US 7,603,822 B2Granted

Panelized wall system with foam core insulation

AssigneeUT-Battelle, LLC

InventorsJan Kosny, Sally Gaskin

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Abstract

A wall system includes a plurality of wall members, the wall members having a first metal panel, a second metal panel, and an insulating core between the first panel and the second panel. At least one of the first panel and the second panel include ridge portions. The insulating core can be a foam, such as a polyurethane foam. The foam can include at least one opacifier to improve the k-factor of the foam.

Claims19

Dependent claims

A wall system, comprising a two wall members, and a structural column,

each said wall member comprising:
a first metal panel having first and second sides opposing each other;
a second metal panel having third and fourth sides opposing each other;
an insulating core between the first panel and the second panel;
at least one of the first panel and the second panel comprising ridge portions;
the second panel being wider than the first panel, wherein the first and third sides are laterally offset from each other, and wherein the second and fourth sides are laterally offset from each other, said first, second, third and fourth sides having flanges directed inwardly in the direction of said core;
and
said structural column being a separate component from the wall members and connectable thereto, said structural column comprising:
a facing member having angled side connection portions adapted to mate on one side with the flange of the first side of the first metal panel of one of said wall members, and adapted to mate on the other side with the flange of the second side of the first metal panel of the other of said wall members;
and a channel member having angled connection portions connected to said angled side connection portions of said facing member and to said flanges of said first and second sides of said wall members, and channel portions forming channels between said facing member and said channel member, said facing member and said channel member forming a structural beam and said facing member covering from view said flanges of said first and second sides of said wall members;
and a connector, said connector having a groove for receiving the flange of third side of the second metal panel of one of said wall members, and the flange of the fourth side of the second metal panel of the other of said wall members, thereby forming a moisture resistent seal;
and an insulating foam positioned in said channels and between said channel member and said connector, said channel member having a plurality of apertures through which the insulating foam extends, whereby the insulating foam secures the structural column together while thermally insulating said structural column.

9 more elements

Dependencies are inferred from the claim text.

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Abstract

A wall system, comprising a two wall members, and a structural column,

each said wall member comprising:
a first metal panel having first and second sides opposing each other;
a second metal panel having third and fourth sides opposing each other;
an insulating core between the first panel and the second panel;
at least one of the first panel and the second panel comprising ridge portions;
the second panel being wider than the first panel, wherein the first and third sides are laterally offset from each other, and wherein the second and fourth sides are laterally offset from each other, said first, second, third and fourth sides having flanges directed inwardly in the direction of said core;
and
said structural column being a separate component from the wall members and connectable thereto, said structural column comprising:
a facing member having angled side connection portions adapted to mate on one side with the flange of the first side of the first metal panel of one of said wall members, and adapted to mate on the other side with the flange of the second side of the first metal panel of the other of said wall members;
and a channel member having angled connection portions connected to said angled side connection portions of said facing member and to said flanges of said first and second sides of said wall members, and channel portions forming channels between said facing member and said channel member, said facing member and said channel member forming a structural beam and said facing member covering from view said flanges of said first and second sides of said wall members;
and a connector, said connector having a groove for receiving the flange of third side of the second metal panel of one of said wall members, and the flange of the fourth side of the second metal panel of the other of said wall members, thereby forming a moisture resistent seal;
and an insulating foam positioned in said channels and between said channel member and said connector, said channel member having a plurality of apertures through which the insulating foam extends, whereby the insulating foam secures the structural column together while thermally insulating said structural column.

9 more elements