Structural wall panel assemblies

Abstract

Novel wall panel assemblies and shear wall assemblies are disclosed herein. Preferred embodiments include novel corner posts, studs, and sill plates for formed of composite materials and suitable for fabricating wall panels and shear wall assemblies for use in the construction of residential and commercial buildings.

1 . A structural corner post suitable for engaging a shear wall assembly thereto in the construction of a building, said corner post having a top end, a bottom end, and a substantially rectangular, longitudinal outer body comprising four corners, said corners including a pair of diagonally opposing corners, at least one of said of said opposing corners comprising a longitudinal channel extending from said top end to said bottom end of said corner and configured to engage an outer edge of a shear wall assembly.  
   
   
       2 . The corner post of  claim 1 , wherein said post has a hollow interior formed by said outer body.  
   
   
       3 . The corner post of  claim 1 , wherein said post is formed of a composite material.  
   
   
       4 . The corner post of  claim 2 , further including a fill material housed within said hollow interior of said post.  
   
   
       5 . The corner post of  claim 4 , wherein said fill material comprises one or more materials suitable for sound attenuation or thermal insulation.  
   
   
       6 . The corner post of  claim 1 , wherein said shear wall assembly comprises either one or more shear wall sheets or cross buck bracing,  
   
   
       7 . The corner post of  claim 1 , wherein said four corners further include an exterior most corner and a diagonally opposing interior corner, said interior corner having an indentation sufficiently large for receiving and having fastened thereto an outer edge of an interior wall sheet.  
   
   
       8 . The corner post of  claim 7 , wherein said post has a hollow interior formed by said outer body.  
   
   
       9 . The corner post of  claim 8 , wherein said post is formed of a composite material  
   
   
       10 . The corner post of  claim 1 , wherein said four corners further include an exterior most corner and a diagonally opposing interior corner, said interior corner having a pair of flanges extending therefrom at substantially right angles to one another, each of said pair of flanges configured for receiving and having fastened thereon an outer edge of an interior wall sheet.  
   
   
       11 . The corner post of  claim 10 , wherein said post is formed of a composite material  
   
   
       12 . A shear wall assembly suitable for use in panelized building construction, said assembly comprising: 
 a pair of connecting studs, each of said studs having a top end, a bottom end, an exterior flange, and an interior flange, each of said flanges extending perpendicularly from of an elongated web portion of said stud and positioned parallel to one another from the top end to the bottom end of said stud, and wherein each of said studs further includes at least one intermediate flange extending perpendicularly from one side of said web portion and positioned subjacent and parallel to a portion of said exterior flange to form, in combination with said exterior flange, a longitudinal channel extending from the top end to the bottom end of the stud; and    one or more shear wall sheets, each having two opposing side edges, each of said side edges engaged in within one of said channels of one of said connecting studs.    
   
   
       13 . The shear wall assembly of  claim 12 , wherein at least one of said connecting studs includes two of said intermediate flanges, each of said two intermediate flanges oriented opposite of one another on opposing surfaces of said web portion such that, in combination with said exterior flange, said intermediate flanges and exterior flange form a pair of adjacent longitudinal channels, each of said channels configured to engage therein the outer edge of a second shear wall sheet.  
   
   
       14 . A shear wall assembly suitable for use in panelized building construction, said assembly comprising: 
 a pair of connecting studs, each of said studs having a top end, a bottom end, an exterior flange and an interior flange, each of said flanges extending perpendicularly from an elongated web portion of said stud and positioned parallel to one another from the top end to the bottom end of said stud, and wherein each of said studs further includes at least one intermediate flange extending perpendicularly from one side of said web portion and positioned subjacent and parallel to a portion of said exterior flange to form, in combination with said exterior flange, a longitudinal channel extending from the top end to the bottom end of the stud; and    a cross-buck bracing assembly comprising at least one pair of buck boards oriented in an overlapping, criss-cross pattern between said connecting studs, each of said buck boards having opposing ends secured within one of said channels of said connecting studs.    
   
   
       15 . The shear wall assembly of  claim 14 , further including: 
 a first board secured to an outer surface of one of said intermediate flanges near the top end of said panel and spanning the width of said panel, such that said first board is oriented adjacent to and parallel with said cross-buck bracing assembly; and    a second board secured an outer surface of one of said intermediate flanges near the bottom end of said panel and spanning the width of said panel, such that said second board is oriented adjacent to and parallel with said cross-buck bracing assembly.    
   
