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  Apparatus and method for fabricating foam wall panelsUSPTO Application #: 20070119118Title: Apparatus and method for fabricating foam wall panels Abstract: A foam wall panel system with a unique Z-shaped wall stud. The Z-shape of the wall stud provides cavities on each side which accept the angled edges of foam wall panels that fit within the cavities. Adjacent foam wall panels having angled edges are secured into the cavities on opposite sides of Z-shaped wall stud to form a continuous foam wall. The Z-shaped wall stud can be fabricated from a single sheet of metal, or other suitable materials capable of replacing metal wall studs. The folded corner edges of the Z-shaped wall stud, and the edges of the foam panels, are rounded to avoid damage to the foam wall panel during the installation process. An alternative embodiment provides angled gripping edges on the Z-shaped wall stud that secures the foam panels to the Z-shaped wall stud. (end of abstract)
Agent: John C. Smith, Esq. - Boca Raton, FL, US Inventor: Marko Gigiakos USPTO Applicaton #: 20070119118 - Class: 052731700 (USPTO) The Patent Description & Claims data below is from USPTO Patent Application 20070119118. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a divisional application and a continuation in part (CIP) of the commonly owned copending application entitled "Apparatus And Method For Fabricating Foam Wall Panels", filed Dec. 16, 2002, bearing U.S. Ser. No. 10/321,198, issued on Jan. 16, 2007, and naming Marko Gigiakos, the named inventor herein, as sole inventor, the contents of which is specifically incorporated by reference herein in its entirety. BACKGROUND OF THE INVENTION [0002] 1. Technical Field [0003] The present invention relates to a foam wall construction system. In particular, it relates to a simplified metal stud for framing foam wall panels, which has opposing cavities on each side to accept the edge of a foam wall panel. In addition, it relates to a method of connecting adjacent foam wall panels with the simplified metal stud, and for providing optional wiring channels within the foam wall panels. [0004] 2. Background [0005] The materials and techniques used in the construction of walls, both for interior and exterior use, have evolved substantially over the years. For example, interior walls were for many years constructed using "lathe and plaster" techniques. In this process, wood studs provided physical support for wooden strips which were attached to them. In turn, a layer of plaster was manually installed on the wood strips. While this process provided a sturdy wall, it was very time consuming to install and required skilled workmen to complete the installation. As a result, installing walls using this process was relatively expensive due to the time needed to install a section of wall and the need for more expensive skilled workmen. Because of these drawbacks, a number of attempts have been made to reduce the time required to install a wall, and to reduce the associated costs. [0006] Plaster walls were eventually replaced with conventional drywall panels. The drywall system uses gypsum-type wall panels which are laminated on both sides with cardboard sheathing. A disadvantage associated with this type of wall system is that in order to provide thermal or sound insulation between rooms adjoining the wall, additional time is required and expense is incurred due to the requirement to install an insulating material between opposing drywall panels installed on the opposite sides of supporting wall studs. While improving over prior art plaster walls, the variety of components and the amount of labor required for this type of wall construction has also resulted in a relatively high installation cost. [0007] Metal framing systems have been developed which eliminate the need for wood studs for non load bearing use. An advantage of metal studs is that they do not warp as wood may when subjected to environmental factors such as changes in humidity. As a result, metal studs allow walls to be constructed which are relatively flat in comparison to walls constructed from wood studs. Another advantage is that while wood studs are at risk of termite damage, metal studs are not. Of course, metal studs do not address the insulation issues discussed above. [0008] More recently, prefabricated insulated wall panels have been developed based on foam core walls. The foam core walls typically are laminated structures in which the central foam core is laminated on both sides with protective layers. One or both of the protective layers may be fabricated from a material such as oriented strand board ("OSB"). This type of wall panel (which can also be used for flooring or roofing purposes, depending on how sturdy their construction is) typically comes in large panel sizes (e.g., 4 ft. by 8 ft.). They typically are heavy and require a substantial effort to install. Likewise, not all wall installations require high strength protective layers on one or more sides. It would be desirable to have a method of installing foam cores for walls which does not require heavy and unwieldy exterior sheathing. [0009] A number of connection methods have been developed for the installation of wall panels. In particular, a variety of edge connecting devices have been developed for interlocking adjacent wall panels such that large segments of walls can be fabricated using a series of wall panels. Typically, these edge connectors are relatively complicated devices which use, tongue and groove structures, spring loaded clamps, etc. in order to secure adjacent panels together. These types of structures often contribute to component failure due to their complexity. Likewise, as the structure of these devices becomes more complicated, the cost of their fabrication also increases. It would be desirable to have a method of connecting adjacent wall panels which is less prone to failure during the installation process, and which is less expensive to manufacture due to its simplicity of design. SUMMARY OF THE INVENTION [0010] The present invention provides an apparatus and method for connecting foam wall panels together with a unique Z-shaped wall panel connection device. The Z-shape of the wall panel connection device provides a cavity on each side which is designed to accept the edge of a foam wall panel which is angled to fit within the cavity. Adjacent foam cores having angled edges are secured into the cavities on opposite sides of Z-shaped wall panel connection devices to form a continuous foam wall. The Z-shaped wall panel connection device can be fabricated from a single sheet of material, and can replace metal wall studs. The folded corner edges of the Z-shaped wall panel connection device, and the edges of the foam cores, are rounded to avoid damage to the foam wall panel during the installation process. BRIEF DESCRIPTION OF THE DRAWINGS [0011] FIG. 1 is a top view of a preferred embodiment of the Z-shaped wall panel connection device. [0012] FIG. 2 is a top view of a preferred embodiment of the Z-shaped wall panel connection device being installed on a foam wall panel. [0013] FIG. 3 is a top view of a preferred embodiment of the Z-shaped wall panel connection device installed on a first foam wall panel, and an adjacent foam wall panel being installed into the cavity on the opposite side of the Z-shaped wall panel connection device. [0014] FIG. 4A is a top view of a preferred embodiment of the Z-shaped wall panel connection device securing two adjacent foam wall panels together. [0015] FIG. 4B is a top view of an alternative preferred embodiment of the Z-shaped wall panel connection device securing two adjacent foam wall panels together. This embodiment includes a recessed ledge to accommodate the thickness of the Z-shaped wall panel connection device. [0016] FIG. 5 is a top view of a preferred embodiment of a foam wall fabricated from a plurality of Z-shaped wall panel connection devices and foam wall panels. External sheathing is attached to one side of the foam wall, and internal sheathing (e.g., drywall) is attached to the other side of the foam wall. [0017] FIG. 6 is a perspective view of a preferred embodiment a foam wall panel inserted into a floor support guide. An optional bead of adhesive is also shown on the side edge of the foam wall panel. [0018] FIG. 7 is a perspective view of a preferred embodiment a foam wall panel inserted into a floor support guide, and a Z-shaped wall panel connection device being installed on the edge of the foam wall panel. [0019] FIG. 8 is a perspective view of a preferred embodiment a foam wall panel inserted into a floor support guide, and a Z-shaped wall panel connection device installed on the edge of the foam panel. An optional bead of adhesive is also shown on the side edge of the Z-shaped wall panel connection device [0020] FIG. 9 is a perspective view of a preferred embodiment of the foam wall panel having a wire channel cut into the surface of the foam panel and an associated electrical output. Continue reading... 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