parallel to the first lateral edge, the second lateral edge comprises a female receiver disposed therein; wherein the first lateral edge comprises a male extension extending therefrom, said female receiver is formed in the core and has a depth greater than a first length of the male extension and a first thickness greater than a second thickness of the male extension, said female receiver defined by a first longitudinal wall and a second longitudinal wall spaced apart by a lateral wall, said lateral wall coupled to the first longitudinal wall with a first radius and coupled to the second longitudinal wall with a second radius, said lateral wall and the male extension having a gap therebetween; the male extension formed from the core comprising a first parallel surface extending parallel to and offset from the first planar skin and a second parallel surface extending parallel to and offset from the second planar skin; and a first tapered portion comprising a first tapered surface extending at an angle relative to a longitudinal axis from the first parallel surface to a rounded end, and a second tapered surface extending at the angle from the second parallel surface to the rounded end. ### Claim 20 (depends on 19) The wall panel of claim 19 wherein the first parallel surface and the second parallel surface comprises a second length, said second length being about 25 percent to about 33 percent of the first length.