Wall and ceiling construction and method providing a finished construction with no exterior penetrations

Abstract

An improved wall and/or ceiling construction and method suitable for both interior and exterior application comprised of compressed straw or other such construction panels wherein the finished wall contains no exterior surface penetrations through the panels, thus providing a substantially seamless outer surface. The improved construction is comprised of spaced and aligned flanged beams, each beam having both interior and exterior flanges. Exterior panels are attached to the exterior flanges so as to provide a continuous exterior wall or roof surface with all attachments made through the exterior flanges and penetrating only the inside surface of the panels. Interior panels are attached to the interior flanges by means of a connecting clip along a first edge and a plurality of disc connectors along a second edge so as to provide a continuous interior wall or ceiling surface with no penetrations therethrough. The flanged beams are provided with a plurality of openings that provide a pathway for cables and wiring along the interior of a finished wall or ceiling. The construction and method may be adapted for use with existing conventional wall constructions to utilize only interior panels and provide an interior wall with no surface penetrations.

1 . An improved method for constructing a wall including a plurality of rigid, self-supporting panels, said panels each having a substantially rectangular shape with an inner and outer face and a top, bottom, front and rear edge, said front and rear edges having, along a centerline, a plurality of symmetric recesses for accepting a symmetric connector inserted therein, each said panel further having a width equal to the distance between said front and rear edges, said method comprising the steps of: 
 placing a plurality of beams along a wall line, said beams placed in substantially parallel alignment and spaced at a lateral distance substantially equal to the width of one panel;    positioning a plurality of exterior panels to span the distance between said beams such that a portion of the inner face of each panel is in contact with two adjacent beams;    attaching said exterior panels to said beams;    attaching a first interior flanged connector to a first interior panel;    attaching said first interior flanged connector to a first beam;    positioning symmetric connectors within said symmetric recesses located along the front edge of said first interior panel;    attaching a second interior flanged connector to a second interior panel;    positioning said second interior panel in edge to edge abutted relation to said first interior panel; and    attaching said second interior flanged connector to a second beam.    
   
   
       2 . The method of  claim 1  which further includes the step of guiding symmetric connectors into said symmetric recesses located along the rear edge of said second interior panel.  
   
   
       3 . The method of  claim 1  which further includes the step of positioning symmetric connectors within said symmetric recesses located along the front edge of said second interior panel.  
   
   
       4 . The method of  claim 1  wherein attachment between said exterior panels and said beams is made by means a nail, screw, bolt, lag screw, rivet, staple, pin, dowel, adhesive, tape or glue.  
   
   
       5 . The method of  claim 1  wherein attachment between said interior flanged connector and said interior panel is made by means of a nail, screw, bolt, lag screw, rivet, staple, pin, dowel, adhesive, tape or glue.  
   
   
       6 . The method of  claim 1  wherein attachment between said interior flanged connector and said beam is made by means of a nail, screw, bolt, lag screw, rivet, staple, pin, dowel, adhesive, tape or glue.  
   
   
       7 . The method of  claim 1  wherein said beams have a cross section that includes a center web member and at least one lateral skirt member attached thereto.  
   
   
       8 . The method of  claim 1  wherein said interior flanged connectors have a cross section that includes a center web member and a lateral flange member attached thereto.  
   
   
       9 . The method of  claim 7  wherein said cross section of said beam substantially comprises a T shape.  
   
   
       10 . The method of  claim 7  wherein said cross section of said beam includes a center web member between opposed interior and exterior skirt members.  
   
   
       11 . The method of  claim 8  wherein said cross section of said interior flanged connector substantially comprises a T shape.  
   
   
       12 . The method of  claim 10  wherein said beams have a cross section that substantially comprises an I shape.  
   
   
       13 . The method of  claim 8  wherein the cross section of said lateral flange member of said interior flanged connector further comprises two substantially parallel clasp members sized to accept a portion of said lateral skirt member of said vertical beam therebetween.  
   
   
       14 . An improved wall construction for positioning a plurality of rigid, self-supporting panels to provide exterior walls and/or divide or partition interior building space comprising: 
 a plurality of parallel and regularly spaced beams, said beams each having a cross section that includes a center web and at least one lateral skirt member;    a plurality of exterior panels, said panels having a substantially rectangular shape with an inner and outer face and a top, bottom, front and rear edge and positioned to span the distance between the center web of two adjacent beam members and rigidly attach thereto;    a plurality of interior panels, said panels having a substantially rectangular shape with an inner and outer face and a top, bottom, front and rear edge, said front and rear edges having, along a centerline, a plurality of symmetric recesses;    a plurality of symmetric connectors, said connectors sized so that substantially one half of each connector will fit inside one said symmetric recess; and    a plurality of flanged connector means each providing for rigid attachment between a panel and a vertical beam;    
   
   
       15 . The wall construction of  claim 14  wherein said interior panels are comprised of compressed straw or other recovered cellulosic material.  
   
   
       16 . The wall construction of  claim 14  wherein said exterior panels are comprised of compressed straw or other recovered cellulosic material.  
   
   
       17 . The wall construction of  claim 14 , wherein rigid attachment between said exterior panels and said adjacent beam members is made by means of nail, screw, bolt, lag screw, rivet, staple, pin, dowel, adhesive, tape or glue.  
   
   
       18 . The wall construction of  claim 14 , wherein said flanged connector means comprise a connector having a cross section that includes a center web member and a lateral flange member attached thereto.  
   
   
       19 . The wall construction of  claim 14 , wherein rigid attachment between said interior panels and said flanged connector means is made by means of nail, screw, bolt, lag screw, rivet, staple, pin, dowel, adhesive, tape or glue.  
   
   
       20 . The wall construction of  claim 18 , wherein attachment between said flanged connector means and said beam is made by means of nail, screw, bolt, lag screw, rivet, staple, pin, dowel, adhesive, tape or glue.  
   
   
       21 . The wall construction of  claim 18  wherein said lateral flange member further comprises two substantially parallel clasp members sized to accept a portion of a said lateral skirt member of said beam therebetween.  
   
   
       22 . The wall construction of  claim 14  wherein cross section of said beams substantially comprises a T or an I shape.  
   
   
       23 . The wall construction of  claim 14  wherein said center web of said vertical beam further comprises a hollow channel.  
   
   
       24 . The wall construction of  claim 23  wherein said hollow channel may have a square, rectangular, round, C-shaped, or D-shaped cross section.  
   
   
       25 . The improved wall construction of  claim 14  wherein said vertical beams and flanged connector means are made from a metal or metal alloy.  
   
   
       26 . The wall construction of  claim 14  wherein said vertical beams and flanged connector means are made from a thermosetting or thermoplastic polymer-based material.