Structual Wall Panel System

Abstract

A structural panel system formed from a substrate (such as cement board or paper) and structural studs (such as lightweight galvanized steel members), where the studs are embedded within an insulating core that is formed onto the substrate, where the studs are gapped from the inner surface of the substrate to prevent thermal energy from transferring from the substrate to the stud or vice versa. In addition, parallel assembly slots may be formed in the gap at the top and bottom ends of each panel assembly to provide connective access to the top and bottom ends of the studs for structural connection to the foundation at the bottom or other overhead structure at the top via connective components. The connective components include a bottom U-channel member and a top U-channel member that are configured to fit into the parallel assembly slots.

1 . A structural panel assembly of rectangular parallelepiped shape that is substantially taller and wider than thick, the structural panel assembly having a first broad side, a second broad side, a bottom end, a top end, a left end, and a right end, the structural panel assembly adapted for use in a structural panel building system, the structural panel assembly comprising:
 a first substrate of sheet material forming the first broad side of the structural panel assembly, the first substrate having an inner face and an outer face;   a second substrate of sheet material forming the second broad side of the structural panel assembly, the second substrate having an inner face and an outer face, the second substrate spaced from the first substrate to define a distance between the inner face of the first substrate and the inner face of the second substrate;   at least one stud having an elongated configuration and external surfaces, the at least one stud extending vertically between the bottom and top ends of the structural panel assembly, positioned in parallel with the first and second substrates, and located adjacent to but spaced from the inner face of the first substrate and the inner face of the second substrate, the at least one stud having a width transverse to the elongated configuration that substantially spans the distance between the inner faces of the first and second substrates;   a first gap formed between the inner face of the first substrate and the at least one stud due to the at least one stud being located adjacent to but spaced from the inner face of the first substrate, to prevent the inner face of the first substrate from making thermal contact with the at least one stud and thereby provide the structural panel assembly with increased thermal insulation capability;   a filling material located between the first substrate of sheet material and the second substrate of sheet material and embedding the at least one stud, the filling material making contact with the external surfaces of the at least one stud embedded therein, the inner face of the first substrate of sheet material, and the inner face of the second substrate of sheet material, wherein the at least one stud, the first substrate, and second substrate are held together as a unit by the filing material, the filling material further occupying the first gap and making further contact therein with the inner face of the first substrate and the at least one stud, to hold together the first substrate of sheet material, the second substrate of sheet material, the at least one stud, and the filling material; and
 a first bottom mounting slot extending along a bottom end of the structural panel assembly and vertically upward to a bottom mounting slot depth, the first bottom mounting slot formed by the absence of filling material in the first gap between the first substrate and the at least one stud at the bottom end of the structural panel assembly, the first bottom slot exposing a bottom end of the at least one stud for structural connection of the bottom end of the structural panel assembly. 
   
     
     
         2 . The structural panel assembly of  claim 1  wherein the at least one stud has a central section and first and second perpendicular side sections extending therefrom that form a U-shaped profile. 
     
     
         3 . The structural panel assembly of  claim 1  wherein the at least one stud has a U-shaped, C-shaped, L-shaped, Sigma-shaped, or Z-shaped profile. 
     
     
         4 . The structural panel assembly of  claim 1  further comprising a plurality of shims that create the first gap between the first substrate and the at least one stud, the shims being positioned on the inner surface of the first substrate, beneath the at least one stud. 
     
     
         5 . The structural panel assembly of  claim 1  wherein the first bottom mounting slot is adapted to receive a bottom mounting member with a first extension that fits into the bottom mounting slot and slides adjacent to the at least one stud and connects the structural panel assembly to a slab located below the structural panel assembly. 
     
     
         6 . The structural panel assembly of  claim 1  further comprising a second bottom mounting slot that is parallel to the first bottom mounting slot, the first and second bottom mounting slots forming a bottom pair of mounting slots at the bottom end of the structural panel assembly. 
     
     
         7 . The structural panel assembly of  claim 8  further wherein the bottom pair of mounting slots are adapted to receive a bottom channel member with first and second extensions that fit into the bottom pair of mounting slots and slide adjacent to opposite sides of the at least one stud. 
     
     
         8 . The structural panel assembly of  claim 9  further comprising a plurality of blind apertures formed in the first broad side and the second broad side of the structural panel assembly, near the bottom end of the structural panel assembly, the plurality of blind apertures adapted to permit mechanical fasteners to be inserted through the first and second extensions of the channel member and then into the opposite sides of the at least one stud to securely connect the first and second extensions of the channel member to the at least one stud. 
     
     
         9 . The structural panel assembly of  claim 1  further comprising:
 a first top mounting slot extending along a top end of the structural panel assembly to and vertically downward to a top mounting slot depth, the first top mounting slot formed by the absence of filling material in the first gap between the first substrate and the at least one stud at the top end of the structural panel assembly, the first top mounting slot exposing a top end of the at least one stud for structural connection of the top end of the structural panel assembly. 
 
     
     
         10 . The structural panel assembly of  claim 9  wherein the first top mounting slot is adapted to receive a top mounting member with a first extension that fits into the top mounting slot and slides adjacent to the at least one stud and connects the structural panel assembly to additional building structure located above the structural panel assembly. 
     
     
         11 . The structural panel assembly of  claim 9  further comprising a second top mounting slot that is parallel to the first top mounting slot, the first and second top mounting slots forming a top pair of mounting slots formed at the top end of the structural panel assembly. 
     
     
         12 . The structural panel assembly of  claim 11  wherein the top pair of mounting slots are adapted to receive a top channel member with first and second extensions that fit into the top pair of mounting slots and slide adjacent to opposite sides of the at least one stud. 
     
     
         13 . The structural panel assembly of  claim 12  further comprising a plurality of blind apertures formed in the first broad side and the second broad side of the structural panel assembly, near the top end of the structural panel assembly, the plurality of blind apertures adapted to permit mechanical fasteners to be inserted through the first and second extensions of the channel member and then into the opposite sides of the at least one stud to securely connect the first and second extensions of the channel member to the at least one stud. 
     
     
         14 . The structural panel assembly of  claim 1  wherein the filling material forms an insulating core that provides the structural panel assembly with increased thermal insulation capability. 
     
     
         15 . The structural panel assembly of  claim 1  wherein the filling material is foamed polyurethane. 
     
     
         16 . The structural panel assembly of  claim 1  wherein the filing material is expanded polystyrene (EPS). 
     
     
         17 . The structural panel assembly of  claim 1  wherein the filling material is foamed polyisocyanurate (PIR). 
     
     
         18 . The structural panel assembly of  claim 1  further comprising a plurality of shims that create the first gap between the inner surface of the first substrate and the at least one stud, the shims being positioned on the inner surface of the first substrate, beneath the at least one stud, the filling material being formed onto the inner face of the first substrate and around the at least one stud, into the first gap created between the first substrate and the at least one stud, the filling material thereby making continuing to make contact with the inner face of the first substrate, the inner face of the second substrate, and the at least one stud. 
     
     
         19 . The structural panel assembly of  claim 1  wherein the structural panel assembly is a wall panel. 
     
     
         20 . The structural panel assembly of  claim 1  wherein the first substrate is flat. 
     
     
         21 . The structural panel assembly of  claim 20  wherein the first substrate is a cement board panel. 
     
     
         22 . The structural panel assembly of  claim 20  wherein the first substrate is a gypsum board panel.