US 9,441,363 B2 · Prefabricated wall apparatus and method

Abstract

A prefabricated wall module may include framing members and one or more insulations members. The insulation member may have pre-incisions, as made by a hot-wire, defining service fitting accommodations. The service fitting accommodations are accessible on the inside face of the insulation. The service fitting accommodations may be either or both of vertically or laterally extending, and are located in the same places in each module, the vertical locations being next to the studs, to which service fittings may typically be mounted, the lateral accommodations being at heights typical of switches and wall outlets. The insulation members may be supplied with tabs filling the accommodations. The tabs may be snapped out as required. The insulation members may have stud channels that are shallower than the studs, such that an air gap is established between the insulation and the internal gypsum board covering.

Claims28

Dependent claims

An insulation member for a wall construction in which the insulation member co-operates with an array of wall framing studs, said insulation member comprising:

a body having a height, a width and a depth;
said body having defined therein at least a first stud accommodation in which to seat a first stud, and a second stud accommodation in which to seat a second stud, said first and second stud accommodations being spaced width-wise apart from each other, and running height-wise;
said body having a first face and a second face;
a first insulation blank, said first insulation blank extending along said first face and being frangibly connected to said body;
said first insulation blank being removable from said body to expose a first service accommodation defined in said body;
said first service accommodation sharing a common side with said first stud accommodation, and having a length, a width, and a depth, said length being greater than each of said width and said depth, said length running along said first face, said depth extending into said body away from said first face;
and
when said first insulation blank has been removed, said first service accommodation being open along said length thereof, whereby said first service accommodation has access from said first face to permit a service member to be laid side-ways into said first service accommodation.

5 more elements

An insulation member haying a height, a width, and a through thickness, said through-thickness being smaller than either of said height and said width, said insulation member having:

a first body portion for installation between spaced-apart first and second wall studs;
said first body portion having a first face, said first face extending height-wise and width-wise;
a second body portion frangibly connected to said first body portion;
said second body portion being disconnectible and removable from said first body portion to expose a first service accommodation pre-defined in said first body portion, as installed said first service accommodation having a side bounded by the first stud;
said first service accommodation having a length, a depth, and a width, said length being greater than each of said depth and said width, said length running along said first face, said depth extending from said first face into said first body portion;
and
with said second body portion removed, said first service accommodation being accessible along said length thereof from said first face, whereby a service fitting can be laid sideways into said first service accommodation from said first face.

4 more elements

A combination of an insulation member for a wall construction and framing members of the wall construction, the framing members including at least first and second spaced-apart studs and a cavity formed therebetween, the wall construction having a height, a width, and a through-thickness, the studs having a thickness and a width, the cavity having a depth in the through-thickness direction of the wall construction;

said insulation member defines a plug for the cavity;
said, plug:
is shorter in the through-thickness direction than the depth of the cavity;
and said plug has at least one frangible blank that is removable to expose a corresponding at least one pre-formed service fitting accommodation defined therein running along and having a side bounded by said first stud, said service fitting accommodation having a length, a width and a depth, said length being greater than each of said width and said depth;
said wall construction has an inside and an outside, said studs stand proud of said plug toward said inside of said wall construction, said length of said service fitting accommodation runs along said inside of said wall construction, said depth of said service fitting accommodation extends from said inside of said wall construction into said plug;
and, when said at least one frangible blank has been removed, said service fitting accommodation, in use, being open along said length thereof to permit a service fitting to be laid sideways therein.

3 more elements

Dependencies are inferred from the claim text.

Prefabricated wall apparatus and method

Life of this patent

Prefabricated wall apparatus and method

Life of this patent

Abstract

Claims28