Apparatus And Method For Fabricating Foam Wall Panels

Abstract

A foam wall panel system with a unique Z-shaped wall stud. The Z-shape of the wall stud provides cavities on each side which accept the angled edges of foam wall panels that fit within the cavities. Adjacent foam wall panels having angled edges are secured into the cavities on opposite sides of Z-shaped wall stud to form a continuous foam wall. The Z-shaped wall stud can be fabricated from a single sheet of metal, or other suitable materials capable of replacing metal wall studs. The folded corner edges of the Z-shaped wall stud, and the edges of the foam panels, are rounded to avoid damage to the foam wall panel during the installation process. An alternative embodiment provides angled gripping edges on the Z-shaped wall stud that secures the foam panels to the Z-shaped wall stud.

1 . A method of fabricating a foam panel wall, including the steps of: 
 connecting a series of foam panels adjacent to one another such that they form a wall; and    connecting adjacent foam panels together using a Z-shaped stud, the Z-shaped stud formed such that the edges of adjacent foam panels fit snugly within opposing cavities formed on opposite sides of the Z-shaped stud.    
   
   
       2 . A method, as in  claim 1 , including the additional steps of: 
 forming the edges of the foam panels such that their edges are angled from the side surfaces of the foam panels and substantially equivalent in shape to one another; and    forming the cavities in the Z-shaped stud such that adjacent foam panels inserted into the opposing cavities of the Z-shaped stud will both fit snugly within the cavities.    
   
   
       3 . A method, as in  claim 2 , including the additional step of: 
 forming the Z-shaped stud with rounded corners, and forming the foam wall panels with rounded leading edges;    whereby damage to the leading edges of the foam wall panels is avoided by illuminating the sharp forward edges.    
   
   
       4 . A method, as in  claim 2 , including the additional step of: 
 providing apertures in the surface of Z-shaped stud which face the angled surfaces of the foam wall panels, the apertures sufficient in size to allow wiring to be run there through.    
   
   
       5 . A method, as in  claim 4 , including the additional step of: 
 forming a cable channel in the foam wall panels, the cable channels positioned such that they aligned with the apertures in the Z-shaped studs.    
   
   
       6 . A method, as in  claim 5 , including the additional step of: 
 pre-forming the cable channels in the foam wall panels during the fabrication of the foam wall panels.    
   
   
       7 . A method, as in  claim 5 , including the additional step of: 
 forming the cable channels in the foam wall panels with a hot knife during the installation of the foam wall panels.    
   
   
       8 . A method, as in  claim 1 , including the additional step of: 
 fabricating the Z-shaped stud from a single sheet of material which is folded such that, when viewed from the end, the Z-shaped stud has a substantially Z-shaped appearance.    
   
   
       9 . A method, as in  claim 1 , including the additional step of: 
 fabricating the Z-shaped stud by extruded or molding material such that, when viewed from the end, the Z-shaped stud has a substantially Z-shaped appearance.    
   
   
       10 . A method, as in  claim 1 , including the additional step of: 
 using gripping edges extending from the side walls of the Z-shaped wall stud that penetrate the side wall of the foam panels when the foam panels are joined to the Z-shaped stud such that the gripping edges secure the foam panels to the Z-shaped wall stud.