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.

1 . A combination comprising; 
 a basement wall having an interior surface; and    a prefabricated wall panel assembly coupled to said basement wall for finishing said interior surface, said prefabricated wall panel assembly 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 coupling to the basement 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 coupled to said basement wall, said inside surface being located further from said basement wall than said outside surface is located from said basement wall.  
   
     
     
         2 . The combination 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 . (canceled)  
     
     
         4 . The combination of  claim 1 , and further comprising top and bottom horizontal frame members; and, 
 wherein said foam layer comprises an in situ foam that has been injected and has been cured within said frame members.    
     
     
         5 - 7 . (canceled)  
     
     
         8 . The combination of  claim 1  wherein said frame is made of 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; and 
 wherein said foam layer is substantially impervious to water and water vapor.    
     
     
         9 - 26 . (canceled)  
     
     
         27 . A combination, comprising: 
 a pre-existing wall; and    a prefabricated wall panel assembly coupled to said pre-existing wall, said prefabricated wall panel assembly comprising: 
 a rectilinear panel of sheet rock having an inside surface defining a portion of an interior wall, an outside surface and a perimeter edge around said surfaces;  
 a rectilinear frame comprising right and left frame members and top and bottom frame members that are aligned substantially along the perimeter edge, said frame being affixed directly to said outside surface of the panel prior to attachment to the pre-existing wall and forming a mold cavity adjacent the outside surface, said frame being a substantially solid structure with one surface abutting the outside surface and another surface abutting said pre-existing wall; and  
 a substantially uninterrupted in situ laminated rigid foam filling said mold cavity and adhered directly to said outside surface and said frame.  
   
     
     
         28 . the combination of  claim 27 , wherein said mold cavity is substantially free of any members located therein and connecting with said frame.  
     
     
         29 . The combination of  claim 27 , wherein there are no additional members located within the volume defined by said right and left frame members and said top and bottom frame members.  
     
     
         30 . The combination of  claim 27 , which further includes at least one member disposed between said frame and said pre-existing wall.  
     
     
         31 . A combination comprising: 
 a basement wall formed of masonry materials;    a wall panel assembly coupled to said basement wall, said wall panel assembly comprising: 
 a sheet rock panel having an inside surface and an outside surface and a perimeter edge around said surfaces;  
 a frame extending along said perimeter edge and attached to said sheet rock panel on said outside surface independently of said basement wall, wherein said frame and outside surface defining a volume; and,  
 an in situ formed laminated rigid foam layer along and adhered to said outside surface and located within said frame, wherein said volume is free of any substantial members and filled by said laminated rigid foam layer.  
   
     
     
         32 . A combination of  claim 31 , wherein said frame is formed of elongated wooden members.  
     
     
         33 . A combination of  claim 31 , wherein said frame is adapted to receive a fastener therethrough and spaces the inside surface away from the pre-existing wall.  
     
     
         34 . The combination of  claim 31 , which further includes at least one furring strip that spaces said wall panel assembly away from said basement wall.