   
       16 . The shear wall assembly of  claim 15 , wherein at least one of said connecting studs includes two of said intermediate flanges, each of said two intermediate flanges oriented opposite of one another on opposing surfaces of said web portion such that, in combination with said exterior flange, said intermediate flanges and exterior flange form a pair of adjacent longitudinal channels, each of said channels configured to engage therein the outer edges of a second set of cross buck bracing boards.  
   
   
       17 . A wall panel for use in panelized building construction, said panel comprising: 
 a) a pair of panel connecting studs, each of said studs located on one end of said wall panel and each having an interlocking component for engagement with a complementary interlocking component of a second wall panel or a corner post;    b) a series of second studs located between said pair of panel connecting studs, said second studs spaced apart to form a gap between adjacent second studs;    c) one or more braces secured between one or more pairs of adjacent second studs to span the gap between said adjacent second studs;    d) an elongated top plate secured to the top ends of said panel connecting studs and said second studs, said top plate having pair of a side walls integral with a top surface of said top plate to form a C-channel within which said studs are engaged;    e) at least one exterior wall sheet secured to one of said top plate side walls and at least one interior wall sheet secured to a second of said top plate side walls and said studs, thereby creating a hollow interior therebetween within said wall panel;    f) one or more window or door opening sections secured between adjacent second studs; and    g) one or more shear wall assembly sections secured between adjacent second studs of said wall panel.    
   
   
       18 . The wall panel of  claim 17 , wherein said pair of panel connecting studs and second studs are formed of a composite material.  
   
   
       19 . The wall panel of  claim 17 , further including a elongated bottom plate secured to the bottom ends of said panel connecting studs and said second studs, said bottom plate having pair of a side walls integral with a bottom surface of said bottom plate to form a C-channel within which said studs are engaged, and wherein said at least one exterior wall sheet and said at least one interior wall sheet are further secured to one of said side walls of said bottom plate and said studs.  
   
   
       20 . The wall panel of  claim 19 , wherein said hollow interior created within said wall panel contains one or more thermal insulation materials.  
   
   
       21 . The wall panel of  claim 19 , wherein said pair of panel connecting studs and second studs are formed of a composite material.  
   
   
       22 . The wall panel of  claim 21 , wherein said window or door opening section further comprises: 
 a) a pair of vertical studs formed of a composite material and spaced apart to form the left and right sides of each of said openings, each of said window or door opening studs having a top end, a bottom end, and a side section adjacent said opening;    b) a pair of elongated boards formed of material selected from the group of wood and thermoplastic composites, each of said pair of boards secured to said side section of each of said pair of vertical studs of said window or door opening to provide a means of attaching a door jamb, door, window jamb, or window within said opening;    c) a second elongated board formed of a material selected from the group of wood and thermoplastic composites, said second board secured near a top jamb of said window or door opening;    d) said top end of said window or door opening having a header assembly secured to the top ends of said pair of vertical studs of said door or window opening, thereby spanning the width of said opening; and    e) one or more second vertical studs secured at one end to said header assembly and at another end to said elongated connecting member of said wall panel.    
   
   
       23 . The wall panel of  claim 17 , wherein said panel comprises a window opening section, said window opening section further comprising: 
 a) a pair of vertical security shutter studs configured to secure thereto a rolling security shutter assembly, said security shutter studs spaced apart to form the left and right sides of each of said openings, each of said security shutter studs having a top end, a bottom end, and a side section adjacent said opening, wherein said side sections of said security shutter studs face one another;    b) said side section of each of said pair of security shutter studs having a longitudinal channel extending from the top end to the bottom end of said security shutter stud, said channel configured to receive a roller mechanism of said rolling security shutter assembly for movement of a said shutter assembly therein; and    c) a third elongated board formed of a material selected from the group of wood and thermoplastic composites, said second board secured near a bottom jamb of said window opening    
   
   
       24 . The wall panel of  claim 23 , wherein said security shutter studs are formed of a composite material.  
   
   
       25 . The wall panel of  claim 23 , further including said rolling security shutter assembly, said security shutter assembly having a shutter and a roller mechanism comprising a series of rollers on each outer edge of said shutter, said rollers engaged within one of said channels of said security shutter studs for movement of said shutter assembly therein.  
   
   
       26 . The wall panel of  claim 25 , wherein said security shutter studs are formed of a composite material.  
   
