Wall system

Abstract

A wall system includes a first wall section a structural portion, such as concrete block construction. A second wall section mounts to the first wall section and includes insulating panels connected in an edge to edge relationship to form a continuous insulating layer. A third wall section of conventional finishing materials such as sheetrock or paneling mounts over the second wall section. Each of the insulating panels includes mounting elements embedded therein that provide for mounting the panels to the first layer and for mounting the third wall section to the second wall section. Each of the panels is lightweight and may be water impervious. The panels have ridges formed therein that define channels for routing wiring and other components. The panels also include complementary edges and complementary alignment features.

1 . A wall construction system, comprising:
 a plurality of molded insulating panels;   a mounting element embedded in each of the insulating panels, wherein the mounting element comprises a first elongate portion, a second elongate portion, and a plurality of spaced apart connecting sections extending from the first portion to the second portion.   
     
     
         2 . A wall construction system according to  claim 1 , wherein the mounting element comprises a glue channel on an outer surface of the first elongate portion. 
     
     
         3 . A wall construction system according to  claim 1 , wherein second elongate portion of the mounting element comprises a first section extending substantially transverse to the connecting sections in a first direction and a second section extending substantially transverse to the ribs in a second direction away from the first direction. 
     
     
         4 . A wall construction system according to  claim 1 , wherein the first and second sections extend slightly away from the first elongate portion. 
     
     
         5 . A wall construction system according to  claim 1 , wherein the first and second sections define a plurality of longitudinally extending channels. 
     
     
         6 . A wall construction system according to  claim 1 , wherein the panel includes a plurality of mounting elements embedded in the panel. 
     
     
         7 . A wall construction system according to  claim 6 , wherein the plurality of mounting elements are aligned in a spaced apart parallel configuration. 
     
     
         8 . A wall construction system according to  claim 1 , wherein a first face of the panels includes a plurality of parallel ridges defining a plurality of channels there between. 
     
     
         9 . A wall construction system according to  claim 1 , wherein the panels comprise closed cell expanded polystyrene material. 
     
     
         10 . A wall construction system according to  claim 1 , further comprising alignment portions along at least two edges of each panel. 
     
     
         11 . A wall construction system according to  claim 1 , further comprising alignment portions along four edges of each panel. 
     
     
         12 . A wall construction system according to  claim 1 , wherein two edges of the panel comprise tongues and two edges of the panel comprise grooves. 
     
     
         13 . A wall construction system according to  claim 1 , wherein a portion of the mounting element is exposed through one surface of the panel. 
     
     
         14 . A wall construction system according to  claim 1 , further comprising alignment tabs along two first edges of each panel and complementary alignment notches along two second edges of each panel. 
     
     
         15 . A wall construction system according to  claim 8 , wherein the first face defines a second channel at the ends of the ridges when connected to another panel, wherein the second channel extends transverse to the first channels. 
     
     
         16 . A wall construction system according to  claim 15 , wherein the first channels intersect the second channel. 
     
     
         17 . A wall comprising:
 a first wall section comprising a structural portion;   a second wall section mounting to the first wall section and comprising a plurality of insulating panels, wherein each of the insulating panels comprises a mounting element embedded therein;   a third wall section proximate the second wall section;   wherein the wall sections mount with attachment devices to the mounting elements.   
     
     
         18 . A wall according to  claim 17 , wherein the mounting element comprises a first elongate portion, a second elongate portion, and a plurality of spaced apart connecting sections extending from the first portion to the second portion. 
     
     
         19 . A wall construction system according to  claim 17 , wherein the panel includes a plurality of mounting elements embedded in the panel. 
     
     
         20 . A wall construction system according to  claim 19 , wherein the plurality of mounting elements are aligned in a spaced apart parallel configuration. 
     
     
         21 . A wall construction system according to  claim 17 , wherein a first face of the panels includes a plurality of parallel ridges defining a plurality of channels there between. 
     
     
         22 . A wall construction system according to  claim 17 , further comprising alignment portions along four edges of each panel. 
     
     
         23 . A method of making a wall, comprising:
 forming a first wall section, wherein the first wall section is a structural;   mounting a second wall section over the first wall section, wherein the second wall section comprises a plurality of rectangular insulating panels interconnected in a continuous manner, and wherein each of the panels includes at least one mounting element embedded therein;   mounting a third wall section over the second wall section;   wherein the second wall section attaches to the first wall section at the mounting element and wherein the third wall section attaches to the second wall section at the mounting element.   
     
     
         24 . A method according to  claims 23 , wherein each of the mounting elements comprises a first elongate portion, a second elongate portion, and a plurality of spaced apart connecting sections extending from the first portion to the second portion. 
     
     
         25 . A method according to  claim 23 , wherein each of the panels comprises complementary connectors along the edges of the panels, and wherein the panels are connected to one another in an edge to edge configuration. 
     
     
         26 . A method according to  claim 23 , wherein a first face of the panels includes a plurality of parallel ridges defining a plurality of channels there between and wherein elements are routed in the channels prior to mounting the third wall section.