Prefabricated wall panel

Abstract

A prefabricated wall panel and method are disclosed. A panel including a sheet rock layer and a laminated in-situ foam layer within a frame is attached to a pre-existing masonry wall, such as a basement wall.

What is claimed is:  
     
         1 . A prefabricated wall panel assembly for finishing an inside surface of a pre-existing wall, comprising; 
 a rectilinear panel of sheet rock having an inside surface and an outside surface and a perimeter edge around said surfaces;    a rectilinear frame comprising right and left vertical frame members, said frame being attached to said panel on its outside surface prior to attachment to the wall; and,    a laminated rigid foam layer along said outside surface of said sheet rock panel and located within said frame with said frame being attachable to the wall.    
     
     
         2 . The prefabricated wall panel assembly of  claim 1  wherein said rigid foam layer comprises an in situ foam that has been injected and has been cured within said frame.  
     
     
         3 . The prefabricated wall panel assembly of  claim 2  wherein said foam comprises rigid polyurethane foam.  
     
     
         4 . The prefabricated wall panel assembly of  claim 3  and further comprising top and bottom horizontal frame members.  
     
     
         5 . The prefabricated wall panel assembly of  claim 4  wherein said foam layer comprises an in situ foam that has been injected and has been cured within said frame members.  
     
     
         6 . The prefabricated wall panel assembly of  claim 5  wherein said frame is flush with said perimeter edge of said wall panel at least along substantial portions of said vertical frame members.  
     
     
         7 . The prefabricated wall panel assembly of  claim 6  wherein said frame is flush with said perimeter edge of said wall panel along the entire perimeter edge.  
     
     
         8 . The prefabricated wall panel assembly of  claim 7  wherein said frame is made elongated wooden boards having a cross-sectional dimension of approximately 1.5 inches by 1.5 inches, and wherein said sheet rock is at least 4 feet wide by 8 feet long, and wherein the insulation R-value through said wall panel assembly is at least 10.  
     
     
         9 . The prefabricated wall panel assembly of  claim 8  wherein said foam layer is substantially impervious to water and water vapor.  
     
     
         10 . The prefabricated wall panel assembly of  claim 9  wherein said wall panel has an overall thickness of less than 3 inches and is substantially planer on both the inside and outside surfaces, and wherein the overall panel thickness is within a tolerance of less than ¼ inch across the panel.  
     
     
         11 . The prefabricated wall panel assembly of  claim 1  wherein said foam comprises rigid polyurethane foam.  
     
     
         12 . The prefabricated wall panel assembly of  claim 1  and further comprising top and bottom horizontal frame members.  
     
     
         13 . The prefabricated wall panel assembly of  claim 12  wherein said foam layer comprises an in situ foam that has been injected and has been cured within said frame members.  
     
     
         14 . The prefabricated wall panel assembly of  claim 1  wherein said frame is flush with said perimeter edge of said wall panel at least along substantial portions of said vertical frame members.  
     
     
         15 . The prefabricated wall panel assembly of  claim 1  wherein said frame is flush with said perimeter edge of said wall panel along the entire perimeter edge.  
     
     
         16 . The prefabricated wall panel assembly of  claim 1  wherein said frame is made elongated wooden boards having a cross-sectional dimension of approximately 1.5 inches by 1.5 inches.  
     
     
         17 . The prefabricated wall panel assembly of  claim 1  wherein said foam layer is substantially impervious to water and water vapor.  
     
     
         18 . The prefabricated wall panel assembly of  claim 1  wherein said wall panel has an overall thickness of less than 3 inches and is substantially planer on both the inside and outside surfaces, and wherein the overall panel thickness is within a tolerance of less than ¼ inch across the panel.  
     
     
         19 . A prefabricated wall panel for finishing an inside surface of a pre-existing wall, consisting essentially of: 
 a rectilinear panel of sheet rock having an inside surface and an outside surface and a perimeter edge around said surfaces;    a rectilinear frame comprising top and bottom horizontal frame members and right and left vertical frame members, said frame being attached to said panel on its outside surface prior to attachment to the wall; and,    a laminated rigid foam layer adhered directly to said outside surface of said sheet rock panel and located within said frame with said frame being attachable to the wall.    
     
     
         20 . The prefabricated wall panel of  claim 19  wherein said frame is flush with said perimeter edge of said wall panel along the entire perimeter edge.  
     
     
         21 . The prefabricated wall panel of  claim 20  wherein said foam comprises rigid polyurethane foam.  
     
     
         22 . The prefabricated wall panel assembly of  claim 19  wherein said foam layer is substantially impervious to water and water vapor.  
     
     
         23 . The prefabricated wall panel assembly of  claim 20  wherein said foam layer is substantially impervious to water and water vapor.  
     
     
         24 . A method for providing a finish wall panel on a pre-existing wall, comprising the acts of: 
 within a factory, providing a sheet rock panel, a foamable media, and a frame member, and in-situ foaming said foamable media directly on a surface of said sheet rock and within said frame member; and, curing said foamable media into a rigid, moisture impervious foam panel adhered directly to said surface of said sheet rock.    
     
     
         25 . The method of  claim 24  and further including the acts of aligning said frame member around and substantially flush with a perimeter edge of said sheet rock before the act of curing said foamable media.  
     
     
         26 . The method of  claim 25  and further comprising the acts of transporting said panel to a job site, and attaching said panel to a pre-existing wall.