   
       27 . A wall panel suitable for use in panelized building construction, said panel comprising: 
 a) a pair of panel connecting studs, each of said studs located on one end of said wall panel and having an interlocking component for engagement with a complementary interlocking component of a second wall panel or a corner post;    b) a series of second studs located between said pair of panel connecting studs, said second studs spaced apart to form a gap between adjacent second studs;    c) an elongated top plate secured to the top ends of said panel connecting studs and said second studs, said top plate having pair of a side walls integral with a top surface of said top plate to form a C-channel within which said studs are engaged;    d) at least one exterior wall sheet secured to one of said top plate side walls and at least one interior wall sheet secured to a second of said top plate side walls, thereby creating a hollow interior therebetween within said wall panel;    e) one or more window opening sections secured between adjacent second studs; and    f) at least one or more of said window openings further including (i) a pair of vertical security shutter studs configured to secure thereto a rolling security shutter assembly, said security shutter studs spaced apart to form the left and right sides of each of said window opening, each of said security shutter studs having top end, a bottom end, and a side section adjacent said opening, wherein said side sections of said security shutter studs face one another, and (ii) said side section of each of said pair of security shutter studs having a longitudinal channel extending from the top end to the bottom end of said security shutter stud, said channel configured to receive a roller mechanism of a rolling security shutter assembly for movement of a said shutter assembly therein.    
   
   
       28 . The wall panel of  claim 27 , wherein said panel connecting studs, said second studs, and said security shutter studs are formed of a composite material.  
   
   
       29 . The wall panel of  claim 28 , further including said rolling security shutter assembly, said security shutter assembly having a shutter and a roller mechanism comprising a series of rollers on each outer edge of said shutter, said rollers engaged within one of said channels of said security shutter studs for movement of said shutter assembly therein.  
   
   
       30 . The wall panel of  claim 27 , further including one or more braces secured between one or more pairs of adjacent second studs to span the gap between said adjacent second studs.  
   
   
       31 . A sill plate for securing structural studs of a framing assembly to a floor pad, said sill plate comprising: 
 a) interior and exterior side walls defining a longitudinal recess for engaging therein a structural stud or a stud mount, said side walls extending upward from a floor portion of said sill plate, said floor portion having an inner surface onto which the structural stud or stud mount rests, and an opposite outer surface for abutment against said floor pad;    b) a shield projecting from an outer surface of said exterior side wall, said shield having a portion angled downward;    c) an inverted T-shaped anchor mount integral with and extending downward from said outer surface of said floor portion of said sill plate for engagement within said floor pad.    
   
   
       32 . The sill plate of  claim 31 , wherein said sill plate is formed of a thermoplastic composite material.  
   
   
       33 . A shear wall corner assembly for use in panelized construction of buildings, said shear wall corner assembly comprising: 
 a structural corner post having a top end, a bottom end, and a substantially rectangular, longitudinal outer body comprising four corners, said corners including a pair of diagonally opposing corners, each of said opposing corners comprising a longitudinal channel extending from said top end to said bottom end of said corner, said four corners further including an interior corner positioned between said diagonally opposing corners;    a pair of vertical connecting studs, each of said connecting studs having a bottom end and a top end and positioned adjacent to one of said diagonally opposed corners of said corner post;    a pair of shear wall assembly sections, each having one outer side edge engaged within one of said channels of said corner post and an opposing outer side edge secured to one of said connecting studs such that said shear wall assembly sections are oriented at a substantially right angle to one another;    a first interior wall sheet having an outer side edge secured to said interior corner of said corner post, such that said interior wall sheet is positioned parallel to one of said shear wall assembly sections; and    a second interior wall sheet having an outer side edge secured to said interior corner of said corner post, perpendicular to said first interior wall sheet.    
   
   
       34 . The shear wall corner assembly of  claim 33 , wherein said interior corner of said corner post includes an indentation sufficiently large for receiving and having fastened thereto said outer edges of said second interior wall sheets.  
   
   
       35 . The shear wall corner assembly of  claim 33 , wherein said interior corner has a pair of flanges extending therefrom at substantially right angles to one another, each of said pair of flanges configured for receiving and having fastened thereon said outer edges of said interior wall sheet.  
   
   
       36 . The shear wall corner assembly of  claim 33 , wherein each of said connecting studs comprises an exterior flange and an interior flange, each of said flanges extending perpendicularly from an elongated web portion of said stud and positioned parallel to one another from the top end to the bottom end of said stud, and wherein each of said studs further includes at least one intermediate flange extending perpendicularly from said web portion and positioned subjacent with and parallel to said exterior flange to form, in combination with said exterior flange, a longitudinal channel extending the top end to the bottom end of said stud.  
   
