Modular wall system with internal air and vapor barrier joints

Abstract

Pre-fabricated panels may consist of multiple layers of materials, which may include (from outside to inside): exterior outer cladding, insulation material, air and vapor barrier (AVB), sheathing board, spray home and studs. In one example, each edge of a sheathing board on the interior side of a wall may be covered by a U-shaped sleeve made of soft plastic, for example rubber, forming a flexible joint between abutting sheathing boards. The edges of the sheathing boards are connected by an interior lap seal system that allows for the application of a sealant through an injection portal. A strip of peel and stick membrane may be applied over the lap seal system as a secondary measure of continuing the AVB membrane. A stud framing system may be used to ensure there is sufficient space to allow the application of AVB membrane from the inside.

We claim: 
     
         1 . A modular pre-fabricated wall panel, the wall panel having an interior side and an exterior side, the wall panel comprising:
 a substantially rectangular sheathing layer;   an AVB layer substantially congruent with the sheathing layer on the exterior side of the sheathing layer, the AVB layer providing an air and/or vapor barrier, the AVB layer protruding beyond each of the four edges of the sheathing layer;   studs and brackets affixed to and on the interior side of the sheathing layer; and   an access portion on the interior side of the wall panel providing access through the studs and brackets to the edge of the sheathing access from the interior side of the panel.   
     
     
         2 . The wall panel of  claim 1 , further comprising a deformable joint connector substantially covering each of the edges of the sheathing layer, the AVB layer being folded around the joint connector. 
     
     
         3 . The wall panel of  claim 1 , wherein the access portion comprises a plurality of stud legs, the stud legs having a depth that is less than a depth of the studs and the stud legs supporting the studs. 
     
     
         4 . The wall panel of  claim 1 , wherein the access portion provides access through the studs and brackets for the affixing a strip of barrier material to the joint between the AVB layer of the panel with the AVB layer of an adjoining panel. 
     
     
         5 . The wall panel of  claim 2 , wherein the access portion comprises a plurality of stud legs, the stud legs having a depth that is less than a depth of the studs and the stud legs supporting the studs. 
     
     
         6 . The wall panel of  claim 2 , wherein the access portion provides access through the studs and brackets for the affixing a strip of barrier material to the joint between the AVB layer of the panel with the AVB layer of an adjoining panel. 
     
     
         7 . The wall panel of  claim 3 , wherein the access portion provides access through the studs and brackets for the affixing a strip of barrier material to the joint between the AVB layer of the panel with the AVB layer of an adjoining panel.