System and method for providing viewports in a closed wall fabrication process

Abstract

The present invention provides one or more viewports formed at predetermined locations that allow inspections of an inside member of a closed wall system. The viewports can be disposed at predetermined locations that do not significantly impair the structural characteristics of the outward layers or inside members. In at least one embodiment, the viewports are formed in one or more outward layers during fabrication of a closed wall system. Generally, the closed wall system can be mass-produced in a manufacturing facility, although the closed wall system may be assembled at the job site.

What is claimed is:  
     
         1 . An inspection system for a closed wall, comprising: 
 a) a closed wall, having at least one inside member disposed between at least two outward layers of material; and    b) at least one viewport formed at a predetermined location in at least one of the two outward layers during fabrication of the closed wall, the viewport location being determined by a known or anticipated location of the inside member in the closed wall.    
     
     
         2 . The system of  claim 1 , wherein the viewport is positioned to align with the inside member, so that the at least one inside member is observable through the viewport when the viewport is open.  
     
     
         3 . The system of  claim 1 , wherein each of the two outward layers comprises a viewport formed therein.  
     
     
         4 . The system of  claim 1 , wherein at least one viewport is open.  
     
     
         5 . The system of  claim 1 , wherein at least one viewport is closed.  
     
     
         6 . The system of  claim 5 , wherein the outward layer having the closed viewport comprises a location indicator of the closed viewport.  
     
     
         7 . The system of  claim 5 , wherein the closed viewport is formed in the outward layer prior to coupling of the outward layer with the inside member.  
     
     
         8 . The system of  claim 1 , wherein the viewport is formed in the outward layer after coupling of the outward layer with the inside member.  
     
     
         9 . The system of  claim 1 , further comprising a building having at least a foundation and a roof associated with the closed wall system.  
     
     
         10 . The system of  claim 1 , wherein a first viewport in a first outward layer is positioned to allow one or more first inside members to be viewed and a second viewport in a second outward layer is positioned to allow one or more second inside members to be viewed.  
     
     
         11 . The system of  claim 1 , wherein a first viewport in a first outward layer is positioned to align with a second viewport in a second outward layer with the inside member disposed between the two outward layers.  
     
     
         12 . A method of preparing an inspection system for a closed wall, comprising: 
 a) providing at least one inside member;    b) coupling at least one outward layer with the inside member; and    c) forming at least one viewport in at least one outward layer of material during fabrication of the closed wall.    
     
     
         13 . The method of  claim 12 , wherein the viewport is formed in the outward layer after coupling of the outward layer with the inside member.  
     
     
         14 . The method of  claim 12 , wherein the viewport is formed in the outward layer prior to coupling of the outward layer with the inside member and wherein the outward layer is aligned with the inside member so that the inside member is visible through one or more viewports when the viewports are open.  
     
     
         15 . The method of  claim 12 , wherein forming the viewport comprises forming the viewport through the outward layer so that the viewport is open.  
     
     
         16 . The method of  claim 12 , wherein forming the viewport comprises forming at least one viewport through only a portion of a thickness of the outward layer so that the viewport is closed.  
     
     
         17 . The method of  claim 16 , further comprising indicating a location of the closed viewport on an opposite surface of the outward layer having the closed viewport.  
     
     
         18 . The method of  claim 12 , further comprising forming a first viewport in a first outward layer and a second viewport in a second outward layer and aligning the first and second viewports during fabrication of the closed wall system.  
     
     
         19 . The method of  claim 12 , further comprising allowing one or more first inside members to be viewed through at least a first viewport and one or more second inside members to be viewed through at least a second viewport.  
     
     
         20 . The method of  claim 12 , further comprising assembling the closed wall to at least a portion of a building structure and assembling further building portions to the closed wall.  
     
     
         21 . An inspection system for a closed wall, comprising: 
 a) a closed wall, having at least one inside member disposed between at least two outward layers of material; and    b) at least one viewport formed at a predetermined location in at least one of the two outward layers during fabrication of the closed wall, and prior to coupling of the outward layer having the viewport with the inside member, the viewport location being determined by a known or anticipated location of the inside member in the closed wall.