Stackable insulated unit for wall construction and method

Abstract

A stackable insulated unit for wall construction for cooperation with conventional wall studs forming a self-supporting wall structure consists of two side wooden planks spaced apart and provided therebetween with an insulating layer which has at least two transverse through openings for reception of respective wall stud sections, either slidably or permanently secured thereto.

1 . A stackable unit for wall construction for cooperation with wall stud members forming a self-supporting wall structure, the unit comprising: first and second opposed elongate side wooden planks secured to one another with an insulating layer bonded thereto, the insulating layer having a plurality of through openings spaced from one another and extending transversely therethrough for receiving a longitudinal section of respective said stud member.  
     
     
         2 . A unit according to  claim 1  wherein respective said stud longitudinal section is permanently secured to the unit when inserted into corresponding said through opening, each said stud longitudinal section being adapted to structurally connect to at least one corresponding said stud longitudinal section of an adjacent said unit via a securing member for forming the self-supporting wall structure and having structural loads transmitted therethrough.  
     
     
         3 . A unit according to  claim 2  wherein each said stud longitudinal section is adapted to be in abutting engagement with and securable to at least one corresponding said stud longitudinal section of an adjacent said unit.  
     
     
         4 . A unit according to  claim 3  wherein each said stud longitudinal section has a through hole extending longitudinally therealong for slidably receiving the securing member therethrough for connection with said at least one corresponding said stud longitudinal section of an adjacent said unit.  
     
     
         5 . A unit according to  claim 4  wherein each said securing member forces corresponding said stud longitudinal section to be in abutting engagement with said at least one corresponding said stud longitudinal section of an adjacent said unit.  
     
     
         6 . A unit according to  claim 5  wherein the securing member is a screw-nut fastener for clamping corresponding said stud longitudinal section in abutting engagement with said at least one corresponding said stud longitudinal section of an adjacent said unit.  
     
     
         7 . A unit according to  claim 3  wherein each said securing member is a screw screwably extending through corresponding said stud longitudinal section and screwing into said at least one corresponding said stud longitudinal section of an adjacent said unit to be in secured abutting engagement therewith.  
     
     
         8 . A unit according to  claim 3  wherein each said stud longitudinal section has a protrusion member extending longitudinally outwardly from a first end thereof and a cavity member extending longitudinally inwardly into an opposed second end thereof, said protrusion member being adapted to engage corresponding said cavity member of a stud longitudinal section of a first adjacent said unit, and said cavity member being adapted to receive corresponding said protrusion member of a stud longitudinal section of a second adjacent said unit.  
     
     
         9 . A unit according to  claim 1  wherein said through openings slidably receive respective said stud longitudinal section therethrough.  
     
     
         10 . A unit according to  claim 9  wherein each wooden plank is provided at its ends with recess means adapted to receive a part of a stud whereby adjacent units sitting end to end accommodate and embrace the stud to its full dimension.  
     
     
         11 . A unit according to  claim 1  wherein the first and second planks are engineered side wooden planks.  
     
     
         12 . A unit according to  claim 11  wherein each wooden plank comprises a plurality of individual planks formed with a tongue and groove interlocking jointing arrangement along respective longitudinal edges thereof.  
     
     
         13 . A unit according to  claim 12  wherein each wooden plank is provided with recess means on the top and on the bottom each being adapted in use to accommodate another building element.  
     
     
         14 . A unit according to  claim 12  wherein the individual planks are of log form and successive planks are disposed with the heartwood in one plank offset with regard to the heartwood of an adjacent plank.  
     
     
         15 . A unit according to  claim 1  wherein said through openings are spaced from at least one of the first and second planks.  
     
     
         16 . A unit according to  claim 15  wherein said through openings are spaced from the first and second planks.  
     
     
         17 . A unit according to  claim 1  wherein said through openings extend from the first plank to the second plank so as to divide the insulating layer in a plurality of spaced longitudinal layer sections.  
     
     
         18 . A unit according to  claim 1  wherein the through openings are generally equally spaced apart along the unit.  
     
     
         19 . A method of constructing a wall composed of stackable wall units prefabricated in accordance with  claim 2 , the method comprising the steps of: 
 mounting a first of said units on a sole plate and securing said stud longitudinal section thereof onto the sole plate using securing members and bonding therebetween; and    assembling a plurality of said units on top of one another in a stack with securing each said stud longitudinal section to respective said stud longitudinal section of a subjacent said unit using said securing members and bonding therebetween.    
     
     
         20 . A method of constructing a wall composed of stackable wall units prefabricated in accordance with  claim 2 , the method comprising the steps of: 
 assembling a plurality of said units on top of one another in a stack with securing each said stud longitudinal section to respective said stud longitudinal section of a subjacent said unit using said securing members and bonding therebetween;    mounting the units on a sole plate; and    securing the units together and to the sole plate using securing members to longitudinally clamp registered said stud longitudinal sections to each adjacent ones and to the sole plate.    
     
     
         21 . A method of constructing a wall composed of prefabricated stackable wall units, the method comprising the steps of: 
 erecting a wood frame including vertical studs upstanding from a sole plate, prefabricating a plurality of stackable wall units in accordance with  claim 9;     feeding the units over the studs thereby to accommodate the studs within the through openings formed in the units; and    bonding together adjacent units to produce a unitary wall structure around the studs.    
     
     
         22 . A method of constructing a wall composed of stackable wall units prefabricated in accordance with  claim 9 , the method comprising the steps of: 
 assembling a plurality of said units on top of one another in a stack with bonding therebetween;    mounting the units on a sole plate; and    inserting vertical studs into the openings for fixture to the sole plate.