   
       37 . The shear wall corner assembly of  claim 33 , wherein said corner post and connecting studs are formed of a composite material, and wherein said corner post has a hollow interior formed by said outer body.  
   
   
       38 . The shear wall corner assembly of  claim 33 , further including a fill material housed within said hollow interior of said corner post.  
   
   
       39 . The shear wall corner assembly of  claim 38 , wherein said fill material comprises one or more materials suitable for sound attenuation or thermal insulation.  
   
   
       40 . The shear wall corner assembly of  claim 33 , wherein said shear wall assembly comprises at least one solid, substantially flat sheet of material.  
   
   
       41 . The shear wall corner assembly of  claim 33 , wherein said shear wall assembly is a cross buck bracing assembly comprising at least one pair of boards oriented in an overlapping criss-cross pattern between said corner post and one of said connecting studs, each of said boards having opposing ends comprising the outer edge of said shear wall assembly engaged within channels of said connecting stud and said corner post.  
   
   
       42 . The shear wall corner assembly of  claim 41 , further including (a) a first board having one outer side edge secured to said corner post near the top end of said corner post and a second outer side edge secured to a top end of one of said adjacent connecting studs, such that said first board is oriented adjacent to and parallel with said sheer wall assembly section; and (b) a second board having an outer side edge secured to said said corner post near the bottom end of said corner post and a second outer side edge secured to said bottom end of one of said adjacent studs, such that said second board is oriented adjacent to and parallel with said sheer wall assembly section.  
   
   
       43 . An elongated structural stud for use in building construction, said stud having an exterior flange extending perpendicularly from an elongated web portion of said stud, said stud further having a first intermediate flange extending perpendicularly from one side of said web portion and positioned subjacent with and parallel to a portion of said exterior flange to form, in combination with said exterior flange, a first channel extending the length of said stud, said first channel configured to receive a roller mechanism of a rolling security shutter assembly for movement of a said shutter assembly therein.  
   
   
       44 . The stud of  claim 43 , wherein said stud is formed of a composite material.  
   
   
       45 . The stud of  claim 43 , wherein said stud further comprises a second intermediate flange extending perpendicularly from a second side of said web portion and oriented opposite said first intermediate flange such that, in combination with said exterior flange, said second intermediate flanges and a portion of said exterior flange form a second channel adjacent said first channel, said second channel extending the length of said stud and configured to engage therein an outer side edge of at least one wall sheet.  
   
   
       46 . The stud of  claim 45 , wherein said stud is formed of a composite material.  
   
   
       47 . A wall panel system for use in panelized construction, said system comprising 
 a) a plurality of wall panels, each of said wall panels comprising:    i) a pair of panel connecting studs formed of a composite material, each of said studs located on one end of said wall panel and having an interlocking component for engagement with a complementary interlocking component of a second wall panel or a corner post, said panel connecting studs further having an exterior flange and an interior flange extending perpendicularly from a central elongated web portion;    ii) a series of second studs located between said pair of panel connecting stud, said second studs spaced apart to form a gap between adjacent second studs;    iii) an elongated top plate secured to the top ends of said panel connecting studs and said second studs, said top plate having pair of a side walls integral with a top surface of said top plate to form a C-channel within which said studs are engaged; and    iv) at least one exterior wall sheet secured to one of said top plate side walls and at least one interior wall sheet secured to a second of said top plate side walls, thereby creating a hollow interior therebetween within said wall panel; and    b) said wall panels secured to one another at opposing ends via the interlocking components of adjacent wall panels, said interlocking components of adjacent wall panels further secured to one another by a plurality of mechanical fasteners, and wherein said interlocking component of the connecting stud of one panel comprises a substantially C-shaped channel formed in part by said exterior and interior flanges and said web portion of said connecting stud, said channel configured for engagement therein of a complementarily configured web portion of the connecting stud of an adjacent panel for interlocking engagement of said wall panels to one another.    
   
   
       48 . The wall panel system of  claim 47 , wherein each of said plurality of mechanical fasteners penetrates said flanges of adjacent connecting studs of adjacent wall panels, wherein said flanges of adjacent panels overlap one another.  
   
   
       49 . The wall panel system of  claim 47 , wherein said wall panels are further secured to one another via an adhesive applied between overlapping flanges of adjacent panels.  
   
   
       50 . The wall panel of  claim 47 , further including one or more braces secured between one or more pairs of adjacent second studs to span the gap between said adjacent second studs.  
   
