Method and system for providing conduit and boxes in a closed wall system

Abstract

The present invention provides an engineered closed wall system that includes one or more preinstalled conduits installed during fabrication of the closed wall system and an associated box that is positioned to intersect the preinstalled conduit at a standard connection port of the box and in a predetermined location. The location of the conduit and/or box can vary according to job-specific requirements. Advantageously, the conduit can be installed equidistant from the first and second outward layers. Specific boxes, and any ring extensions mounted to the boxes, can be sized to flexibly mount from either outward layer and still be substantially flush with the face of the outward layer and still intersect the conduit at a standard connection port provided on the box.

1 . An engineered closed wall system, comprising: 
 a) a first outward layer;    b) an inside insulation core having a first and a second face, the first face being coupled to the first outward layer;    c) a second outward layer coupled to the second face of the inside insulation core;    d) at least one preinstalled conduit installed in the insulation core during fabrication of the closed wall system; and    e) at least one box installed in the insulation core and aligned with the conduit, the preinstalled conduit intersecting the box at a standard connection port of the box.    
     
     
         2 . The system of  claim 1 , wherein the conduit and box locations installed in the engineered closed wall system vary according to job specific requirements.  
     
     
         3 . The system of  claim 1 , wherein the conduit is disposed equidistant from the first outward layer and the second outward layer in the insulation core.  
     
     
         4 . The system of  claim 3 , further comprising an extension coupled to the box to allow the box to intersect the conduit at the standard connection port of the box.  
     
     
         5 . The system of  claim 1 , wherein the conduit is installed vertically through the insulation core and extends beyond the insulation core.  
     
     
         6 . The system of  claim 1 , wherein the conduit is installed laterally through the core.  
     
     
         7 . The system of  claim 1 , wherein at least one of the outward layers comprises oriented strand board (OSB).  
     
     
         8 . The system of  claim 1 , wherein: 
 a) the two outward layers have a thickness of about {fraction (7/16)} inches;    b) the insulation core has a thickness of about 3-½ inches;    c) the box is about 1-½ inches in depth; and    d) an extension ring having a depth of about 1-½ inches coupled to the box.    
     
     
         9 . The system of  claim 8 , wherein the conduit is centrally disposed in the insulation core and the combination of the extension ring and box allow the box to be inserted into the core with the extension ring substantially flush with the outer face of the outward layer and to allow the box to be aligned with the conduit at the standard connection port of the box.  
     
     
         10 . The system of  claim 9 , wherein the extension ring is mounted to the outward layer through which the ring extends.  
     
     
         11 . An engineered closed wall system, comprising: 
 a) a first outward layer;    b) an inside insulation core having a first and a second face, the first face being coupled to the first outward layer;    c) a second outward layer coupled to the second face of the inside insulation core;    d) at least one preinstalled electrical conduit installed in the insulation core during fabrication of the closed wall system, the electrical conduit being centrally disposed in the insulation core by being substantially equidistant from both outward layers;    e) at least one electrical box installed in the insulation core and positioned to intersect the preinstalled electrical conduit at a standard connection port of the box; and    f) an extension ring coupled to the electrical box and adapted to align the standard connection port of the box with the centrally disposed electrical conduit.    
     
     
         12 . The system of  claim 1 , wherein the conduit and box locations installed in the engineered closed wall system vary according to job specific requirements.  
     
     
         13 . The system of  claim 1 , wherein system comprises two or more modular closed walls, one of the modular closed walls having a first conduit and a first box installed in predetermined positions that are different from positions of a second conduit and a second box installed in a second modular closed wall.  
     
     
         14 . The system of  claim 1 , wherein the conduit is installed vertically through the insulation core and extends beyond the insulation core.  
     
     
         15 . The system of  claim 1 , wherein the conduit is installed laterally through the core.  
     
     
         16 . The system of  claim 1 , wherein at least one of the outward layers comprises oriented strand board (OSB).  
     
     
         17 . The system of  claim 1 , wherein: 
 a) the two outward layers have a thickness of about {fraction (7/16)} inches;    b) the insulation core has a thickness of about 3-½ inches;    c) the box is about 1-½ inches in depth; and    d) the extension ring has a depth of about 1-½ inches.    
     
     
         18 . The system of  claim 17 , wherein the extension ring is mounted to the outward layer through which the ring extends.  
     
     
         19 . A method of preparing an engineered closed wall system, comprising: 
 a) providing at least two outward layers of material and an insulation core;    b) coupling the two outward layers with the insulation core;    c) forming an elongated opening in the insulation core;    d) installing a conduit in the elongated opening;    e) forming a second opening in the insulation core and an opening in at least one outward layer, the second opening in the insulation core being substantially aligned with the opening in the outward layer;    f) installing a box into the second opening; and    g) aligning a standard connection port of the box with the conduit.    
     
     
         20 . The method of  claim 19 , further comprising coupling the box with an extension ring that is disposed outwardly from the box toward the opening formed in at least one of the outward layers.  
     
     
         21 . The method of  claim 20 , wherein the extension ring does not extend substantially beyond the outer face of the outward layer having the opening.