   
       51 . The wall panel system of  claim 47 , further including a corner post, said corner post having an outer body and an interlocking component extending from said outer body for engagement with a complementarily configured interlocking component of one of said wall panels.  
   
   
       52 . The wall panel system of  claim 51 , wherein said corner post had an exterior corner and a diagonally opposing interior corner, said interior corner having a pair of flanges extending therefrom at substantially right angles to one another, each of said pair of flanges configured for receiving and having fastened thereon an outer edge of said interior wall sheet.  
   
   
       53 . A shear wall assembly suitable for use in panelized building construction, said assembly comprising: 
 a pair of connecting studs, each of said studs having a top end, a bottom end, a first flange, and a second flange, each of said flanges extending perpendicularly from opposing ends of an elongated web portion of said stud and positioned parallel to one another from the top end to the bottom end of said stud, and wherein each of said studs further includes at least one intermediate flange extending from one side of said web portion and positioned subjacent and parallel to a portion of said exterior flange to form, in combination with said exterior flange, a longitudinal channel extending from the top end to the bottom end of the stud;    each of said connecting studs having an interlocking component extending from said web portion of said stud and comprising said exterior and interior flanges, said interlocking component configured to engage a complementary interlocking component of a connecting stud of an adjacent wall panel; and    a shear wall assembly section having opposing outer edges, each of said edges engaged within one of said channels of said connecting studs.    
   
   
       54 . The shear wall assembly of  claim 53 , wherein said exterior and interior flanges of said connecting stud, in combination with a flange subjacent to said exterior flange and extending from a side of said web portion, comprise said interlocking component of said stud, said exterior flange and subjacent flange forming a groove for engagement of an interior flange of a complementary configured interlocking component of an adjacent wall panel.  
   
   
       55 . A wall panel system for use in panelized construction, said system comprising 
 a) a plurality of wall panels, each of said wall panels comprising:    i) a pair of panel connecting studs formed of a composite material, each of said studs located on one end of said wall panel and having an interlocking component for engagement with a complementary interlocking component of a second wall panel or a corner post, said panel connecting studs further having an exterior flange and an interior flange extending perpendicularly from a central elongated web portion;    ii) a series of second studs located between said pair of panel connecting studs, said second studs spaced apart to form a gap between adjacent second studs;    iii) an elongated top plate secured to the top ends of said panel connecting studs and said second studs, said top plate having pair of a side walls integral with a top surface of said top plate to form a C-channel within which said studs are engaged;    iv) at least one exterior wall sheet secured to one of said top plate side walls and at least one interior wall sheet secured to a second of said top plate side walls, thereby creating a hollow interior therebetween within said wall panel; and    b) said wall panels secured to one another at opposing ends via the interlocking components of adjacent wall panels, said interlocking components of adjacent wall panels further secured to one another by a plurality of mechanical fasteners, and wherein said interlocking component of the connecting stud of one panel comprises said exterior and interior flanges of said connecting stud, in combination with a flange extending from a side of said web portion subjacent to said exterior flange, said exterior flange and subjacent flange, in combination, forming a groove for engagement of an interior flange of a complementary configured interlocking component of an adjacent wall panel;    
   
   
       56 . The wall panel system of  claim 55 , wherein each of said plurality of mechanical fasteners penetrates said flanges of adjacent connecting studs of adjacent wall panels, wherein said flanges of adjacent panels overlap one another.  
   
   
       57 . The wall panel system of  claim 55 , wherein said wall panels are further secured to one another via an adhesive applied between overlapping flanges of adjacent panels.  
   
   
       58 . The wall panel of  claim 55 , further including one or more braces secured between one or more pairs of adjacent second studs to span the gap between said adjacent second studs.  
   
   
       59 . The wall panel system of  claim 55 , further including a corner post, said corner post having an outer body and an interlocking component extending from said outer body for engagement with a complementarily configured interlocking component of one of said wall panels.  
   
   
       60 . The wall panel system of  claim 59 , wherein said corner post has an exterior corner and a diagonally opposing interior corner, said interior corner having a pair of flanges extending therefrom at substantially right angles to one another, each of said pair of flanges configured for receiving and having fastened thereon an outer edge of said interior wall sheet.  
   
   
       61 . The wall panel system of  claim 59 , wherein said corner post had an exterior corner and a diagonally opposing interior corner, wherein said interior corner of said corner post includes an indentation sufficiently large for receiving and having fastened thereto said outer edge of an interior wall sheet.